Yanmar TVK-YL610P User manual

1
Third Function Valve Kit for YL610
Introduction
This document outlines the assembly and installation procedures for the Third Function Valve Kit for YL610. It is
designed for use by authorized YANMAR personnel only. All non-authorized personnel should seek the
assistance from an authorized YANMAR service technician to perform the procedures as outlined in this
document.
Table of Contents
3.1 Remove the Loader...............................................................................................................5
3.2 Assembling the Front Couplers..............................................................................................6
3.3 Installing the Hydraulic Tubes................................................................................................6
3.4 Installing the Third Function Valve and Hoses.......................................................................8
3.5 Installing the Regen Lock Unit.............................................................................................12
3.6 Installing the Wire Harness..................................................................................................13
1. General Precautions...............................................................................................2
2. Kit Contents.............................................................................................................3
3. Installation Instructions..........................................................................................5
4. Operator Manual....................................................................................................18
INSTALLATION INSTRUCTIONS
Third Function Valve Kit
TVK-YL610P for YL610 on YT347/359

2
Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
1. General Precautions
1.1 The Third Function Valve Kit TVK-YL610P is designed for use on the YL610 YANMAR loader only. Any
unauthorized use, modification or changes to this kit may result in equipment damage, component failure or
possible injury. Only approved YANMAR accessories for this Third Function Valve Kit shall be used. Any
other attachments not approved by YANMAR could cause injury or damage to the Third Function Valve Kit or
tractor.
1.2 This Third Function Valve Kit may be impaired by structural damage, sudden impact, excessive heat or
alteration. Never heat, weld or drill the Third Function Valve Kit. Applying heat, welding or drilling on the Third
Function Valve Kit will reduce the support capacity of the material resulting in unexpected component failure.
If any of these conditions occur, this structure must be replaced.
WARNING
• All work must be performed on a solid, dry, stable and level surface.
• Always use Personnel Protective Equipment (PPE) when servicing, testing, performing
repairs or installations to YANMAR equipment.
• Never use flammable fluids to clean parts. Use only approved non flammable cleaning
solvents.
• Always follow the procedures as outlined in this document. Deviation or skipping a
procedure may result in sudden failure to the component or equipment.
• Always support the equipment using the proper jack stands rated for the weight of the
machine. Never support equipment with a hydraulic jack.
• When working on the machine, always set the parking brake and chock the wheels.
• Always keep your work area clean and free from spills or trip hazards.
• When making electrical repairs or installing an electrical component always disconnect the
battery first.
• Make sure that there is no stored energy in a pressurized system before performing
service, repairs, installations or troubleshooting.

3
Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
2. Kit Contents
Your Third Function Valve Kit TVK-YL610P comes complete with all the parts needed. Before assembling and
installing the Third Function Valve Kit, take inventory and check to be sure all the parts listed in the parts list and
shown in the illustrations below are in the kit.
If you should find any parts missing, contact your YANMAR dealer to obtain the missing parts. Do not install the
Third Function Valve Kit to the loader or tractor with after market parts, incorrect parts or missing parts. Possible
injury or damage to the machine may result.
Item No. Part Number Part Description Qty.
1 1TN323-43110 VALVE ASSEMBLY 1
2 1A8160-46960 CONNECTOR 5
3 1A8160-46310 PLUG, DUST GREEN 1
4 198240-46260 RING, SNAP 4
5 1A8160-46250 COUPLER, QUICK 3/8F 2
6 1TN323-43701 REGEN LOCK UNIT 1
7 1TN340-43050 PLATE, VALVE 1
8 1A8160-46910 ELBOW, 8-8 1
9 1A8160-46300 PLUG, DUST YELLOW 1
10 1A8300-51210 BAND, REPEAT 12
11 26106-060122 BOLT, 6 X 12 4
12 1TN340-43350 STAY, COUPLER 1
13 194464-45930 O-RING, 8-1 (Use if original o-ring is missing or damaged) 4
14 1TN322-41550 COVER, CLAMP 4
15 26106-080902 BOLT, 8 X 90 2
16 26366-080002 NUT 8 2
17 26106-080502 BOLT, 8X50 2
18 1TN323-43550 STOPPER, REGEN 1
19 1TN340-43620 HARNESS ASSEMBLY, 3RDV 1
20 1TN340-43610 HARNESS ASSEMBLY, LOADER 1
21 1TN322-41770 DUST PLUG YELLOW M 1
22 1TN322-41780 DUST PLUG GREEN M 1
23 1TN340-43230 HOSE, VALVE 4
24 1TN340-43060 HOSE 3RD A (YELLOW) 1
25 1TN340-43070 HOSE 3RD B (GREEN) 1
26 1TN340-43030 PIPE ASSEMBLY, 3RD B (Green Line) 1
27 1TN340-43020 PIPE ASSEMBLY, 3RD A (Yellow Line) 1
28 0F052-EN0010 ASSEMBLY BRIEF 1

