6284 5 00 PDF

SECTION 5.
00
TROUBLESHOOTING
TROUBLESHOOTING CHART
The following table is provided to assist the user in
determining the possible causes of unsatisfactory
engine operation, as well as point out the corrective
action that may be undertaken to remedy the problem.
Knowledge of how the engine operates along with the
current readings from the engine instrument panel can
be combined with this information to provide a framework for resolving actual or potential problems.
NOTE: This chart is only provided as a service to our
customers. It should not be viewed as a reflection of
Waukesha Engine's actual experience with this
product. This chart is not all inclusive. Refer to
respective sections in this manual for details.
Table 5.00-1 Troubleshooting Table (Part 1 of 9)

SYMPTOM
PROBABLE CAUSE
REMEDY
Engine crankshaft cannot be barred

over.
Load not disengaged from engine.
Disengage load.
Engine will crank, but will not start.

Ambient minimum Temperature
10 C (50 F)
ON-OFF switch in OFF position or defective

(if used).
Place switch in the ON position or replace if

defective.
Fuel throttle or manual shutoff control in OFF

position.
Place fuel throttle or manual shutoff control in ON

position.
Safeties tripped.
Determine cause, correct, and reset.
Insufficient cranking speed:

a. Low starting air/gas pressure.
a. Build up air/gas pressure. 100 125 rpm

required to start engine.
b. Oil temperature too low or viscosity too high.
b. Change oil or raise the oil temperature.
Fuel system inoperative:

a. Insufficient fuel supply or fuel pressure.
a. Check gas pressure.
Faulty ignition system:
FORM 6284 Third Edition
a. No power to CEC Ignition Module.
a. Reconnect.
b. Low or no output from CEC Ignition Module.
b. Replace CEC Ignition Module as required.
c. Hall-effect pickup disconnected or damaged.
c. Reconnect.
d. Incorrect ignition timing.
d. Reset the timing.
e. Broken or damaged wiring.
e. Repair or replace.
f. Spark plug(s) not firing.
f. Check gap/replace as required.
Insufficient or no air intake:
NOTE: Bar the engine over by hand to verify that

cylinders are clear. Inspect the intake manifold for
accumulations of oil.
a. Clogged intake air filters.
a. Remove and clean.
b. Clogged/dirty intercooler (air side).
b. Remove and clean.
5.00-1
TROUBLESHOOTING
Table 5.00-1 Troubleshooting Table (Continued), (Part 2 of 9)
SYMPTOM
Engine will crank, but will not start.
(cont'd.)
PROBABLE CAUSE
REMEDY
Detonation Sensing Module inoperative or in

shutdown condition (Vee Engines):
a. DSM in shutdown mode.
a. Check DSM diagnostic display codes, and

perform appropriate procedures as outlined in
Form 6268 (Version 5.3c) or Form 6278 (Version 6 Series) Custom Engine Control Detonation Sensing Module Installation, Operation,
And Maintenance Manual. Contact your
Waukesha Engine Distributor for assistance.
b. Wiring from sensors to DSM damaged.
b. Repair or replace wiring as required. Refer to

Form 6268 (Version 2.8a) or Form 6286 (Version 4 Series) Custom Engine Control Detonation Sensing Module Installation, Operation,
And Maintenance Manual, and rerun AutoCal
program. Contact your Waukesha Engine Distributor for assistance.
Knock Detection Module inoperative or in shutdown condition (Inline Engines):

a. KDM in shutdown mode.
a. Check KDM diagnostic display codes, and

Form 6285 Custom Engine Control Knock
Detection Module Installation, Operation, And
Maintenance Manual. Contact your Waukesha
Engine Distributor for assistance.
b. Wiring from sensors to KDM damaged.
b. Repair or replace wiring as required. Refer to

