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Old 09-07-2015, 16:50   #16
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Put (old) screw driver from power wire on starter to tickle switch post on solenoid. If it works a few times then you have a wiring fault.
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Old 09-07-2015, 17:27   #17
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

HI: If you tap the starter a few good raps and you're lucky enough to get it to turn then it's a sure fire indicator that the bushings in the starter are worn out. They are iolite bushings at both ends of the armature and when they wear they allow the armature to short to the fields by touching them. When you hit the starter while the solenoid is engaged you knock the armature off the field and it begins to spin, once spinning the magnetic fields and the centrifugal force hold it centered and it works fine until you stop it. When cold the bushings are contracted enough to keep the armature off the fields.
Remove the starter and have it rebuilt.
Hope this helps clarify.
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Old 09-07-2015, 21:27   #18
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

I would guess that it is the starter, but two things to check and here they are:

Run a hot wire from the battery to the push button switch with fairly heavy wire. 12 or 10 gauge. There is a fuse in the harness of these engines and sometimes there is a voltage drop because of corrosion. If it starts easily hot you have a corrosion problem in the hot to the panel.

Clean all the connections at the starter and the ground to the engine.

Probably the starter. I had the same issue.
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Old 09-07-2015, 21:33   #19
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Two years ago, my 3gm had a start issue when recommissioning. When the start switch was pushed the solenoid clicked, but wouldn't turn starter over. Pulled starter and discovered bendix shaft was corroded to gear. Pulled everything apart, used some scotch brite to clean shaft and all has been well since.
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Old 10-07-2015, 08:24   #20
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

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Originally Posted by MikePz View Post
Try this it worked for me on 3 different Yanmar engines! The problem is the voltage loss in the starter solenoid circuit (wiring between the instrument panel and engine).

Yanmar solved the problem with the installation of a small starter relay in the circuit on newer engines. Addition of a homemade starter relay is very easy - let me know if you would like a diagram.

Mike Pz
Yep, this is a common problem. The start wires in wiring harnesses that connect the standard Yanmar instrument panel to the engine wiring harness are too small, making the voltage drop to the solenoid too high for reliable starting.

Yammer offered an "optional" starter relay to solve this problem. You can go to any auto parts store and get a starter relay instead of getting the Yanmar version (its hard to find, anyway. the part number isn't in their part book).

Hook the start wire from the start switch to the pull down terminal on the relay. Connect the other pull down terminal to ground. Connect one of the switched terminals to the battery by building a cable that connects the main battery cable at the starter to the relay. Connect the other switched terminal to the starter solenoid, and you're done.

Scott
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Old 10-07-2015, 20:03   #21
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

not turning when hot could be the bendix or internal wear in the starter. shimming may help but if the starter hasn't been replaced pryer to the problem it's not likely. could even be a main ground cable run under the engine or near some hot section of the engine that needs replacing, as an old wire has reduced conductivity and when hot even less. check your batt cables, if they've lost their luster replace them. if the problem isn't solved replace the starter. As mentioned above, I'd choose the time of replacement rather than in some isolated location.
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Old 11-07-2015, 03:46   #22
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

A new starter is very cheap in US.
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Old 13-07-2015, 18:49   #23
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Measure the voltage at the solenoid when holding the starter button/key. Less than 8V and the solenoid won't pull in far enough to power the starter.

I had very intermittent no-start issues solved by cleaning up all the connections in the harness and control panel, but the final solution was to install an automotive cube relay right at the solenoid, activated by the key switch. Zero problems since then.
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Old 28-03-2020, 15:36   #24
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

I notice this thread is a few years old, but anyway, here goes


I have had some intermittent starting issues with my Yanmar 2GM20, sometimes when I press the start button, nothing happens.
I see some say to connect directly from the start button to the solenoid with a new and lower gauge wire. So I did that. However, the wire that's always been there is the same as always, so changing for a different wire is really just "covering up" for something else. This was more or less confirmed when I noticed that after the swap, parts of the starter button had melted. So, at one time when I had this problem, I measured the current, and when pressing the start button, a very high current was drawn. Hence, the problem was not the connection, in which case the current would be weak, too weak to get the solenoid to act.
Then there are some solutions to add a relay next to the solenoid. That's one way of overcoming the issue with the high current melting the starter button. But the original problem is actually still there.

So, my belief is that the issue is with the starter solenoid itself, after years of operation it's not working as smoothly as before, and requires more current to act, and sometimes get stuck. A couple of times when the motor didn't start, I tapped the solenoid with a tool, and both times it started perfectly directly after the tapping. So this strengthens my belief in the solenoid issue.

So, now the next step is to remove, disassemble and service the solenoid. Did anyone do this before? Any experience, information etc, to share? Or any links to info on the web. I haven't found anything yet, after some searching.

Thanks, Thomas
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Old 28-03-2020, 16:15   #25
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Quote:
Originally Posted by Thomasx View Post
I notice this thread is a few years old, but anyway, here goes


I have had some intermittent starting issues with my Yanmar 2GM20, sometimes when I press the start button, nothing happens.
I see some say to connect directly from the start button to the solenoid with a new and lower gauge wire. So I did that. However, the wire that's always been there is the same as always, so changing for a different wire is really just "covering up" for something else. This was more or less confirmed when I noticed that after the swap, parts of the starter button had melted. So, at one time when I had this problem, I measured the current, and when pressing the start button, a very high current was drawn. Hence, the problem was not the connection, in which case the current would be weak, too weak to get the solenoid to act.
Then there are some solutions to add a relay next to the solenoid. That's one way of overcoming the issue with the high current melting the starter button. But the original problem is actually still there.

