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FORM 6284 Third Edition 5.

00-1
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 frame-
work 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:
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:
a. Clogged intake air filters.
b. Clogged/dirty intercooler (air side).
NOTE: Bar the engine over by hand to verify that
cylinders are clear. Inspect the intake manifold for
accumulations of oil.
a. Remove and clean.
b. Remove and clean.
TROUBLESHOOTING
5.00-2 FORM 6284 Third Edition
Engine will crank, but will not start.
(cont'd.)
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 (Ver-
sion 6 Series) Custom Engine Control Detona-
tion 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 (Ver-
sion 4 Series) Custom Engine Control Detona-
tion Sensing Module Installation, Operation,
And Maintenance Manual, and rerun AutoCal
program. Contact your Waukesha Engine Dis-
tributor for assistance.
Knock Detection Module inoperative or in shut-
down condition (Inline Engines):
a. KDM in shutdown mode. a. Check KDM diagnostic display codes, and
perform appropriate procedures as outlined in
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
Form 6285 Custom Engine Control Knock
Detection Module Installation, Operation, And
Maintenance Manual. Contact your Waukesha
Engine Distributor for assistance.
AFM inoperative or in Alarm Condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
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.
c. Binding control linkage:
Linkage dirty. Clean.
Table 5.00-1 Troubleshooting Table (Continued), (Part 2 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
TROUBLESHOOTING
FORM 6284 Third Edition 5.00-3
Engine stops suddenly. Safeties tripped. Determine cause, correct, and reset.
Insufficient fuel supply. Check gas pressure.
Low oil pressure causes engine protection control
to shut down engine.
Inspect lubricating oil system and components;
correct cause.
High coolant temperature causes engine protec-
tion 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-
trol to shut down engine.
Determine and correct cause.
Excessive load causes engine to stall. Determine and correct cause of overload.
Insufficient intake air:
a. Clogged intake air filter(s). 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
pin or camshaft.
Replace bearings clean up or replace crank-
shaft, 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
Form 6268 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Detona-
tion Sensing Module Installation, Operation,
And Maintenance Manual, and rerun AutoCal
program. Contact your Waukesha Engine Dis-
tributor for assistance.
b. DSM in shutdown mode. b. Check DSM diagnostic display codes, and
perform appropriate procedures as outlined in
Form 6268 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Detona-
tion Sensing Module Installation, Operation,
And Maintenance Manual. Contact your
Waukesha Engine Distributor for assistance.
AFM inoperative or in Alarm Condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 2.8a) or Form 6286 (Ver-
sion 4 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 2.8a) or Form 6286 (Ver-
sion 4 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
Table 5.00-1 Troubleshooting Table (Continued), (Part 3 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
TROUBLESHOOTING
5.00-4 FORM 6284 Third Edition
Engine loses power. Insufficient fuel:
a. Low gas pressure. a. Check gas fuel system.
Air intake system malfunction:
a. Dirty intake air filters. a. Remove and clean.
b. Clogged intercooler. b. Remove and clean.
Bar the engine over by hand
to verify that the cylinders
are clear. Inspect the intake manifold for accu-
mulations of oil.
Detonation Sensing Module, sensing detonation
condition in one or more cylinders:
a. Hot or unprocessed gas has gone through
engine that could cause detonation.
a. Determine if hot or unprocessed gas has
gone through engine that could cause detona-
tion. Check DSM diagnostic display codes,
and perform appropriate procedures as out-
lined in Form 6268 (Version 5.3c) or Form
6278 (Version 6 Series) Custom Engine Con-
trol Detonation Sensing Module Installation,
Operation, And Maintenance Manual.
AFM inoperative or in Alarm Condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
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
recently overhauled).
a. Readjust.
Excessive exhaust system backpressure. Correct as required.
Engine will not shut down using nor-
mal stopping procedures.
Defective ON-OFF switch. Shut off fuel supply.
Shut off the gas supply for positive
shutdown of gas engines. Inspect
the intake manifold for accumula-
tions of oil.
