Service manual

ManualsBrandsYanmar ManualsBusiness equipmentMP series

Summary of content (104 pages)

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FUEL INJECTION PUMP 4. lnspect the pump housing (Figure 5-19, (1,2)). If the pump housing is worn, replace the complete pump assembly. 5. lnspect the drive gear (Figure 5-20, (I)), rotor assembly (Figure 5-20, (2)), drive pin (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 5-20 Figure 5-19 Figure 5-21 mNMAR.
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FUEL INJECTION PUMP Note: Be careful not to lose the secondary check balls during disassembly of the delivery valves. Hydraulic Head 1. Mark the positions of the fuel inlet (Figure 5-22, (1)) and return fittings (Figure 5-22, (2)) and remove. 3. Disassemble each delivery valve (Figure 5-24). Note: Keep and identify all parts in order during disassembly. Do not mix valve parts. If reused, each valve must be reassembled with the original parts and reinstalled in the original port.
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FUEL INJECTION PUMP IMPORTANT Do not use magnetized tools, as this may cause fuel pump components to become magnetized and attract metal debris. 5. Remove the distribution shaft (Figure 5-26). 7. Note the position of the coolant fitting (Figure 5-28, (3)) and remove the coolant plug (Figure 5-28, (I)), gasket (Figure 5-28, (2)) and fitting.
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FUEL INJECTION PUMP Remove the charge pump fuel outlet strainer plug (Figure 5-29, (1)) and gasket (Figure 5-29, (2)). Do not remove the strainer. Remove the accumulator plug (Figure 5-29, (3)) washer (Figure 5-29, (4)), spring and piston (Figure 5-29, (5,6)). 10. Remove the hydraulic head assembly and gasket (Figure 5-31, (1)). 0003554 Figure 5-29 Remove the four hydraulic head bolts (Figure 5-30, (1)). Figure 5-31 11.
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FUEL INJECTION PUMP 14. Remove the spring retainer (Figure 5-36, (I)), control sleeve (Figure 5-36, (2)) and plunger (Figure 5-36, (3)). 1. Spring ~ e t a i n e r ' 2. Spring Compressor Tool 3. Hydraulic Head Figure 5-33 12. Remove the control rack return spring (Figure 5-34, (1)). 00001 2 17 Figure 5-36 Note: Store all valves (Figure 5-37) removed from hydraulic head assembly in clean oil to prevent oxidation. 0001214a Figure 5-34 13. Remove the control rack guide and bolts (Figure 5-35, (1)).
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L FUEL INJECTION PUMP Distribution Shaft. Camshaft and Roller Lifter Removal 3. Remove the roller lifter alignment pin (Figure 5-40, (1)) and O-ring and the link lifter (Figure 5-40, (2)) and O-ring. 1. Remove the distribution shaft coupler (Figure 5-38, (1)). Figure 5-40 0001196 Figure 5-38 4. Remove the roller lifter (Figure 5-41, (2)). Retain the shim (Figure 5-41, (1)) located in the lifter bore. 2. Remove the distribution shaft retainer bolts (Figure 5-39, (1)) and retainer (Figure 5-39, (2)).
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FUEL INJECTION PUMP Remove the camshaft bearing retainer bolts and retainer (Figure 5-42, (1)). (MP4 Model Pump) Align the camshaft keyway (Figure 5-44, (2))with the embossed mark (Figure 5-44, (1))on the body. Figure 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)).
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FUEL INJECTION PUMP 9. Remove the distribution shaft assembly (Figure 5-46). FUEL PUMP REASSEMBLY Distribution Shaft and Camshaft 1. Invert the 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. 0001210 Figure 5-46 0001237 Figure 5-47 2. Apply assembly grease to the camshaft lobes, bushing journal and ball bearing.
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FUEL INJECTION PUMP 3. With the distribution shaft gear touching the pump body, insert the camshaft into the body. During installation prevent the cam lobes from hitting the distribution shaft gear and the camshaft key from hitting the camshaft bushing. (Figure 5-48). 4. Install the camshaft bearing retainer and bolts (Figure 5-49, (1)) and tighten to 6 - 7 ft-lb. (8 - 10 N.m). -. Note: 4-cylinder camshafts require special care during reassembly due to tight tolerances.
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FUEL INJECTION PUMP Gear Alignment Note: Verify model of fuel injection pump before proceeding 1. Rotate the camshaft to the correct angle (aligning keyway to marks) for the model pump being serviced (Figure 5-50) and hold in position. 2. Look through the charge pump opening in the case and slightly lift the distribution shaft and rotate to align the distribution shaft gear and camshaft gears marks.