Maintenance Manual. Contact your Waukesha
Engine Distributor for assistance.
AFM inoperative or in Alarm Condition:

a. Wiring from sensors, Air/Fuel Module or AFM a. Repair or replace wiring as required. Refer to
actuator damaged.
Form 6263 (Version 5.3c) or Form 6278 (Version 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Distributor for assistance.
b. AFM in alarm mode.
b. Check AFM diagnostic display codes, and perform appropriate procedures as outlined in
Governor inoperative:
a. Governor set incorrectly.
Contact your Waukesha Engine Distributor for

assistance.
b. Insufficient oil:
Water/sludge in oil passages.
Clean or replace governor.
Clean.
c. Binding control linkage:
5.00-2
Linkage dirty.
TROUBLESHOOTING
SYMPTOM
Engine stops suddenly.
PROBABLE CAUSE
REMEDY
Safeties tripped.
Determine cause, correct, and reset.
Insufficient fuel supply.
Check gas pressure.
Low oil pressure causes engine protection control Inspect lubricating oil system and components;
to shut down engine.
correct cause.
High coolant temperature causes engine protection control to shut engine down.
Inspect cooling system and components;

correct cause.
High intake manifold temperature.
Correct cause.
High oil temperature.
Correct cause.
Engine overspeed causes engine protection con- Determine and correct cause.
trol to shut down engine.
Excessive load causes engine to stall.
Determine and correct cause of overload.
Insufficient intake air:

a. Clogged intake air filter(s).
b. Clogged intercooler (air side).
Obstructed exhaust manifold.
Locate and remove obstruction.
Seizure of bearings main, connecting rod, piston

pin or camshaft.
Replace bearings clean up or replace crankshaft, camshaft or piston pins, as required.
a. Lack of lubrication.
a. Check oil system; correct cause.
b. Dirt in oil.
b. Check oil filters.
Detonation Sensing Module inoperative or in

Shutdown Condition:
a. Wiring from sensors to DSM damaged.
a. Repair or replace wiring as required. Refer to

And Maintenance Manual, and rerun AutoCal
program. Contact your Waukesha Engine Distributor for assistance.
b. DSM in shutdown mode.
b. Check DSM diagnostic display codes, and

And Maintenance Manual. Contact your
Waukesha Engine Distributor for assistance.

actuator damaged.
Form 6263 (Version 2.8a) or Form 6286 (Version 4 Series) Custom Engine Control Air/Fuel
Form 6263 (Version 2.8a) or Form 6286 (Version 4 Series) Custom Engine Control Air/Fuel
5.00-3
TROUBLESHOOTING
SYMPTOM
Engine loses power.
PROBABLE CAUSE
REMEDY
Insufficient fuel:
a. Low gas pressure.
a. Check gas fuel system.
Air intake system malfunction:

a. Dirty intake air filters.
b. Clogged intercooler.

Bar the engine over by hand
CAUTION to verify that the cylinders
are clear. Inspect the intake manifold for accumulations of oil.
Detonation Sensing Module, sensing detonation

condition in one or more cylinders:
a. Hot or unprocessed gas has gone through a. Determine if hot or unprocessed gas has
engine that could cause detonation.
gone through engine that could cause detonation. Check DSM diagnostic display codes,
and perform appropriate procedures as outlined in Form 6268 (Version 5.3c) or Form
6278 (Version 6 Series) Custom Engine Control Detonation Sensing Module Installation,
Operation, And Maintenance Manual.
actuator damaged.
Air leaks in intake system.
Find and correct as required.
Turbocharger malfunction or failure:

a. Lack of lubrication.
a. Contact your Waukesha Engine Distributor for

assistance.
Ignition system timing incorrect.
Re-time.
Low compression pressure:

a. Misadjusted intake and exhaust valves (if a. Readjust.
recently overhauled).
Excessive exhaust system backpressure.
Correct as required.
Engine will not shut down using normal stopping procedures.
Defective ON-OFF switch.
Shut off fuel supply.
WARNING
Shut off the gas supply for positive
shutdown of gas engines. Inspect
the intake manifold for accumulations of oil.
Overheated combustion chamber deposits cause Allow engine to cool down before attempting to
the engine to run on auto ignition.
stop.
5.00-4
TROUBLESHOOTING
SYMPTOM
Engine will not reach rated speed.
PROBABLE CAUSE
REMEDY
Engine overloaded.
Determine and correct cause.
Insufficient fuel supply.
Check fuel supply system.
AFM inoperative or in Alarm condition:

actuator damaged.
Individual cylinders misfire.
Restricted air intake.
Correct cause.
Ignition not properly timed.
Re-time.
Tachometer inaccurate.
Calibrate or replace tachometer.
Prechamber gas admission valve stuck shut.
Clean or replace valve.
Engine will not run at maximum power. Engine misfiring:

a. Fuel system setting incorrect.

