Yanmar 3JH4E Service Manual page 66

TROUBLE AND TROUBLESHOOTING
(I-1) Tighten.
(I-2) Repair using sandpaper or replace.
(I-3) Replace.
(I-4) Repair using sandpaper and
then grease.
(I-5) Adjust.
(I-6) Adjust.
(I-7) Replace.
(I) Pinion gears do not mesh
(1) Loose battery engage
magnet terminal
(5) Edges of gear
teeth misshapen
(2) Faulty connection
in starting switch
(6) Faulty positioning of
pinion and ring gears
(3) Cut battery engage
magnet coil
(7) Seizure of
starter metal
(4) Rough cap movement
(1) Worn plunger
(3) Plunger sticks
(2) Damaged
(4) Oil leakage from exhaust valve
plunger spring
(5) Air inside pump
(6) Damaged exhaust valve spring
(V) Faulty fuel injection pump
(V-1) Replace plunger and barrel as a unit.
(V-2) Replace.
(V-3) Disassemble and repair or replace.
(V-4) Lap valves.
(V-5) Bleed air.
(V-6) Replace.
(II-1) Tighten.
(II-2) Repair using sandpaper.
(II-3) Replace.
(II-4) Repair using sandpaper
(Type 500 600).
(II-5) Replace.
(II-6) Undercut and repair or replace.
(II-7) Replace.
(II-8) Replace with thicker or shorter wire.
(II-9) Charge.
(II) Ring gears do not mesh
(1) Loose battery
(5) Cut starter coil
starter terminal
(6) Worn commutator
(2) Faulty connection in
engage magnet switch
(7) Slippage of starter clutch
(3) Worn brushes
(8) Excessive resistance
between battery and starter
(4) Commutator
rough and dirty
(9) Insufficient battery charge
(1) Fuel injection pump
timing irregular
(2) Loose high pressure fuel pipe
(3) Damaged high pressure fuel pipe
(4) Air in high pressure fuel pipe
(VI) Faulty fuel injection system
(VI-1) Adjust. (VII-1) Lap valves.
(VI-2) Tighten firmly. (VII-2) Adjust .
(VI-3) Replace. (VII-3) (VII-4) (VII-5) Replace.
(VI-4) Bleed air. (VII-6) Disassemble and
(VII-7) Tighten tightening
(VII-8) Replace.
(III-1) Prime well.
(III-2) Adjust.
(III-3) Clean out matter causing clogging.
(III-4) Add fuel to fuel tank.
(III-5) Open cock.
(III-6) Clean.
(III-7) Disassemble and repair or replace.
(III-8) Drain water from fuel system
and prime.
(III) Fuel oil not injected
(1) Imperfect priming of fuel oil system
(2) Injection cut off due to faulty governor
(3) Clogging of fuel inlet filter
(4) Insufficient fuel oil in tank
(5) Fuel oil tank cock closed
(6) Clogging in fuel oil pipe
(7) Damaged fuel oil supply pump
(8) Water in fuel oil tank
(1) Air leakage from suction/exhaust valves
(2) No tappet clearance
(3) Faulty gasket packing
(4) Upper part of cylinder liner worn
(5) Worn piston ring
(6) Piston ring sticks
(7) Insufficient tightening of head bolts
(8) Damaged valve spring
(VII) Leakage of pressurized air
(VII-1) Replace.
(VII-2) Adjust .
(VII-3) Move governor handle to acceleration position.
(VII-4) Check and repair.
repair or replace. (VII-5) Clean.
nuts uniformly.
Chart 7
TROUBLE WITH STARTING
(IV-1) Lap.
(IV-2) Lap.
(IV-3) Replace.
(IV-4) Clean or replace.
(IV-5) Adjust.
(IV) Faulty fuel injection valve
(1) Faulty valve seat
(2) Sticking of valve needle
(3) Worn valve needle
(4) Clogged outlet
(5) Low injection pressure
STARTING
TROUBLE
(1) Incorrect thickness
of gasket packing
(2) Faulty installation of
governor ring and lever
(3) Governor handle is in stop position
(4) Faulty engine starter
(5) Clogging of suction/exhaust pipes
(VIII) Miscellaneous