Engine Troubleshooting - Westerbeke 7.5 MCGA Operator's Manual

Operator Manual for Gasoline Generators

6.2 Engine Troubleshooting

The following troubleshooting chart describes common engine problems and possible causes.
NOTE: When servicing the engine/generator, the main circuit breaker (control panel) disconnects all AC power and can
be switched off and reset manually.
Engine does not crank:
Engine cranks, does not start:
(Engine will crank 8 seconds; 3 crank cycles before
underspeed fault occurs.)
Engine starts, runs, and then shuts down:
Engine hunts:
Engine misfires or backfires:
Engine overheats/engine temp LED is illuminated:
Exhaust temp LED is illuminated:
Low oil pressure/oil pressure LED is illuminated:
No DC charge to starting battery:
High DC Charge to battery:
Starter stays energized after start:
Poor performance at generator speed:
Black exhaust smoke:
Blue exhaust smoke:
Check engine LEDs are illuminated:
Speed LEDs are illuminated but not flashing:
Pair of Speed LEDs are illuminated and flashing:
External alarm LED is illuminated:
Problem: Possible Cause:
1. DC panel breaker OFF.
2. DC battery OFF.
3. K2 relay faulty.
4. Faulty starter solenoid.
5. DC battery low/dead.
6. Water filled cylinder.
7. Faulty DC panel 8.0-amp bus fuse.
1. Fuel starvation.
2. Air in fuel system.
3. Fouled spark plugs.
4. Faulty ignition coil.
1. Fuel starvation.
2. Air in fuel system.
3. Faulty shutdown switch/sensor.
4. Faulty fuel pump.
5. Open Oil Switch
1. Air in fuel system.
2. Faulty fuel pump.
3. Low octane fuel (lower than 89).
4. Faulty speed sensor (crankshaft).
1. Low octane fuel (lower than 89).
2. Dirty air intake screen.
3. Faulty coil pack.
4. Exhaust restriction.
5. Worn/fouled spark plug.
6. TCI system.
7. Low or no fuel pressure. Poor quality fuel.
1. Raw water coolant flow obstruction.
2. Coolant level low.
3. Faulty impeller.
4. Pump belt loose/broken.
5. Stuck thermostat.
6. Air in cooling system (fresh water).
1. Loss of raw water flow/faulty pump.
2. Faulty exhaust temperature switch.
3. External device fault.
1. Oil level low.
2. Faulty oil pressure sensor.
3. Oil viscosity incorrect.
1. Circuit fuse faulty/blown (two fuses).
2. Faulty circuit connection.
3. Faulty regulator/battery charger.
4. Bridge rectifier.
1. Battery charger misadjusted.
1. Faulty K1 relay.
2. Faulty starter solenoid.
1. Low octane fuel.
2. Fuel supply issue.
3. High engine compartment temperature.
1. Dirty air screen.
2. Faulty injector.
1. Lube oil is diluted.
2. Crankcase breather tube is clogged.
3. High lube oil level.
4. High crank case pressure
5. Low compression.
1. Diagnostic software required.
1. Faulty speed sensor.
2. Intake manifold vacuum leak.
1. AC generator overload.
2. Fuel starvation.
1. Loose connection.
2. Faulty fire suppression shutdown device.
6 Diagnostics and Troubleshooting
page
37