Yanmar EF-494T EXCAVATOR DIESEL TRACTOR TECHNICAL MANUAL – PDF DOWNLOAD

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Yanmar EF-494T EXCAVATOR DIESEL TRACTOR TECHNICAL MANUAL – PDF DOWNLOAD

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Yanmar EF-494T EXCAVATOR DIESEL TRACTOR TECHNICAL MANUAL – PDF DOWNLOAD

INTRODUCTION:
To the owner of this manual
 This machine is carefully designed and manufactured to give years of dependable service. To do
the better and safer job, read the instructions in this manual. Failure to do so could result in
personal injury or machine damage.
 The parts used in this machine are subject to change to improve the quality and capacity of the
machine, and for safety.
 Therefore, please understand that the contents, photos and illustrations in the manual may differ
from your machine.

TABLE OF CONTENTS:

Yanmar EF-494T EXCAVATOR DIESEL TRACTOR TECHNICAL MANUAL – PDF DOWNLOAD

0 INTRODUCTION
To The Owner
MAINTENANCE
SUPPLY PERIOD FOR MAINTENANCE PARTS
IMPROVEMENTS
SYMBOL INDICATION
0.1 PRECAUTIONS FOR THE SAFE SERVICES
0.2 AFTER SALES SERVICE
0.3 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 FUSE BOX
0.3.5 PART NAMES
0.3.6 SAFETY LABEL LOCATION
0.3.7 SPECIFICATIONS
0.3.8 TRACTOR MASS AND TIRE SPECIFICATION
1 PERIODICAL INSPECTION 22
1.1 CHECK INTERVALS
1.2 OIL AND GREASE
1.3 OIL AND WATER VOLUME
1.4 EQUIVALENT TO TF-500
1.5 REPLACING OIL
1.6 REPLACING FILTER ELEMENTS
1.7 REPLACING COOLING WATER
1.8 REMOVING WATER FROM WATER SEPARATOR
1.9 CLEANING AND REPLACING AIR CLEANER
ELEMENT, CLEANING RADIATOR SCREEN
1.10 CHECKING BATTERY
1.11 CHECKING HOSE AND PIPE
1.12 CHECKING ELECTRICAL WIRING
1.13 GREASING
1.14 ADJUSTING BRAKE
1.15 ADJUSTING CLUTCH
1.16 ADJUSTING STEERING WHEEL
1.17 ADJUSTING FAN BELT
1.18 ADJUSTING TOW-IN
1.19 REPLACING FUSE
1.20 CHECKING TIRES
1.21 COLOR OF EXHAUST GAS
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TABLE OF CONTENTS TABLE OF CONTENTS
EF494T ii TM 06/2011 edition
2 DISASSEMBLY OF COMPONENTS 41
2.1 REMOVING THE ENGINE BONNET COVER
2.1.1 Removing/mounting the side covers
2.1.2 Removing the engine bonnet cover
2.2 REMOVING THE FENDER
2.2.1 Removing the fuel tank cover
2.2.2 Removing the nuts and bolts that fixing the fender
2.3 REMOVING THE STEP
2.4 REMOVING THE SEAT STAY
2.5 CLUTCH HOUSING
2.5.1 Separation
2.5.2 Docking
2.6 TRANSMISSION
2.6.1 Separating the hydraulic cylinder case
2.6.2 Separating the clutch housing and transmission
2.6.3 Rear axle
2.6.4 PTO module
2.7 FRONT AXLE UNIT
3 ENGINE 64
3.1 FUEL SYSTEM
3.1.1 Flow of fuel and layout of components
3.1.2 Water separator
3.1.3 Fuel feed pump
3.1.4 Fuel filter
3.1.5 Fuel injection pump (Type MP4 direct-injection
pump)
3.1.6 Fuel injection nozzles
3.2 COMBUSTION SYSTEM
3.2.1 Low emission technology applied to TNV engine
3.2.2 Cold starter
3.2.3 Revolution timer
3.2.4 Load timer
3.3 LUBRICATING OIL SYSTEM
3.3.1 Flow of lubricating oil
3.3.2 Lubrication oil pump (LO pump)
3.3.3 Lubricating oil filter (LO filter)
3.3.4 Oil pressure switch
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TABLE OF CONTENTS TABLE OF CONTENTS
EF494T iii TM 06/2011 edition
