Engine Troubleshooting - Westerbeke 5.0KW BCG-60Hz Operator's Manual

ENGINE TROUBLESHOOTING
The following troubleshooting tables are based upon eertain
engine problem indicators and the most likely causes of the
problems.
When troubleshooting indicates an electrical problem, see the
ELECTRICAL SYSTEM WIRING DIAGRAM, as these
may reveal other possible causes of the problem which are
not listed below.
PROBLEM PROBABLE CAUSE
Engine does not 1. Voltage drop at starter solenoid
crank.
terminal.
2. Engine circuit breaker has tripped.
3. 8 amp fuse/holder is faulty.
4. Battery is low or dead.
5. Loose battery connections.
6. Faulty wire connection.
7.
Faulty start switch.
8. Faulty start relay
(Kl).
9. Faulty starter solenoid
10. Raw water filled cylinders.
Engine starts, runs 1. Faulty shutdown switch,
and then shuts (oil pressure, water or exhaust
down. temperature).
2. Faulty overspeed switch
(See note below).
3. Dirty fuel/water separator filter.
4. Mechanical check valve at the fuel
supply faulty (if installed).
5.
Low oil level in sump.
6. Faulty fuel pump.
7.
High engine water or
exhaust temperature.
Engine starts. runs 1. Faulty mag-pickup sensor.
but does not come
2. Electronic governor controller faulty,
up to speed.
3. Fuel pump.
4. Fuel supply to engine restricted.
5.
Throttle linkage binding.
6. Actuator or electrical connections
faulty.
7. AC generator overload.lshort.
8. Air intake restricted.
9. Exhaust restricted.
NOTE:
171e engines control system (electrical system) is
protected by a 20 Ampere manual reset circuit breaker
located on the control panel.
PROBLEM PROBABLE CAUSE
Engine cranks but 1. Out of fuel.
fails to start.
2. Engine is flooded.
3. Faulty carburetor.
4. Faulty choke solenoid.
Engine hunts. 1. Controller gain adjustment needed.
2. Faulty fuel pump.
3. Mag pick-up sensor needs adjustment.
4. Low DC battery voltage.
5.
Generator overload.
6.
Valves need adjustment.
Engine misfires. 1. Poor quality fuel.
2. Incorrect timing.
3. Dirty flame arrester.
4. Cracked distributor cap.
5. Faulty ignition wires.
6.
Spark plugs are worn.
7. High exhaust back-pressure.
S.
Valve clearances are incorrect.
Engine backfires.
1,. Spark plug wires are connected wrong.
2. Incorrect timing.
3. Engine is flooded. See Engine is
flooded under Engine cranks but
fails to start.
4.
Dirty flame arrester.
5.
Cracked distributor cap.
6.
High exhaust back-pressure.
Engine overheats, 1. Coolant loss. Pressure test
cooling system.
2. Faulty raw water pump impeller.
3. Belts are loose or broken.
4. Raw water pump worn.
5. Faulty thermostat.
NOTE:
OVERSPEED SWITCH: TO BY-PASS THE OVERS PEED SWITCH WHEN TROUBLESHOOTING
MOVE CONNECTION #3 AND CONNECT IT ONTO AND WITH #5.
REFER TO WIRING DIAGRAM #46876.
Engines & Generators
35