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Old 21-07-2012, 10:23   #46
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Dockhead, I have a 4JH3-TE, but I believe our engines share the same owners manual.

On page 41 of the English manual, there is a procedure for washing the turbocharger blower. The manual advises using this procedure "When engine revolution seems sluggish or the exhaust colour poor, the blades of the turbocharger blower may be dirty."

You can apparently do this procedure with liquid detergent (dishwashing detergent?) although I understand that Yanmar also makes a product called "Turbowash" or "Turbo Wash."

I have never done the procedure, but it seems like it wouldn't hurt in your situation. If you can't find it in your manual, let me know and I'll type out the procedure.

Good luck.
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Old 21-07-2012, 12:09   #47
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Re: Yanmar Problems

Quote:
Originally Posted by Bash View Post
Dockhead, I have a 4JH3-TE, but I believe our engines share the same owners manual.

On page 41 of the English manual, there is a procedure for washing the turbocharger blower. The manual advises using this procedure "When engine revolution seems sluggish or the exhaust colour poor, the blades of the turbocharger blower may be dirty."

You can apparently do this procedure with liquid detergent (dishwashing detergent?) although I understand that Yanmar also makes a product called "Turbowash" or "Turbo Wash."

I have never done the procedure, but it seems like it wouldn't hurt in your situation. If you can't find it in your manual, let me know and I'll type out the procedure.

Good luck.
Thanks, Bash. Yes, you have exactly the same engine except without the intercooler.

I have tried to follow all the procedures in the manual, but it is pretty meager. I did wash the turbo exactly as they prescribed. It didn't help. The turbo was not really very dirty to begin with.
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Old 21-07-2012, 13:50   #48
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Re: Yanmar Problems

I think I recall in the thread that you have changed the engine mounted fuel filter?? If the secondary filter was clogged and the racor was clean you wouldn't get a suction reading on the vacuum gauge. Had that happen on a Perkins during a delivery - T handle vacuum gauge on racor read zero and engine conked out, secondary filter was fouled. I don't think that situation would lead to your intermittent issues though.
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Old 21-07-2012, 14:16   #49
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Re: Yanmar Problems

Bad tach? Happens a lot. They tend to fail in intermittent ways. They don't just stop.

Clean and check every tach connection. Check the main engine ground. Yanmar also uses un-tinned wire a lot. Might be resistance from corrosion in the middle of the wire.

Do you get your tach signal off the alternator? If so, any chance the belt is slipping at full RPM?

I realize the tach wouldn't explain the entire problem but it might be obscuring what's really wrong.

Carl
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Old 21-07-2012, 14:22   #50
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Re: Yanmar Problems

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Originally Posted by CarlF View Post
Bad tach? Happens a lot. They tend to fail in intermittent ways. They don't just stop.

Clean and check every tach connection. Check the main engine ground. Yanmar also uses un-tinned wire a lot. Might be resistance from corrosion in the middle of the wire.

Do you get your tach signal off the alternator? If so, any chance the belt is slipping at full RPM?

I realize the tach wouldn't explain the entire problem but it might be obscuring what's really wrong.

Carl
Well, I can tell by ear that the tach is more or less right.
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Old 21-07-2012, 14:23   #51
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Re: Yanmar Problems

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Originally Posted by S/V Pearl View Post
I think I recall in the thread that you have changed the engine mounted fuel filter?? If the secondary filter was clogged and the racor was clean you wouldn't get a suction reading on the vacuum gauge. Had that happen on a Perkins during a delivery - T handle vacuum gauge on racor read zero and engine conked out, secondary filter was fouled. I don't think that situation would lead to your intermittent issues though.
Yes, I changed the fine filter on the engine in the middle of the problem. No effect.
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Old 22-07-2012, 04:56   #52
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Re: Yanmar Problems

Maybe something to try
Quote:
Took Sarayu out for the first sail of the season today. The yanmar 1gm still was running at lower than normal rpms...2200-2300 rpms. ran it about 30 minutes wide open, no change. put it in neutral and opened the engine hatch and tried pumping that lever thing about 200 times. Put it in gear and gave it full throttle and low and behold, went up to 3000 rpms, then slip back to 2500-2800 for a second or two then it loaded up and back to 3000. went back down and pumped the lever thing again another and tried it again. Bam, running 3000-3200... go figure???
Link

He's talking about working the primer on the lift pump when the rev's are low.
Might at least confirm its fuel related.
I seem to have in the back of my head on a differant model Yanmar that there may have been a wire mesh filter sitting inside of the fitting where the fuel delivery line connects to the injector pump....maybe i'm wrong but simple to check.
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Old 22-07-2012, 05:15   #53
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Re: Yanmar Problems

Dockhead

Quote:
The simple check is to find a place to crack open the fuel return line. Diesel should be flowing back to the tank. If not this is a sure sign the engine is starving for fuel, but no so starved it shuts the engine down, thus the mystery.
I like this simple test, one can always learn more! You could still rig a day tank (use your dinghy tank, filled with clean diesel) and bypass all filters and pumps. Let gravity do the job: Mount tank higher than engine.

