Westerbeke generator troubleshooting

Westerbeke EDT Series generator troubleshooting

Problem	Probable Cause	Verification/Remedy
START BUTTON depressed, no panel indications.	1. Battery Switch not on.	1. Check switch and/or battery connections.
	2. Circuit breaker tripped/off.	2. Reset breaker if breaker trips again, check preheat solenoid circuit and check circuit for shorts to ground.
	3. Loose battery connections..	3. Check (+) connection to starter solenoid and (-) connection to engine ground stud. Check battery cable connections.
START BUTTON DEPRESSED, no starter engagement.	1. Connection to solenoid faulty.	1. Check connection.
	2. Faulty solenoid.	2. Check that 12 volts are present at the solenoid connection.
	3. Loose battery connections.	3. Check battery connections.
	4. Low battery.	4. Check battery charge state.
	5. K1 relay.	5. Check K1 relay.
START switch is depressed; panel indications^; starter solenoid OK fuel solenoid not functioning.	1. Poor connections to fuel solenoid.	1. Check connections.
	2. Defective fuel solenoid.	2. Check that 12 volts are present at the ( ♦ ) connection on the fuel run solenoid.
Generator engine cranks, but does not start, fuel solenoid energized.	1. Faulty fueling system.	1. Check that fuel valves are open.
	2. Preheat solenoid faulty.	1a. Switch to combine house and start batteries. 1b. Replace batteries.
		1c. Check fuel lift pump.
		1d. Change inlet fuel filter.
		2. Check solenoid.
Battery runs down.	1. High resistance leak to ground.	1. Check wiring. Insert sensitive (0 - 25 amp) meter in battery lines. (Do not start engine.) Remove connections and replace after short is located.
	2. Low resistance leak.	2. Check all wires for temperature rise to locate the fault.
	3. Poor battery connections.	3. Check cable connections at battery for loose connections, corrosion
	4. DC atlemator not charging.	4. Check connections check belt tension, test alternator.
Battery not charging	1. DC charge circuit faulty.	1. Perform D.C. voltage check of generator charging circuit.
	2. Alternatot drive.	2. Check drive belt tension. Alternator should turn freely. Check for loose connections. Check output voltmeter. Ensure 12 volts are present at the Ecx. terminal.
Generator engine stops. (Fault displace under speed) NOTE: The engine's DC electrical system is protected by a 20 amp manual reset circuit breaker on the front of the control panel.	1.Switches and/or wiring loose or disconnected.	1. Inspect wiring for short circuits and loose connections. Inspect switches for proper operation.
	2. Fuel starvation.	2. Check fuel supply, fuel valves, fuel feed strainer.
	3. 20 Amp circuit breaker tripping. (LCD display blank)	3. Check for high DC amperage draw during operation. Ensure breaker is not overly sensitive to heat which would cause tripping.
	4. Exhaust system is restricted.	4. Check for blockage or collapsed muffler.
	5. Water in fuel.	5. Pump water from fuel tank(s); change filters and bleed fuel system.
	6. Air intake obstruction..	6. Check air intake filter cartridge.
Exhaust smoking problems	1. Blue smoke.	1. Incorrect grade of engine oil.
	2. White smoke	1a. Crankcase is overfilled with engine oil (oil is blowing out through the exhaust).
	3. Black smoke.	2. Engine is running cokJ.
		2a. Faulty injector or Incorrect injector timing.
		3. Improper grade of fuel.
		3a. Fuel bum incomplete due to high back pressure In exhaust or insufficient air for proper combustion (Check for restrictions in exhaust system; check air intake.).
		3b. Improperly timed injectors or valves or poor compression.
		3c. Lack of air — check air intake and air filter. Check for proper ventilation.
		3d. Overload.
LCD DISPLAYS No LCD Display	1. Check battery.	1. Battery on.
	2. 20 amp breaker off.	2. Turn breaker on.
Oil Pressure	1. Oil level low/oil leak.	1. Check oil level, add oil and repair leaks.
	2. Lack of oil pressure	2. Test oil pressure. If OK, test oil pressure sendor, inspect oil filter, inspect oil pump.
	3. Ground connection.	3. Check ground connection.
	4. Faulty control module.	4. Inspect all the plug connections/replace.
Coolant Temperature	1. Check system coolant level.	1. Add coolant Check for leaks.
	2. Check water pump drive belt. _	2. Adjust belt tension, replace belt
	3. Faulty Temp sensor.	3. Check sensor/replace.
	4. Ground Connection.	4. Check ground circuit
	5. Faulty control module.	5. Check plug connections/replace.
Exhaust Temperature	1. Check sea water flow.	1. Inspect thru hull fitting, hose and strainer. Correct as needed.
	2. Faulty exhaust temp switch.	2. Test/replace.
	3. Ground Connection.	3. Check ground circuit.
	4. Faulty control module.	4. Check plug connections.
	5. Sea water pump.	5. Inspect impeller/replace.
Battery Voltage	1. Check alternator drive belt.	1. Adjust tension/replace if worn.
	2. Check charge voltage.	2. Check excitation, replace/repair alternator
	3. Check battery connections.	3. Check + and - cables from battery to engine.
	4. Faulty control module.	4. Check plug connections/replace.
Generator Voltage	1. Check AC voltage output	1. Adjust voltage/troubleshoot generator for cause.
	2. Faulty control module.	2. Check plug connections/replace.
Generator Frequency	1. Check engine speed.	1. Adjust.
	2. Check fuel supply.	2. Inspect filters/replace filters. Test fuel pump operation.
	3. Amperage load.	3. Check load with amprobe.
LED Display edges turn pink.	1. Compartment ambient temperature too high.	1. Ventilate compartment. NOTE: Heat will often change the color of an LCD display. This will not effect the operation of the engine.

