Westerbeke weird starting issue?

[Skybolt]

I have a 12KW Westerbeke four cylinder engine. I had gone through the whole engine and put a new back end on ~5 years ago. Since then standard maintenance, filters oil and such, the generator has been flawless, always started within 2-3 secs on cranking over. About a month ago it started up very strangely, it started like it always does but did not ramp up in rpm and stayed at some much lower rpm and died, like no fuel. So I started it again and then shut it off right away, re-started and ran great like nothing ever happened. It has ran this way every weekend since and will run for hours/days with no problems. But continues to need to be started twice.

I checked the lift pump, primes just fine and keeps running on/off as needed to keep pressure up, filters are clean (just changed). Checked the run solenoid snaps into place correctly and stays there, moves free and easy no binding of any kind. No smoke or exhaust residue to speak of in water.

I am completely stumped over this. Any ideas would be greatly appreciated.

 

[fwebster]

The fuel solenoid on many Westerbeke generators has 2 stages. The first is for starting and the second just supports the running stage of operation. A loose electrical connection, corrosion inside the case can both cut the voltage to the run side and that alters the fuel volume and pressure which can affect the generator's operation.

Like other Westerbeke parts, the fuel run solenoid is proprietary to Westerbeke and they are pricey (about $165).

This may be a reach, but it is all I can come up with…………...

 

[ttmott]

The fuel solenoid on many Westerbeke generators has 2 stages. The first is for starting and the second just supports the running stage of operation. A loose electrical connection, corrosion inside the case can both cut the voltage to the run side and that alters the fuel volume and pressure which can affect the generator's operation.

Like other Westerbeke parts, the fuel run solenoid is proprietary to Westerbeke and they are pricey (about $165).

This may be a reach, but it is all I can come up with…………...

And, look to see if the fuel solenoid is operated by a little Bosch style relay (the newer generators are); that may be acting up. Easy and cheap to R&R.

 

[Skybolt]

The fuel solenoid on many Westerbeke generators has 2 stages. ...

Thank you Frank, I did not know they were two stage as that is exactly what it is acting like, not going to the 2nd stage. The manual I have doesn't mention that.

 

[Skybolt]

And, look to see if the fuel solenoid is operated by a little Bosch style relay (the newer generators are); that may be acting up. Easy and cheap to R&R.

Thanks Tom, I am going to study the schematic and see what is going on electrically. I wasn't thinking this was electrical at all.

 

[Skybolt]

Well I definitely have a two stage relay, there are three wires going to it. I had no idea that was how this worked, it's not mentioned in any of the manuals I have and I have never come across this issue. Man do I feel better knowing this now. Thankfully I take detailed pictures of everything for looking at things away from the boat. Thanks again @fwebster and @ttmott great advice for someone that wasn't thinking it was electrical.

EDIT: This is an interesting tech bulletin on the fore mentioned solenoid. https://www.westerbeke.com/service bulletin/sb_175.pdf

 

[Skybolt]

Well I definitely have a two stage relay, there are three wires going to it. ...

Well I spoke too soon and pic's are only good when there the entire picture. I do have a two stage relay, but only one stage is being used. The three wires are a ground and two to the same lug, one of which is the extra wire in the bulletin which is not in the schematic ...

 

[Skybolt]

So I have narrowed it down to leaky injectors. Looking at the exhaust as it started up, black smoke and residue in the water. Cleared right up and no smoke. I can only think it's leaky injectors?

Can any one recommend a good injector shop to send them too? The shop I use to use is now closed since covid.

 

[Cocktail Time]

So I have narrowed it down to leaky injectors. Looking at the exhaust as it started up, black smoke and residue in the water. Cleared right up and no smoke. I can only think it's leaky injectors?

Can any one recommend a good injector shop to send them too? The shop I use to use is now closed since covid.

Skybolt, I had very similar symptoms and the problem was an intermittent lift pump. It would work then not work on it's own. Symptoms sound just like what you describe above. Replaced and zero issues since with running.

 

[Skybolt]

Skybolt, I had very similar symptoms and the problem was an intermittent lift pump. It would work then not work on it's own. Symptoms sound just like what you describe above. Replaced and zero issues since with running.

Thanks, that could be the issue since I don't know the age of the existing one. Mine is the cylindrical pump with the internal filter on the bottom, it is always clean, but not an expensive pump so might be worth the try. Thanks.