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Содержание 3MP2

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Страница 59: ...ump 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 or worn replace the complete pump assembly 0003559 Figure 5 19 Figure 5 20 Figure 5 21 mNMAR MP SeriesService Manual ...

Страница 60: ...econdary 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 each valve mustbe reassembled with the original parts and reinstalled in the original port 1 Valve Seat 2 Return Spring 3 Secondary Check Ball Spring Seat 4 Secondary Check Ball 5 Delivery Valve 6 Pri...

Страница 61: ...28 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 gaskets Figure 5 28 8 and seal Figure 5 28 9 0001185 Figure 5 26 Note Store parts in clean oil to prevent oxidation 6 Remove the plunger and barrel plug Figure 5 27 I O ring Figure 5 27 2 and copper s...

Страница 62: ...ton 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 Figure 5 33 2 Includedin Yanmar Special Tool Kit P N 458091 to compress the plunger spring Figure 5 32 1 and removethe spring retainer Figure 5 33 1 0001193A Figure 5 30 Figure 5 32 MP Series Service M...

Страница 63: ...3 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 oxidation 0001214a Figure 5 34 13 Remove the control rack guide and bolts Figure 5 35 1 00001215a Figure 5 35 YANMAR MP seriesservice Manual i 0001220 Figure 5 37 ...

Страница 64: ...5 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 ring Figure 5 40 4 Remove the roller lifter Figure 5 41 2 Retain the shim Figure 5 41 1 located in the lifter bore Figure 5 41 5 22 MP e r e s ervlce Manual YANMAFI ...

Страница 65: ...igure 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 Lift the distribution shaft Figure5 45 1 slightly and pull out the camshaft Figure 5 45 2 being careful to avoid damaging the camshaft lobes Figure 5 43 Figure 5 45 YANMAR MP series service Manual ...

Страница 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 installation 0001237 Figure 5 47 2 Apply assembly grease to the camshaft lobes bushingjournal and ball bearing 5 24 MP series service Manual YANMAR ...

Страница 67: ...body 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 Note 4 cylinder camshafts requirespecial care during reassembly due to tight tolerances 0001239 Figure 5 48 Figure 5 49 VANMAR MP seriesservice Manual 5 25 ...

Страница 68: ...gage 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 proper angle from step 1 4 While holdingthe gear alignment installthe distribution shaft retaining plate and tighten screws to 6 7 ft lb 8 10 N m 5 Verify proper gear alignment by checking gear timing mar...

Страница 69: ...and 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 Plunger and Control Rack 1 Installthe plunger Figure 5 53 1 into the head assembly Figure 5 53 2 Installthe control sleeve Figure 5 55 2 aligningthe plunger identificationmarking example W4 Figure 5 54 4...

Страница 70: ...2 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 00001233A Figure 5 56 000012338 Figure 5 57 Figure 5 58 Install and tighten the four bolts Figure5 59 1 to 2 3 ft lb 3 4 N m 00001215a Figure 5 59 MP Series Service Manual YANMAR ...

Страница 71: ...ld 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 Rack Auxiliary 6 Distribution Shaft Spring Sleeve Figure 5 60 YANMAR MP Series Service Manual 10 Installthe plunger spring Figure 5 62 1 and spring retainer Figure 5 62 2 Use the spring compressor to...

Страница 72: ...e 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 each other Then tighten to torque of MP2 13 16ft lb 18 22 N m MP4 21 24 ft lb 28 32 N m in a diagonal order Figure 5 64 12 Installa new head gasket Figure 5 65 1 0001259 Figure 5 67 Figure 5 65 5 30 MP...

Страница 73: ...ng 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 bottom of the cam profile 3 Removethe dial indicator and adapter and zero the dial indicator Figure 5 68 1 using the specifiedspacer Figure 5 68 2 The correct size spacer can be found in the calibrati...

Страница 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 old style hydraulic heads have a distributionshaft plug with a flat bottom The replacement will require a new plug to allow clearance for the taller distributionshaft The parts catalog lists the new ...

Страница 75: ...5 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 timer housing tightening to 30 33 ft lb 40 45 N m 11 lnstall the timer spring Figure 5 75 6 and piston Figure 5 75 5 into the housing Figure 5 75 0001279 Figure 5 74 YANMAReMP Series Service Manual 5...

Страница 76: ...1 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 of damage or failure replace the complete pump assembly 1 lnstalland align pump gears Figure 5 78 1 into pump housing 2 lnstall the new pump housing O ring Figure 5 78 2 into groove and assembly pum...

Страница 77: ...10 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 0001251a Figure 5 82 Note Be careful not to bend or damage the governor housinggasket 3 Align and installa new governor housing gasket Figure 5 83 1 00013Wa Figure 5 83 YANMAR MP Series Service Manual ...

