Yanmar EF-494T Technical Manual
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Yanmar EF-494T Technical Manual

Diesel tractor
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EF494T TM 06/2011 edition

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Frederick Rock
January 25, 2025

Tractor completely dead. No lights, horn, signals, nothing. Batt connections cleaned, r good

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1 comments:
Mr. Anderson
February 10, 2025

The Yanmar tractor EF-494T could be completely dead with no lights, horn, or signals due to several possible causes:

1. Battery Issues – A dead or disconnected battery can cause a total power loss. Check the battery connections, charge level, and condition.
2. Blown Main Fuse – If the main fuse is blown, it will cut off power to all electrical components. Inspect and replace if necessary.
3. Faulty Ignition Switch – A malfunctioning ignition switch can prevent power from reaching the electrical system.
4. Loose or Damaged Wiring – Check for disconnected, corroded, or damaged wiring, especially around the battery and fuse box.
5. Failed Relay or Control Module – A defective relay or control module may prevent electrical components from functioning.

If the issue persists, refer to the troubleshooting section in the manual or consult a service representative.

This answer is automatically generated

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Summary of Contents for Yanmar EF-494T

  • Page 1 EF494T TM 06/2011 edition...
  • Page 2 SAFETY Never attempt to operate or service this machine until you have first read and understood all of the applicable Safety Instructions that are set forth in this Manual. The failure to comply with all relevant Safety Instructions could result in bodily injury.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION To The Owner MAINTENANCE SUPPLY PERIOD FOR MAINTENANCE PARTS IMPROVEMENTS SYMBOL INDICATION PRECAUTIONS FOR THE SAFE SERVICES AFTER SALES SERVICE GENERAL PRECAUTIONS FOR SERVICES 0.3.1 GENERAL 0.3.2 USAGE OF THE LIQUID GASKET 0.3.3 SCREW TIGHTENING TORQUE TABLE 0.3.4...
  • Page 4 TABLE OF CONTENTS TABLE OF CONTENTS DISASSEMBLY OF COMPONENTS REMOVING THE ENGINE BONNET COVER 2.1.1 Removing/mounting the side covers 2.1.2 Removing the engine bonnet cover REMOVING THE FENDER 2.2.1 Removing the fuel tank cover 2.2.2 Removing the nuts and bolts that fixing the fender REMOVING THE STEP REMOVING THE SEAT STAY CLUTCH HOUSING...
  • Page 5 TABLE OF CONTENTS TABLE OF CONTENTS COOLING WATER SYSTEM 3.4.1 Flow of cooling water 3.4.2 Main components 3.4.3 Fuel injection pump 3.4.4 Piston 3.4.5 Checking pressures 3.4.6 Maintenance criteria ADJUSTMENT SPECIFICATIONS 3.5.1 Engine adjustments 3.5.2 Cylinder head 3.5.3 Intake/exhaust valve and guide 3.5.4 Valve spring 3.5.5...
  • Page 6 TABLE OF CONTENTS TABLE OF CONTENTS TRANSMISSION (CLUTCH HOUSING CASE SIDE) 5.4.1 Disassembly 5.4.2 Main shift section TRANSMISSION (TRANSMISSION HOUSING CASE SIDE) 5.5.1 Disassembly 5.5.2 PTO module REAR AXLE AND BRAKE STRUCTURE AND FUNCTIONS 6.1.1 Structure drawing 6.1.2 Differential system 6.1.3 Final drive system 6.1.4...
  • Page 7 TABLE OF CONTENTS TABLE OF CONTENTS HYDRAULIC LIFT UNIT STRUCTURE AND FUNCTIONS 9.1.1 Hydraulic line 9.1.2 Hydraulic cylinder case 9.1.3 Control valve 9.1.4 Relief valve 9.1.5 Safety valve 9.1.6 Stop valve 9.1.7 Hydraulic pump, exploded view 9.1.8 Position feedback link 9.1.9 Oil flow 9.1.10...
  • Page 8 TABLE OF CONTENTS TABLE OF CONTENTS 11 APEENDIXES 11.1 HYDRAULIC CIRCUIT DIAGRAM 11.2 ELECTRICAL DIAGRAM AND PARTS 11.2.1 WIRING HARNESS 11.2.2 LOCATION OF ELECTRICAL PARTS 11.2.3 ELECTRICAL WIRING DIAGRAM EF494T TM 06/2011 edition...

  • Page 9: Introduction

     Therefore, please understand that the contents, photos and illustrations in the manual may differ from your machine. MAINTENANCE When the machine is in abnormal condition, take the remedies. If the machine is still abnormal, ask Yanmar and give the following information:  Machine model  Serial number  Detailed description of abnormal condition...

  • Page 10: Symbol Indication

    0 INTRODUCTION 0 INTRODUCTION SYMBOL INDICATION Safety-alert Symbol This is the safety-alert symbol. When you see this symbol on your tractor or in this manual, personal injury is possible or even likely if you do not follow the advice given. Read the messages that follow carefully.
  • Page 11  Do not try to adjust engine speed adjuster screw (A) located on engine fuel injection pump. Any accident or failure resulting from adjusting the screw would not be covered by Yanmar's guarantee.  Do not try to unseal and adjust engine fuel injection pump (B).

  • Page 12: Precautions For The Safe Services

    0 INTRODUCTION 0 INTRODUCTION PRECAUTIONS FOR THE SAFE SERVICES DANGER SUFFICIENT VENTILATION Be sure to work in the well-ventilated place when the engine runs, welding or grinding a painted part. [If not] Exhaust gas and paint dirt is poisonous and hazardous to human bodies.
  • Page 13 0 INTRODUCTION 0 INTRODUCTION CAUTION KEEP A FIRE EXTINGUISHER AND FIRST AID KIT HANDY  The workplace must be provided with a fire extinguisher. Read instructions on the label to familiarize yourself with how to use it.  Keep a first aid kit in a prescribed place. ...
  • Page 14 0 INTRODUCTION 0 INTRODUCTION CAUTION GENUINE PRODUCTS Be sure to use and install genuine products and spare parts. [If not obeyed] It may cause unexpected failures and shorten the machine life span. WARNING TIGHTEN BOLTS AND NUTS WITH THE SPECIFIED TORQUE Be sure to tighten bolts and nuts with the specified torque in this manual.
  • Page 15 0 INTRODUCTION 0 INTRODUCTION WARNING HANDLING BATTERY ELECTROLYTE The battery electrolyte is diluted sulfuric acid and poisonous. Refill battery electrolyte in well ventilated area and wear eye protection and rubber gloves. [If not] Splashed solution can cause burning skin, cloths and blindness if it get into eyes.
  • Page 16 0 INTRODUCTION 0 INTRODUCTION DANGER WORKING UNDER THE MACHINE  Before performing service or repairs underneath the machine, place the implement on the ground in its lowest position.  Be sure to apply blocks to the tracks to lock the tracks securely.
  • Page 17 0 INTRODUCTION 0 INTRODUCTION WARNING BE CAREFUL WHEN SERVICING SYSTEMS UNDER HIGH TEMPERATURE AND HIGH PRESSURE The engine cooling water and each lube oil system are still under high temperature and pressure immediately after the engine has stopped. Removing caps, draining oil and water, or replacing filter elements at that time may cause a burn.
  • Page 18 0 INTRODUCTION 0 INTRODUCTION WARNING INFLATING TIRE When you inflate tire, use long hose with self-attaching air chuck for not standing in front of or over tire. Use safe cage if available. Do not inflate tire beyond maximum recommended pressure in operator's manual. [If not] An over-inflated tire can explode and cause injury or death.

  • Page 19: After Sales Service

    Maintenance parts and spare parts will be available for 10 years after the production of this tractor series has been discontinued. However, special parts will be available subject to consultation. Yanmar may be able to supply a particular part after the normal supply period.

  • Page 20: General Precautions For Services

    0 INTRODUCTION 0 INTRODUCTION GENERAL PRECAUTIONS FOR SERVICES 0.3.1 GENERAL When contacting us about your machine identify it with the model and serial numbers of the tractor and its engine, and the usage hours displayed on the hour meter. Hour meter The hour meter numerically indicates the operating hours of the tractor.
  • Page 21 0 INTRODUCTION 0 INTRODUCTION To replace components, always use the Yanmar genuine parts. Be sure to replace packing and O-ring with new one. Apply the grease slightly on O-ring and oil seal prior to install. To install a snap ring, place the edged side in the direction that the force is loaded as the right figure shows.

  • Page 22: Usage Of The Liquid Gasket

    0 INTRODUCTION 0 INTRODUCTION 0.3.2 USAGE OF THE LIQUID GASKET <Paring sealant> Pare off sealing material on the surface with a scraper. Do not to scratch or damage on the mating surface. If the surface gets scratch or damage, correct them by grinding with oilstone. (A) Scraper <Applying the liquid gasket>...
  • Page 23 0 INTRODUCTION 0 INTRODUCTION <Deterioration of a liquid gasket> 1. When using the liquid gasket again after a tube is opened, the gasket in the nozzle part may have been hardened or deteriorated. Squeeze out the liquid gasket a little and then use it. 2.

