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Old 19-07-2011, 15:23   #1
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Yanmar 3GM30 - No Fuel at Injectors 2 and 3

Hi to all from NZ,
I have posted in another thread but I think this subject deserves its own heading for those in the same situ later.
My motor has been sitting for 7yrs whilst we rebuild our boat .(& find the funds to do so!)
Symptoms : No fuel at injector 2&3 High pressure side of IP.
Fully bled to IP. (Several times)

It had 550hrs on it & was running fine when pulled.

Governor lever is stuck & cutoff lever seems to have incomplete
travel.

Is this a no-go zone for a talented amateur? The govenor system seems to rely on multiple small springs/levers/transfer shafts with precise tensions?
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Old 19-07-2011, 15:37   #2
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Check the fuel delivery valves sitting atop the injector pump. They may be stuck open.
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Old 19-07-2011, 15:55   #3
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Open the HP pipes at the injectors, engauge the compression release levers and crank the dam thing untill you get fuel. This may take a while. Crank for a min or so thent again later to keep the starter from over heating
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Old 19-07-2011, 16:09   #4
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It depends...

Have you had a chat with your local rebuild shops and/or local mechanics?

Its only a small engine, not hard to pull out, and the cost to do so may not be huge.

Doing fine, delicate work in a well lit, warm, dry, sheltered workshop with all necessary tools on hand is much easier than dangling upside down in a rocking boat.

I'm guessing that the injectors, injector pump and lift pump are pretty close to needing recalibrating, that there is some corrosion in the bores, and that the valves will need regrinding.

The gearbox will need a change of oil and a good checkover as well.

In the long run its going to be better to do a good job, and that's what this project is about, right?
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Old 19-07-2011, 16:12   #5
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Quote:
Originally Posted by lateral View Post
Governor lever is stuck & cutoff lever seems to have incomplete travel.
This is somewhat concerning. The governor rests at full throttle when the engine is stopped. If it's truly stuck, if/when it does start will there be any control over the engine speed?

I would pull the IP before trying any further. It's not a bad job, just make sure you preserve the shims underneath it. If there is full travel of the fuel rack, you might just put it back together and try it again. If no, let a professional pump repair disassemble, clean, and adjust the output. As long as you're at it, take the injectors in for cleaning also.

If you do pull the IP, make sure the governor arm is engaged with the pump on reassembly, it's the only fuel control on the engine. There is an inspection hole on the block to verify it's hooked up correctly.
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Old 19-07-2011, 17:20   #6
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Dotdun
Quote:
if/when it does start will there be any control over the engine speed?
Possibly not, but at this point only #1 injector is getting fuel so it will not start anyway.
I did have a rubber sheet ready to block of air filter if it did start.
I think I will try to lift the IP & get the governor lever & rack to move. I am curious to why the shutoff lever has incomplete travel tho.
If this does not produce the desired result into the dealership it goes.
Just trying to save a few boatbucks.

Boracay- You are 100% right, its just the closet grease monkey in me trying to escape!


Ahoy Antares- been there done that- haven't tried the 5lb'r yet.

Perchance- All ok as far as I can tell.

Thanks guys
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Old 19-07-2011, 18:52   #7
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Did the one cyl kick off? I recently replaced the head on an old yanmar. It would not start on the 10 year old fuel. A gallon bottle of new diesel did the trick.
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Old 19-07-2011, 19:00   #8
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Quote:
Originally Posted by lateral View Post
I think I will try to lift the IP & get the governor lever & rack to move. I am curious to why the shutoff lever has incomplete travel tho.
The governor lever connects to the rack on the IP. Everything else works by manipulating the governor lever. If the fuel shutoff doesn't have full travel, that indicates that most likely the fuel rack doesn't have full travel. It could be the governor mechanism itself is stuck, but since you have no fuel from 2 of the 3 plungers in the IP, it points to the IP itself. Diesel fuel will varnish up just like gas. With it sitting for so long, I would guess the IP is just gummed up so bad the plungers won't turn.
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Old 19-07-2011, 19:30   #9
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Quote:
that most likely the fuel rack doesn't have full travel.
The fuel rack does not have any travel.
The shutoff lever moves toward the vertical about 9/16" until it engages governor lever
and takes up clearance in slot of governor lever & fuel rack pin. The fuel rack I fear is frozen in the fully forward, against front casing position. Prob. varnished up as you said previously. Gonna be difficult to get IP out without being able to put the rack in mid position.
Quote:
I would guess the IP is just gummed up so bad the plungers won't turn
Sounds spot on. Do they turn (spin) or just go up & down?
Thanks for your time.
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Old 19-07-2011, 19:30   #10
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