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FUEL INJECTION PUMP Roller Lifter Plunger and Control Rack 1. lnstall the link lifter (Figure 5-51, (1)) and 1. Install the plunger (Figure 5-53, (1)) into the O-ring. 2. Install the roller lifter (Figure 5-51, (2)) with the groove on the side of the lifter aligned with the lifter alignment pin hole. head assembly. 0001248A Figure 5-51 Figure 5-53 3. With roller lifter groove aligned, install the roller lifter alignment pin (Figure 5-52, (1)).
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FUEL INJECTION PUMP - -- -- - 3. Install the spring retainer (Figure 5-55, (1)). 5. Installing the slide into the spring retainer (Figure 5-57, (I)), (Figure 5-58, (1)). 0000 12338 1. Spring Retainer 2. Control Sleeve 3. Plunger 00001217 Figure 5-57 Figure 5-55 4. Install the control rack guide (Figure 5-56, (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.
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FUEL INJECTION PUMP 7. Measure the rack (Figure 5-60, (4)) movement, the range of rack motion should be approximately 14 mm of total travel. 8. Measure rack backlash, the total backlash should be equal to or less than 0.008 in. (0.2 mm). If the backlash is excessive, replace the rack assembly and control sleeve. 9. Install the rack return spring (Figure 5-61, (1)). The spring must be able to return the rack from the maximum decreased fuel position to the maximum increased fuel position. Figure 5-61 10.
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FUEL INJECTION PUMP 13. Install the original plunger shim(s) (Figure 5-66, (1)) inside the lifter. 0001213 1. Spring Retainer 2. Spring Compressor Tool 3. Hydraulic Head Figure 5-631 11. Install the distribution shaft coupler (Figure 5-64, (1)). Figure 5-66 14. Install the 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.
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FUEL INJECTION PUMP Plunger (Bottom Clearance) Measurement The MP fuel pump injection timing is set by adjusting the plunger height. This is accomplished using shims in the roller lifter body to move the plunger up or down (bottom clearance) from the camshaft base circle. 5. Using shims from the shim kit in the Yanmar Parts Catalog (MP2 - PIN 158553-51250), (MP4 - PIN 129906-51400), increase or decrease the shim pack (Figure 5-69, (3)) in the roller lifter bore to obtain the zero mark (+ 0.
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FUEL INJECTION PUMP Hydraulic Head and Valve(s) Reassembly Install new delivery valve seat seal(s) (Figure 5-71, (1)). 1. Set the camshaft to the correct angle as used during the gear alignment. 2. Lubricate the distribution shaft. 3. Align the drive lugs on the bottom of the distribution shaft and install to engage the distribution shaft coupler. Note: The flat on the distribution shaft (Figure 5-70, (1)) should face toward the engine side of the pump (or away from the accumulator piston side). 4.
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FUEL INJECTION PUMP 8. lnstall the accumulator piston (Figure 5-73, (6)) and check that it moves freely. lnstall the spring (Figure 5-73, (5)), seal (Figure 5-73, (4)) and tighten the plug (Figure 5-73, (3)) to 37 - 4lft-lb. (50 - 55 N.m). 10. lnstall a new seal (Figure 5-75, (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.
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FUEL INJECTION PUMP 12. Install a new O-ring (Figure 5-76, (2)) on the thermo-element (Figure 5-76, (1)) and tighten to 22 - 26 ft-lb. (30 - 35 N-m). Do not over-torque. Charge Pump Note: If charge pump was disassembled for inspection, clean all parts thoroughly before reassembly. If any part is suspected of damage or failure, replace the complete pump assembly. 1. lnstall and align pump gears (Figure 5-78, (1)) into pump housing. 2.
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FUEL INJECTION PUMP 4. Install the charge pump (Figure 5-80, (1)) and tighten the four mount screws (Figure 5-80, (2)) to 6 - 7 ft-lb. (8 - 10 N.m). 2. Attach a stop to the camshaft. Tighten the governor weight nut (Figure 5-82, (1)) to 58 - 62 ft-lb. (79 - 84 N-m). Install the governor sleeve. 0001251a Figure 5-82 Note: Be careful not to bend or damage the governor housing gasket. Figure 5-80 3. Align and install a new governor housing gasket (Figure 5-83, (1)). Governor Installation 1.
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FUEL INJECTION PUMP 4. Turn the link lifter plate counterclockwise to the 6 o'clock position and install the governor assembly and link into the pump body (Figure 5-84). 1. Control Rack 2. Governor Link 3. Link Lifter 4. During Assembly 5. During Operation Figure 5-85 00013Ma Figure 5-84 Note: Do not force the link during installation, as damage can occur to the link and control rack pin. 6. Install two governor housing bolts by hand to hold the governor in place. 7.
