Yanmar 2210 injection pump plungers and barrels alignment

[topfli8979]

I had a local diesel shop replace barrels and plungers in my yanmar pump. No local tractor dealers know how to work on yanmar stuff. Tractor runs but runs wide open. Pumps lots of fuel no matter where the throttle is positioned, injection rack does move freely lock to lock.

So they only charged me for the parts and no labor, :shock: . I know I could send it off to another actual tractor shop, but don't want to put out anymore money. I have the old parts and see it's just a alignment issue between the barrels and plungers. Any manuals or help aligning these pieces out there?

 

[clemsonfor]

I think someone posted a similar process to rebuild it as to the yanmar pump. We had a member here successfully rebuild his!! First one ever that I remember.

Also we have a member that drops in from time to tI'm that knows what he is talking about and rebuilds them his name is like thepumpguysc or something like that. He can give advice and has rebuilt many of these.

But here is the weird thing....it's an injection pump ...there all similar, and either the same pump or a very similar one is used on JD tractors esp the ones made by hanmar, so any mechanic that can work on JD compacts from the 80s should know something about them.

 

[thepumpguysc]

The problem isn't with the pump{probably} its with the installation..
I've seen it happen 1000x..
When you installed the engine control rack onto the pump, {little hole in rack & that goes over a pin on the inj. pump}
The engine rack is not ON the hi-lo idle screws.. its BESIDE them.. so now the gov. doesn't know what to do or where to stop..
Basically what I'm saying is, it fell to the side.. off the screws.
Unfortunatly, the pump has to come back up.. the engine control rack repositioned & the pump reinstalled..
Its not a hard job, its just, ya gotta do the job twice..
I'M VERY SUPRISED the fuel shop didn't know this.. they must not do a lot of "drive-in" or "field/service call" work.??
I've seen it SO MANY TIMES, I can diagnose & fix it over the phone.. Lol
You didn't have them do something "goofy" to your pump did you?? install different P&B's than called for??
Did THEY tell you it needed P&B's "OR" did YOU tell them?? & what p# to use?? alittle history would be nice..

 

[winston1]

For what it is worth.

 

[topfli8979]

You may be on to something thepumpguysc, I did just as you said, put pump in tractor and put engine control rack directly onto pin. BUT it did seem to be at the lowest throttle setting on the rack. How do I verify I have it right?

I took pump into diesel shop complaining about tractor not getting enough fuel, lol, now it's got to much. Anyway they disassembled it and found scarring on one plunger and the other plunger sticking in barrel. They ordered the stock parts, they look identical anyway. Don't have part numbers handy right now.

So the barrels with a hole in one side and slot on other don't have to be installed any certain way for pump to operate correctly? Manual says nothing about it. Thanks for the link winston1

 

[thepumpguysc]

Yes the slot & the hole have to be aligned a certain way to operate correctly..
BUT.. if they got it backwards, the pump would pump in the shut-off position & NOT PUMP in the run position..
All the "fueling" screws are on the engine, not on the pump.. Basically the pump is limited by the screws on the engine..
I hope you didn't turn THOSE..??
Before installing the PUMP.. grab ahold of the ENGINE rack w/your hand & move it back & forth..
NOW, take it & twist it towards the engine alittle bit & move it back & forth.. you feel the difference..
When moving it STRAIGHT back & forth, the rack hits the stop screws.. if you twist it slightly, it miss's the screws..hence the hi speed & over fueling.. just a thought..

 

[topfli8979]

Ok. I will give that shot just like you instructed pumpguysc. For reference, how should the barrels be aligned at 0/off throttle. I pulled the nozzles on the pump to take a look and I can see inside the barrels. I see the holes in the sideof the barrels both facing down?

 

[thepumpguysc]

There are no nozzles on the pump.. are you talking about the delivery valve holders{top nuts}?? & delivery valves & springs??
You messed up..
Or did you flip the pump over & disassemble it from the bottom??
I don't know the position at shut off..
WHY would you disassemble a freshly rebuilt pump?? ESPECIALLY when you have no experience doing so..
The pumping plungers are assembled from the bottom... they are inserted into the barrels w/ the slot on the plunger towards the hole..
BUT like I said>> if it was assembled wrong at the fuel shop.. it would pump fuel when the stop was pulled.. & that's it.. no black smoke..

 

[topfli8979]

Sorry for the delay, have been out of town.

Pumpguysc I was referring to the delivery valve "nozzle" connections or whatever they are called. Yes , I unscrewed them. After you told me about the fuel screws , and having to put pressure on the engine rack when installing pump. Then still having issues. I figured I should just remove the injection lines at pump and see what kind of flow is coming out. The right side has lots of fuel coming out, and left side is just spitting at full throttle. Vice versa at throttle stop , left side lots of fuel, right side spits. Obviously is not right inside. So I took a look from the bottom. I can figure this thing out with some helpful advice, rebuilt my CV pump on my Perkins with no problems. This has alot less parts to it.

 

[thepumpguysc]

If you had gone into the bottom of the pump??
you either have a segment out of time w/ the control rack or a plunger turned around the wrong way.. see Winstons link..
IF you ONLY went into the top??
you have pulled the barrel up & out of its holding pin in the housing, when you removed the delivery valve & gasket.
IF THAT HAPPENED, when you went to tighten it, you sheared the pin in the housing.. not good.. & crushed the gasket under the barrel..
Why not send it off to me before you HAVE TO BUY ANOTHER PUMP..?? I can probably save the pump housing & you already have new orings & gaskets, besides the 1 that's probably crushed.. I'll fix it & treat you right..

I got a call yesterday from a fella that "worked" on his pump.. the engine ran away & his wife called 911 before he had gotten it shut down..
It was REAL hot outside so he had pushed it in their attached garage.. when it fired up, it went straight to wide open, about 3000 rpms & shot enough black smoke to where the wife thought the house was on fire..
He couldn't get it shut down so he pushed it out of the garage & shut off the fuel.. & sat & watched.. as it S L O W L Y died off..
Do you know how long it takes to shut off, AFTER you turn off the fuel??!!! a LONG TIME.. & it filled the neighborhood w/ JET BLACK smoke.
The police, fire trucks & EMS were on-scene.. Not a pretty site..
I now have the pump, while he's checking out his engine..
That's just 1 horror story.. it coulda been worse.. it could of blown up & serious injuries could of been in the future for this guy..
Not to mention the oil clean up or fire, from the engine coming apart, in his nice attached garage..
I've got hundreds of stories like, that in my 30 years of rebuilding injection pumps..