Westerbeke 7.0 BCG shut down issue

J

J Levine

New Member
Oct 5, 2006
753
New Jersey
Boat Info
1995 Sea Ray 370 Sundancer
Engines
Mercruiser 7.4L Blue Water inboard V Drives
Typical boat stuff, last October when I winterized my genni was running fine. Yesterday I commissioned it while still on the hard and it is giving me problems. It initially started and then ran for about 90 seconds and then shut down. I restarted it a number of times and each time it would run for a few seconds and then shut down. I have reviewed the Westerbeke owners and technical manuals and I know the shut down system has 4 components: oil pressure (normally open) water temp (normally closed) exhaust temp (normally closed) and engine overspeed. I know I can jump out each of these sensors to see which one may be causing the problem but based on the fact that it started and ran I am thinking that the over speed switch may be the problem. I plan on jumping out each switch and if the over speed is the culprit to then measure the RPM with the switch jumped out to see if it is within the 1800 RPM spec. If it is then I guess I will suck it up and spend the $195 for the over speed switch. Anyone been here and done this? Got any other thoughts for me?
 
Typically if you have an issue with one of your sensors, the moment you let go of the bypass toggle switch the engine will stop. Not to say that you do not have a problem with one of your sensors. Bypass them one -by-one at least you can eliminate them. Check your fuel filter especially the one that is on your carburtor and check your fuel filter as it been mentioned. As far as overspeed does it sound like it going into overspeed?
 
Jon, When I bought my boat the generator did the same thing... The marina added an additional ground wire to the fuel pump and the problem was fixed...
 
Did you have water flowing to the generator? If not, both of the temp sensors will open ...............just a thought since you are still on the hill.
 
It was drawing water out of a bucket and was pumping it overboard normally. The engine block and exhaust risers were only warm to the touch when it quit so I doubt those sensors were tripped. The oil pressure switch could be a problem but the systems monitor is not alarming do I dont think i have a oil pressure issue. The fuel pump is a thought but it does start and run and then shuts down so some fuel is getting to it, plus when it dies it doesn't sound like it is starved for fuel, it sounds like it was turned off. I am going to jump out the switches one at a time as the manual suggests starting with the overspeed board and see what happens. If it is still shutting down with the switches jumped out I guess the fuel pump will be my next focus.
 
You can sort of do this in a gross or total manner but holding the pre-heat switch in the on position to see if the generator will run. It by-passes all of the safety switches so you can start an engine with no oil pressure/no water flow. If it runs normally with the pre-heat switch held on but dies when you release it, then you know it is one of your safety switches, and you can resume your testing procedure of one switch/sensor at a time to isolate the culprit.
 
Good point Frank but I don't think it is the case with the overspeed board? The oil pressure, water temp and exhaust temp switches all are in series and control voltage to the coil while the overspeed board grounds out the coil to stop the motor.
 
Jon,

I have the same generator as you, last season mine would run for about 20 minutes and then shut down. I checked everything that I knew how to check and all seemed o.k. Finally called in a generator mechanic and it turned out to be a simple carb adjustment............hmmm, carb adjustment / overspeed.........might be something to look at.

John
 
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I finally got back to messing with this. The boat is now in the water. I jumped out each of the auto shut down sensors including the over speed module with no change in the condition. The generator is hard to start, finally starts after some cranking, runs normally for a few moments and shuts down. I will say that when I jumped out the overspeed module it actually ran for a few minutes before it died and for a moment there I though I had my problem identified. The next potential cause on the trouble shooting chart in the owners manual for this condition is "fuel pump" which make some sense to me.... it is failing and provides just enough fuel after extensive cranking to get it started but not keep in running? Damn thing is $175 so I sure hope I am right. Any thoughts are appreciated. I did replace the water separating fuel filter and checked the filter screen in the carburator. When it did run for a few minutes after I jumped out the over speed module, it ran pretty well before it died.
 
Just as it is about to die, spray in some carb cleaner and see if it comes back to life. If it does, it's a sure sign that the fuel lift pump is the culprit.
 
Just to close this out I replaced the fuel pump yesterday and the generator started and ran as it should. The Westerbeke pump which has a $175 list price is actually a Facet pump I found at Amazon for 40 bucks.
 
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