Overheated combustion chamber deposits cause
the engine to run on auto ignition.
Allow engine to cool down before attempting to
stop.
Table 5.00-1 Troubleshooting Table (Continued), (Part 4 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
CAUTION
WARNING
TROUBLESHOOTING
FORM 6284 Third Edition 5.00-5
Engine will not reach rated speed. Engine overloaded. Determine and correct cause.
Insufficient fuel supply. Check fuel supply system.
AFM inoperative or in Alarm condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
Restricted air intake. Correct cause.
Ignition not properly timed. Re-time.
Tachometer inaccurate. Calibrate or replace tachometer.
Individual cylinders misfire. Prechamber gas admission valve stuck shut. Clean or replace valve.
Engine will not run at maximum power. Engine misfiring:
a. Fuel system setting incorrect. a. Contact your Waukesha Engine Distributor for
assistance.
AFM inoperative or in Alarm condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
Engine detonates. Engine overloaded. Determine and correct cause of overload.
Incorrect ignition timing. Reset to specification.
Engine misfiring:
a. Spark plugs misfiring. a. Clean and regap, or replace spark plugs.
Emission levels too high. Advanced ignition timing. Reset to specification.
Air/fuel ratio incorrect. Reset to specification.
AFM inoperative or in Alarm condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
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.
Table 5.00-1 Troubleshooting Table (Continued), (Part 5 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
TROUBLESHOOTING
5.00-6 FORM 6284 Third Edition
Low or fluctuating oil pressure.
Shut down engine
immediately.
Insufficient oil. Add oil as required.
Oil pressure gauge inaccurate.
Compare to master gauge. Replace gauge if nec-
essary.
Oil gauge line plugged. Renew gauge line.
Oil filters plugged. Change elements; clean filter.
Oil pressure regulating valve stuck in open posi-
tion.
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.
Low gas/air pressure. Insufficient line pressure. Increase line pressure.
High gas/air pressure. Incorrectly adjusted gas regulator. Readjust.
Incorrect spring in gas regulator. Replace spring.
Excessive line pressure. Reduce line pressure.
AFM inoperative or in Alarm Condition:
a. Wiring from sensors, Air/Fuel Module or AFM
actuator damaged.
a. Repair or replace wiring as required. Refer to
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
b. AFM in alarm mode. b. Check AFM diagnostic display codes, and per-
form appropriate procedures as outlined in
Form 6263 (Version 5.3c) or Form 6278 (Ver-
sion 6 Series) Custom Engine Control Air/Fuel
Module. Contact your Waukesha Engine Dis-
tributor for assistance.
High oil pressure.
Misadjusted oil pressure regulating valve.
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.
Low jacket water temperature.
Gauge inaccurate.
Compare to master gauge; replace gauge if nec-
essary.
High jacket water temperature.
Gauge inaccurate.
Allow engine to cool.
Compare to master gauge; replace gauge if nec-
essary.
Gauge line clogged or valve shut. Replace line, open valve.
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. Determine and correct cause.
Leaking pump seals. Repair pump.
Frozen coolant.
Completely thaw cooling system before restarting
engine.
Incorrect ignition timing. Reset ignition timing.
Table 5.00-1 Troubleshooting Table (Continued), (Part 6 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
CAUTION
CAUTION
TROUBLESHOOTING
FORM 6284 Third Edition 5.00-7
High auxiliary water temperature.
Gauge inaccurate.
Compare to master gauge; replace gauge if nec-
essary.
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.
High oil consumption. Oil leaks in oil system. Locate and repair leaks.
Improper viscosity.
Change to a viscosity recommended for operat-
ing temperatures.
Worn piston rings or liners.
Contact your Waukesha Engine Distributor for
assistance.
Oil contamination. Oil contaminated with water.
NOTE: Change oil.
