Yanmar MP series Service Manual Download

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Summary of Contents for MP series

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Page 59: ...mp housing is worn replace the assembly Figure 5 20 2 drive pin complete pump assembly Figure 5 20 3 seal Figure 5 21 2 oil ports Figure 5 21 3 and O ring seal areas Figure 5 21 1 for wear If damaged...

Page 60: ...condary check balls during disassembly of the delivery valves 3 Disassembleeach delivery valve Figure 5 24 Note Keepand identifyall parts in order during disassembly Do not mix valve parts If reused e...

Page 61: ...8 I gasket Figure 5 28 2 and fitting Removethe thermo element assembly Figure 5 28 4 which includesthe timer piston Figure 5 28 5 timer piston return spring Figure 5 28 6 timer housing Figure 5 28 7 g...

Page 62: ...on Figure 5 29 5 6 0003554 Figure 5 29 Remove the four hydraulic head bolts Figure 5 30 1 10 Removethe hydraulic head assembly and gasket Figure 5 31 1 Figure 5 31 11 Use the spring compressor tool Fi...

Page 63: ...Hydraulic Head Figure 5 33 12 Remove the control rack return spring Figure 5 34 1 000012 17 Figure 5 36 Note Store all valves Figure 5 37 removed from hydraulicheadassembly in clean oil to prevent ox...

Page 64: ...38 1 0001196 Figure 5 38 2 Remove the distribution shaft retainer bolts Figure 5 39 1 and retainer Figure 5 39 2 _ _ i _ Figure 5 39 Figure 5 40 1 and O ring and the link lifter Figure 5 40 2 and O r...

Page 65: ...gure 5 42 MP2 3 Cylinder Model Pumps Align the camshaft keyway Figure 5 43 1 with the appropriate timing mark on the body 3 Cylinder Model Figure 5 43 2 or 4 Cylinder Model Figure 5 43 3 Figure 5 44 L...

Page 66: ...1 Invertthe pump body and apply assembly grease to the distribution shaft and gears Figure 5 47 1 before installing it into the pump body Note Check that the distribution shaft rotates freely after in...

Page 67: ...ody Figure 5 49 1 and tighten to 6 7 ft lb During installation prevent the cam lobes from 8 10 N m hitting the distributionshaft gear and the camshaft key from hittingthe camshaft bushing Figure 5 48...

Page 68: ...age and misalign 3 The gears are properlyalignedwhen the gear marks are aligned the distribution shaft drive lugs are in parallel alignment with the retainer screws and the camshaft keyway is at prope...

Page 69: ...nd 4 mm hex wrench while turning camshaft to ensure the lifter movesfreely with pin in position Torque the pin to 3 4 ft lb 4 5 N m Lifter must movefreely after pin is torqued 0001249 Figure 5 52 Plun...

Page 70: ...into the corresponding positions hole and pin on the spring retainer Figure 5 56 1 Also see Figure 5 57 and Figure 5 58 5 Installing the slide into the spring retainer Figure 5 57 I Figure 5 58 1 000...

Page 71: ...d be equal to or less than 0 008 in 0 2 mm If the backlash is excessive replace the rack assembly and control sleeve Figure 5 61 1 Control Rack 4 Rack Guide 5 Upper Spring 2 Control Sleeve Retainer 3...

Page 72: ...5 66 14 Installthe hydraulic head assembly and temporarily tighten the 6 mm hex head bolts evenly in the order as shown Figure 5 67 1 2 3 4 until the surfaces of the head and the pump body contact ea...

Page 73: ...g use the dial indicator extension alone 1 Mount the dial indicator from Yanmar Special Tool Kit PIN 458091 in the adapter and thread into barrel 2 Positionthe camshaft with the roller lifter at the b...

Page 74: ...valve seat seal s Figure 5 71 1 M01274 Figure 5 71 Assemble and install each delivery valve Figure 5 72 Tighten each delivery valve housing to 30 33 ft lb 40 45 N m Figure 5 70 1 Valve Seat Note Some...

Page 75: ...N m Figure 5 73 9 lnstall a new timer housing seal Figure 5 74 1 10 lnstall a new seal Figure5 75 9 into the head lnstall new O rings Figure 5 75 8 on the timer housing Figure 5 75 7 and install the...

Page 76: ...and tighten to 16 18ft lb 22 25 N m Do not over torque 15 lnstallthe fuel return Figure 5 77 2 and inletfittings Figure 5 77 I seals and plugs to positions marked in disassembly Figure 5 77 suspected...

Page 77: ...0 N m 58 62 ft lb 79 84 N m Installthe governor Figure 5 80 Governor Installation 1 Install the governor weight assembly and nut Figure 5 81 1 to the fuel injection pump camshaft Figure 5 81 sleeve 00...

Page 78: ...e in to align with the control rack pin 1 Control Rack 4 DuringAssembly 2 Governor Link 5 DuringOperation 3 Link Lifter Figure 5 85 6 Installtwo governor housing bolts by hand to hold the governor in...

Page 79: ...en to 6 7 ft lb 8 10 N m Figure 5 88 0001305a Figure 5 88 the governor housing Tighten the solenoid bolts to 6 7 ft lb 8 10 N m 0001306a Figure 5 89 13 Pre set the adjustment of the angleich assembly...