Westerbeke 8.0KW-60Hz SBEG generator troubleshooting

PROBLEM	PROBABLE CAUSE
Engine does not crank.	1. Battery is low or dead.
	2. Loose battery connections.
	3. Faulty wire connections.
	4. Faulty start switch.
	5. Faulty starter solenoid.
	6. Raw water filled cylinders.
	7. Filters are clogged by contaminated fuel.
Engine cranks but fails to start.	1. Out of fuel.
	2. Engine is flooded.
	3. Fuel pump inoperative.
	4. Worn or faulty spark plugs.
	5. High tension wires grounding (wet system).
	6. Faulty ignition coil.
	7. Faulty distributor.
	8. Faulty wire connections.
	9. Low engine compression.
	10. Air in the fuel system.
	See BLEEDING THE FUEL SYSTEM
Engine starts, runs but then shuts down.	1. Faulty shutdown switch. (oil pressure, coolant or exhaust temperature).
	2. High engine water or exhaust temperature.
	3. Dirty fuel/water separator fitter.
	4. Low oil level in sump.
	5. Faulty fuel pump
	6. Faulty engine temperature sensor.
	7. Air in the fuel system.
	See BLEEDING THE FUEL SYSTEM
Engine starts, runs	8. Fuel line restriction.
and then shuts down	9. Mechanical check valve at the fuel
	supply is faulty
	10. Throttle plate binding.
	11. Faulty wire connection.
	12. AC generator overload.
	13. High 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.
	8. Dirty fuel filters.
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.
	8. Valve clearances are incorrect.
Engine backfires.	1. Spark plug wires are connected wrong.
	2. Incorrect timing.
	3. Engine is flooded.
	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 v/ater pump v/om.
	5. Faulty thermostat.
Low oil pressure.	1. Low oil level.
	2. Wrong SAE type oil in the engine.
	3. Faulty or wrong type oil filter.
	4. Relief valve is stuck.
	5. Faulty oil pump.
	6. Faulty engine bearings.
	7. Faulty oil filter.
High oil pressure.	1. Dirty oil or v/rong SAE type oil in the engine.
	2. Relief valve is stuck
No DC charge to the starting battery.	1. Faulty connections to battery charging control.
	2. Faulty battery charging control.
	3. Faulty bridge rectifier.
	4. Faulty generator charger windings.
Blue exhaust smoke discharged from the engine.	1. Lube oil is diluted.
	2. High lube oil level.
	3. Crankcase breather hose is clogged.
	4. Valves are worn or adjusted incorrectly.
	5. Piston rings are worn or unseated.
Black exhaust smoke discharged from the engine.	1. Dirty flame arrester.
	2. Valves are worn or incorrectly adjusted.
	3. Lube oil is diluted.
	4. Piston rings are worn or unseated.
	5. Crankcase breather hose is clogged.
Poor performance at generator speed	1. Main jet clogged. Remove and clean.
	2. Fuel pump clogged. Remove and replace.
	3. Throttle body filter screen dirty. Remove and clean.