  • Page 24: Screw Tightening Torque Table

     To tighten any aluminum part, apply torque equivalent to 80% of the specified value.  Recently, all the bolts may be standardized to 7T bolts under the plant line management of Yanmar.  When 7T bolt is used with rubber, rubber packing or aluminum parts, tighten the bolt following the values in the 4T-bolt table.

  • Page 25: Fuse Box

    0 INTRODUCTION 0 INTRODUCTION 0.3.4 FUSE BOX (1) The alternator and main fuses are 60A, slow- blow fuses. (A) Alternator fuse: (B) Main fuse: (2) The electrical fuses are in the engine compartment. START : Starter motor WORK : Working light TURN : Turn signal light TAIL : Tail light...

  • Page 26: Part Names

    0 INTRODUCTION 0 INTRODUCTION 0.3.5 PART NAMES Bonnet (10) Rear tire Headlights (11) Hydraulic stop-slow return valve Side lens (12) Step Front axle bracket (13) Operator’s seat Front tires (14) Top link Steering wheel (15) Lower link Safety frame (ROPS) (16) PTO shift lever Tail lamp (17) Flasher lamp (Side marker lamps)
  • Page 27 0 INTRODUCTION 0 INTRODUCTION Light switch, Horn switch, Flasher switch (10) Accelerator lever Reverser lever (11) Main shift lever Clutch pedal (12) Brake pedal Parking brake lever (13) Accelerator pedal Operator's seat adjusting lever (14) Differential lock pedal Range shift lever (15) Position control lever Front wheel drive lever (16) Hydraulic stop slow return valve...

  • Page 28: Safety Label Location

    0 INTRODUCTION 0 INTRODUCTION 0.3.6 SAFETY LABEL LOCATION (1) Label, Brake coupling (6) Label, Tractor ID (10) Label, ROPS ID (2) Label, CAUTION (7) Label, Engine ID (11) Label, ROPS safety (3) Label, Fire caution (on the engine) (12) Label, Seat belt (4) Label, Danger shaft rotate (8) Label, Caution muffler (13) Label, speed...

  • Page 29: Specifications

    0 INTRODUCTION 0 INTRODUCTION 0.3.7 SPECIFICATIONS Model EF494T Drive type 4-wheel Drive Dimensions Overall length (mm) 3,230 Overall width (mm) 1,605 Overall height (mm) 2,355 (ROPS) Wheelbase (mm) 1,830 Tread Front (mm) 1,300, 1,466 Rear (mm) 1,270, 1,352 Ground clearance (mm) Weight (kg) 1,540 Engine...

  • Page 30: Periodical Inspection

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION PERIODICAL INSPECTION EF494T TM 06/2011 edition...

  • Page 31: Check Intervals

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.1 CHECK INTERVALS x: Checks required CHECK ITEMS 50 h 100h 150h 200h 250h 300h 350h 400h 450h 500h 550h 600h Engine lubrication oil Replace Replace Replace Replace Replace Replace Replace Engine oil element Replace Replace Replace...

  • Page 32: Oil And Grease

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION OIL AND GREASE OIL, GREASE Type Fuel Diesel fuel only SAE 30 or 40 API Grade CD or better Engine oil YES-EO Grease Multipurpose Grease TF-500 Transmission fluid Transmission oil, Hydraulic system oil YES-HO * At temperature below –...

  • Page 33: Replacing Oil

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.5 REPLACING OIL DANGER Never add oil while the engine is warm or running. A fire may occur. CAUTION Never add oil just after stopping the engine. You may be burned. Engine oil Check Draw out the dipstick on the right side of the engine and wipe off oil with a cloth.
  • Page 34  Transmission oil is commonly used with hydraulic oil and power steering oil.  Use Yanmar transmission fluid TF-500 or equivalent for transmission oil. (A) Drain plug Replace: First 50 hrs, then every 300 hrs.

  • Page 35: Replacing Filter Elements

    Add oil through the right port. Use Yanmar transmission fluid TF-500A or equivalent for front axle oil. (A) Center drain plug (B) Gear case R drain plug (C) Gear case L drain plug Replace: First 50 hrs, then every 300 hrs.

  • Page 36: Replacing Cooling Water

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION Line filter (Transmission oil element) The line filter is of a cartridge type. Replace it with a new one first 50 hours and then every 300 hours. Replacing Remove the transmission oil and remove the cartridge by turning anticlockwise.

  • Page 37: Removing Water From Water Separator

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION Replacing Remove the radiator cap and the drain plug (A) to drain off the engine cooling water. Clean the radiator with tap water until dust or rust is all drained out. • It is suggested to use radiator detergent. Run engine in idling speed for more than 15 minutes and remove the water.

  • Page 38: Cleaning And Replacing Air Cleaner

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.9 CLEANING AND REPLACING AIR CLEANER ELEMENT, CLEANING RADIATOR SCREEN The air cleaner serves to keep the engine in favorable conditions by removing dust in air and preventing the cylinder liner and piston ring from wearing.

  • Page 39: Checking Battery

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.10 CHECKING BATTERY DANGER  Never use a fire while checking the battery or the battery cap is removed. Otherwise, a fire or gas explosion may result.  Do not touch battery electrolyte with bare hand. If the electrolyte is spilled on your body or cloth, wash it out immediately with water.

  • Page 40: Checking Hose And Pipe

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION Battery type IMPORTANT  Be sure the tractor is level when checking electrolyte Specified battery Parts code No. 75D26R 1A7781-51510 level.  When connecting the battery cables, wipe oil away from the terminal contacts. After connecting cables, Voltage 12Volts apply grease to the terminals.

  • Page 41: Greasing

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.13 GREASING Before initiating day's work, check the greasing condition at each point. Grease up after a work on a muddy field. As a general rule, grease up various points at intervals of 50 hours. (A) Brake pedal shaft (B) Clutch pedal (C) Tie rod end...
  • Page 42 1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION Lubricating propeller shaft with grease Lubricate the propeller shaft connection with grease every 500 hr. When working in the wet field, shorter lubrication intervals are suggested. 1. Front end (1) Loosen the band (A). (2) Remove the bolt (B) and the collar (C).
  • Page 43 1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 2. Rear end (1) Remove the bolt (B) and collar (C) from rear shaft cover (H). (2) Slide the rear shaft cover (H) backward as the right picture shows. (3) Turn over the rubber boots (E) as the right illustration shows.

  • Page 44: Adjusting Brake

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.14 ADJUSTING BRAKE WARNING  Check if the brake is effective or not one-sided. An accident can result.  Unbalanced play at left and right brake pedals can cause one-sided braking effect. Keep the same amount of play;...

  • Page 45: Adjusting Clutch

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.15 ADJUSTING CLUTCH Standard version Depress the clutch pedal to see it there is a specified play of 15-25 mm. It not, adjust the turnbuckle for a play of 15-25 mm. Securely lock the nut after adjustment.

  • Page 46: Adjusting Fan Belt

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.17 ADJUSTING FAN BELT CAUTION Wait until the engine is sufficiently cooled down. Otherwise, you may be burned. Switch off the engine. Open the bonnet, then the left side cover of the engine. Press the fan belt with a finger at the midpoint to see the belt deflections 10-15 mm.

  • Page 47: Replacing Fuse

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.19 REPLACING FUSE Remove the lid of the fuse box and check the fuse. Replace the blown fuse with new one. Stop the engine and check the main fuse (slow blow fuse) which shuts off the electrical circuit when an excessive current flows.

  • Page 48: Checking Tires

    1 PERIODICAL INSPECTION 1 PERIODICAL INSPECTION 1.20 CHECKING TIRES Adjust the air pressure of front and rear tires to the standard pressure. Check the tires for cracks or damage. Adjust the front tire pressure for a maximum in the following table if a load is to be imposed on the front tires through the front weight or front loader.

  • Page 49: Disassembly Of Components

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS DISASSEMBLY OF COMPONENTS EF494T TM 06/2011 edition...

  • Page 50: Removing The Engine Bonnet Cover

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS REMOVING THE ENGINE BONNET COVER 2.1.1 Removing/mounting the side covers <Removing> Open the bonnet. Put the locking knobs in the vertical position (each forward and rear). Remove the side covers. <Mounting> Clamp the cover lower hooks (x 2). Fix the cover top with the locking knob.

  • Page 51: Removing The Fender

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS REMOVING THE FENDER 2.2.1 Removing the fuel tank cover (A) Fuel tank cover (B) Bolt M8x16, 7pieces. Note: Pay attention to the electrical wiring. 2.2.2 Removing the nuts and bolts that fixing the fender Note: ...
  • Page 52 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Remove the 4 mounting pins (D), and remove the right floor (C). Remove the left floor following the same sequence of right side floor. Remove the three M8x20 bolts (A), and remove the right floor stay. IMPORTANT The entire parking brake assembly can be removed.