So, my belief is that the issue is with the starter solenoid itself, after years of operation it's not working as smoothly as before, and requires more current to act, and sometimes get stuck. A couple of times when the motor didn't start, I tapped the solenoid with a tool, and both times it started perfectly directly after the tapping. So this strengthens my belief in the solenoid issue.

So, now the next step is to remove, disassemble and service the solenoid. Did anyone do this before? Any experience, information etc, to share? Or any links to info on the web. I haven't found anything yet, after some searching.

Thanks, Thomas
If your start button was corroded it could have high resistance which could make for intermittent starts and/or produce heat to melt the switch.
There's a 30 amp fuse on that circuit so there will be something less than 30 amps drawing normally. If the fuse didn't blow chances are there isn't a short in the starter.

When my 3GM30 was intermittent I checked the wiring and found a loose barrel crimp connector in the harness in the start circuit. I tightened it and the problem went away for me. (the barrel, not the wire crimp)
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Old 28-03-2020, 17:42   #26
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

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Originally Posted by roverhi View Post
After a haul out for a bottom job, my 3GM30F was dead. Turn the key and nothing. Yard electrician found an open wire in the wire loom of the engine. added a jumper outside the wire bundle and all was fine. Will be going down to the boat later and see if I can identify the wire.

If you have jumper cables, you can go direct from the battery to the starter and the starter solenoid to rule out a broken wire. Most starting issues I've found are caused by the starter motor ground wire. Might pull the wires to the starter and ground connection on the engine, clean them up if necessary and reattach.
It is the white wire. On the Yanmar wiring harness, the wire gauge is too small. After a few years, there's not enough amps to turn over the starter solenoid. Solutions are: (1) replace white wire with bigger gauge or (2) add solenoid to the starter solenoid.
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Old 28-03-2020, 18:02   #27
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Quote:
Originally Posted by Thomasx View Post
............. This was more or less confirmed when I noticed that after the swap, parts of the starter button had melted. So, at one time when I had this problem, I measured the current, and when pressing the start button, a very high current was drawn. Hence, the problem was not the connection, in which case the current would be weak, too weak to get the solenoid to act.
Then there are some solutions to add a relay next to the solenoid. That's one way of overcoming the issue with the high current melting the starter button. But the original problem is actually still there.

So, my belief is that the issue is with the starter solenoid itself, after years of operation it's not working as smoothly as before, and requires more current to act, and sometimes get stuck. A couple of times when the motor didn't start, I tapped the solenoid with a tool, and both times it started perfectly directly after the tapping. So this strengthens my belief in the solenoid issue.

So, now the next step is to remove, disassemble and service the solenoid. Did anyone do this before? Any experience, information etc, to share? Or any links to info on the web. I haven't found anything yet, after some searching.

Thanks, Thomas
I can't think of any way the starter motor solenoid could fail that would cause a dramatic increase in the solenoid's operating current, certainly not enough to melt the starter button switch. Its coil should draw the same current regardless of where the plunger is and how good (or bad) the high current contacts are. Do you recall the actual value of the current when you measured it?

I think you have at least two seperate issues. High resistance contacts in the starter button and a faulty solenoid / bendix
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Old 28-03-2020, 18:46   #28
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

Quote:
Originally Posted by Thomasx View Post
............
So, my belief is that the issue is with the starter solenoid itself, after years of operation it's not working as smoothly as before, and requires more current to act, and sometimes get stuck. A couple of times when the motor didn't start, I tapped the solenoid with a tool, and both times it started perfectly directly after the tapping. So this strengthens my belief in the solenoid issue.

So, now the next step is to remove, disassemble and service the solenoid. Did anyone do this before? Any experience, information etc, to share? Or any links to info on the web. I haven't found anything yet, after some searching.

Thanks, Thomas
Further to the operating current of the starter solenoid. Initially it is determined by the coil resistance and the coil inductance. After a few moments (say <1sec), the current stabilises and then is solely determined by the coil resistance.

FWIW, the inductance is determined by the number of turns of the coil (and wire size) plus the position of the plunger. However once the plunger reaches its final position whether that be the correct position or not, the inductance remains the constant.

So regardless of the position of the plunger, the steady state coil current is determined solely by the coil resistance which is not altered by the plunger position.

However the mechanical aspects of the plunger and bendix can be affected by wear and corrosion etc and it would be good to look at these areas.
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Old 28-03-2020, 23:16   #29
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

I had the problem too, checked all sorts of things, yada yada yada

Turns out there is a hidden fuse ... it is on the wiring diagram, check it for corrosion. Not my idea, here is how I found out about it



- - Gotta love these old English chaps who know how to do things and love to share their knowledge.
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Old 29-03-2020, 09:54   #30
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Re: Yanmar 3GM30 Starting issues - Starter? Solenoid? Wiring?

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Originally Posted by Lemsteraak View Post
I had the problem too, checked all sorts of things, yada yada yada



Turns out there is a hidden fuse ... it is on the wiring diagram, check it for corrosion. Not my idea, here is how I found out about it







- - Gotta love these old English chaps who know how to do things and love to share their knowledge.


Thanks for the tutorial. Still attending, “the school of life.”
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