Oil contaminated with dirt:
a. Oil filter bypass valves opening because ele-
ments are plugged.
a. Replace elements.
b. Oil filter elements punctured. b. Replace elements.
c. Air intake filters punctured. c. Replace air intake filters.
Excessive vibration.
Stop engine at
once; investigate
cause.
Engine misfiring. See Engine detonates. on page 5.00-5 causes.
Foundation bolts:
a. Loose. a. Contact your Waukesha Engine Distributor for
assistance.
Vibration damper:
a. Loose. a. Contact your Waukesha Engine Distributor for
assistance.
Crankshaft:
a. Broken. a. Contact your Waukesha Engine Distributor for
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.
Contact your Waukesha Engine Distributor for
assistance.
High oil temperature.
Gauge inaccurate.
Compare to master gauge; replace gauge if nec-
essary.
Engine overloaded. Determine and correct cause.
Insufficient cooling:
a. High auxiliary water temperature. a. See High auxiliary water temperature.
causes.
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.
Table 5.00-1 Troubleshooting Table (Continued), (Part 7 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
CAUTION
TROUBLESHOOTING
5.00-8 FORM 6284 Third Edition
Knocking or unusual noises. Low octane fuel. Adjust timing for the fuel used.
Engine overloaded. Determine and correct cause.
Overly advanced ignition timing. Retime.
Detonation Sensing Module, sensing detonation
condition in one or more cylinders:
a. Hot or unprocessed gas has gone through
engine that could cause detonation.
a. Determine if hot or unprocessed gas has
gone through engine that could cause detona-
tion. Check DSM diagnostic display codes,
and perform appropriate procedures as out-
lined in Form 6268 (Version 5.3c) or Form
6278 (Version 6 Series) Custom Engine Con-
trol Detonation Sensing Module Installation,
Operation, And Maintenance Manual.
Knock Detection Module sensing detonation con-
dition in one or more cylinders (Inline Engines):
a. KDM in shutdown mode. a. Check KDM diagnostic display codes, and
perform appropriate procedures as outlined in
Form 6285 Custom Engine Control Knock
Detection Module Installation, Operation, And
Maintenance Manual.
Excessive valve clearance. Adjust to specification.
Loose bearings (failed).
Contact your Waukesha Engine Distributor for
assistance.
Loose piston pins (failed).
Contact your Waukesha Engine Distributor for
assistance.
Excessive crankshaft end play.
Contact your Waukesha Engine Distributor for
assistance.
Misfitted or excessively worn timing gears.
Contact your Waukesha Engine Distributor for
assistance.
Excessive fuel consumption.
Leaks in fuel system.
Contact your Waukesha Engine Distributor for
assistance.
Retarded ignition timing. Set timing to specifications.
Engine overloaded. Determine and correct cause.
TURBOCHARGER: Excessive noise
or vibration.
Low oil pressure. Improper bearing lubrication.
Load engine before warm oil is supplied to the
turbocharger.
Contact your Waukesha Engine Distributor for
assistance.
GOVERNOR: Engine hunts or surges. Compensation adjustments incorrect. Adjust needle valve to specification.
Dirty oil in governor. 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.
Table 5.00-1 Troubleshooting Table (Continued), (Part 8 of 9)
SYMPTOM PROBABLE CAUSE REMEDY
TROUBLESHOOTING
FORM 6284 Third Edition 5.00-9
GOVERNOR: Terminal shaft/engine
linkage jiggles.
Compensating spring adjustment at critical set-
ting.
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.
Load does not divide properly in interconnected
engines.
Speed droop adjustment incorrect:
a. Adjust droop to divide load properly.
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.
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.
GOVERNOR: Engine is slow to
respond to speed or load changes. Needle valve adjustment incorrect.
Readjust compensating needle valve. Open fur-
ther 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 pro-
tect 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.
GOVERNOR: Engine will not pick up
rated load.
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 interfer-
ence on lever control governor.
Table 5.00-1 Troubleshooting Table (Continued), (Part 9 of 9)
SYMPTOM PROBABLE CAUSE REMEDY