  • Page 53: Removing The Seat Stay

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS REMOVING THE SEAT STAY Note: It is necessary to remove the fuel tank. Remove the seat, lever knobs (A), and housing cover (B) (M6x16: 8 pieces.). Remove fender. Refer “2.2 REMOVING THE FENDER”. Drain the fuel from the fuel tank.
  • Page 54 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Remove the return pipe (A) from the fuel tank, and disconnect coupler to fuel gauge (B) located in section C. Then, remove the bolts (D). CAUTION The rubber packing (A) is used when installing the fuel tank.

  • Page 55: Clutch Housing

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS CLUTCH HOUSING 2.5.1 Separation Place chocks at front and rear wheels. Disconnect battery. Insert wedges (A) to the left and right of the front axle swing section. WARNING Be sure to insert the wedges. If not, engine would tilt when clutch housing is separated and front axle section might turn over.
  • Page 56 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Remove the following parts from the left side of the machine. (A) (B) Low-pressure hydraulic pipes (C) High-pressure hydraulic pipe: M6 Bolts x 4 pieces. (D) Generator wirings (E) Electric wire clamps: 3 places (F) Hydraulic pipe fixing bolts under clutch housing Remove the following parts from the upper part of the engine.
  • Page 57 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Remove bonnet. See “2.1 REMOVING THE ENGINE BONNET COVER”. Remove the front column cover (A) and the dashboard cover (B). (10) Remove bonnet stay fixing bolt (A), air cut plate (air deflection plate) fixing bolts (B), and hydraulic pipe fixing bolt (C).
  • Page 58 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (12) Remove the following parts from the power steering valve. (A) Pipe from the hydraulic pump (High pressure) (B) Return pipe (Low pressure) IMPORTANT  When the clutch housing section is separated without removing the pipes (A) and (B), the pipes could get caught in the starter and be destroyed.
  • Page 59 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (13) Remove the bolt (A), M12 x 34, on rear end and upper of front axle bracket, left and right sides. Install lifting bolt on left and right sides, as shown in the photo. Lifting bolt Bolt size: Dia.
  • Page 60 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (16) Remove nuts and bolts that connect engine and clutch housing. (A) Bolt M12x30: 3 pieces. (B) Bolt M12x170: 2 pieces. (C) Bolt M12x100: 2 pieces. (D) Nut M12: 1 pc. (17) Separate the engine and the clutch housing. Note: If clutch housing adhered to engine by liquid gasket too strongly, place a piece of wood as right photo...

  • Page 61: Docking

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS 2.5.2 Docking Remove the old liquid gasket on mating surface of engine and clutch housing. Apply Three bond 1215 or equivalent type of liquid gasket. WARNING The disassembled machine is very unstable. Be careful not to let it fall over and be sure to attach a wedge to the front axle swing section.
  • Page 62 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Raise the lift arms (A) and the stopper & slow return valve section (B), and then separate the hydraulic cylinder case. WARNING It should be done by at least 2 people because hydraulic cylinder case is heavy.

  • Page 63: Separating The Clutch Housing And Transmission

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS 2.6.2 Separating the clutch housing and transmission WARNING The disassembled machine is very unstable. Be careful not to let it fall over. Drain the transmission oil. Remove the step. See 2.3. Remove the seat stay. See 2.4. Remove the propeller shaft.
  • Page 64 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Remove the right step stays (A) and (B), and remove the left and right brake rods (C). (G) Separation position IMPORTANT The brake pedal return springs (D) must be installed in the correct directions. Note: Remember the position of the parking brake (E).
  • Page 65 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (10) Remove the high-pressure pipe (A). (11) Move the reverser lever to the neutral position, and remove the reverser rod (A). IMPORTANT Before removing the reverser rod, be sure that the reverser lever is in the neutral position. (12) Remove the nut (B) and pull the reverser (C) change arm out about 15 mm.
  • Page 66 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (14) Remove the four M12 bolts (A) and the 2 nuts (B), and separate the clutch housing and the transmission slowly. CAUTION This operation should be done by at least 2 people. IMPORTANT Before joining the clutch housing and the transmission, remove the old packing (C)

  • Page 67: Rear Axle

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS 2.6.3 Rear axle Disassembling the rear axle housing Drain the transmission oil. Remove the fender seat and rear Remove the 3-point link. Remove the roll guard. Remove the rear wheels. (jack set as well) Remove the brake rod.

  • Page 68: Pto Module

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS 2.6.4 PTO module Removing PTO covers Drain the transmission oil. Remove the 3-point link. Remove the draw-bar hitch and braw-bar bracket. Set the PTO to first or second gear. Remove the keeper plate and pull the shift arm out of the PTO shift module.

  • Page 69: Front Axle Unit

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS FRONT AXLE UNIT <Disassembly> Drain the oil from the front axle. Remove the propeller shaft. See 2.5.1 (2) (3). (A) Propeller shaft Remove the power steering hose (B). It loosens bolts of the front wheels. Jack up the front part of the tractor and take out front wheels.
  • Page 70 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS <Reassembling> Jack up the front axle, after that insert the center pin, and tighten 2 bolts. Then, check the free play of the front axle to be 0-0.6 mm adjusted by shims. Apply threadlocker (Loctite) on bolt thread.
  • Page 71 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS Reinstall the front wheels, lower the jack, and tighten the wheel bolts. IMPORTANT Wheel bolt torque 177-196 N-m (18.0-20.0 kgf-m, 130-145 lb-ft) Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.

  • Page 72: Engine

    2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder. Supply oil to the front axle. ENGINE FUEL SYSTEM 3.1.1 Flow of fuel and layout of components EF494T TM 06/2011 edition...
  • Page 73 3 ENGINE 3 ENGINE (1) Fuel tank (2) Water separator (3) Fuel feed pump (4) Fuel filter (4) Fuel filter (5) Fuel injection pump (6) High-pressure tubes (6) High-pressure tubes (7) Injection nozzles (A) Feed (A) Feed EF494T TM 06/2011 edition...
  • Page 74 3 ENGINE 3 ENGINE (B) Return Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.  Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side. ...
  • Page 75 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS ENGINE Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.  Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side. ...
  • Page 76 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder. Supply oil to the front axle. EF494T TM 06/2011 edition...
  • Page 77 3 ENGINE 3 ENGINE Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.  Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side. ...
  • Page 78 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS cylinder. Supply oil to the front axle. Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.  Replace the split pin (B) with a new one. ...
  • Page 79 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder. Supply oil to the front axle. Reinstall the propeller shaft and shaft cover. IMPORTANT ...
  • Page 80 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder. Supply oil to the front axle. Reinstall the propeller shaft and shaft cover. IMPORTANT ...
  • Page 81 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS side. If not, cover may be broken in a short time. (A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder.
  • Page 82 3 ENGINE 3 ENGINE Reinstall the propeller shaft and shaft cover. IMPORTANT  Put grease into the rubber boots on both sides.  Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side. ...
  • Page 83 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS sides.  Replace the split pin (B) with a new one.  There are 6 steel balls (C) on each side.  Be sure to install spacer (E) on rear and front side.
  • Page 84 2 DISASSEMBLY OF COMPONENTS 2 DISASSEMBLY OF COMPONENTS (A) Mounting bolt (B) Split pin (C) Steel balls (D) Rubber boots (E) Spacer Connect the pipe to the power steering cylinder. Supply oil to the front axle. EF494T TM 06/2011 edition...
  • Page 85 3 ENGINE 3 ENGINE ENGINE EF494T TM 06/2011 edition...
  • Page 86 3 ENGINE 3 ENGINE FUEL SYSTEM 3.1.1 Flow of fuel and layout of components EF494T TM 06/2011 edition...
  • Page 87 3 ENGINE 3 ENGINE (1) Fuel tank (2) Water separator (3) Fuel feed pump (4) Fuel filter (4) Fuel filter (5) Fuel injection pump (6) High-pressure tubes (6) High-pressure tubes (7) Injection nozzles (A) Feed (A) Feed EF494T TM 06/2011 edition...
  • Page 88 3 ENGINE 3 ENGINE (B) Return EF494T TM 06/2011 edition...

  • Page 89: Water Separator

    3 ENGINE 3 ENGINE 3.1.2 Water separator Eliminates contaminants, sediments and water from the fuel to prevent them from entering the fuel feed pump. [C] Close [O] Open (A) Water separator (B) Fuel cock (C) Drain cock Cleaning the water separator Move the fuel cock to position C (close) and loosen the cup mounting screws.

  • Page 90: Fuel Filter

    3 ENGINE 3 ENGINE (A) Water indicator ring 3.1.3 Fuel feed pump Draws the fuel from the fuel tank and delivers it to the fuel injection pump. (A) Fuel feed pump 3.1.4 Fuel filter Removes foreign particles from the fuel to prevent them from entering the fuel injection pump.
  • Page 91 3 ENGINE 3 ENGINE Replacement interval Every 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier Fuel filter Replacement interval Every 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier Fuel...

  • Page 92: Fuel Injection Pump

    3 ENGINE 3 ENGINE Replacement interval Every 300 operating hours or 6 months, whichever is earlier Every 300 operating hours or 6 months, whichever is earlier Fuel filter 3.1.5 Fuel injection pump (Type direct- injection pump) A mono-plunger pump where, in response to the signal from the actuator of the...