4
Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
1
2345
67
8
9
10
11 12
x12
13 14 15 16
x2
17
18
19
20
21
22
28
23
24
25
26
27
YM730

5
Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
Regen Lock Unit 1TN323-43701
Sub-parts listing.
3. Installation Instructions
• Always keep in mind when installing parts or components to the tractor, the reference points may be stated
according to the operators seated position on the tractor facing forward.
• Be sure you have enough room around you and the tractor to perform the procedures as outlined in this
document.
• It is advised to lay the parts out in an orderly fashion for each step listed in this document so confusion during
the installation process can be avoided.
• Be aware of the tools you are using, always use the proper tool for the task you are performing. Failure to do
so may result in damage to the component or possible injury.
• Whenever a specific torque value is listed in this document, always torque the fastener to the value as listed.
Failure to do so may result in equipment or component failure.
• If you should need assistance during your installation process, contact your YANMAR distributor.
3.1.1 Park the tractor and loader in a level stable and well
illuminated area.
3.1.2 Remove the front loader from the tractor. Refer to (YL610
Operators Manual) for details.
3.1.3 With the loader off the tractor and the engine OFF, slowly
move the control lever in all directions to release any
residual hydraulic pressure in the system before
disconnecting the hydraulic couplers.
3.1.4 Park the tractor near the loader, turn the engine off, set
the parking brake and chock the wheels.
No. Part No. Part Description Qty.
A 1TN323-43810 LEVER ASSY. REGEN 1
B 1TN323-43710 PLATE ASSY. REGEN 1
C 1TN323-43760 COLLAR, LEVER 1
D 22157-080000 WASHER, 8 1
E 26106-080252 BOLT, 8 X 25 1
F 26106-060122 BOLT, 6 X 12 3
G 1TN323-43751 COVER, RELAY 1
H 119247-77100 RELAY, CA C-TYPE 1
I 1A7550-08300 PUSH SWITCH 1
J 26023-040162 SCREW, 4 X1 6 2
K 1TN323-43890 COTTER PIN 3/8 1
L 1TN323-43870 PIN, REGEN 1
M 129927-91151 HARNESS, DIODE 1
3.1 Removing the Loader
A
C
D
E
F
HBG F
J
ILK M F
YM357c

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Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
Parts needed:
3.2.1 Attach Ring, Snap (4) to Coupler, Quick 3/8 Female (5)
body and install the Coupler, Quick 3/8 Female (5) into
the Stay, Coupler (12) as shown in the illustration.
3.2.2 Secure the Couplers, Quick 3/8 Female (5) in place on
the Stay, Coupler (12) using the other Rings, Snap (4) as
shown in the illustration.
Parts needed:
3.3.1 Remove 8X16 bolt (A) from the right side of the loader
hydraulic line cover to attach Stay, Coupler (12).
Reinstall 8X16 bolt (A) through Stay, Coupler (12) and
hydraulic line cover.
3.3.2 Install Plug, Dust Yellow (9) to the right Coupler, Quick
3/8 Female and Plug, Dust Green (3) to the left Coupler,
Quick 3/8 Female as shown in the illustration.
3.2 Assembling Front Couplers
Item No. Part No. Description Qty.
4 198240-46260 RING, SNAP 4
5 1A8160-46250 COUPLER, QUICK 3/8F 2
12 1TN340-43350 STAY, COUPLER 1
NOTE
Be sure the Ring, Snap (4) is in the grooves on
the Coupler, Quick 3/8 Female (5).
3.3 Installing the Hydraulic Tubes
Item No. Part No. Description Qty.
3 1A8160-46310 PLUG, DUST GREEN 1
9 1A8160-46300 PLUG, DUST YELLOW 1
13 194464-45930 O-RING, 8-1 (Use if original O-ring is missing or damaged) 2
14 1TN322-41550 COVER, CLAMP 4
17 26106-080502 BOLT, 8 X 50 2
26 1TN340-43030 PIPE ASSEMBLY, 3RD B (Green line) 1
27 1TN340-43020 PIPE ASSEMBLY, 3RD A (Yellow line) 1
NOTE
Leave 8X16 bolt (A) loose until hydraulic piping
has been installed and torqued.
YM670
44
5
12
5
Yellow
Green
9
3
12 A
Left
Right
YM671

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Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
3.3.3 Remove both bolts (B) as shown in the illustration and discard them.
3.3.4 Attach Pipe Assemblies 3RD A&B (26)&(27) to each Coupler, Quick 1/2 Female (5) connections as shown
in the illustration below. Leave Coupler, Quick 1/2 Female (5) and Pipe Assemblies 3RD A&B (26)&(27)
connections loose.
3.3.5 Adjust and secure Pipe Assemblies 3RD A&B (26)&(27) to the loader arm using Cover, Clamps (14) and
Bolts, 8X50 (17). Leave Bolts, 8X50 (17) loose until the Coupler, Quick 1/2 Female (5) connection to Pipe
Assemblies 3RD A&B (26)&(27) are properly torqued.
3.3.6. Torque Pipe Assemblies 3RD A&B (26)&(27) to Coupler, Quick 1/2 Female (5) connections to the value
listed below.
3.3.7 Torque Bolt 8X16 (A) and Bolts, 8X50 (17) to the value listed below.
NOTE Extra O-Rings are provided in case the O-Rings on the pipe end fittings are damaged or lost.
Tightening Torque: 40–42 ft-lbs (54–59 Nm)
Tightening Torque: 17–22 ft-lbs (23–29 Nm)
B
B
YM673
27
26
14
17
YM672
A17
14
14
17