Westerbeke 5.0KW BCG-60Hz generator troubleshooting

Problem	Probable Cause	Verification/Remedy
HARD STARTING OR FAILURE TO START	1. High exhaust pressure.	1. Install a larger diameter exhaust.
	2. Timing belt.	2. Inspect timing belt-replace.
	3. AC generator overload.	3. Remove loads before starting.
	4. Check valve at fuel supply.	4. Repair or replace..
	5. Defective starter.	5. Repair or replace starter.
	6. Faulty fuel regulator.	6. Replace regulator.
	7. Raw water in cylinders.	7. Failure of exhaust system or syphon break. Clear cylindersEngine may need overhaul.
SMOKY EXHAUST	WHITISH , PURPLE OR BLUE SMOKE
	1. Excessive engine oil.	1. Correct oil level.
	2. Excessive rise of oil into combustion chamber.	2. Engine overhaul.
	a. Poor piston contact.	a. Check standard.
	b. Seized piston ring.	b. Replace or clean.
	c. Excessive piston-to-cylinder clearance.	c. Replace or correct
	d. Worn valve stem and valve guide.	d. Replace.
	e. Low engine oil viscosity.	e. Replace.
	f. Excessive oil pressure.	f. Correct.
	g. Piston rings are worn or unseated.	g. Engine overhaul.
	3. Insufficient compression.	3. See LOW COMPRESSION; HARD STARTING.
	BLACKISH OR DARK GRAY
	1. Poor compression.	1. See LOW COMPRESSION.
	2. Improper valve clearance.	2. Valve adjustment
	3. Insufficient intake air (air cleaner clogged).	3. Replace air cleaner.
	4. Improper fuel.	4. Replace with proper fuel.
EXCESSIVE OIL CONSUMPTION	OIL LEAKAGE	1. Replace oil seals.
	1. Defective oil seals.
	2. Broken gear case gaskeL	2. Replace gasket.
	3. Loose gear case attaching bolts.	3. Retighten bolts.
	4. Loose drain plug.	4. Retighten plug.
	5. Loose oil pipe connector.	5. Retighten oil connections.
	6. Broken rocker cover gasket.	6. Replace gasket
	7. Loose rocker cover attaching bolts.	7. Retighten attaching bolts.
	OIL LEVEL RISING
	1. Dead cylinder.	1. Check compression.
	2. Displaced or twisted connecting rod.	2. Replace connecting rod.
	3. Worn piston ring.	3. Replace ring.
ENGINE BACKFIRES, MISFIRES	1. Incorrect valve clearances.	1. Adjust valves and clearances.
	2. Valves are out of adjustment.	2. Adjust valves and clearances.
ABNORMAL SOUND OR NOISE	CRANKSHAFT AND MAIN BEARING	1. Replace bearing and grind crankshaft.
	1. Badly worn bearing.	2. Grind crankshaft.
	2. Badly worn crankshaft.	3. Replace bearing and check lubrication system.
	3. Melted bearing.
	CONNECTING ROD AND CONNECTING ROD BEARING	1. Replace bearing.
	1. Worn connecting rod big end bearing.	2. Grind crankshaft.
	2. Worn crankpin.	3. Correct bend or replace.
	3. Bent connecting rod.
	PISTON, PISTON PIN, AND PISTON RING	1. Rebore cylinder to oversize and replace piston.
	1. Worn cylinder.	2. Replace piston.
	2. Worn piston pin.	3. Replace piston and rebore cylinder.
	3. Piston seized.	4. Replace piston and rings.
	4. Piston seized and ring worn or damaged.
	VALVE MECHANISM	1. Replace.
	1. Worn camshaft.	2. Adjust.
	2. Excessive valve clearance.	3. Replace.
	3. Worn timing gear.	4. Replace.
	4. Worn fan pulley bearing.
LOW COMPRESSION	MAIN ENGINE TROUBLES	1. Adjust valve clearance.
	1. Incorrect valve clearance.	2. Lap valve.
	2. Inadequate contact of valve seat	3. Replace valve and valve guide.
	3. Valve stem seized.	4. Replace valve spring.
	4. Broken valve spring.	5. Replace gasket.
	5. Compression leaks through cylinder head gasket.	6. Replace piston and piston ring.
	6. Piston ring seized.	7. Overhaul engine.
	7. Worn piston ring and cylinder,	8. Overhaul engine.
	8. Worn engine bearings.
EXCESSIVE FUEL CONSUMPTION	1. Noisy knocking.	1. See KNOCKING.
	2. Smoky exhaust.	2. See SMOKY EXHAUST.
	3. Moving parts nearly seized or excessively worn.	3. Repair or replace.
	4. Poor compression.	4. See LOW COMPRESSION; HARD STARTING.
	5. Improper valve timing.	5. Adjust.
	6. Improper valve clearance.	6. Adjust.
	INSUFFICIENT INTAKE AIR	1. Remove obstruction.
	1. Air intake obstructed.
	NOZZLE TROUBLES
	1. Seized nozzle.	1. Replace.
	2. Worn nozzle.	2. Replace.
KNOCKING	ENGINE KNOCKS WITHOUT MUCH SMOKE
	1. Main engine troubles.
	a.Overheated cylinder.	a. See OVERHEATING; LOW OUTPUT.
	b.Carbon deposits in cylinder.	b. Clean.
	KNOCKING WITH DARK SMOKE	1. See LOW COMPRESSION; HARD STARTING.
	1. Poor compression.
LOW OIL PRESSURE	1. Worn Bearings.	1. Engine overhaul replace bearings.
	2. Relief valve malfunction.	2. Overhaul oil pump.
	3. Clogged oil cooler/filter.	3. Repair and replace.
	4. Diesel dilution of the oil.	4. Injection pump repair.

