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Page 59
FUEL
INJECTION
PUMP
4.
lnspect the pump housing
(Figure 5-19, (1,2)).
5.
lnspect the drive gear
(Figure 5-20, (I)),
rotor
If the pump 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
5-1
9
Figure
5-20
Figure
5-21
mNMAR.
MP
Series
Service
Manual
Page 60
FUEL
INJECTION
PUMP
Hydraulic Head
1.
Mark the positions of the fuel inlet
(Figure 5-22, (1))
and return fittings
(Figure 5-22, (2))
and remove.
Figure
5-22
IMPORTANT
The delivery valve has many parts that are
very
small. Do not drop or lose the check
valve.
2.
Remove each of the delivery valve housings
valves and gaskets
(Figure 5-23).
0001
181
Figure
5-23
Note: Be careful not to lose the secondary
check balls during disassembly of the
delivery valves.
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.
1.
Valve Seat
2.
Return Spring
3.
Secondary Check Ball Spring Seat
4.
Secondary Check Ball
5.
Delivery Valve
6.
Primary Spring
7.
Delivery Valve Housing
Figure
5-24
4.
Remove the distribution shaft plug
(Figure 5-25, (I)),
and O-ring
(Figure 5-25, (2)).
GO03552b
Figure
5-25
MP
Series
Service
Manual
YANMAR,
Page 61
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. Remove the thermo-element
assembly
(Figure 5-28,
(4)),
which includes the
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)).
0001
185
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 seal
(Figure 5-27, (3)).
Figure
5-27
YANMAR,
MP
series service
Manual
0003551
Figure
5-28
Page 62
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)).
0003554
Figure 5-29
Remove the four hydraulic head bolts
(Figure 5-30, (1)).
10.
Remove the hydraulic head assembly and
gasket
(Figure 5-31, (1)).
Figure 5-31
11.
Use the spring compressor tool
(Figure 5-33, (2))
(Included in Yanmar Special
Tool Kit P/N 458091) to compress the plunger
spring
(Figure 5-32, (1))
and remove the spring
retainer
(Figure 5-33, (1)).
0001
193A
Figure 5-30
Figure 5-32
MP
Series
Service
Manual
YANMAR
Page 63
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 ~etainer
'
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)).
00001215a
Figure
5-35
YANMAR.
MP
series service
Manual
i
0001220
Figure
5-37
Page 64
-
FUEL INJECTION PUMP
Distribution Shaft. Camshaft and
3.
Remove the roller lifter alignment pin
Roller Lifter Removal
1.
Remove the distribution shaft coupler
(Figure 5-38, (1)).
0001
196
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
~er~es ~ervlce
Manual
YANMAFI,
Page 65
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)).
Figure 5-44
Lift the distribution shaft
(Figure 5-45,
(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
Page 66
FUEL INJECTION
PUMP
9.
Remove the distribution shaft assembly
(Figure 5-46).
FUEL PUMP REASSEMBLY
0001210
Figure
5-46
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.
0001237
Figure
5-47
2.
Apply assembly grease to the camshaft lobes,
bushing journal and ball bearing.
5-24
MP
series service
Manual
YA
NMAR
Page 67
FUEL
INJECTION
PUMP
3.
With the distribution shaft gear touching the
4. Install the camshaft bearing retainer and bolts
pump body, insert the camshaft into the 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 distribution shaft gear and the
-
.
camshaft key from hitting the camshaft bushing.
(Figure 5-48).
Note: 4-cylinder camshafts require special care
during reassembly due to tight
tolerances.
0001
239
Figure
5-48
Figure
5-49
VANMAR.
MP
series service
Manual
5-25
Page 68
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. Once the marks are aligned, do not raise the
distribution shaft too far or the gears will disengage and misalign.
3.
The gears are properly aligned when 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 holding the gear alignment, install the 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 marks for proper alignment.
Distribution Shaft Angle
Camshaft Angle MP2
-
3
Cyl.
Camshaft Angle MP2
-
4
Cyl.
'.
