Engine Troubleshooting - Westerbeke 4.5KW BCGB-60HZ Operator's Manual

ENGINE TROUBLESHOOTING
The following troubleshooting tables are based upon certain
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 20A circuit breaker has
tripped.
3. Battery is low or dead.
4.
Loose battery connections.
5.
Faulty wire connection.
6. Faulty start switch.
7. Faulty start relay (K1).
S.
Faulty starter solenoid
9. Raw water filled cylinders.
10.
Filters are clogged by contaminated
fuel.
11. Voltage drop at (+) at overspeed
switch.
12. Faulty overspeed switch (reset &
start).
Engine cranks but 1. Out of fuel.
fails to start.
2. Engine is flooded.
a. Carburetor float needle valve open
or damaged. Clean or replace the
needle valve.
b. Float in carburetor is leaking.
Repair or replace float.
c. Float chamber gasket damaged or
securing screws are loose. Replace
gasket and/or tighten screws.
3. Fuel pump inoperative.
4. Worn or faulty spark plugs.
5. High tension wires grounding
(wet system).
6. Faulty ignition coil.
7. Faulty distributor.
S.
Faulty run relay (K2).
9. Faulty wire connection.
10.
No engine compression.
11. Faulty idle adjustment.
NOTE:
The engines control system (electrical system) is
protected by a 20 Ampere manual reset circuit breaker
located on the control panel.
PROBLEM PROBABLE CAUSE
Engine starts, runs 1. Faulty shutdown switch,
and then shuts (oil pressure, water or exhaust
down. temperature) .
2. High engine water or exhaust
temperature.
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.
Faulty engine temperature
sensor.
Engine starts, runs 1. Fuel line restriction.
but does not come
2. Mechanical check valve at the
up to speed.
fuel supply is faulty.
3. Throttle plate binding.
4.
Faulty fuel pump.
5. Faulty wire connection.
6. Faulty engine temperature
sensor.
7. AC generator overload.
S.
HiQh exhaust pressure.
Engine hunts. 1. Low battery voltage.
2.
Generator is overloaded.
3. Cracked distributor cap.
4. Faulty high tension wires.
5. Faulty fuel pump.
6. High exhaust back-pressure.
7.
Valves are out of adjustment.
S.
Governor is out of adjustment.
9. Dirty fuel filters.
10.
Throttle linkage is binding.
NOTE: When troubleshooting a loss of ignition spark and the overspeed switch is suspect: By-pass the switch by lifting the
T3 connector (overspeed terminal board) and connecting
it
to the vacant T4 spade connector. Start the engine and
if
the
spark returns, the overspeed switch is at fault. Refer to the OVERSPEED WIRING DIAGRAM .
.....v'
WESTERBEKE
Engines & Generators
34