A simple test for your turbo: remove one of the plugs in the intake manifold (where you would connect a pressure gauge if you had one). Run engine at 2000rpm, (check your specs, for an engine speed where the turbo starts producing)
The turbo should create boost = positive pressure = air coming out of the hole.

I bet the turbo is OK.

Quote:
Originally Posted by impi View Post
..... Sounds like a damaged spring or something in the governor i.e. the rack is not moving all the way...
This is a good hint. But I don't know of any simple test, short of taking the injection-pump to a properly equipped service station. Before you do that, make sure you understand how to mark parts and pieces so you can mount it back with the correct timing.

Dirk
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Old 22-07-2012, 21:02   #54
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Re: Yanmar Problems

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Originally Posted by Dockhead View Post
I have tried to follow all the procedures in the manual, but it is pretty meager. I did wash the turbo exactly as they prescribed. It didn't help. The turbo was not really very dirty to begin with.
Shoot. This one's got me scratching my head. (Which is okay, since I've spent the weekend on the hook as well.)

Best I can do at this point is bump the thread.

Still thinking, of course. And wondering whether it could be a boost leak. That would make sense in terms of how intermittent the problem is. When the engine gets hot....
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Old 24-07-2012, 08:41   #55
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Re: Yanmar Problems

If you are absolutely sure that you have no lift pump on your engine then for sure install an electric pump. Connect it to the "ignition" switch.
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Old 24-07-2012, 16:36   #56
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Re: Yanmar Problems

I had a similar problem a couple of years ago. The problem was found to be blockage in the fuel line from the tank to the filter. The gunk was diesel bug residue that had built up over 2-3 years.
The cure at the time was to disconnect the fuel line at the filter and blow back down the line to the tank. Under normal circumstances I could do this with lung pressure and hear the bubbles in the tank as the air came through the suction pipe. On this occasion I didn't have enough blow power but did have one of those battery booster packs on board that had a small air compressor incorporated in it (for auto use blowing up tyres). I connected this to the fuel line and it cleared the fuel line and this got me out of trouble until I was able to get the tank out and clear the crud out of it. This only happened after a rough voyage under sail when the engine was required to enter port. I guess it stirred up the tank and hence put debris down the fuel line.
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Old 25-07-2012, 12:14   #57
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Re: Yanmar Problems

Well, I am now at anchor in St. Aubin's Bay, Jersey, Channel Islands. I found a very good Yanmar engineer who came out in his own boat to have a look. He washed the turbo with some special (and very expensive) Yanmar proprietary liquid. And pronounced the turbo to be in reasonable condition -- spinning up properly and still spinning after shutdown. Not the turbo.

He watched the Racor vacuum gauge and felt the fuel hoses while I ran the engine up in gear. He does not think that there is a fuel system clog problem -- not the profile. He says such problems get worse and worse -- not like this.

He says injection pump problems are exceptionally rare, but this may be one of them.

We shall see. Now I have to get through the infamous Alderny Race (currents up to 10 knots if you hit it at the wrong state of tide) and back home. In intense high pressure days with no wind, or North wind, in other words, motoring weather. Then i guess I'll pull the pump off and take it to the specialist engineers. The saga continues.
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Old 27-07-2012, 21:13   #58
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We have essentially the same engine. I agree, your turbo seems fine. Btw I swear the turbo cleaner smells exactly like the cleaner Fantastic.

Are you getting a good stream of return fuel to your tank? You should get much more than you burn. Several times. That should eliminate the fuel system up to the fuel injection pump.
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Old 27-07-2012, 22:25   #59
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Re: Yanmar Problems

400 gal. is a lot of fuel. How long does it take you to go through it? Maybe gunk has had a chance to form. What additive do you use in your fuel? Some of the most highly advertised additives to prevent algae can really aggravate the problem.
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Old 27-07-2012, 23:09   #60
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Re: Yanmar Problems

Quote:
Originally Posted by Acushla View Post
I had a similar problem a couple of years ago. The problem was found to be blockage in the fuel line from the tank to the filter. The gunk was diesel bug residue that had built up over 2-3 years.
The cure at the time was to disconnect the fuel line at the filter and blow back down the line to the tank. Under normal circumstances I could do this with lung pressure and hear the bubbles in the tank as the air came through the suction pipe. On this occasion I didn't have enough blow power but did have one of those battery booster packs on board that had a small air compressor incorporated in it (for auto use blowing up tyres). I connected this to the fuel line and it cleared the fuel line and this got me out of trouble until I was able to get the tank out and clear the crud out of it. This only happened after a rough voyage under sail when the engine was required to enter port. I guess it stirred up the tank and hence put debris down the fuel line.
+1 My fuel lines were full of the black **** and allowed sufficient fuel to start and run for a while but not very reliably. Solution was to remove fuel lines and clean out and reinstall. Even the shutoff valve in each tank had crap in it.
Now I filter each tank twice a year and use the recomended addative at the recomended rate. Touch wood no more problems.
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