PI
0003556A
0001207BB W1207B
1.
Retaining Plate
3.
Housing Timing Marks
2. Distribution Drive Shaft Lugs 4. Camshaft Key
Camshaft Angle MP4
0001 207CC
Figure
5-50
MP
Series
Service
Manual
YANMAR,
Page 69
FUEL INJECTION PUMP
Roller Lifter
1.
lnstall the link lifter
(Figure 5-51, (1))
and
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.
0001248A
Figure
5-51
3.
With roller lifter groove aligned, install the roller
lifter alignment pin
(Figure 5-52, (1)).
Slowly
tighten the pin by hand
(4
mm hex wrench)
while turning camshaft to ensure the lifter
moves freely with pin in position. Torque the pin
to
3
-
4
ft-lb.
(4
-
5
N-m). Lifter must move freely
after pin is torqued.
0001249
Figure
5-52
Plunger and Control Rack
1.
Install the plunger
(Figure 5-53, (1))
into the
head assembly.
Figure
5-53
2.
Install the control sleeve
(Figure 5-55, (2))
aligning the plunger identification marking
(example:
"W4")
(Figure 5-54, (4))
with the ball
(Figure 5-54, (2))
of the control sleeve.
1.
Upper Lead
4.
Identification
2.
Ball Marking
3.
Sub-lead
Figure
5-54
YANMAR.
MP
series service
Manual
Page 70
FUEL INJECTION PUMP
-
--
--
-
3. Install the spring retainer
(Figure
5-55,
(1)).
00001217
1.
Spring Retainer
2.
Control Sleeve
3. Plunger
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.
5.
Installing the slide into the spring retainer
(Figure
5-57,
(I)), (Figure
5-58,
(1)).
00001 233A
Figure 5-56
0000 12338
Figure 5-57
Figure 5-58
Install and tighten the four bolts
(Figure
5-59,
(1))
to
2
-
3 ft-lb. (3
-
4
N-m).
00001215a
Figure 5-59
MP
Series Service
Manual
YANMAR*
Page 71
FUEL INJECTION
PUMP
7.
Measure the rack (Figure 5-60,
(4))
movement,
9.
Install the rack return spring (Figure 5-61,
(1)).
the range of rack motion should be The spring must be able to return the rack from
approximately 14 mm of total travel. the maximum decreased fuel position to the
8. Measure rack backlash, the total backlash
maximum increased fuel position.
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.
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. Install the plunger spring (Figure 5-62, (1)) and
spring retainer (Figure 5-62,
(2)).
Use the
spring compressor tool (Figure 5-63, (2))
(Included in Yanmar Special Tool Kit
PIN
458091) to compress the plunger spring and
install the spring retainer.
OKl12128
Figure 5-62
Page 72
FUEL
INJECTION
PUMP
0001213
1. Spring Retainer
2.
Spring Compressor Tool
3. Hydraulic Head
Figure
5-631
11. Install the distribution shaft coupler
(Figure 5-64, (1)).
13. Install the original plunger shim(s)
(Figure 5-66, (1)) inside the lifter.
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. Then tighten to
torque of
(MP2 - 13 - 16 ft-lb. (18 - 22 N.m))
(MP4 - 21
-
24
ft-lb.
(28
-
32 N-m)) in a diagonal
order.
Figure
5-64
12.
Install a new head gasket (Figure 5-65, (1)).
0001259
Figure
5-67
Figure.
5-65
5-30
MP
series
service
Manual
YANMAR,
Page 73
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 129906-51 400), increase or
decrease the shim pack (Figure
5-69,
(3))
in
the roller lifter bore to obtain the zero
mark
(+
0.03 mm) on the dial indicator.
Note: Do not use the ball tip on the dial
indicator when measuring, 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.
Position the camshaft with the roller lifter at the
bottom of the cam profile.
3. Remove the dial indicator and adapter and zero
the dial indicator (Figure
5-68,
(1)) using the
specified spacer (Figure
5-68,
(2)).