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FUEL INJECTION PUMP 10. Tighten the link lifter retainer bolt (Figure 5-87, (1)) to 6- 7 ft-lb (8 - 10 N.m). 12. Install a new O-ring (Figure 5-89, (1)) to the stop solenoid and install the stop solenoid to the governor housing. Tighten the solenoid bolts to 6 - 7 ft-lb (8 - 10 N-m). OD01 304a Figure 5-87 11. Install the governor housing screws and tighten to 6 - 7 ft-lb (8 - 10 N-m) (Figure 5-88). 0001306a Figure 5-89 13. Pre-set the adjustment of the angleich . .
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FUEL INJECTION PUMP I 16. Install a new governor housing cover gasket (Figure 5-91). 0001307a Figure 5-91 17. Install the governor housing cover to the case (Figure 5-92). Tighten the governor housing cover bolts to 6 - 7 ft-lb (8 - 10 N-m).
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Section 6 ADJUSTMENT Page Introduction................................................................................ 6-3 Setup and Inspection....................................................................... 6-3 Adjustment ...................................................................................... 6-4 Component Identification........................................................... 6-4 High Idle Fuel Delivery ..............................................................
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ADJUSTMENT INTRODUCTION This section of the Service Manual describes the adjustment procedures necessary to setup and adjust the fuel injection pump and governor. 3. Mount the fuel injection pump (Figure 6-2) on the pump tester platform. The fuel injection pump delivery must be calibrated, whenever the pump is disassembled. A fuel pump test bench (Figure 6-1) is required to make the necessary adjustments. I SETUP AND INSPECTION I 1. Verify adjusting nozzle assembly and injection I starting pressure.
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ADJUSTMENT ADJUSTMENT High ldle Fuel Delivery The adjustment of fuel delivery requires correct specifications. Before performing any of the adjustments in this section, obtain the correct calibration data sheet for the fuel injection pump being tested. Contact your Yanmar Fuel Injection Equipment Central Distributor to obtain the data sheet. 1. Set the fuel pump speed at the high idle speed specified. (See Calibration Data Sheet).
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ADJUSTMENT Torque Fuel Delivery Reverse Angleich Spring Adjustment Torque fuel delivery adjustment requires adjustment of the fuel limiter torque spring (Figure 6-7, (3)) or angleich, when applicable. Note:) Do not thread past the reverse angleich lever or the reverse angleich lever will move in a direction of fuel reduction. 1. Set the pump speed at the torque rise speed (See Calibration Data Sheet) and move the control lever until it contacts the high idle speed limit bolt. 1.
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ADJUSTMENT Start Fuel Delivery 5. Recheck the rated fuel delivery. 1. Set the pump speed at the specified starting injection RPM (see Calibration Data Sheet), and set the control lever at the high idle position. 2. Turn the starting fuel adjustment bolt (Figure 6-11, (1)) to obtain the specified injection amount. (See Calibration Data Sheet) 3. Tighten the locknut (Figure 6-1 1, (2)) and install the hex cap. (3) 1. Governor Rear Cover 2. Reverse Angleich Spring 000 1324 3. Governor Tension Lever 4.
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ADJUSTMENT Note: There are a few turbo charged engines that incorporate a boost compensator on the governor assembly. Additional calibration data, procedures and adjustments can be found in the calibration data field of the Yanmar Distributor Web Site. Tamper-Proof Cap Installation 1. Install a new tab washer (Figure 6-12, (1)) and tamper-proof cap (Figure 6-12, (2)) on the fuel limiter assembly. 2. Install a new tamper-proof cap (Figure 6-13, (1)) on the high idle adjustment assembly.
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Section 7 FUEL INJECTION NOZZLE Page Introduction...................................................................................... 7-2 Specifications ................................................................................. 7-2 Nozzle Body Identification Number ................................................. 7-3 Special Torque Chart .................................................................. 7-4 Special Service Tools ....................................................................
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FUEL INJECTION NOZZLE INTRODUCTION SPECIFICATIONS This section of the Service Manual describes the operation and procedures necessary to disassemble and reassemble the fuel injection nozzles. All TNV fuel injectors have a three character identification mark (Figure 7-1, (1)).The first character starts with "V" or " W . Yar~marMP fuel injection pumps are designed for use on TNV (Dl) Direct lnjection engines, equipped with hole type nozzles.
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FUEL INJECTION NOZZLE NOZZLE BODY IDENTIFICATION NUMBER The type of nozzle can be determined from the identification number (Figure 7-1, (1)) inscribed on the outside of the nozzle body.