3.4 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
3.5 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 Locker arm and shaft
3.5.6 Push rod
3.5.7 Camshaft
3.5.8 Idle gear shaft and bushing
3.5.9 Timing gear backlash
3.5.10 Cylinder block
3.5.11 Crankshaft
3.5.12 Thrust bearing
3.5.13 Piston
3.5.14 Piston rings
3.5.15 Connecting rod
3.5.16 Tappet
3.5.17 Lubricating oil pump (Trochoid pump)
3.5.18 Tightening torque tables
4 CLUTCH 100
4.1 STRUCTURE AND FUNCTIONS
4.1.1 Outline
4.2 DISASSEMBLY AND ASSEMBLY
4.2.1 Disassembly
4.2.2 Assembly
5 TRANMISSION 105
5.1 POWER TRANSMITTING DIAGRAM
5.2 TRANSMISSION SYSTEM CROSS-SECTION
5.3 TRANSMISSION SYSTEM
5.3.1 Main shift module
5.3.2 Reverse shift module
5.3.3 Range shift module
5.3.4 Front drive
5.3.5 PTO shift module
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TABLE OF CONTENTS TABLE OF CONTENTS
EF494T iv TM 06/2011 edition
5.4 TRANSMISSION (CLUTCH HOUSING CASE SIDE)
5.4.1 Disassembly
5.4.2 Main shift section
5.5 TRANSMISSION (TRANSMISSION HOUSING
CASE SIDE)
5.5.1 Disassembly
5.5.2 PTO module
6 REAR AXLE AND BRAKE 130
6.1 STRUCTURE AND FUNCTIONS
6.1.1 Structure drawing
6.1.2 Differential system
6.1.3 Final drive system
6.1.4 Brake
6.2 DISASSEMBLY AND ASSEMBLY
6.2.1 Differential system
6.2.2 Rear axle oil seal
7 FRONT AXLE 139
7.1 STRUCTURE AND FUNCTIONS
7.2 CROSS-SECTION VIEW
7.3 FRONT WHEEL ALIGNMENT
7.4 DISASSEMBLING THE FRONT BEARING CASE
7.5 DISASSEMBLING THE FRONT GEAR BOX
7.6 DISASSEMBLING AND ASSEMBLING THE FRONT
DIFFERENTIAL SECTION
7.6.1 Disassembly
7.6.2 Assembly
8 POWER STEERING 148
8.1 STRUCTURE AND FUNCTIONS
8.1.1 Structure drawing
8.1.2 Hydraulic circuit
8.1.3 Power steering valve functions
8.1.4 Hydraulic pump
8.1.5 Power steering
8.2 POWER STEERING VALVE
8.2.1 Removing power steering valve assembly
8.2.2 Power steering relief pressure
8.2.3 Disassembly
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TABLE OF CONTENTS TABLE OF CONTENTS
EF494T v TM 06/2011 edition
9 HYDRAULIC LIFT UNIT 159
9.1 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 Oil flow at Neutral
9.2 ASSEMBLY AND CHECK
9.2.1 Assembling/disassembling the control valve
9.2.2 Control valve, exploded view
9.2.3 Main relief pressure
9.2.4 Adjusting the position feedback rod
9.3 HYDRAULIC POWER TAKE OFF
9.3.1 For single action, pump trailer etc.
9.3.2 For double action, front blade etc.
9.3.3 Hydraulic pressure flow
10 ELECTRIC EQUIPMENT 182
10.1 ENGINE START CIRCUIT
10.1.1 Location and operation of components
10.1.2 Circuit diagram
10.1.3 Checkpoints of electrical equipment
10.2 CHARGING CIRCUIT
10.2.1 Location and operation of components
10.2.2 Circuit diagram
10.2.3 Checkpoints of electrical equipment
10.3 ALARM CIRCUIT
10.3.1 Location and operation of components
10.3.2 Circuit diagram
10.3.3 Checkpoints of electrical equipment
10.4 SAFETY CIRCUIT
10.4.1 Location and operation of components
10.4.2 Circuit diagram
10.4.3 Checkpoints of electrical equipment
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TABLE OF CONTENTS TABLE OF CONTENTS
EF494T vi TM 06/2011 edition
11 APEENDIXES 206
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
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