The correct
size spacer can be found in the calibration data
sheet (bottom clearance [mm]) for each pump
number.
0001314AA
1. Dial Indicator 3. Flat Surface
2. Plunger Spacer
Figure
5-68
4. Reinstall the dial indicator (Figure
5-69,
(4))
into the barrel (Figure
5-69,
(1)) and record the
measurement.
YANMAR,
MP
series
service
Manual
1. Barrel
U
0001315A
4. Dial Indicator
2. Plunger 5. Plunger
3.
Shim(s) Adjustment
Dimension
"An
Figure
5-69
Page 74
FUEL INJECTION PUMP
Hydraulic Head and Valve(s)
Reassembly
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. Install the distribution shaft plug
(Figure 5-70, (3))
and O-ring
(Figure 5-70,
(2))
and tighten to
11
ft-lb. (15 N-m).
Install new delivery 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
distribution shaft plug with a flat bottom.
The replacement will require a new plug
to allow clearance for the taller
distribution shaft. The parts catalog lists
the new plug with a machined recess on
the bottom.
2.
Return Spring
3.
Secondary Check Ball Spring Seat
4. Secondary Check Ball
5.
Delivery Valve
6.
Primary Spring
7.
Delivery Valve Housing
Figure 5-72
7.
Install the charge pump fuel outlet strainer
gasket
(Figure 5-73,
(2))
and tighten the plug
(Figure 5-73, (1))
to
16
-
21 ft-lb. (25
-
29
N.m).
5-32
MP
series service
Manual
VANMAR.
Page 75
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).
Figure 5-73
9.
lnstall a new timer housing seal
(Figure 5-74,
(1))
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. lnstall the timer spring
(Figure 5-75, (6))
and
piston
(Figure 5-75, (5))
into the housing.
Figure 5-75
0001279
Figure 5-74
YANMARe
MP
Series
Service
Manual
5-33
Page 76
FUEL INJECTION PUMP
12. Install a new O-ring
(Figure 5-76, (2))
on the
Charge Pump
thermo-element
(Figure 5-76, (1))
and tighten
Note: If charge pump was disassembled for
to 22 - 26 ft-lb. (30 - 35
N-m).
inspection, clean all parts thoroughly
Do not over-torque.
before reassembly. If any part is
Figure 5-76
13. lnstall the engine coolant fitting
(Figure 5-75, (3))
and seals in their original
position.
14. lnstall the coolant plug
(Figure 5-75, (1))
and
tighten to 16 - 18 ft-lb. (22 - 25 N-m). Do not
over-torque.
15. lnstall the fuel return
(Figure 5-77, (2))
and
inlet fittings
(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. lnstall and 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
pump housings. Tighten the two
(5
mm hex)
pump housing screws
(Figure 5-78,
(3))
to
6
-
7
ft-lb. (8 - 10 N-m).
0003559A
Figure 5-78
lnstall new charge pump housing O-rings
(Figure 5-79, (1)).
Figure 5-79
5-34
MP
Series
Service
Manual
YANMAR,
Page 77
FUEL
INJECTION
PUMP
4. Install the charge pump
(Figure 5-80, (1))
and
2.
Attach a stop to the camshaft. Tighten the
tighten the four mount screws
(Figure 5-80,
(2))
governor weight nut
(Figure 5-82, (1))
to
to
6
-
7
ft-lb. (8
-
10
N.m).
58
-
62
ft-lb.
(79
-
84 N-m). Install the 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 housing gasket.
3.
Align and install a new governor housing gasket
(Figure 5-83,
(1)).
000
13Wa
Figure
5-83
YANMAR,
MP
Series
Service
Manual
5-35
Page 78
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).
00013Ma
Figure 5-84
Note: Do not force the link during installation,
as damage can occur to the link and
control rack pin.
Note: Figure 5-85 illustrates the governor link
connection to the control rack. The
actual connection is blind, therefore this
illustration is used to assist during
assembly.
5. While installing the governor assembly, slide
the link lifter as shown (Figure
5-85,4), to allow
the link to slide in to align with the control rack
pin.