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FUEL INJECTION NOZZLE SPECIAL TORQUE CHART Component I Lubricating Oil Application (Thread Portion and Seat Surface) (39 - 44 N-m; 4 - 5 kgf.m) Injector Nozzle Case Nut I I I Tightening Torque I Not Applied SPECIAL SERVICE TOOLS No. 1. Tool Name Fuel Nozzle Mount Plate Yanmar Part No. 158090-51700 Illustration Application For holding and protecting fuel nozzle when servicing @ 0001340 2.
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FUEL INJECTION NOZZLE FUEL INJECTION NOZZLE Operation High pressure fuel from the fuel injection pump flows through the high pressure pipe into the oil passage in the nozzle housing and enters the nozzle body reservoir. When the fuel reaches the specified pressure, it pushes open the nozzle valve (held down by spring pressure) and is injected into the combustion chamber at high pressure.
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FUEL INJECTION NOZZLE Disassembly Note: Keep all parts in order by cylinder during disassembly and reinstall all small parts to their mating part as the components as components are matched. 1. Mount the hole type injection nozzle into the YANMAR special fuel nozzle mount plate PIN 158090-51700 (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.
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FUEL INJECTION NOZZLE I l I Cleaning Note: Before inspecting or assembling, all components must be washed with clean diesel fuel or standard cleaning solution and completely clean and free of contaminants. 1. Clean carbon from outside of nozzle body using a brass brush. 2. Clean nozzle opening with small length of deburred steel 0.0055 in. (0.14 mm) wire (Figure 7-6, (1)). 0001332A Figure 7-7 4. lnspect the nozzle valve stop for scratches and/or wear at the sealing surfaces on both sides.
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FUEL INJECTION NOZZLE Reassembly Injection Test The fuel injection nozzle is assembled in the reverse order of disassembly. After adjusting the nozzle to the specified opening pressure, check the fuel spray condition and make sure the nozzle does not leak. 1. Insert the adjusting shims, spring and spring seat in the nozzle holder, mount the nozzle valve stop plate with the pin, insert the nozzle assembly and tighten the nozzle case nut. 2. Use the nozzle holder when tightening the case nut to 28.8 - 32.
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FUEL INJECTION NOZZLE 3. Replace the nozzle assembly after all checks above if: Leakage is evident. Spray angle is incorrect. Atomization of fuel is incomplete. Opening and closing of nozzle is incomplete. WANMAR.
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Section 8 TROUBLESHOOTING Page Introduction...................................................................................... 8-2 Troubleshooting ............................................................................... 8-2 Preliminary Checks.................................................................... 8-2 Fuel System Troubleshooting Chart ................................................ 8-3 YAMMAR.
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TROUBLESHOOTING INTRODUCTION This section of the Service Manual includes troubleshooting procedures and troubleshooting charts used in the diagnosis of the fuel injection pump and fuel system problems. TROUBLESHOOTING Troubleshooting a fuel system related problem involves: Identifying the problem accurately. Duplicating the problem. Correctly identifying the cause of the problem. Correcting the problem. Eliminating the cause of the damage. Repairing the damage.
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TROUBLESHOOTING FUEL SYSTEM TROUBLESHOOTING CHART Use this troubleshooting chart to assist in the diagnosis of the fuel system prior to removing the fuel injection P'-"nP. Complaint Cause (1) No fuel in the fuel tank. (2) Fuel tank valve is closed. (3) Fuel line or valve is clogged. delivered to injection Pump- (4) Fuel filter element is clogged. (5) Air in fuel lines. (6) Fuel feed pump inoperable. (7) Fuel has gelled. (1) Stop solenoid is Inoperative. (2) Throttle control inoperative.
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TROUBLESHOOTING Complaint Correction Fill with fuel. Disassemble and clean, or replace element. Find and repair source of debris in fuel. Clean complete fuel system. Locate air leak using clear fuel line and repair. Repair or replace. Replace. Replace. Check and refill with proper fuel. Repair or replace. Determine cause of high fuel temperature and repair. Cause (1) Engine is out of fuel. (2) Fuel filter element is clogged. 2. Engine starts, but immediately stops. (3) Fuel line is clogged.
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TROUBLESHOOTING Complaint Cause (1) Air in fuel lines. (2) Fuel filter clogged. (3) Poor feed pump performance. (4) Delivery holder is too tight. (5) Plunger is worn and fuel injection adjustment is difficult. 4. Rough idle. (6) Movement of control rack is defective (6 a) Stiff plunger movement or sticking. (6 b) Rack and guide is defective. (6 c) Poor delivery valve operation. (7) Movement of governor is improper. (7 a) Shifter is worn. (7 b) Governor spring is too weak.
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TROUBLESHOOTING This Page Intentionally Left Blank MP Pump Service Manual YANMACI,