assistance.

actuator damaged.
Engine detonates.
Engine overloaded.
Determine and correct cause of overload.
Incorrect ignition timing.
Reset to specification.
Engine misfiring:
Emission levels too high.
a. Spark plugs misfiring.
a. Clean and regap, or replace spark plugs.
Advanced ignition timing.
Air/fuel ratio incorrect.

actuator damaged.
Engine misfiring:
a. Faulty ignition system.
a. Repair or replace components as required.
b. Prechamber fuel system incorrectly set.
b. Reset per fuel system specification.
c. Sticking gas admission valve.
c. Clean or replace valve.
5.00-5
TROUBLESHOOTING
SYMPTOM
Low or fluctuating oil pressure.
CAUTION
PROBABLE CAUSE
Insufficient oil.
Shut down engine Oil pressure gauge inaccurate.

immediately.
Oil gauge line plugged.
Low gas/air pressure.

High gas/air pressure.
REMEDY
Add oil as required.
Compare to master gauge. Replace gauge if necessary.
Renew gauge line.
Oil filters plugged.
Change elements; clean filter.
Oil pressure regulating valve stuck in open position.
Clean and polish valve.
Oil dilution.
Change oil and filter elements. Determine and

correct source of dilution.
Oil of low viscosity.
Change to higher viscosity oil as recommended.
Oil foaming.
Use oil grade recommended. Check for water

leaks into oil.
Clogged oil inlet screen.
Remove and clean screen.
Dirty oil cooler.
Clean.
Insufficient line pressure.
Increase line pressure.
Incorrectly adjusted gas regulator.
Readjust.
Incorrect spring in gas regulator.
Replace spring.
Excessive line pressure.
Reduce line pressure.

actuator damaged.
High oil pressure.

Misadjusted oil pressure regulating valve.
Low jacket water temperature.
Refer to VGF Repair and Overhaul Form 6243

(F18/H24) or Form 6264 (L36/P48) to adjust oil
pressure regulating valve.
Lubricating oil of high viscosity.
Change to lower viscosity oil as recommended.
Gauge inaccurate.
Compare to master gauge; replace gauge if necessary.
Gauge inaccurate.
Allow engine to cool.

CAUTION
Gauge line clogged or valve shut.
Replace line, open valve.
High jacket water temperature.
5.00-6
Low coolant level.
Fill cooling system.
Broken or loose water pump belts.
Replace or adjust belts.
Air bound cooling system.
Purge air from cooling system.
Engine overloaded.
Leaking pump seals.
Repair pump.
Frozen coolant.
Completely thaw cooling system before restarting

engine.
Incorrect ignition timing.
Reset ignition timing.
TROUBLESHOOTING
SYMPTOM
High auxiliary water temperature.
High oil consumption.
Oil contamination.
PROBABLE CAUSE
REMEDY
Gauge inaccurate.
Clogged gauge line or the gauge line valve is

shut.
Replace line or open valve.
Broken or loose auxiliary water pump belts.
Replace or adjust belts.
Clogged heat exchanger or intercooler.
Clean heat exchanger/intercooler.
Oil leaks in oil system.
Locate and repair leaks.
Improper viscosity.
Change to a viscosity recommended for operating temperatures.
Worn piston rings or liners.

assistance.
Oil contaminated with water.
NOTE: Change oil.
Oil contaminated with dirt:

a. Oil filter bypass valves opening because ele- a. Replace elements.
ments are plugged.
Excessive vibration.
CAUTION
Stop engine at
once; investigate
cause.
b. Oil filter elements punctured.
b. Replace elements.
c. Air intake filters punctured.
c. Replace air intake filters.
Engine misfiring.
See Engine detonates. on page 5.00-5 causes.
Foundation bolts:
a. Loose.

assistance.
Vibration damper:
a. Loose.

assistance.
Crankshaft:
High oil temperature.
a. Broken.