Page 80: ...nor housing cover gasket I Figure 5 91 0001307a Figure 5 91 17 Installthe governor housing cover to the case Figure 5 92 Tighten the governor housing cover bolts to 6 7 ft lb 8 10 N m 0001308a Figure...

Page 81: ...uel Delivery 6 4 Rated Fuel Delivery 6 4 Torque Fuel Delivery 6 5 Reverse Angleich Spring Adjustment 6 5 Low Idle Fuel Delivery 6 6 Start Fuel Delivery 6 6 Ultra LowSpeed Delivery 6 6 Stop Fuel Delive...

Page 82: ...ADJUSTMENT This Page Intentionally Left Blank MP Series Service Manual YANMAR...

Page 83: ...essure injection line YANMAR MP seriesserviceManual Inner diameter Outer diameter x length Minimum bending radius 3 Mount the fuel injectionpump Figure 6 2 on the pump tester platform 0 08 in 2 0 mm 0...

Page 84: ...Figure 6 5 High ldle Fuel Delivery 1 Set the fuel pump speed at the high idle speed specified See Calibration Data Sheet 2 Set the control lever Figure 6 5 6 to the high idle position while turning th...

Page 85: ...t the reverse angleich lever or the reverse angleich lever will move in a direction of fuel reduction 1 With the pump stopped remove the governor housing rear cover Figure 6 9 1 and adjust the angleic...

Page 86: ...el adjustment bolt Figure 6 11 1 to obtain the specified injectionamount See CalibrationData Sheet 3 Tighten the locknut Figure 6 11 2 and installthe hex cap Figure 6 11 Ultra Low Speed Delivery 1 Set...

Page 87: ...inal fuel pump hydraulicheadare neededfor the engine technician to set fuel injection timing Replacement hydraulic heads do not have the necessary timing index numbers stamped on the engine side boss...

Page 88: ...ADJUSTMENT This Page Intentionally Left Blank MP Series Service Manual YANMAR...

Page 89: ...s 7 2 Nozzle Body IdentificationNumber 7 3 Special Torque Chart 7 4 Special Service Tools 7 4 Measuring Instruments 7 4 Fuel Injection Nozzle 7 5 Operation 7 5 Disassembly 7 6 Cleaning 7 7 Inspection...

Page 90: ...ctors have a three character identification mark Figure 7 1 1 The first character starts with V or W 0004105 Figure 7 1 Fuelinjector identificationis criticalas eachengine has a unique fuel injection...

Page 91: ...entificationnumber Figure 7 1 1 inscribedon the outside of the nozzle body 0001328 Figure 7 1 Y DLL A 150 P 244JO Design Code Nozzle Size P Size S Size Spray Angle Mounting Angle of Nozzleon Cylinder...

Page 92: ...Applied Note Tools not having Yanmar part numbers must be acquired locally Tool Name Fuel Nozzle Mount Plate Yanmar Part No 158090 51700 Ultra Sonic Parts Cleaner Locally Available No 1 MP Series Serv...

Page 93: ...niformly with the air in the combustion chamber How well the fuel is mixed with high temperature air directly affects combustion efficiency engine performance and fuel economy Note Fuel injectionnozzl...

Page 94: ...090 51700 Figure 7 4 2 Carefully mount the holder and nozzle in to a vise Figure 7 4 3 to ensure the high pressure mounting threads are not damaged 2 Use a socket wrench Figure 7 4 1 to remove the noz...

Page 95: ...r wear replaceas necessary 2 lnspect nozzle body for scratches and wear on nozzle body and tip Replace the nozzle if the nozzle sliding surface or seat are scratched or abnormallyworn 3 Rotateand slid...

Page 96: ...in the injectionopening pressure of about 290 psi 2 MPa 20 kgf cm2 COO1335 Figure 7 10 Injection Test After adjustingthe nozzle to the specified opening pressure check the fuel spray condition and mak...

Page 97: ...OZZLE 3 Replacethe nozzle assembly after all checks above if Leakage is evident Spray angle is incorrect Atomization of fuel is incomplete Openingand closingof nozzleis incomplete WANMAR MP Series Ser...

Page 98: ...FUEL INJECTION NOZZLE This Page Intentionally Left Blank MP Series Service Manual VANMAR...

Page 99: ...Section 8 TROUBLESHOOTING Page Introduction 8 2 Troubleshooting 8 2 Preliminary Checks 8 2 Fuel System Troubleshooting Chart 8 3 YAMMAR MP Pump Service Manual...

Page 100: ...pump is removed When possible provide troubleshooting assistance to the customer before the fuel injection pump is removed This will prevent unnecessary costs that can result from an incorrect diagnos...

Page 101: ...jection pump is installedincorrectly 2 lnjectiontiming is excessively advanced or retarded due to failed key or coupler 3 Internal failure of injectionpump delivered to injection Pump Fuel delivered t...

Page 102: ...in fuel lines 5 Insufficientfuel delivery from the feed pump 6 Stop solenoid is defective 7 Charge pump is defective 1 Type of fuel is incorrect 2 Insufficientfuel delivery from feed pump 3 Fuel temp...

Page 103: ...rack is defective 6 a Stiff plunger movement or sticking 6 b Rack and guide is defective 6c Poor delivery valve operation 7 Movement of governor is improper 7 a Shifter is worn 7 b Governor spring is...

Page 104: ...TROUBLESHOOTING This Page Intentionally Left Blank MP Pump Service Manual YANMACI...

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