Sixty-one pages, ten tractor variants: this Yanmar YM135–YM330 series shop manual PDF covers the full YM family (YM135, 135D, YM155, 155D, YM195, 195D, YM240, 240D, YM330, and 330D) in both 2WD and 4WD configurations. Inside: exploded-view diagrams, step-by-step procedures, and service specifications for the engine, clutch, front axle, hydraulic system, and more.
What's Inside This Yanmar YM135, YM135D, YM155, YM155D, YM195, YM195D, YM240, YM240D, YM330, YM330D Manual
| System | Pages | Key Topics |
|---|---|---|
| 24356861 | 1 | Brakes, Clutch, Cooling System, Diesel Fuel System (Filters & Bleeding, Nozzles, Thermostart, Timing), Differential (Front, Rear) |
| 24356862 | 2-5 | Front Axle Assembly, Steering Gear, Four Wheel Drive Axle, Center Pivot Pin, Spindle |
| Front Wheel Drive | 6 | Outer Drive Housing, YM135D and YM155D Models, R&R and Overhaul, Front Split |
| Engine and Clutch | 6-7 | Clutch Removal and Inspection, Clutch Reinstallation, Adjustment, All Models |
| Cylinder Head | 8-52 | All Models, Remove and Reinstall, Overhaul, Valve Clearance Adjustment |
| 24356877 | 53-54 | Output Shaft, Drive Pinion Shaft, PTO Drive Shaft, Shift Linkage, Gear End Play, Pinion End Play |
| 24356878 | 55-61 | Fluid and Filter, Hydraulic Pump, Selective Control Valve Relief Valve, Rockshaft Relief Valve, Rockshaft Lift Cycle, Rockshaft Housing |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| YM135, YM135D, YM155, YM155D | ||
| Valve Tappet Gap - Cold Exhaust | 0.2 mm (0.008 in.) | p. 2 |
| Valve Tappet Gap - Cold Inlet | 0.2 mm (0.008 in.) | p. 2 |
| Fuel delivery valve holder torque | 39.23-44.13 N·m (29-32 ft.-lbs.) torque | p. 25 |
| YM195, YM195D, YM240, YM240D, YM330, YM330D | ||
| Valve Tappet Gap - Cold Exhaust | 0.15 mm (0.006 in.) | p. 2 |
| Valve Tappet Gap - Cold Inlet | 0.15 mm (0.006 in.) | p. 2 |
| Cylinder head retaining nut torque | 171.6-181.4 N·m (127-134 ft.-lbs.) torque | p. 15 |
| Fuel delivery valve holder torque | 39.23-44.13 N·m (29-32 ft.-lbs.) torque | p. 25 |
| YM135, YM135D, YM155, YM155D, YM240, YM240D | ||
| Rocker arm support retaining nuts torque | 78.5-98.1 N·m (58-72 ft.-lbs.) torque | p. 15 |
| All Models | ||
| Fuel filter check interval | daily | p. 25 |
| Fuel filter cleaning interval | at least every 100 hours of operation | p. 25 |
| Pump drive coupling retaining nut torque | 15 N·m (11 ft.-lbs.) torque | p. 55 |
| Pump mounting screws torque | 26 N·m (19 ft.-lbs.) torque | p. 55 |
Yanmar YM135, YM135D, YM155, YM155D, YM195, YM195D, YM240, YM240D, YM330, YM330D Common Problems This Manual Covers
Yanmar YM240 three-point hitch raises slowly, drops under load, or won't lift p. 55
Check transmission and hydraulic fluid level; low fluid is the leading cause of slow lift. Inspect and clean the filter. If removing the pump, torque the drive coupling retaining nut to 15 N·m (11 ft.-lbs.) and pump mounting screws to 26 N·m (19 ft.-lbs.) per page 55. Run a full lift cycle test before returning to work.