Страница 78: ...de 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 place 7 While pushing the governor lever assembly to the full stop positionthrough the stop solenoid opening rotate the link lifter clockwise to the 12 o clock position 8 Verify the link installation...

Страница 79: ...ten 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 by loosingthe angleich lock nut Figure 5 90 1 0001306C Figure 5 90 14 Turn the angleich adjustment screw in until it contacts the governor lever and then back out one quarter 114 turn 15 Tighten the ...

Страница 80: ...rnor 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 5 92 5 38 MP seriesservice Manual YANMAR ...

Страница 81: ...Fuel 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 Delivery 6 6 Tamper Proof Cap Installation 6 7 Fuel Pump Timing Index Stamping Identification 6 7 YANMAR MP Series Service Manual ...

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

Страница 83: ...ressure 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 24 x 23 62 in 6 0 x 600 mm 0 98 in 25 mm Figure 6 2 4 Remove the oil fill plug on the top of the governor case Fill Figure 6 3 1 the pump with about 6 75 oz 200 cc of pump oil or engine oil Figure 6...

Страница 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 the high idle speed limit bolt Figure 6 5 3 to obtain the specified injection amount See Calibration Data Sheet 3 Tighten the lock nut after completing the adjustment to lock the high idle speed limit ...

Страница 85: ...st 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 angleichassembly Figure 6 8 1 until contact isjust made with the reverse angleich lever Figure 6 9 4 2 Shift the control lever to the high idle position Set the fuel pump speed to the specified torque rise ...

Страница 86: ...uel 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 the pump speed at 50 RPM and check the ultra low speed setting injectionvolume specification See Calibration Data Sheet Note The Ultra Low Speed Test checks the condition of the plunger and barrel D...

Страница 87: ...ginal 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 like the originalfuel pumps The timing index numbers are neededto properly set injectiontiming when reinstallingthe fuel injection pump Upon completion of fuel pump repairs when the hydraulic head is...

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

Страница 89: ...ns 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 7 7 Reassembly 7 8 Opening PressureAdjustment 7 8 InjectionTest 7 8 ...

Страница 90: ...ectors 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 pressure The fuel nozzle is specifically matchedto the fuel injector by engine model and engine speed Note Fuel injection pressure of a new fuel injector is reduced approximately 72 5 psi 0 5 MPa 5 0...

Страница 91: ...dentificationnumber 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 Head Code A At Angle No Code Not At Angle Type DLL Semi Long Type YANMAR YANMAR MP seriesservice Manual ...

Страница 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 Service Manual YANmAR Application For holding and protecting fuel nozzle when servicing For cleaning parts Illustration 0001340 0004195 Illustration Instrument Name Fuel InjectorTester Locally Available ...

Страница 93: ...uniformly 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 injectionnozzles must be kept intop condition to maintain performance and operating efficiency The nozzle valve is automatically closed by the nozzle spring pressureat the end of the fuel injectionpump stroke Unus...

Страница 94: ...8090 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 nozzle nut 0001330 Figure 7 4 3 Remove all nozzle components including the spring seat and shims 0002093D Fuel Return Passage Injector Body Pressure Adjusting Shims Spring Spring Seat Valve Stop Spacer ...

Страница 95: ...or 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 slide the nozzleto check for smooth movement Figure 7 8 replace the nozzle assembly if the nozzledoes not slide smoothly YANM R MP Series Service Manual 0001332A Figure 7 7 4 lnspect the nozzle valve sto...

Страница 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 make sure the nozzledoes not leak 1 Check the injection spray condition by operating the nozzletester lever once or twice per second to check for abnormal injection Correct Spray from each nozzle hole i...

Страница 97: ...NOZZLE 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 Service Manual 7 9 ...

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

Страница 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 ...

Страница 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 diagnosis If the pump is removed prematurely the initial cause of the problem may never be known Check the mechanical condition of the engine Check the condition of the fuel type and quality fuel flow and f...

Страница 101: ...njection 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 to injection Pump inoperative lnjection timing is defective Correction Fillwith fuel Open Clean complete fuel system Disassembleand clean or replaceelement Findand repair source of debris in fuel Loca...

Страница 102: ...r 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 temperature is high 4 Knockingsounds caused by improper too fast injection timing 5 Engine overheats or emits large amount of smoke due to improper too slow injectiontiming 6 Charge pump is defective 1 D...

Страница 103: ...l 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 too weak 7 c Governor weight assembly worn 8 One or morefaulty nozzles 9 Charge pump is worn 1 Low idling stopper bolt is abnormal 2 Calibration of low speed incorrect 1 Throttle improperly adjusted...

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

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