  • Page 93: Fuel Injection Nozzles

    3 ENGINE 3 ENGINE 3.1.6 Fuel injection nozzles The use of Yanmar's original direct-injection combustion chamber plus hole valve ensures the ideal mixing of fuel with air, thereby enabling complete combustion. Combustion chamber Direct-injection type Nozzle Hole valve (5 injection holes) Initial injection pressure 21.6MPa (220kg/cm2)

  • Page 94: Combustion System

    3 ENGINE 3 ENGINE COMBUSTION SYSTEM 3.2.1 Low emission technology applied to TNV engine <Fuel injection technology> (1) MP4 pump  Atomization by high-pressure injection (70 MPa)  Injection timing optimized by using a multi- functional timer mechanism <Fuel injection technology> (2) New type nozzle Increased number of nozzle hoes (5 nozzle holes) Finer atomization by making the nozzle hole...
  • Page 95 3 ENGINE 3 ENGINE <Emission control technology> (3) : The TNV engine features 2 intake valves and 2 exhaust valves per cylinder. The fuel direct- injection valve is of vertical type and is center located and the combustion chamber is located at the center of the cylinder, thereby enabling a decrease in emission of PM and NOx.

  • Page 96: Cold Starter

    3 ENGINE 3 ENGINE 3.2.2 Cold starter The injection timing at cold start is made earlier to improve startability. The piston of the cold starter is operated by the CSD solenoid valve depending upon the temperature of cooling water for the engine, thereby opening/closing the sub-port.

  • Page 97: Revolution Timer

    3 ENGINE 3 ENGINE 3.2.3 Revolution timer Clean exhaust gas is assured over the entire range of engine speeds by changing the fuel injection timing according to the engine speed. At low engine speed Fuel injection is less affected by the viscosity of fuel and starts after the sub-port has been closed.

  • Page 98: Lubricating Oil System

    3 ENGINE 3 ENGINE LUBRICATING OIL SYSTEM 3.3.1 Flow of lubricating oil The oil in the oil pan passes through the strainer, is sucked up by the lubricating oil pump, and then lubricates the interior of the engine block and cylinder head through the oil filter and cooler.

  • Page 99: Lubrication Oil Pump (Lo Pump)

    3 ENGINE 3 ENGINE (A) Fuel injection pump (E) Valve arm shaft (I) Pump (B) Hydraulic switch activation (F) Camshaft (J) Strainer Pressure (0.5±0.1 kg/cm (G) Crankshaft (K) Oil filter(secondary) (C) Blancer shaft (H) Filter (L) Oil pump (D) Oil circuit 3.3.2 Lubrication oil pump (LO pump) A trochoid pump installed on the cylinder block,...

  • Page 100: Lubricating Oil Filter (Lo Filter)

    3 ENGINE 3 ENGINE 3.3.3 Lubricating oil filter (LO filter) Has a built-in bypass valve in case of blockage. The vale will be activated at a differential pressure of 1.0 0.2 kgf/cm across the paper filter element and enable the oil to flow through the bypass circuit.

  • Page 101: Cooling Water System

    3 ENGINE 3 ENGINE COOLING WATER SYSTEM 3.4.1 Flow of cooling water (A) Cylinder head (B) Cylinder block (C) Bypass (D) Cooling water pump (E) Thermostat (F) Radiator (G) Sub-tank 3.4.2 Main components <Thermostat> Maintains a constant temperature for the cooling water, thereby preventing the engine from being excessively cooled.
  • Page 102 3 ENGINE 3 ENGINE <Radiator (with sub-tank)> Sub-tank The sub-tank is used to store evaporated cooling water, thereby preventing cooling water from being consumed. (A) Sub-tank (B) Supply port (C) Upper limit (D) Lower limit Radiator cap When the internal pressure of the radiator rises because of an increase in water temperature, the valve opens to send water vapor to the sub-tank to prevent the radiator from deforming or...

  • Page 103: Fuel Injection Pump

    3 ENGINE 3 ENGINE Checking the radiator cap Put the cap on the tester adaptor. Run the pump to apply pressure. If the gauge stays in the normal range for 6 seconds it means the cap is holding the correct pressure. If the pressure does not go up, suspect a damaged spring or worn gaskets.
  • Page 104 3 ENGINE 3 ENGINE Remove the high-pressure fuel injection lines as an assembly (Figure 2, (1)). Note: To prevent "rounding" the fuel line nuts always use a "line" or "flare nut" wrench. When loosening the fuel line nuts, always hold the fuel injection pump delivery valves with a "back up"...
  • Page 105 3 ENGINE 3 ENGINE (14) Disconnect the lube oil line (Figure 4, (1)) and the clamp (Figure 4, (2)) from the pump. IMPORTANT Take care to not damage or bend the oil line. In some applications, it may be preferable to remove the complete oil line assembly from the engine before proceeding.
  • Page 106 3 ENGINE 3 ENGINE (17) To aid in reassembly, make reference marks on the fuel injection pump drive gear, and on either the gear case cover or idler gear. CAUTION After marking the position of the pump drive gear, do not rotate the engine crankshaft. Rotating the crankshaft will cause the fuel injection pump to become misaligned.
  • Page 107 3 ENGINE 3 ENGINE (20) Remove the pump drive gear and hub as an assembly using an appropriate 2-bolt gear puller (Figure 8). Note: The injection pump drive gear will remain "captured" in the gear case. Figure 8 (21) Once the fuel injection pump drive gear and hub assembly has "popped"...
  • Page 108 Do not rotate the crankshaft with the injection pump removed. (25) If the fuel injection pump requires servicing, it must be sent to an authorized Yanmar FIE repair facility for repair and calibration, or replaced with a new fuel injection pump.
  • Page 109 ID label. To locate the timing index number for the engine being serviced use the Timing Index Chart under "FIE Specs" on the Yanmar Distributor Website (http://distributor.yanmar. co.jp). If additional assistance is needed in locating the engine timing index number See To Locate an...
  • Page 110 3 ENGINE 3 ENGINE Align the pump drive gear with the idler gear using the reference marks made earlier. Figure 13 If installing the fuel injection pump on an engine with the front gear case cover removed, the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks (A, B, C) on the fuel injection pump drive gear, idler...
  • Page 111 3 ENGINE 3 ENGINE Reinstall the fuel injection pump drive gear lock washer (Figure 15, (2)) and nut (Figure 15, (1)). Do not lubricate the threads of the nuts or shaft. Hold the crankshaft pulley bolt with a socket wrench and tighten the drive gear nut to the specified torque.
  • Page 112 3 ENGINE 3 ENGINE If installing a new fuel injection pump:  Reinstall the timing grid sticker, provided with the new fuel injection pump, onto the back of the gear case / front plate (Figure 17). Align the "standard mark" (Figure 17, (1)) with the reference mark (Figure 17, (2)) made on the gear case during disassembly.
  • Page 113 3 ENGINE 3 ENGINE Adjusting the fuel injection timing to compensate for the difference in pump timing index numbers: Calculation Example Timing Index Number Original injection pump= Replacement injection pump= Difference= +0.5  If the difference between the timing index numbers is a positive number, the fuel injection pump mounting position must be advanced (Figure 19, (2)) (rotated away from...

  • Page 114: Piston

    3 ENGINE 3 ENGINE 3.4.4 Piston Disassembling Remove the cylinder head. Drain the engine oil. Remove the propeller shaft. Remove the oil pan. Assembling Use Three Bond 1212. Remove the dual-axis balancer assembly. Note: Mate the balancer gear A (hollow) with the crankshaft balancer gear (mark A) (tooth).
  • Page 115 3 ENGINE 3 ENGINE Notes when assembling  Aim the piston seal mark at the camshaft (away from the nozzle).  Aim the embossed mark on the connecting rod to the flywheel.  Match the marks on the connecting rod cap to those on the connecting rod.

  • Page 116: Checking Pressures

    3 ENGINE 3 ENGINE 3.4.5 Checking pressures Checking the lubrication oil Run the engine to warm it up and raise the oil temperature. Remove the pressure switch and install the oil tester. If the pressure is not working properly, check the oil level. Regulator valve pressure: 3-4 kgf/cm (43-57 lb/sq.in) (A) Oil switch...
  • Page 117 3 ENGINE 3 ENGINE Engine compression pressure After warming up the engine, stop it and remove the air cleaner and all the fuel injectors. Install the diesel engine compression gauge in the injector hole of each cylinder. Move the accelerator lever to the STOP position (the zero position for fuel injection) and operate the starting motor for 5-10 seconds (at 200-300 rpm).

  • Page 118: Maintenance Criteria

    3 ENGINE 3 ENGINE 3.4.6 Maintenance criteria For any other details, refer to the relevant technical manuals for the TNV series. (Unit: kgf • m) Parts Lube oil Torque Model Head bolt 8.7-9.3 (M10 x 1.25) Rod bolt 4.5-5.0 (M9 x 1.0) Flywheel bolt 8.5-9.0 (M10 x 1.25) Metal cap bolt...
  • Page 119 3 ENGINE 3 ENGINE Unit: mm Parts 4TNV88 Criteria Limit － Top ring Groove width 2.060-2.075 Dimension B 1.970-1.990 1.950 － 0.070-0.105 Min gap between groove and ring Opening 0.200-0.400 0.490 Second ring Groove width 2.025-2.040 2.140 Dimension B 1.970-1.990 0.195 Min gap between groove and ring 0.035-0.070...