assistance.
b. Main bearing nuts loose.
b. Contact your Waukesha Engine Distributor for

assistance.
c. Crankshaft counterweight loose.
c. Contact your Waukesha Engine Distributor for

assistance.
Loose flywheel.

assistance.
Gauge inaccurate.
Engine overloaded.
Insufficient cooling:
a. High auxiliary water temperature.
a. See High
causes.
auxiliary
water
temperature.
b. Dirty oil cooler.
b. Clean or replace.
c. Broken or loose auxiliary water pump belts.
c. Replace or adjust belts.
Dirty jacket water heat exchanger or radiator.
Clean or replace.
Low lubricating oil pressure.
See Low or fluctuating oil pressure. causes.
5.00-7
TROUBLESHOOTING
SYMPTOM
Knocking or unusual noises.
PROBABLE CAUSE
REMEDY
Low octane fuel.
Adjust timing for the fuel used.
Engine overloaded.
Overly advanced ignition timing.
Retime.
Detonation Sensing Module, sensing detonation

condition in one or more cylinders:
a. Hot or unprocessed gas has gone through a. Determine if hot or unprocessed gas has
engine that could cause detonation.
gone through engine that could cause detonation. Check DSM diagnostic display codes,
and perform appropriate procedures as outlined in Form 6268 (Version 5.3c) or Form
6278 (Version 6 Series) Custom Engine Control Detonation Sensing Module Installation,
Operation, And Maintenance Manual.
Knock Detection Module sensing detonation condition in one or more cylinders (Inline Engines):
Excessive fuel consumption.
TURBOCHARGER: Excessive noise

or vibration.
a. KDM in shutdown mode.
a. Check KDM diagnostic display codes, and

Maintenance Manual.
Excessive valve clearance.
Adjust to specification.
Loose bearings (failed).

assistance.
Loose piston pins (failed).

assistance.
Excessive crankshaft end play.

assistance.
Misfitted or excessively worn timing gears.

assistance.
Leaks in fuel system.

assistance.
Retarded ignition timing.
Set timing to specifications.
Engine overloaded.
Low oil pressure. Improper bearing lubrication.

Load engine before warm oil is supplied to the
turbocharger.

assistance.
GOVERNOR: Engine hunts or surges. Compensation adjustments incorrect.

Dirty oil in governor.
5.00-8
Adjust needle valve to specification.

Drain oil, clean governor and refill.
Foamy oil in governor.
Drain oil and refill.
Low oil level.
Add oil to correct level on gauge glass. Check for

leaks, especially at drive shaft.
Lost motion in engine linkage.
Repair linkage.
Binding in engine linkage.
Repair and realign linkage.
Governor worn or not correctly adjusted.
Repair and adjust governor.
Engine misfiring.
See Engine misfiring: on page 5.00-5 under

Engine detonates.
Compensating spring incorrectly adjusted.
Adjust.
Low oil pressure. Normal operating pressure is

110 120 psi.
Replace governor.
Power piston sticking inside (PSG or SG).
Replace governor.
Misadjusted linkage.
Adjust.
Fluctuating or unstable fuel gas pressure.
Adjust.
Rough drive.
Repair or replace.
TROUBLESHOOTING
SYMPTOM
GOVERNOR: Terminal shaft/engine
linkage jiggles.
PROBABLE CAUSE
REMEDY
Compensating spring adjustment at critical setting.
Change compensating spring pre-compression

approximately 0.005 in. (0.13 mm) either way.
Speed droop (if used) at critical setting.
Increase droop to eliminate critical setting. Load

division will be affected if this is done. Readjust
droop on units affected.
Governor base not bolted down evenly.
Loosen bolts, realign and secure.

Speed droop adjustment incorrect:
a. Adjust droop to divide load properly.
Load does not divide properly in interconnected

engines.
b. Increase droop to resist picking up

(or dropping off) load.
c. Reduce droop to increase picking up
(or dropping off) load.
Speed droop shaft vibrating out of position.
Increase tension of speed droop friction spring.
Rough engine drive.

