The problem I am encountering is that the Universal engine is "shutting down" at 2300RPM after 4-5 minutes under load (prop engaged). It shuts down almost immediately at 2800RPM. I can run it for extended periods below 2300RPM (2-3 hours) without any issues. The shut down is fairly quick with no smoke or sputtering. There is a 200RPM decay @ 30 seconds before the shutdown. This has been duplicated 10-12 times. It does not shutdown at any speed when not under load.
Initially the mech thought it might be a fuel injector pump issue. We pulled the fuel injector pump, had it "rebuilt", and bench tested. No issues were found. The fuel injector pump timing was checked and found to be correct. We replaced the electric fuel pump (since I had a spare) and the output was measures at 5.1 PSI. We were thinking air was getting in and placed clear plastic pipe directly into the electric fuel pump and at the diesel return. No air was present at the input to the electric fuel pump and flow was not disrupted to the electric fuel pump. Interestingly we saw no fuel in the diesel return at any RPM. RPM was measured with digital gauge. Engine temperature does not increase before, after or during the shutdown. The engine starts up normally immediately after the shutdown.
The mech contacted the engine manufacturer but did not get any good ideas. She is out of ideas and has reached out to some others for ideas. Westerbeke has indicated they will get back to her but is leaning towards the governor. The mech does not buy that since the problem only happens under load and the governor only perceives RPM.
Background: I bought the Catalina 30 1983 boat in October 2015. The survey showed a very high metal content in the oil and antifreeze. I tore the engine down right after I took possession and did a major overhaul. Major included: Head valve job, new pistons and cylider liners, new crank shaft, new glo plugs, new fuel injectors, and a new heat exchanger. The machine shop really did a poor job in estimating and most of the costs crept up on me. I could have bought a new engine for the costs I have invested to date. Also I have found several things the shop did incorrectly so I have little/no confidence in their technical competence. The machine shop did all the "core work" and I did the work on the peripheries (pumps, alternator, starter, heat exchanger, etc).
Does anyone have any ideas as to what is going on?
Initially the mech thought it might be a fuel injector pump issue. We pulled the fuel injector pump, had it "rebuilt", and bench tested. No issues were found. The fuel injector pump timing was checked and found to be correct. We replaced the electric fuel pump (since I had a spare) and the output was measures at 5.1 PSI. We were thinking air was getting in and placed clear plastic pipe directly into the electric fuel pump and at the diesel return. No air was present at the input to the electric fuel pump and flow was not disrupted to the electric fuel pump. Interestingly we saw no fuel in the diesel return at any RPM. RPM was measured with digital gauge. Engine temperature does not increase before, after or during the shutdown. The engine starts up normally immediately after the shutdown.
The mech contacted the engine manufacturer but did not get any good ideas. She is out of ideas and has reached out to some others for ideas. Westerbeke has indicated they will get back to her but is leaning towards the governor. The mech does not buy that since the problem only happens under load and the governor only perceives RPM.
Background: I bought the Catalina 30 1983 boat in October 2015. The survey showed a very high metal content in the oil and antifreeze. I tore the engine down right after I took possession and did a major overhaul. Major included: Head valve job, new pistons and cylider liners, new crank shaft, new glo plugs, new fuel injectors, and a new heat exchanger. The machine shop really did a poor job in estimating and most of the costs crept up on me. I could have bought a new engine for the costs I have invested to date. Also I have found several things the shop did incorrectly so I have little/no confidence in their technical competence. The machine shop did all the "core work" and I did the work on the peripheries (pumps, alternator, starter, heat exchanger, etc).
Does anyone have any ideas as to what is going on?