PROBLEM	TEST/CHECK	CORRECTION
Unit starts, then over speeds and shuts down.	1. Check DC voltage between terminal #12 and + connection on hour meter when ON switch is depressed.	1. Charge starting battery. Start unit, troubleshoot battery, charge circuit.
	2. Check the AC signal from the MPU while cranking, voltage should be 1.5-2.5 VAC.	2. Check the MPU resistance value and positioning. Adjust and replace as needed.
	3. Check the actuator.	3. Check the resistance value. Apply 12VDC across leds. Should fully retract. Replace as needed.
	4. Check the controller.	4. Manually control unit. Start and check DC voltage between #9 and #8, between #11 and #10. Replace controller or OS board as needed.
Unit starts, runs at idle.	1. Incorrect speed adjustments..	1. Check and adjust speed adjustment.
	2. Faulty governor controller..	2. Check DC voltages from controller to O/S board and 0/S board to actuator.
Actuator hunts during operation.	1. Improper controller adjustment.	1. Lessen GAIN adjustment
	2. Linkage or rod end bearings are sticking or binding.	2. Lubricate and replace as needed.
	3. Inadequate DC supply voltage.	3. Manually stabilize the unit. Check the DC voltage to the controller. Correct as needed.
	4. MPU positioned marginally too far away from the flywheel teeth, giving an erratic AC input signal to the controller.	4. Check the MPU signal. Adjust positioning as needed.