Yanmar MP Series Industrial Diesel Engine Repair Service Manual

-
This Workshop Service Repair manual PDF download for the 3MP2, 4MP2 & 4MP4 Yanmar Industrial Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

This manual describes the features, service, adjustment and troubleshooting procedures of the Yanmar MP2 and MP4 fuel injection pump models used on TNV Direct Injection (DI) engines.


APPLICABLE MODELS :

Yanmar 3MP2
Yanmar 4MP2
Yanmar 4MP4


TABLE OF CONTENTS :

Introduction
Safety
General Service Information
Governor
Fuel Injection Pump
Adjustment
Fuel Injection Nozzle
Troubleshooting
Safety of 2G-ECO-GOVERNOR
Structural Description
Disassembly, Reassembly, and Inspection
Tightening Torque List for 2G-ECO-GOVERNOR
Adjustment Items for Injection Quantity of 2G-ECO-GOVERNOR
Tool
Attached Table


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 0BMP0-G00101
Total Pages : 147


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

COVER
Table of Contents
Introduction
Safety
Safety Statements 2-3
Safety Precautions 2-4
Safety Statements
Safety Precautions
General Service Information
Fuel Injection Pump 3-3
Fuel Injection Pump Nameplate 3-3
Specifications 3-4
Measuring Instruments 3-4
Pump Torque Specifications (MP2 / MP4 Models) 3-6
Pump Torque Specifications (MP2 / MP4 Models) 3-7
Governor Torque Specifications (MP2 / MP4 Models) 3-8
Governor Torque Specifications (MP2 / MP4 Models) 3-9
Fuel Injection Pump
Fuel Injection Pump Nameplate
Specifications
Measuring Instruments
Pump Torque Specifications (MP2 / MP4 Models)
Pump Torque Specifications (MP2 / MP4 Models)
Governor Torque Specifications (MP2 / MP4 Models)
Governor Torque Specifications (MP2 / MP4 Models)
Governor
Introduction 4-3
Governor Operation 4-4
Governor Components (MP2 / MP4 Models) 4-6
Governor Components (MP2 / MP4 Models) 4-7
Governor Service 4-8
Assembly 4-12
Installation 4-15
Introduction
Governor Operation
Governor Components (MP2 / MP4 Models)
Governor Components (MP2 / MP4 Models)
Governor Service
Removal
Disassembly
Assembly
Installation
Fuel Injection Pump
Introduction 5-3
Specifications 5-3
Pump Torque Specifications (MP2 / MP4 Models) 5-4
MP-Fuel Pump Components 5-5
MP-Fuel Pump Components 5-6
Fuel Flow 5-7
Fuel Flow Diagram 5-8
Charge Pump 5-9
Timer Control Mechanisms 5-10
Speed Timer Function 5-10
Load Timer Function 5-11
Cold Start Timer 5-12
Fuel Pump Disassembly 5-13
Fuel Pump Reassembly 5-22
Introduction
Specifications
Pump Torque Specifications (MP2 / MP4 Models)
MP-Fuel Pump Components
MP-Fuel Pump Components
Fuel Flow
Fuel Flow Diagram
Charge Pump
Specifications
Timer Control Mechanisms
Speed Timer Function
Load Timer Function
Cold Start Timer
Fuel Pump Disassembly
Governor
Charge Pump
Hydraulic Head
Distribution Shaft, Camshaft and Roller Lifter Removal
Fuel Pump Reassembly
Distribution Shaft and Camshaft
Gear Alignment
Roller Lifter
Plunger and Control Rack
Plunger (Bottom Clearance) Measurement
Hydraulic Head and Valve(s) Reassembly
Charge Pump
Governor Installation
Adjustment
Introduction 6-3
Adjustment 6-4
Rated Fuel Delivery 6-4
Torque Fuel Delivery 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
Introduction
Setup and Inspection
Adjustment
Component Identification
High Idle Fuel Delivery
Rated Fuel Delivery
Torque Fuel Delivery
Reverse Angleich Spring Adjustment
Low Idle Fuel Delivery
Start Fuel Delivery
Ultra-Low Speed Delivery
Stop Fuel Delivery
Tamper-Proof Cap Installation
Fuel Pump Timing Index Stamping Identification
Fuel Injection Nozzle
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
Inspection 7-7
Introduction
Specifications
Nozzle Body Identification Number
Special Torque Chart
Special Service Tools
Measuring Instruments
Fuel Injection Nozzle
Operation
Disassembly
Cleaning
Inspection
Reassembly
Opening Pressure Adjustment
Injection Test
Troubleshooting
Introduction 8-2
Troubleshooting 8-2
Preliminary Checks 8-2
Fuel System Troubleshooting Chart 8-3
Introduction
Troubleshooting
Preliminary Checks
Fuel Injection Pump Repair
Fuel System Troubleshooting Chart
2G-ECO-GOVERNOR SAFETY
Safety Labels 9-2
Precaution For Safe Servicing 9-3
Working Wear 9-4
Safety Labels
Precaution For Safe Servicing
Service Shop (place)
Working Wear
Tools to be Used
Use of Genuine Parts, Oil and Grease
Bolt and Nut Tightening Torque
STRUCTURAL DESCRIPTION
DISASSEMBLY, REASSEMBLY, AND INSPECTION
Disassembling 11-2
Removing Pump Body and Governor Body 11-2
Removing Speed Sensor 11-4
Removing Actuator 11-4
Removing Governor Lever 11-5
Removing Governor-Lever Shaft 11-6
Removing Rack-Restoring Assisting Spring 11-7
Disassembling the Governor Lever Component 11-7
Assembling 11-9
Assembling the Governor Case Component 11-9
Attaching Speed Sensor 11-14
Attaching Actuator 11-14
Attaching Speed Sensor Gear 11-16
Attaching Governor Assembly 11-17
Checking Speed-Sensor Output 11-19
Adjusting Eccentric Shaft 11-19
Routing and Arranging Wire Harness 11-21
Supplement 11-23
Assembling solenoid valve type CSD 11-23
Disassembling
Removing Pump Body and Governor Body
Removing Speed Sensor
Removing Actuator
Removing Governor Lever
Removing Governor-Lever Shaft
Removing Rack-Restoring Assisting Spring
Disassembling the Governor Lever Component
Assembling
Assembling the Governor Case Component
Attaching Speed Sensor
Attaching Actuator
Attaching Speed Sensor Gear
Attaching Governor Assembly
Checking Speed-Sensor Output
Adjusting Eccentric Shaft
Routing and Arranging Wire Harness
Supplement
Assembling solenoid valve type CSD
TIGHTENING TORQUE LIST FOR 2G-ECO-GOVERNOR
ADJUSTMENT ITEMS FOR INJECTION QUANTITY OF 2G-TYPE ECO-GOVERNOR
TOOL
ATTACHED TABLE
BACK COVER

-