a. Check alignment of gears.
b. Check gear backlash.
GOVERNOR: Load does not divide
properly in inter-connected engines.
GOVERNOR: Engine is slow to

respond to speed or load changes.
GOVERNOR: Engine will not pick up

rated load.
NOTE: If droop adjustment is not provided, the governor is isochronous only, and cannot be used for
parallel operation. Speed droop is not essential in a DC electrical system. The equivalent of speed
droop in a DC system is obtained by changing the compounding of the generators at the bus between
generators. An under-compounded generator is equivalent to a speed droop governor. Governors
with speed droop adjustment are commonly used for DC service since the droop adjustment may be
used to correct errors or inequalities of generator compounding.
Slippage in hydraulic or electric couplings (if
used).
Adjust coupling.
Needle valve adjustment incorrect.
Readjust compensating needle valve. Open further only if possible to do so without causing
instability when running without load.
Governor is not sensitive in measuring speed

change.
Repair and adjust governor.
Governor may be intentionally designed to protect engine from overloading during a load
change.
No field correction.
Pivot valve not centered. It must open control

ports equally in both directions.
Adjust pivot valve.
Low oil pressure in governor.
See Low or fluctuating oil pressure.
Engine overloaded.
Reduce load.
Restricted fuel supply.
Clean fuel supply line and filters.
Load limit knob set to restrict fuel.
Open up the load limit.
Lean air/fuel ratio.
Adjust carburetor mixture value.
Butterfly valves will not open far enough.
a. Adjust engine-to-governor fuel linkage.

b. Adjust load limiting device.
Restricted fuel supply.
Clean fuel supply line and filters.
Voltage regulator (if used) not functioning.
Adjust or repair.
Engine misfiring (Spark plugs misfiring).
Clean and regap, or replace spark plugs.
Slipping clutch (if used) between engine and

driven load.
Foaming oil or low oil level in hydraulic clutch.
Speed adjustment of the governor is restricted.

a. Check the maximum speed limit adjustment
on dial control governor.
b. Inspect speed adjusting linkage for interference on lever control governor.
5.00-9

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SECTION 5.

Table 5.00-1 Troubleshooting Table (Part 1 of 9)

Engine crankshaft cannot be barred

Load not disengaged from engine.

Engine will crank, but will not start.

ON-OFF switch in OFF position or defective

Place switch in the ON position or replace if

Fuel throttle or manual shutoff control in OFF

Place fuel throttle or manual shutoff control in ON

Determine cause, correct, and reset.

Insufficient cranking speed:

a. Build up air/gas pressure. 100 125 rpm

b. Oil temperature too low or viscosity too high.

b. Change oil or raise the oil temperature.

Fuel system inoperative:

a. Check gas pressure.

Faulty ignition system:

FORM 6284 Third Edition

a. No power to CEC Ignition Module.

b. Low or no output from CEC Ignition Module.

b. Replace CEC Ignition Module as required.

c. Hall-effect pickup disconnected or damaged.

d. Incorrect ignition timing.

d. Reset the timing.

e. Broken or damaged wiring.

f. Spark plug(s) not firing.

f. Check gap/replace as required.

Insufficient or no air intake:

NOTE: Bar the engine over by hand to verify that

a. Clogged intake air filters.

a. Remove and clean.

b. Clogged/dirty intercooler (air side).

b. Remove and clean.

Detonation Sensing Module inoperative or in

a. Check DSM diagnostic display codes, and

b. Wiring from sensors to DSM damaged.

b. Repair or replace wiring as required. Refer to

Knock Detection Module inoperative or in shutdown condition (Inline Engines):

a. Check KDM diagnostic display codes, and

b. Wiring from sensors to KDM damaged.

b. Repair or replace wiring as required. Refer to

AFM inoperative or in Alarm Condition:

Contact your Waukesha Engine Distributor for

Water/sludge in oil passages.

Clean or replace governor.

c. Binding control linkage:

FORM 6284 Third Edition

Determine cause, correct, and reset.

Insufficient fuel supply.

Check gas pressure.

Inspect cooling system and components;

High intake manifold temperature.

High oil temperature.

Determine and correct cause of overload.

Insufficient intake air:

a. Remove and clean.

b. Clogged intercooler (air side).

b. Remove and clean.

Obstructed exhaust manifold.

Locate and remove obstruction.

Seizure of bearings main, connecting rod, piston

Replace bearings clean up or replace crankshaft, camshaft or piston pins, as required.

a. Check oil system; correct cause.