  • Page 120: Adjustment Specifications

    3 ENGINE 3 ENGINE ADJUSTMENT SPECIFICATIONS 3.5.1 Engine adjustments Inspection item Standard Limit ― Intake/exhaust valve clearance (mm) 0.15 to 0.25 For used ― 10 to 14 Between product Tension of V-belt at alternator and 98 N (10 kgf) (mm) crank pulley ―...

  • Page 121: Valve Spring

    3 ENGINE 3 ENGINE 3.5.4 Valve spring Inspection item Standard Limit Free length (mm) 42.0 41.5 ― Squareness (mm) 3.5.5 Locker arm and shaft Inspection item Standard Limit Arm hole I.D. (mm) 16.000 to 16.020 16.07 Shaft O.D. (mm) 15.966 to 15.984 15.94 Clearance (mm) 0.016 to 0.54...

  • Page 122: Timing Gear Backlash

    3 ENGINE 3 ENGINE 3.5.9 Timing gear backlash Inspection item Standard Limit Crank gear, cam gear, idle gear, fuel injection pump gear, 0.07 to 0.15 0.17 PTO gear (mm) 3.5.10 Cylinder block Inspection item Standard Limit Cylinder I.D. (mm) 88.000 to 88.030 88.200 Circularity (mm) Cylinder bore...

  • Page 123: Piston Rings

    3 ENGINE 3 ENGINE 3.5.14 Piston rings Inspection item Standard Limit Ring groove width 2.060 to 2.075 2.170 Ring width 1.970 to 1.990 1.950 Top ring (mm) Clearance 0.070 to 0.105 0.200 End gap 0.200 to 0.400 0.490 Ring groove width 2.025 to 2.040 2.140 Ring width...

  • Page 124: Lubricating Oil Pump (Trochoid Pump)

    3 ENGINE 3 ENGINE 3.5.17 Lubricating oil pump (trochoid pump) Outer rotor outside clearance Standard Limit 0.12 to 0.21 0.30 Outer rotor side clearance Standard Limit 0.02 to 0.07 0.12 Inner rotor-to-gear boss clearance Standard Inspection item Standard Limit dimension Gear box 53.05 to 53.15 Inside clearance of...

  • Page 125: Tightening Torque Tables

    3 ENGINE 3 ENGINE 3.5.18 Tightening torque tables Main bolts and nuts Tightening Application of Thread size x pitch Bolt/nut torque lubricating oil Remarks (mm) N•m (kgf•m ) (to threads/seat) 85.3 to 91.1 ― Cylinder head bolt M10× 1.25 (8.7 to 9.3) 44.1 to 49.0 Connecting rod bolt M9×...

  • Page 126: Clutch

    4 CLUTCH 4 CLUTCH CLUTCH EF494T TM 06/2011 edition...

  • Page 127: Structure And Functions

    4 CLUTCH 4 CLUTCH STRUCTURE AND FUNCTIONS 4.1.1 Outline Diaphragm type dry single plate clutch is adopted. It has a simple structure, and a pressure works on the circumference of it uniformly. It also features light release load (pedal depressing force), and reduction in decrease of spring pressure regardless of wear of the clutch fading.

  • Page 128: Disassembly And Assembly

    4 CLUTCH 4 CLUTCH DISASSEMBLY AND ASSEMBLY 4.2.1 Disassembly As for disassembly of the clutch housing, refer to 2.5. Remove the nine M8x16 bolts (A). Remove the pressure plate (B) together with the clutch disc (C) from section D using a flathead screwdriver.
  • Page 129 4 CLUTCH 4 CLUTCH  Pressure plate  Clutch disk IMPORTANT Pay attention to the direction of the clutch disc. Pressure plate side Flywheel side Inspecting the clutch disc  Measure the wear on the clutch face (measure the depth of the rivet). If there is 0.5 mm or less of clutch face remaining, replace the clutch disc.
  • Page 130 4 CLUTCH 4 CLUTCH EF494T TM 06/2011 edition...

  • Page 131: Assembly

    4 CLUTCH 4 CLUTCH IMPORTANT If the release bearing (A) has backlash or does not rotate smoothly, replace the release bearing. (A) Release bearing (B) Bearing sleeve Release spring 4.2.2 Assembly Match the clutch disc and pressure plate to the flywheel of the engine with the clutch guide tool.
  • Page 132 4 CLUTCH 4 CLUTCH IMPORTANT  Clean each part off oil, dirt.  Pay attention to the direction of the clutch disc. See 2.1 (3).  When reassembling, apply heat-resistant grease to the inside (A) of the clutch disc splines. Note: If the tool is not available, make a jig.

  • Page 133: Tranmission

    5 TRANSMISSION 5 TRANSMISSION TRANMISSION EF494T TM 06/2011 edition...

  • Page 134: Power Transmitting Diagram

    5 TRANSMISSION 5 TRANSMISSION POWER TRANSMITTING DIAGRAM Engine model: 4TNV88, HP: 49, RPM: 2,800 EF494T TM 06/2011 edition...
  • Page 135 5 TRANSMISSION 5 TRANSMISSION 13.6-26 GEAR Km/h Mile/h 1.63 1.01 2.26 1.41 3.30 2.05 4.00 2.49 5.57 3.46 8.14 5.06 14.18 8.81 19.72 12.25 28.80 17.90 1.68 1.04 2.33 1.45 3.41 2.12 4.13 2.57 5.74 3.57 8.39 5.21 14.62 9.09 20.33 12.64 29.70...

  • Page 136: Transmission System Cross-Section

    5 TRANSMISSION 5 TRANSMISSION TRANSMISSION SYSTEM CROSS-SECTION EF494T TM 06/2011 edition...
  • Page 137 5 TRANSMISSION 5 TRANSMISSION (A) Main shifting lever (C) Range-shifting lever (E) Front drive lever (B) Reverser lever (D) PTO lever EF494T TM 06/2011 edition...

  • Page 138: Transmission System

    5 TRANSMISSION 5 TRANSMISSION TRANSMISSION SYSTEM 5.3.1 Main shift module The main shift module is a constant-mesh type transmission. Operating the main shift lever activates the shifter (A) (B) so that they engage gears 53R, 49L and 41R. Gears 53R, 49L and 41R are always engaged with gears 21L/27R/33L on the main shaft (C).

  • Page 139: Reverse Shift Module

    5 TRANSMISSION 5 TRANSMISSION 5.3.2 Reverse shift module The reverse shift module is a constant-mesh type transmission. Operating the reverser shift lever activates the shifter (A) so that it engages gears 44R and 48L. Gear 48L is always engaged with the connecting shaft (B). The rotation of the driven shaft (C) is transferred to the reduction gear (D) by way of the connecting shaft (B) to provide forward force.

  • Page 140: Range Shift Module

    5 TRANSMISSION 5 TRANSMISSION 5.3.3 Range shift module The range shift module is a constant-mesh type transmission. Operating the range shift lever activates the shifter (A) (B) so that they engage gears 21L, 45L and 53. These gears are always engaged with the reduction gear (C) and the range shift shaft (D).

  • Page 141: Pto Shift Module

    5 TRANSMISSION 5 TRANSMISSION 5.3.5 PTO shift module The PTO shift module is a constant-mesh type transmission. Operating the PTO shift lever activates the shifter (A) so that it engages gears 51R and 74T. They are always engaged with gears 14L and 15L on the PTO pinion shaft (B).

  • Page 142: Transmission (Clutch Housing Case Side)

    5 TRANSMISSION 5 TRANSMISSION TRANSMISSION (CLUTCH HOUSING CASE SIDE) Each gear in the main shift module (A) and reverse module (B) is contained in the front of the transmission. Left side of the reverser section (A) Reverser shift fork (B) Reverser gear (C) Reverse gear Rear of the reverser section (D) Engine to PTO...

  • Page 143: Disassembly

    5 TRANSMISSION 5 TRANSMISSION 5.4.1 Disassembly Disassembly of components Perform the steps described in 2.6.2 “Separating the clutch housing and transmission”. Remove the M10x55 bolts (A), the M10x85 bolt (B), and the M10x150 bolt (C). IMPORTANT Pay attention so that the idle gear shaft (E) fits securely into the keeper plate (D) when reassembling these parts.
  • Page 144 5 TRANSMISSION 5 TRANSMISSION (1) Driven shaft (12) Driven gear 48L (23) Steel ball 5/16 (2) Center plate (13) Connecting shaft (24) Flat head pin 4x35 (3) Needle bearing (14) Bearing retainer (25) Spring (4) Snap ring 35H (15) Thrust washer 17x32 (26) Reverser shift arm (5) Drive gear 44 (16) Needle 202615...
  • Page 145 5 TRANSMISSION 5 TRANSMISSION Remove the mounting bolts in order to remove the main shift lever mounting section (A), located under the steering wheel, and the reverser lever mounting section (B). Remove bolts (A) and (B) on the lower part of the steering wheel and the five M8x25 bolts that secure the change lever retainer.
  • Page 146 5 TRANSMISSION 5 TRANSMISSION Remove the change lever retainer (C). (G) Main shift arm IMPORTANT Pay attention so that the main shift arm (G) fits into the main shift shifter (H) when reassembling them. EF494T TM 06/2011 edition...
  • Page 147 5 TRANSMISSION 5 TRANSMISSION Remove the center plate section (B) from section (A) using a wrench, and take it out. CAUTION Be careful because the center plate section (B) is heavy and it will be slippery because it is covered in oil.