1.
Control Rack
4.
During Assembly
2. Governor Link 5. During Operation
3. Link Lifter
Figure 5-85
6. Install two governor housing bolts by hand to
hold the governor in place.
7.
While pushing the governor lever assembly to
the full stop position through the stop solenoid
opening, rotate the link lifter clockwise to the
12 o'clock position.
8.
Verify the link installation by watching plunger
rotation from the top of the hydraulic head. The
plunger should rotate in both directions while
moving the control rack in and out.
9.
Install a new copper seal (Figure 5-86,
(3)),
plunger and barrel plug (Figure 5-86,
(1))
and
O-ring (Figure 5-86,
(2)).
Tighten to
(MP2
-
22 - 26 ft-lb. (30 - 35 N.m))
(MP4 - 33 - 37 ft-lb. (45 - 50 N.m)).
Figure 5-86
5-36
MP
Series Service
Manual
YANmAR
Page 79
FUEL
INJECTION
PUMP
10. Tighten the link lifter retainer bolt
12. Install a new O-ring
(Figure
5-89,
(1))
to the
(Figure
5-87,
(1))
to
6-
7
ft-lb (8 - 10 N.m). stop solenoid and install the stop solenoid to
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).
0001305a
Figure 5-88
the governor housing. Tighten the solenoid
bolts to
6
-
7
ft-lb
(8
-
10
N-m).
0001
306a
Figure 5-89
13.
Pre-set the adjustment of the angleich
.
.
assembly, by loosing the angleich lock nut
(Figure
5-90,
(1)).
0001
306C
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 angleich lock nut.
YANMAR.
MP
series service
Manual
5-37
Page 80
FUEL INJECTION PUMP
16.
Install a new governor housing cover gasket
I
(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).
0001 308a
Figure 5-92
5-38
MP
series service
Manual
YANMAR*
Page 81
Section
6
ADJUSTMENT
Page
Introduction
................................................................................
6-3
Setup and Inspection
.......................................................................
6-3
Adjustment
......................................................................................
6-4
Component Identification
...........................................................
6-4
High
Idle 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-Low Speed 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
Page 82
ADJUSTMENT
This Page Intentionally Left Blank
MP Series Service
Manual
YANMAR.
Page 83
ADJUSTMENT
INTRODUCTION
This section of the Service
Manual
describes the
adjustment procedures necessary to setup and
adjust the fuel injection pump and governor.
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.
Figure
6-1
2.
Inspect the high pressure injection line.
YANMAR
MP
series service
Manual
Inner diameter
Outer diameter
x
length
Minimum bending radius
3. Mount the fuel injection pump
(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
6-3
5.
Securely tighten all fuel lines to the fuel pump
and tester.
6. Set the oil feed pressure
(Figure 6-4)
at
2.8-4.3 psi
(1
9.6 - 29.4 kPa, 0.2 - 0.3 kgf/cm2),
temperature at 40 * 2°C
(1
04 3.6"F).
Figure
6-4
7. Operate the pump tester to purge the fuel lines
of all air.
Page 84
ADJUSTMENT
ADJUSTMENT
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.
Adjustments must be performed in the following
order when adjusting the governor:
1.
High ldle Fuel Delivery
2.
Rated Fuel Delivery
3.
Torque Fuel Delivery
4. Reverse Angleich Spring Adjustment
5.
Low ldle Fuel Delivery
6.
Starting Fuel Delivery
7.
Stop Fuel Delivery
8.
Re-check Rated Fuel Delivery
9.
Tamper-Proof Cap Installation
Component Identification
1. Rated Fuel Limiter Adjustment Assembly
2. Starting Fuel Adjustment Assembly
3.
High ldle Speed Limit Bolt
4. Reverse Angleich Adjustment Assembly
5.
Low ldle Speed Limit Bolt
6.
Control Lever
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 bolt
from turning.
Rated Fuel Delivery
The MP2 pump has a rated fuel limiter adjustment
assembly
Figure 6-6
as standard equipment.