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Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
Parts needed:
3.4.1 Attach Plate, Valve (7) to Valve Assembly (1) using two
Bolts, 8X90 (15) and two Nuts 8 (16) as shown in the
illustration.
3.4.2 Torque Bolts, 8X90 (15) to the value listed below.
3.4 Installing the Third Function Valve and Hoses
Item No. Part No. Description Qty.
1 1TN323-43110 VALVE ASSY 1
2 1A8160-46960 CONNECTOR 5
7 1TN340-43050 PLATE, VALVE 1
8 1A8160-46910 ELBOW, 8-8 1
10 1A8300-51210 BAND, REPEAT 6
13 194464-45930 O-RING, 8-1 (Use if original O-ring is missing or damaged) 4
15 26106-080902 BOLT, 8 X 90 2
16 26366-080002 NUT 8 2
19 1TN340-43620 HARNESS ASSEMBLY, 3RD V 1
21 1TN322-41770 DUST PLUG YELLOW M 1
22 1TN322-41780 DUST PLUG GREEN M 1
23 1TN340-43230 HOSE, VALVE 4
24 1TN340-43060 HOSE 3RD A (Yellow) 1
25 1TN340-43070 HOSE 3RD B (Green) 1
Tightening Torque: 17–22 ft-lbs (23–29 Nm)
NOTE
If the valve ports are not covered, be careful not to
allow debris to fall into the valve ports when
handling the Valve Assembly (1). If necessary,
cover the ports with masking tape.
7
1
15
16
YM674

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Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
3.4.3 Remove the two M12 carriage bolts (C) and nuts (D) from
loader stand and mast on the right side of the loader and
install Plate, Valve (7) to the inside of the loader mast.
3.4.4 Reuse the two M12 carriage bolts (C) and nuts (D) as
shown in the illustration to mount Plate, Valve (7) to the
inside of the loader mast.
3.4.5 Torque M12 carriage nuts (D) to the value listed below.
3.4.6 Install four Connectors (2) to the Valve Assembly body
(1) as shown in the illustration.
3.4.7 Torque Connectors (2) to the value listed below.
3.4.8 On the underside of the Valve Assembly (1) install one
Connector (2) and Elbow, 8-8 (8) as shown in the
illustration.
3.4.9 Torque Connector (2) and Elbow, 8-8 (8) to the value
listed below.
3.4.10 Disconnect hose to port C(Yellow-Bucket Curl) and
hose to port B(Green-Bucket Dump).
Tightening Torque: 80–94 ft-lbs (108–127 Nm)
Tightening Torque: 40–42 ft-lbs (54–59 Nm)
NOTE: Make sure Elbow 8-8 (8) is angled toward
the front of the loader as shown in the illustration.
Tightening Torque: 40–42 ft-lbs (54–59 Nm)
WARNING
Before performing this procedure, make sure
there is no pressure in the lines by following the
procedure in step 3.1.3.Wait until the tractors
hydraulic system has cooled down to avoid
burns. Be careful when disconnecting any
hydraulic lines, the system may still be under
pressure. It is advised to use safety glasses and
gloves when performing this task.
C
7
YM675
D
2
YM676
1
1
2
8
YM731
C
B
YM679

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Third Function Valve Kit TVK-YL610P for YL610 on YT347/359
Third Function Valve Kit for YL610
3.4.11 Remove these hoses from the hose bundle, disconnect
both hose Couplers, Quick 3/8 Male from the hose ends
and retain for reuse in step 3.4.17 on hoses from Valve
Assembly (1).
3.4.12 Install four Hose, Valve (23) as shown in the illustration
and bundle hoses using three Band Repeat (10) as
shown in the illustration.
3.4.13 Torque Hose, Valve (23) fittings to the value
listed below.
3.4.14 Attach Hoses 3RD A&B (24)&(25) to the Valve
Assembly (1) as shown in the illustration and secure in
place with three Band, Repeat (10). See reference 3.6.8.
for locations.
3.4.15 Torque Hoses 3RD A&B (24)&(25) fittings to the value
listed below.
Tightening Torque: 36–39 ft-lbs (49–53 Nm)
Tightening Torque: 36–39 ft-lbs (49–53 Nm)
23
10
YM678
Hose bundle to
loader valve
YM680
25
24
1
Top View
Support
Valve
Third Function Valve (12)
Hydraulic Piping on Right Side of
Loader Mast, Rear.
Piping