  • Page 148: Main Shift Section

    5 TRANSMISSION 5 TRANSMISSION 5.4.2 Main shift section (A) Reverser section (D) Clutch (F) Drive shaft (H) Shifters (B) Main shift section (E) Main shift (G) Center plate (I) Shift forks (C) Main shaft The main shift detent (A) is located on the reverser side of the center plate.

  • Page 149: Transmission (Transmission Housing Case Side)

    5 TRANSMISSION 5 TRANSMISSION TRANSMISSION (TRANSMISSION HOUSING CASE SIDE) You will find the range shift, PTO, and rear axle gears in the section located on the back of the transmission. The hydraulic cylinder case is in the upper part, inside the transmission.
  • Page 150 5 TRANSMISSION 5 TRANSMISSION Center plate side 1. PTO shaft 4. Reverser shift arm 7. Front wheel drive shift arm 2. Reduction shaft 5. Range shift arm 8. Front wheel drive shifter 3. Counter shaft Hard Lock nut 6. Range shift shaft 9.

  • Page 151: Disassembly

    5 TRANSMISSION 5 TRANSMISSION 5.5.1 Disassembly Remove the hydraulic cylinder case. See “2.6.1”. Wheel Separate the transmission and clutch housing. Remove the retainer plate and pull the front shift arm outward about 5mm. (A) Retainer plate (B) Keep the spring pin as it is. (C) Front shift arm (D) Shift block IMPORTANT...
  • Page 152 5 TRANSMISSION 5 TRANSMISSION Remove the Hard Lock nut (B), and take out the inside gear. (B) Hard lock nut (C) Bearing retainer (D) Counter shaft (E) Reduction shaft IMPORTANT The Hard Lock nut is a special type of double nut. Both nuts must be tightened to the specified torque.
  • Page 153 5 TRANSMISSION 5 TRANSMISSION Remove the reduction shaft (E). Remove the nut (A), and pull out the shift arm holder (B) about 5 mm. Remove the bolt (C), and take out the ball (D) in the detent. Remove the spring pins (F), and remove the fork shaft (E) and the shift forks (G).
  • Page 154 5 TRANSMISSION 5 TRANSMISSION Remove the four M8x25 bolts that secure the bearing retainer (C) on the counter shaft (D). Note: The bearing retainer can only be mounted in the position shown in the photo. Remove the bearing retainer (A) using a coupler.
  • Page 155 5 TRANSMISSION 5 TRANSMISSION (11) Remove the spring pins (C) and (D), and remove the fork (A) and the differential lock shaft (B). (A) Fork (B) Differential lock shaft EF494T TM 06/2011 edition...

  • Page 156: Pto Module

    5 TRANSMISSION 5 TRANSMISSION 5.5.2 PTO module To remove the PTO module, see “2.6.4”. Note: When the hydraulic cylinder case is removed, the PTO module can be seen, as shown in the photo on the right. EF494T TM 06/2011 edition...
  • Page 157 5 TRANSMISSION 5 TRANSMISSION To remove the PTO module, see “2.6.4”. (A) Shift arm (B) Change arm position (C) Oil level check port (D) PTO shaft (E) Shifter (F) PTO shift Note: When the PTO lever is in the neutral position, the change arm (G) pushes on the neutral switch (H).

  • Page 158: Rear Axle And Brake

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE REAR AXLE AND BRAKE EF494T TM 06/2011 edition...

  • Page 159: Structure And Functions

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE STRUCTURE AND FUNCTIONS 6.1.1 Structure drawing The rear axle is designed to effectively convey the transmission output to the rear wheels. It consists of a differential gear and final reduction gears (planetary gears). EF494T TM 06/2011 edition...

  • Page 160: Differential System

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE 6.1.2 Differential system The differential gear provides the left and right wheels with different revolutions to permit a smooth turning or cornering. Depending on the traveling conditions, if one of wheels slips resulting in a difficulty of travel, the differential gear could be locked.

  • Page 161: Final Drive System

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE 6.1.3 Final drive system The final drive is a ring gears type planetary system. This provides high torque load capabilities and proper reduction ratio. (A) Planetary carrier (B) Ring gear (C) Planetary gear (D) Final drive pinion shaft (E) Rear axle shaft...

  • Page 162: Brake

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE 6.1.4 Brake The brake is a wet type disk system. When This compresses the disks between the friction brake pedal is depressed, the brake rod plates and stops rotation of the shaft. pulls brake lever to rotate cam lever that The parking brake is of the pedal lock system rotates actuator.
  • Page 163 6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE <Actuator, exploded view> IMPORTANT When disassembling the actuator, lay out the steel plates (l) and the friction plate (E) in the order and position they were in when removed. When reassembling them, do not change the position of any of the plates (front, back, left, and right) or the order in which they are reassembled.

  • Page 164: Disassembly And Assembly

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE DISASSEMBLY AND ASSEMBLY 6.2.1 Differential system Remove the hydraulic cylinder case. Remove the left rear axle housing assembly. 4: Nut M10 x 2 pieces 9: Bolt M12 x 40 x 8 pieces 10: Bolt M12 x 50 x 2 pieces Note: Refer to “2.6.3 Rear axle”...

  • Page 165: Rear Axle Oil Seal

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE Remove the friction plate of the brake system, and remove the differential carrier. Notes to assemble:  Shims are required to adjust a backlash. Be sure to install.  When the ring gear has been disassembled, apply the screw lock glue to bolts and tighten them with a torque of 450-600 kgf-cm for M10 (fine thread) size.

  • Page 166: Planetary Gears And Axle Shaft

    6 REAR AXLE AND BRAKE 6 REAR AXLE AND BRAKE 6.2.3 Planetary gears and axle shaft Remove the rear axle housing. Remove bolt (A) below to remove the planetary gears (B). Assembling Bolt (fine thread) (A) 12 x 30: 8 pieces. 800-1000 kgf-cm Bolt (C) M10x55 700-890 kgf-cm (A) Shaft end bolt...

  • Page 167: Front Axle

    7 FRONT AXLE 7 FRONT AXLE FRONT AXLE EF494T TM 06/2011 edition...

  • Page 168: Structure And Functions

    7 FRONT AXLE 7 FRONT AXLE STRUCTURE AND FUNCTIONS Four-wheel drive front axle has a wheel speed proportional to the rear axle. The drive power is conveyed from the drive pinion of the rear axle assembly (counter shaft) to the drive gear and drive shaft, then to the front axle through the propeller shaft.

  • Page 169: Cross-Section View

    7 FRONT AXLE 7 FRONT AXLE CROSS-SECTION VIEW EF494T TM 06/2011 edition...

  • Page 170: Front Wheel Alignment

    7 FRONT AXLE 7 FRONT AXLE FRONT WHEEL ALIGNMENT The tractor front wheels have a certain angle in This is called "front wheel alignment" and the lateral and back-and-forth direction for easy includes the following 4 factors: steering performance; reliability, safety, stability and linearity of motion;...

  • Page 171: Disassembling The Front Bearing Case

    7 FRONT AXLE 7 FRONT AXLE DISASSEMBLING THE FRONT BEARING CASE Remove the front wheels. Drain the front axle oil. Remove the nine M8 bolts. Put a bolt into the 3 places marked with an asterisk. Tighten the bolts evenly to remove the bearing case (A).

  • Page 172: Disassembling And Assembling The Front Differential Section

    7 FRONT AXLE 7 FRONT AXLE DISASSEMBLING AND REASSEMBLING THE FRONT DIFFERENTIAL SECTION 7.6.1 Disassembly Drain the front axle oil. Remove the propeller shaft. See “2.5.1”. Remove the left front wheel. Remove the tie rod (A). Put a rope around the front gear case and prepare to lift the front gear case with a crane.
  • Page 173 7 FRONT AXLE 7 FRONT AXLE Remove the pinion and the bearing as an assembly. Note: There are some ring gear adjustment shims (A). IMPORTANT Apply screw lock to the six M10x70 bolts (C) shown in the drawing on the right. (A) Ring gear CMP (B) Differential gear (C) M10x70 bolt...

  • Page 174: Assembly

    7 FRONT AXLE 7 FRONT AXLE 7.6.2 Assembly IMPORTANT When assembling the drive pinion (A), perform a preload adjustment of the tapered roller bearings (B) using the following method. (C) Seal collar (D) Bearing retainer Set the drive pinion (A), tapered roller bearings (B), O-ring, and oil seal into the bearing retainer (D).
  • Page 175 7 FRONT AXLE 7 FRONT AXLE Set up a spring balance as shown in the drawing on the right. Measure the torque created when the drive pinion starts rotating. Tighten the seal collar little by little until the torque reaches the specified level of 0.032 to 0.160 kgf-m.