1. Remove the tamper-proof cap and screw in the
fuel limiter assembly
(Figure 6-6, (1))
until it
contacts the governor tension lever and then
back off one-quarter
(114) turn.
0003465m
Figure
6-6
2.
Set the pump speed at the rated speed
(see
Calibration Data Sheet)
and move the control
lever until it contacts the high idle speed limit
bolt
(Figure
6-5,
(3)).
3.
Adjust the rated injection amount by turning the
fuel limiter assembly
(Figure 6-6, (1))
in or out
to obtain the correct specification,
(See
Calibration Data Sheet).
MP
Series Service
Manual
Page 85
Torque Fuel Delivery
Torque fuel delivery adjustment requires
adjustment of the fuel limiter torque spring
(Figure
6-7,
(3))
or angleich, when applicable.
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.
If the fuel limiter assembly has a torque spring:
Screw in the fuel limiter torque spring
adjustment screw
(Figure
6-7,
(4))
to obtain
the specified injection amount
(See Calibration
Data Sheet)
and fasten the lock nut.
ADJUSTMENT
Reverse Angleich Spring Adjustment
Note:) Do not thread past 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 angleich assembly
(Figure
6-8,
(1))
until
contact is just 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
RPM
number.
(See Calibration Data
Sheet).
00034651
Figure
6-8
3.
Set the angleich assembly to the specified
injection quantity.
(See Calibration Data Sheet).
4. Tighten the lock nut
(Figure
6-8,
(2))
to
24.5
-
29.4
N-m
(2.5
-
3.0
kgf.m).
0003465p
Figure
6-7
If the fuel limiter assembly does not have torque
spring:
See
Reverse Angleich Spring Adjustment
on
this page.
YANMAR,
MP
series service
Manual
Page 86
ADJUSTMENT
5.
Recheck the rated fuel delivery.
(3)
000
1324
1.
Governor Rear
3.
Governor Tension
Cover Lever
2.
Reverse Angleich
4.
Reverse Angleich
Spring Lever
Figure
6-9
Low Idle Fuel Delivery
1.
Set the pump speed at the low idle pump speed
(see Calibration Data Sheet)
with the control
lever
(Figure 6-10, (1))
in the idle position.
2.
Turn the low idle speed limit bolt
(Figure 6-10, (2)
to achieve the correct idling
delivery amount.
(See Calibration Data Sheet)
3.
Tighten the lock nut.
0003465h
Figure
6-1
0
Start 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 6-1 1, (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.
Figure
6-1 1
Ultra-Low Speed Delivery
1.
Set the pump speed at
50
RPM and check the
ultra-low speed setting injection volume
specification.
(See Calibration Data Sheet)
Note: The Ultra Low Speed Test checks the
condition of the plunger and barrel.
Delivery below specifications indicates
excessive leakage.
Stop Fuel Delivery
Set the control lever at the high idle position.
1.
Set the pump speed at
50
RPM higher than the
specified high idle speed
(see Calibration Data
Sheet)
and check that the (governor cut out)
injection amount reduces to zero.
(See
Calibration Data Sheet)
2.
Set the pump at the rated speed and turn off the
stop solenoid and check that the injection
amount reduces to zero.
MP
Series
Service
Manual
YANMAR.
Page 87
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 6-1 2, (1))
and
tamper-proof cap
(Figure 6-1
2,
(2))
on the fuel
limiter assembly.
2.
Install a new tamper-proof cap
(Figure 6-13, (1))
on the high idle adjustment
assembly.
0003465q
Figure
6-12
Figure
6-13
YANMAR.
MP
Series
Service
Manual
Fuel Pump Timing lndex Stamping
Identification
The timing index numbers stamped on the original
fuel pump hydraulic head are needed for 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 original fuel pumps. The
timing index numbers are needed to properly set
injection timing when reinstalling the fuel injection
pump.
Upon completion of fuel pump repairs when the
hydraulic head
is
replaced the correct timing index
number must be manually stamped
(Figure 6-14, (1))
onto the boss on the engine side
of the hydraulic head.