Manual Section: Hydraulic Lift System Tests & TroubleshootingEngine cranks but won't fire, surges at idle, or blows black smoke p. 28
Check the fuel filter daily; clean at least every 100 hours and replace whenever plugged, minimum every 300 hours per page 25. After any filter service, bleed air from the system. Test injector nozzle opening pressure on a bench tester: minimum acceptable is 11769 kPa (1707 psi), target opening pressure is 15692 kPa (2276 psi) per page 28.
Manual Section: Diesel Fuel System Service (Filters, Nozzles, Timing)Clutch slips under heavy load or pedal free travel is out of adjustment p. 31
Measure clutch pedal free travel. On YM135 and YM155 series it should be 30-40 mm (1.18-1.57 in.); on YM195 through YM330 series, 15-25 mm (5/8-1 in.) per page 31. If adjusting free travel doesn't resolve the slip, remove the clutch and measure disc thickness; replace the lined disc if free thickness falls below 7.6 mm (0.2992 in.).
Manual Section: Engine & Clutch Removal and ReinstallationEngine ticks at idle or loses power and smokes after extended hours p. 16
Remove the valve cover and check tappet clearance with the engine cold. Set both intake and exhaust to 0.2 mm (0.008 in.) on YM135 and YM155 series (page 15), or 0.15 mm (0.006 in.) on YM195 through YM330 series (page 16). After any head R&R, torque cylinder head nuts to model spec per page 15 before resetting valve clearance.
Manual Section: Cylinder Head R&R, Overhaul & Valve Clearance AdjustmentSteering requires excessive effort or has too much free play at the wheel p. 4
Verify front axle toe-in measures 4-8 mm per page 2; out-of-spec toe causes binding and accelerates component wear. Inspect the steering gear assembly and lubrication per the overhaul procedure starting on page 4. Check for worn spindle bushings and center pivot pin clearance while the front axle is accessible. Replace any components that show measurable slop.
Manual Section: Steering Gear Removal, Reinstallation & OverhaulStarter cranks slowly or won't turn engine over, especially in cold weather p. 30
Pull the starter and measure brush length. On all models except YM330 and YM330D, brushes are new at 16 mm (0.630 in.) and must be replaced at 4.5 mm per page 30. On YM330 and YM330D, replace brushes when worn to 7 mm. Before pulling the starter, test the 12V negative-ground battery and clean all cable connections.
Manual Section: Electrical System (Alternator, Starter, Safety Switch)Frequently Asked Questions
How do I reset the PTO/clutch safety switch on a Yanmar YM135D?
The starter safety switch on all models is actuated by the clutch pedal or clutch linkage. To ensure proper operation, starting should be impossible unless the clutch pedal is fully depressed. Adjustment is accomplished by moving the switch, as detailed in paragraph 126 on page 32.
What are the torque specs for the head bolts on a Yanmar YM155 engine?
For YM155 models, tighten the cylinder head retaining nuts to 152.0-156.9 N·m (112-116 ft.-lbs.) torque. For all other models, the torque specification is 171.6-181.4 N·m (127-134 ft.-lbs.).
How do I bleed the fuel system on a Yanmar YM240D?
To bleed the fuel system, locate the two bleed screws (35) on top of the fuel filter housing (34) and an additional bleed screw (36) on the fuel pump inlet line. Partially open the throttle and attempt to start the engine. If the engine does not start, loosen the high-pressure fuel line at each injector and continue cranking until fuel escapes, then tighten the compression nuts.
How do I adjust the valve clearance on a Yanmar YM330D?
For YM330D models, the recommended cold valve clearance (tappet gap) for both inlet and exhaust valves is 0.15 mm (0.006 in.). Valve clearance should be checked after assembling the cylinder head and approximately every 300 hours of operation.
What are the replacement specifications for fuel filters?
The fuel filter should be checked daily and cleaned at least every 100 hours of operation. It should be renewed whenever plugged with contaminants, or at least every 300 hours of operation.
What do I get after purchasing this Yanmar YM135–YM330 Series manual?
Immediate download of the complete 61-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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