  • Page 176: Power Steering

    8 POWER STEERING 8 POWER STEERING POWER STEERING EF494T TM 06/2011 edition...

  • Page 177: Structure And Functions

    8 POWER STEERING 8 POWER STEERING STRUCTURE AND FUNCTIONS 8.1.1 Structure drawing (A) Power steering cylinder (B) Power steering valve (C) Hydraulic pump EF494T TM 06/2011 edition...

  • Page 178: Hydraulic Circuit

    8 POWER STEERING 8 POWER STEERING 8.1.2 Hydraulic circuit (A) Power steering cylinder (a) Power steering relief valve: (B) Power steering valve Pressure 12.2～12.9 MPa (125-132 kgf/cm (C) To transmission Remarks The power steering system is fully hydraulic. The cylinder is a double rod type featuring excellent stability while moving.

  • Page 179: Power Steering Valve Functions

    8 POWER STEERING 8 POWER STEERING 8.1.3 Power steering valve functions * When in neutral The oil from the hydraulic pump flows into the power steering valve. However, since the control spool is in "neutral," the oil will return to the tank. * During rotation The oil from the hydraulic pump flows into the power steering valve.

  • Page 180: Hydraulic Pump

    8 POWER STEERING 8 POWER STEERING 8.1.4 Hydraulic pump Parts name Gasket (HO-P) Nut (Supack 8) Hydraulic pump CMP (7C) Ring Housing CMP Pin 11x 7 Cover CMP Snap ring (Hole 32) Oil seal TC153207 Bolt M8 x 35 Bolt M8 x 80 Stud bolt (A) Front H.
  • Page 181 8 POWER STEERING 8 POWER STEERING 8.1.5 Power steering Q’ty Parts name Castle nut Cylinder assy. Dust cover Ring Rod assy. Cylinder tube Cap assy. Packing 22 Packing 34 Scraper seal Cylinder cap Bush Adapter 1/4 Packing Bearing Piston Ring 40x3.2 Snap ring 36S O-ring 1B P- 18.0...

  • Page 182: Power Steering Valve

    8 POWER STEERING 8 POWER STEERING POWER STEERING VALVE 8.2.1 Removing power steering valve assembly Remove the covers around the dashboard and take out the accelerator lever assembly (A). (A) Accelerator lever assembly (B) Instrument support Loosen or remove pipe clamp bolts (21, 22, 23).

  • Page 183: Power Steering Relief Pressure

    8 POWER STEERING 8 POWER STEERING 8.2.2 Power steering relief pressure NOTE: A reduced relief pressure in the power steering system can cause the steering to seem heavy. HOW TO MEASURE THE RELIEF PRESSURE: Remove the right hose from the power steering cylinder.

  • Page 184: Disassembly

    8 POWER STEERING 8 POWER STEERING 8.2.3 Disassembly When the oil leak occurs, o-ring, packing, bush, and the oil seal are replaced referring to this item. Parts name Q’ty Plate, Spacer Ring Bush Screw Screw Bearing comp., Needle Bearing Thrush needle Kit, Seal O-ring O-ring...
  • Page 185 8 POWER STEERING 8 POWER STEERING <DISASSEMBLE AND INSPECT THE POWER STEERING VALVE> Take off the cap screw (C). Turn the valve upside down to remove ball (B). Put the valve in a vise with padded jaws and take off the 6 screws from cap (A). IMPORTANT The steel ball is only in 1 place.
  • Page 186 8 POWER STEERING 8 POWER STEERING Take off the valve from the padded-jaw vise. Use a screwdriver to pry ring (H) out of the valve housing. Rotate spool and sleeve (D), while pushing the assembly toward the top of the housing just far enough to unseat bushing (F).

  • Page 187: Hydraulic Lift Unit

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT HYDRAULIC LIFT UNIT EF494T TM 06/2011 edition...

  • Page 188: Structure And Functions

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT STRUCTURE AND FUNCTIONS 9.1.1 Hydraulic line (A) Hydraulic pump (B) Filter (C) Hydraulic cylinder case EF494T TM 06/2011 edition...

  • Page 189: Hydraulic Cylinder Case

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.2 Hydraulic cylinder case Parts Piston Sleeve Packing Piston rod Lift crank Lifting shaft Sleeve (Lifting shaft) Washer 65x82x2 Lift arm O-ring 1A G 65.0 Spline shaft seal Seal plate Packing Plug 3/4-16UNF Plug NPTF 1/4 Packing 19 Filter adapter...
  • Page 190 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.3 Control valve Operate the spool according to the control lever position to allow the lift arm to be put in the "neutral," "up" or "down" position. Unload valve Prevents the oil temperature from rising excessively.

  • Page 191: Stop Valve

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.5 Safety valve If an external impact force is applied to the implement, this valve will open to protect the hydraulic system and cause oil in the cylinder to escape to the tank. The pressure setting can be adjusted by increasing or decreasing the size of shims.

  • Page 192: Hydraulic Pump, Exploded View

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.7 Hydraulic pump, exploded view Parts name Gasket (HO-P) Nut (Supack 8) Hydraulic pump CMP (13A) Flange Bolt 8 x 83.5 Oil sea] End plate Seal kit Pin 6x 12 Snap ring (30 dia.) Bolt 8 x 120 Stud bolt 8 x 40 (A) Rear H.

  • Page 193: Position Feedback Link

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.8 Position feedback link When the control lever is set to the "up" position, it will push the spool of the control valve, located at the rear of the hydraulic cylinder case, through the link. The oil will flow into the cylinder to push up the piston, causing the lift arm to rise.
  • Page 194 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT When the control lever is set to the "down" position When the control lever is set to the "down" position, the force applied by the spool will be released, and the spool will return to its original position by the action of the spring, and the oil in the cylinder will return to the tank.

  • Page 195: Oil Flow At Neutral

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.9 Oil flow Oil flow at Neutral (1) Tank (3) Filter (5) Intake block (7) Control valve (2) Strainer (4) Hydraulic pump (6) Relief valve (8) Tank Circuit in the control valve Back pressure (b) of the unload valve spring chamber disappears and the oil pressure (a) from the pump pushes up the unload valve.
  • Page 196 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Oil flow in lift operation (1) Tank (4) Hydraulic pump (7) Control valve (9) Cylinder head (Check valve) (2) Strainer (5) Intake block (8) Load check valve (10) Hydraulic cylinder (3) Filter (6) Relief valve Circuit in the control valve The unload valve is applied with the pilot pressure (a) and (b) at...
  • Page 197 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Oil flow in lowering operation Oil in hydraulic pump (1) Tank (3) Filter (5) Intake block (7) Control valve (2) Strainer (4) Hydraulic pump (6) Relief valve (8) Tank Oil in hydraulic cylinder (1) Cylinder (2) Slow return valve (3) Mechanical check valve...
  • Page 198 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.1.10 Oil flow at Neutral (1) Safety Valve (5) Unload Valve Hydraulic power port (2) Relief Valve (6) Stop Valve Single action (3) Flow Control Valve (7) Check Valve (10) Out/IN (to/from actuator) (4) Valve Spool (8) Mechanical Check Valve Double action...
  • Page 199 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT When operating the relief valve For details about the valve operating principle, see “9.1.4”. When operating the safety valve For details about the valve operating principle, see “9.1.5”. EF494T TM 06/2011 edition...

  • Page 200: Assembly And Check

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT ASSEMBLY AND CHECK 9.2.1 Assembling/disassembling the control valve The control valve is located in the back of the hydraulic cylinder case. First remove the hydraulic cylinder case assembly. NOTE: Never fail to adjust the feedback link after the control valve assembly is adjusted and installed.

  • Page 201: Control Valve, Exploded View

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.2.2 Control valve, exploded view Parts name Valve body CMP 0-ring 113 P 14.0 0-ring IB P 7.0 Unload SP Plug (unload) Spool (flow control) Flow control SP Plug (flow control) Load check SP Spring (Spool) Spring seat Shim (0.2)

  • Page 202: Main Relief Pressure

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Caution when assembling Lift arm and lift shaft The lift arm, lift crank and lift shaft on the hydraulic cylinder casing have alignment marks. The photos show white paint on the mark, for reference.

  • Page 203: Adjusting The Position Feedback Rod

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.2.4 Adjusting the position feedback rod <Adjustment> Position control feedback Turn hydraulic stop valve to open fully. Start engine. Put the position control lever in “Lowest” position and put lift arm (A) in lowest position.

  • Page 204: Hydraulic Power Take Off

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT HYDRAULIC POWER TAKE OFF The hydraulic pressure for single and double action devices can be taken from the hydraulic cylinder case. The hydraulic pressure capacity is as follows: Oil flow: 32.2 lit./min/2700 rpm (engine) Pressure: 170-178 kg/sq.cm 9.3.1 For single action;...

  • Page 205: For Double Action, Front Blade Etc

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.3.2 For double action; front blade etc. <Operation> (1) Remove the plug (A). Insert and tighten the screw plug (B) to switch inner hydraulic oil flow. (2) Remove plugs (D) on the right side of hydraulic housing.