.
-
T
0004666
Figure
6-14
The correct timing index number can be found on
,
the Yanmar Distributor Web Site under the "F.I.E."
heading or under the document search function.
Use category F.I.E. to locate the timing lndex
Information for replacement of the MP Fuel
Injection Pump. ISD-05-001, Page
4.
Page 88
ADJUSTMENT
This
Page Intentionally Left Blank
MP
Series Service
Manual
YANMAR*
Page 89
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
......................................................................
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 Pressure Adjustment
...................................................
7-8
Injection Test
............................................................................
7-8
Page 90
FUEL INJECTION NOZZLE
INTRODUCTION
This section of the
Service
Manual
describes the
operation and procedures necessary to
disassemble and reassemble the fuel injection
nozzles.
Yar~mar MP fuel injection pumps are designed for
use on TNV
(Dl) Direct lnjection engines, equipped
with hole type nozzles.
A
list of Yanmar MP fuel
injection pump equipped engines is provided in the
following chart.
Yanmar Engines equipped
with
MP Fuel
Injection Pumps
3TNV82A
SPECIFICATIONS
All TNV fuel injectors have a three character
identification mark
(Figure
7-1,
(1)).
The first
character starts with
"V"
or
"W.
00041
05
Figure
7-1
*
Fuel injector identification is critical as each engine
has a unique fuel injection pressure. The fuel
nozzle is specifically matched to 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 kgf/cm2) after about 5 hours of operation
due to the initial break in of the spring.
When adjusting a new fuel injector or after it
has been disassembled for service, adjust
the fuel injector
72.5 psi (0.5
MPa; 5.0 kgf/cm2) higher than
the above standard.
MP
Series Service
Manual
YANMAR*
Page 91
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.
0001328
Figure
7-1
Y DLL A
-
150
P
244JO
Design Code
Nozzle Size
(P
Size, S Size)
Spray Angle
Mounting Angle of Nozzle on Cylinder Head
Code
"A:
At Angle
No Code: Not At Angle
Type (DLL: Semi-Long Type)
YANMAR
YANMAR,
MP
series service
Manual
Page 92
FUEL INJECTION NOZZLE
SPECIAL TORQUE CHART
Component
I
Tightening Torque
Lubricating Oil Application
I
(Thread Portion and Seat Surface)
I
I
SPECIAL SERVICE TOOLS
I
Note: Tools not having Yanmar part numbers must be acquired locally.
Injector Nozzle Case Nut
MEASURING INSTRUMENTS
(39
-
44
N-m;
4-
5 kgf.m)
No.
1.
2.
Not Applied
Note: Tools not having Yanmar part numbers must be acquired locally.
Tool Name
Fuel Nozzle Mount Plate
Yanmar Part No. 158090-51 700
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 Injector Tester (Locally Available)
Application
For observing injection spray pattern of fuel
injection nozzle and measuring injection
pressure
Page 93
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. lnjection nozzle opening
pressure is adjusted using shims to increase or
decrease the spring pressure on the nozzle valve.
(See Opening Pressure
Adjustment on page
7-8)
As fuel passes through the nozzle, it
is
atomized to
mix 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 injection nozzles must be kept in top
condition to maintain performance and
operating efficiency.
The nozzle valve is automatically closed by the
nozzle spring pressure at the end of the fuel
injection pump stroke.
Unused fuel between the nozzle valve and nozzle
body flows from the hole above the nozzle spring
through the fuel return fitting and back into the fuel
tank.
1.
Fuel Return
4.
Nozzle Spring
Fitting
Seat
2.
Nozzle Housing
5.
Fllter
3.
Nozzle Spring (Non-serviceable)
Figure
7-2
1.
Reservoir Port
4.
Nozzle Body
2.
Nozzle Valve
5.
Injection Port
3.
Fuel Reservoir
6.
Spray Angle
Figure
7-3
YAMMAR.