I would get the cut off & any other lever working but using a penetrating oil. It does not take much movement to prevent fuel getting to the injector pump.

Bill
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Old 19-07-2011, 19:36   #11
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Thanks Ant,
Quote:
Did the one cyl kick off?
Yup, #1 fired up and nearly ran the motor.
It is possible that cams two & three have jammed the plungers in the "up" position
'cos of the varnish. Therefore they cant pump diesel to hp lines.
All new diesel, filters etc. Mtr is on my garage floor.
I think this this IP needs TLC in a shop.

Gidday Bill,
Quote:
I would get the cut off & any other lever working but using a penetrating oil
The problem is the fuel rack not going in to the body of the IP.
Would penetrating oil be appropriate for this 'cos it will enter the
fuel lines? The partially dissolved varnish will end up in the injectors.
Would CRC eat the varnish & leave the O rings etc alone?
Can you use a flush fluid on the injector system and eject into a container?
Assuming I can get the fuel rack to move with penetrating oil.
The whole thing looks pretty clean to me. Weird.
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Old 19-07-2011, 19:57   #12
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

External only!! The vibration of the one cylinder trying to start may free up the internal pump parts if the have dried out. All parts must be free to move. (I had wasp nest in mine after lying open for 5yrs & cleaned all parts up under a bath of diesel.)

Regards
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Old 19-07-2011, 20:02   #13
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Re: Yanmar 3GM30 -No fuel at injectors 2 & 3

Quote:
Originally Posted by lateral View Post
Do they turn (spin) or just go up & down?
The rack turning the plungers allows more/less fuel to go thru them. The cam provides the timing and pressure. The governor maintains rpm by moving the rack which turns the plungers. The stop mechanism moves the governor arm, hence the rack to the no fuel position.

Let the professionals clean/adjust the IP and injectors, it's money well spent.
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Old 20-07-2011, 04:32   #14
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Re: Yanmar 3GM30 - No Fuel at Injectors 2 and 3

I would prefer to get the rack moving the plungers before the shop gets it.
The rack is not actually stuck it is #2 & #3 plungers that won't rotate or are out of alignment with detents on rack, to rotate, that is the problem. I have top loaded them in CRC hoping to get them moving so the rack can get to mid position to remove IP.
Then its off to the shop.
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Old 20-07-2011, 19:50   #15
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Re: Yanmar 3GM30 - No Fuel at Injectors 2 and 3

First off I numbered cly's wrongly.
From flywheel #1 &#2 not pumping.
#3 pumping fuel. Nearest crank pulley's.

I removed hp pipes on top of IP, Delivery valve spring, Cu washer,Delivery valve seat to expose top of plunger. #1 &#2 were stuck in the up position.
With #3 fully up, I gently tapped the plunger until the spring retracted them.

Walaa!- full movement on Cutoff lever & governor lever

Now fuel rack readily slides.
The IP can now be removed for pro shop clean.
This is probably basic for the initiated. Although, out of all the many shops I called, this procedure was not explained to me.
Every situation requires the person on the spots discretion. If the plungers had been grossly stuck I would not advocate more than light tapping to push them down. There is a distinct chance of damage to the barrels.

Thanks to all! Esp. DotDun for the working details.
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