Technical information

TROUBLE SHOOTING
28 Copyright © 2009 Mastervolt / December 2009 / WHISPER 3.5 / EN
5.2.3 Other engine related problems
Problem Possible cause What to do?
• Almost certainly this is an electrical problem.
The remote control panel will indicate a failure
code related to the DC voltage (see 5.1.2)
• One other possibility is that the engine is
locked by water in the cylinder or there is
other severe damage.
Check on water in the cylinder and further
damage by cranking while lifting the valves with
the decompression handle. When there is water
in the cylinder, then deactivate the control
system, disconnect the battery, remove the glow
plug. Crank the engine to remove the water
through the opening of the glow plug. Check oil
on the presence of water and change oil. Find
out how the water entered the cylinder (check
the air vent). Take precautions to prevent it from
happening again. When there is no mechanical
malfunction the problem must be an electric
malfunction.
• Starter battery switched "OFF".
Check position of the battery switch and switch
"ON".
• Starter battery voltage insufficient (battery too
weak).
Check battery voltage. Recharge the battery.
Inspect battery terminals and cables for a good
electrical connection (inspect against corrosion,
tattered wires, etc.)
• Wiring control system faulty
During the normal starting process, the battery
voltage drops to 11V (with a fully charged
battery). If the voltage does not drop during
starting, the electrical connection is faulty. If the
battery voltage drops lower than 11V, then the
battery has been discharged too deep.
• Starter broken
Repair the starter motor
Diesel engine fails to
crank, the starter
makes clicking noises,
or the engine cranks
very slowly
• To thick engine lubricating oil.
Change oil for a lower viscosity.
• Out of fuel or faulty fuel, water in the fuel.
Fill up with fuel or replace with better quality.
• Fuel solenoid is not opening (no “click” can be
heard).
Check wire connections and circuitry to
solenoid. (Refer to DC wiring diagram)
• Fuel lift pump is not working.
• Fuel filter is blocked.
• Air in fuel lines.
Check fuel filter and fuel lift pump: clean or
replace if necessary.
Bleed air from fuel system (refer to maintenance
section).
• Wrong valve clearance.
Adjust valve clearance,
• Low compression because of dirty valves.
Clean valves. Take off the injection bent and
inspect the outlet port. When little rust in the port
clean the valve by taking off the valve spring and
rotate until rust is removed. When the outlet port
is strongly affected by rust, the exhaust system
is not properly installed (refer to paragraph
5.4.3).
Contact Mastervolt service department for
advice.
• Blocked injector.
Have the injector tested and cleaned if
necessary.
Starter is turning
engine smoothly, but
engine fails to start
• Loss of compression by wear out or damage
Repair by Mastervolt service
• Unsuitable contaminated fuel
• Lack of fuel.
Fill up with fuel or replace by better quality.
• Choked fuel filter.
Check fuel filter and fuel lift pump: clean or
replace if necessary.
• Disturbances on the electrical system/ user
side.
Check if electrical load is fluctuating
• Faulty fuel lift pump.
Check and repair
• Choked air filter.
• Lack of air.
Check the air intake
Engine runs irregularly.
• Choked exhaust system, exhaust chocked
rubber exhaust hose kinked.
Check the exhaust hose