MP
series
service
Manual
Page 94
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
158090-51 700
(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
Nozzle Valve
Nozzle Body
Nozzle Case Nut
Figure
7-5
MP
Series Service
Manual
YANMAR.
Page 95
FUEL INJECTION NOZZLE
I
Cleaning
Note: Before inspecting or assembling, all
components must be washed with clean
diesel fuel or standard cleaning solution
l
and completely clean and free of
contaminants.
1. Clean carbon from outside of nozzle body using
a brass brush.
I
2.
Clean nozzle opening with small length of
deburred steel 0.0055 in. (0.14 mm) wire
(Figure
7-6,
(1)).
0001331
Figure
7-6
3.
Clean nozzle seat with cleaning spray.
Note: An ultra sonic cleaner can be used to
effectively clean the injector body and
inner components after loose material is
removed.
Inspection
1. lnspect oil seal surfaces for abnormal scratches
or wear, replace as 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
abnormally worn.
3.
Rotate and slide the nozzle to check for smooth
movement
(Figure
7-8), replace the nozzle
assembly if the nozzle does not slide smoothly.
YANM'R.
MP
Series Service
Manual
0001
332A
Figure
7-7
4.
lnspect the nozzle valve stop for scratches
and/or wear at the sealing surfaces on both
sides. Check for abnormal wear at stop plate
center hole where it makes contact with the
nozzle
(Figure
7-8, (I)), replace if worn.
0001333b
Figure
7-8
5. lnspect the nozzle spring, replace it if
deformed, or the surface is scratched or rusted.
0001530
Figure
7-9
6.
lnspect the nozzle oil sealing surface for
scratches
and/or wear, replace it if wear is
excessive.
Page 96
FUEL
INJECTION NOZZLE
Reassembly
The fuel injection nozzle is assembled in the
reverse order of disassembly.
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
-
32.5 ft-lb (39 - 44 N-m, 4 - 5 kgf.m).
Opening Pressure Adjustment
Mount the fuel injection nozzle on the nozzle tester
(Figure 7-10, (1))
and use the handle to measure
injection opening pressure. If it is not at specified
pressure, add or remove adjusting shims to
increase or decrease the pressure, see
Specifications
on
page
7-2
for fuel injector opening
pressures.
Note: Adjusting by 0.004 in (0.1 mm) results in
a change in the injection opening
pressure of about 290 psi (2
MPa,
20 kgf/cm2)
COO1
335
Figure
7-1
0
Injection Test
After adjusting the nozzle to the specified opening
pressure, check the fuel spray condition and make
sure the nozzle does not leak.
1. Check the injection spray condition, by
operating the nozzle tester lever once or twice
per second to check for abnormal injection.
Correct
Spray from each nozzle hole is uniform.
-
Spray is fully atomized (no streams of fuel).
Start and stop of injection is "sharp" (a
clean chatter sound should be heard).
Poor
0001337A
Excessive difference in spray angle.
lncomplete atomization
Causes - lncomplete opening/closing of
injection nozzle.
Figure
7-1
1
2.
Check that the nozzle tip is not leaking after two
or three injections, then gradually increase the
pressure up to 200 psi (1.38
MPa;
14.06 kg/cm2). Maintain the pressure for 5
seconds and make sure that no oil is dripping
from the opening pass the nozzle.
MP
Series Service
Manual
YANMAIP.
Page 97
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.
MP
Series
Service
Manual
7-9
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
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.
Verify corrections made have corrected the initial problem.
Preliminary
Checks
To quickly and accurately troubleshoot fuel system problems, the following preliminary checks should be
performed before the fuel injection 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 fuel pressure throughout the fuel system.
Check for restrictions and leaks throughout the fuel system.
Verify fuel injection timing is within specifications.
Verify fuel nozzle operation and nozzle spray condition.
Fuel Injection Pump Repair
If the fuel injection pump is found to be faulty, remove it from the engine for repair.
It is very important that the root cause of the failure is eliminated before installing and I or repairing the fuel
injection pump.
MP Pump
Service
Manual
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