  • Page 206: Hydraulic Pressure Flow

    9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT 9.3.3 Hydraulic pressure flow Hydraulic circuit, 3-P, Neutral New hydraulic lift units are set up to use a 3-point hitch. ① The hydraulic oil that is highly pressurized by the gear pump is fed to the hydraulic cylinder case.
  • Page 207 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Hydraulic take off, double action, neutral If a 1/4-18 PTF screw plug is mounted on the hydraulic cylinder case in order to create a take off for the double-action hydraulic pressure: ① Since high-pressure hydraulic oil fed into the hydraulic cylinder case can not escape through the hole closed by the screw plug, it will be fed to the implement’s valve through the external takeoff port.
  • Page 208 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Hydraulic take off, double action, move L & R The implement’s cylinder moves in the direction controlled by the implement’s valve, and the returning hydraulic oil is sent to the transmission through the control valve. ①...
  • Page 209 9 HYDRAULIC LIFT UNIT 9 HYDRAULIC LIFT UNIT Hydraulic take off, wrong connection If the lines between the gear pump and the hydraulic cylinder case are modified and a connection is made that goes directly to the implement’s valve. When the implement’s cylinder stops moving, due to an obstacle, and since there is no relief valve in the hydraulic circuit, there is no place where the high-pressure hydraulic oil can escape.

  • Page 210: Electric Equipment

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT ELECTRIC EQUIPMENT EF494T TM 06/2011 edition...

  • Page 211: Engine Start Circuit

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.1 ENGINE START CIRCUIT 10.1.1 Location and operation of components (1) Battery (2) Slow blow fuse (4) Fuel shut off solenoid (3) Starter motor (5) Diode (6) Fuel feed pump (7) Body earth (8) Fuse box (9) Starter relay (10) Solenoid relay (11) Timer...
  • Page 212 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT (9) (10) (11) (12) (13) Main shift (N) switch Key switch Start relay Solenoid relay Timer (Either of these) (14) PTO (N) switch EF494T TM 06/2011 edition...
  • Page 213 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT Name and number of Location Parts name Operation and remarks Parts catalogue Battery 75D26R Battery Supplies power to the circuits. 1A7781-51500 Engine front Fuse 60A slow blow Protects wiring & electric equipment Slow blow fuse (main) 1A6380-52700 related to engine start.

  • Page 214: Circuit Diagram

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.1.2 Circuit diagram (Engine start) EF494T TM 06/2011 edition...

  • Page 215: Checkpoints Of Electrical Equipment

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.1.3 Checkpoints of electrical equipment 3. Starter motor Starter (129407-77010) Terminal B Continuity test of single item Measuring point Range Status Result Tester probe Tester probe  Starter body Terminal S Continuity Terminal M Terminal S Continuity Continuity...
  • Page 216 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 4. Fuel shut off solenoid Stop solenoid (119653-77950) Measurements on an individual component basis (A-end coupler) (1) 3B (3) 3W (2) 3R Measuring point Range Status Result Tester probe Tester probe  Approx.12.4 Ω Ω...
  • Page 217 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT The hold coil The hold coil is holds the magnetized plunger. The return The pull coil is spring urges magnetized and the plunger to the plunger is move back. pulled. (1) White (hold coil) (2) Red (pull coil) (3) Black (ground) (4) Hold coil...
  • Page 218 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 6. Fuel feed pump Fuel feed pump : 1A7781-52100 Individual component check (A-end) Measuring point Range Status Result Tester probe Tester probe  A-end coupler Approx. Resistance 11 M Ω (1) 0.5R Continuity None (2) 0.5B A digital tester is used.
  • Page 219 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 12. Key switch Starter switch CMP: 198162-52110 Switch terminal connection table Single item check Measuring point Key switch Tester Range Result Tester probe status probe Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity 13. Transfer (N) switch 14.

  • Page 220: Charging Circuit

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.2 CHARGING CIRCUIT 10.2.1 Location and operation of components (1) Battery (3) Alternator (2) Slow blow fuse (4) Fuse box (5) Instrument Panel (6) Key switch Battery Starting motor Slow blow fuse Key switch Instrument Panel Fuse box EF494T TM 06/2011 edition...

  • Page 221: Circuit Diagram

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT Name and number of Location Parts name Operation and remarks Parts catalogue Battery: 75D26R Battery It supplies power to the circuits. 1A7781-51500 Engine front Slow blow fuse Fuse 60A slow blow It protects wiring & electric equipment (Main) (Alternator) 1A6380-52700 related to battery charge.

  • Page 222: Checkpoints Of Electrical Equipment

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.2.3 Checkpoints of electrical equipment Alternator B terminal Generator 40A: 119620-77201 The alternator has a built-in IC regulator. The alternating current produced by the alternator is rectified into direct IG and L current. terminal 1.

  • Page 223: Alarm Circuit

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.3 ALARM CIRCUIT 10.3.1 Location and operation of components (1) Battery (3) Water temperature sensor (9) Alternator 40 A (2) Slow blow fuse (4) Oil pressure switch (5) Body earth (6) Fuse box (7) Instrument panel (8) Key switch (10) Fuel gauge sensor Battery...
  • Page 224 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT Alternator Key switch (10) Fuel gauge sensor Name and number of Location Parts name Operation and remarks Parts catalogue Battery 75D26R Battery Supplies power to the circuits. 1A7781-51500 Engine front Slow blow fuse Fuse 60A slow blow Protects wiring &...
  • Page 225 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.3.2 Circuit diagram (Alarm) EF494T TM 06/2011 edition...

  • Page 226: Checkpoints Of Electrical Equipment

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.3.3 Checkpoints of electrical equipment Water temperature sensor Coolant temperature: 124250-49351 Measuring point Range Result Tester probe Tester probe  Resistance alters Chassis Ω depending on the coolant grounding temperature. Approx. 5.0 V DC when Chassis the key switch is turned grounding...
  • Page 227 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 7. Instrument panel Panel assy. Inst.: 1A7780-56502 (1) Fuel gage (2) Oil pressure lamp (3) Water temperature gage 8. Key switch See. ■ Electric equipment 10.1.1 “12. Key switch”. 9. Alternator 40 A See. ■ Electric equipment, 10.2.3. “2. Alternator”. 10.

  • Page 228: Safety Circuit

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.4 SAFETY CIRCUIT 10.4.1 Location and operation of components (1) Head lamp (3) Battery (2) Horn (5) Body earth (6) Fuse box (4) Slow blow fuse (7) Head lamp relay (8) Flasher relay (10) Combination switch (9) Key switch (11) Turn signal lamp (13) Working lamp...
  • Page 229 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT (7) (8) Head lamp relay, 2pcs. Flasher relay For High & Low beams Fuse box (10) (11) (12) Turn signal Key switch lamp Tail lamp (A): Combination switch EF494T TM 06/2011 edition...
  • Page 230 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT Name and number of Location Parts name Operation and remarks Parts catalogue Head lamp ASSY Head lamp 1A7780-53200 (L) Bulb: 198448-53320 (12V/45W) 1A7780-53300 (R) Horn Horn Alarm horn 1A8115-57150 Front of hood Battery 75D26R Battery (80R26R) Supplies power to the circuits.

  • Page 231: Circuit Diagram

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.4.2 Circuit diagram (Safety) EF494T TM 06/2011 edition...

  • Page 232: Checkpoints Of Electrical Equipment

    10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT 10.4.3 Checkpoints of electrical equipment 1. Head lamp (12V45W/45W) Head lamp CMP: 1A7780-53200(L) Bulb (12V45W): 198448-53320 Single item check Range Measuring point Result Remarks Low beam Approx. 0.3 Ω [1] - [2] side Resistance High beam Approx.
  • Page 233 10 ELECTRIC EQUIPMENT 10 ELECTRIC EQUIPMENT Key switch Starter switch CMP: 198162-52110 Switch terminal connection table Single item check Measuring point switch Range Result Tester probe Tester probe status Continuity Continuity Continuity Continuity Continuity Continuity Continuity Continuity 11. Combination switch Combination switch : 198200-52140 Single item check Measuring point...
  • Page 234 11 APPENDIXES 11 APPENDIXES APPENDIXES EF494T TM 06/2011 edition...

  • Page 235: Hydraulic Circuit Diagram

    11 APPENDIXES 11 APPENDIXES 11.1 HYDRAULIC CIRCUIT DIAGRAM EF494T TM 06/2011 edition...
  • Page 236 11.2 ELECTRICAL CIRCUIT DIAGRAM 11.2.1 WIRING HARNESS...
  • Page 237 11.2.2 LOCATION OF ELECTRICAL PARTS (1) Slow blow fuse 60A (2) Horn (3) Battery earth cable (4) Generator (5) Thermometer Start relay Solenoid relay (7) FO pump (8) Oil pressure switch (9) Timer, 1 sec (10) Battery (11) Battery cable (+) (12) Harness (Head lamp) (13) Harness A (14) Meter cable...
  • Page 238 11.2.3 ELECTRICAL WIRING DIAGRAM...

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