SECTION 7.

00
TROUBLESHOOTING

TROUBLESHOOTING current readings from the engine instrument panel can

be combined with this information to provide a frame-
The following table is provided to assist the user in
work for resolving actual or potential problems.
determining the possible causes of unsatisfactory
engine operation, as well as point out the corrective NOTE: This chart is only provided as a service to our
action that may be undertaken to remedy the problem. customers. It should not be viewed as a reflection of
Knowledge of how the engine operates along with the Waukesha Engine’s actual experience with this product.
Table 7.00-1. Troubleshooting Table
SYMPTOM PROBABLE CAUSE REMEDY
Engine crankshaft cannot be barred Load not disengaged from engine. Disengage load.
over.
Do not attempt to Coolant or obstruction in cylinder: NOTE: Remove spark plugs to vent cylinders of
rotate crankshaft accumulated coolant.
with starter.
a. Cracked exhaust manifold. a. Replace.
b. Cracked head. b. Replace.
c. Cracked sleeve. c. Replace.
Seized piston. Determine cause of seizure: insufficient
lubrication, inadequate cooling, overload, etc.
Replace piston assembly and sleeve, as
required.
Main bearings too tight:
a. Main bearing caps installed out of a. Check each bearing cap; place in proper
location. location.
b. Improper bolt torque. b. Adjust bearing caps. Torque to
specifications.
c. High spots on bearings. c. Replace.
Engine will crank but will not start. On-off switch in OFF position or defective (if Place switch in the ON position or replace if
((50° F minimum ambient used). defective.
temperature)
Fuel throttle or manual shut-off control in OFF Place fuel throttle or manual shut-off control in
position. ON position.
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 b. Change oil or raise the oil temperature.
high.
Fuel system inoperative:
a. Insufficient fuel supply or fuel pressure. a. Check gas pressure.
b. Fuel system settings incorrect. b. Reset regulators.
c. Stiff carburetor diaphragm. c. Replace diaphragm.
d. Worn carburetor mixing valve assembly. d. Replace assembly.

FORM 6296 First Edition 7.00 -- 1

TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY

Engine will crank but will not start
(cont’d).
Engine stops suddenly.
e. Ruptured line pressure regulator e. Replace diaphragm.
diaphragm.
f. Bent pressure regulator control rod. f. Replace control rod.
g. Main gas valve stuck closed. g Replace or repair main gas valve.
Faulty ignition system:
a. Low or no output from ignition module . a. Replace ignition module as required.
b. Hall-effect pickup not properly gapped, b. Check gap, reconnect, or replace as
disconnected, or damaged. required.
c. Incorrect ignition timing. c. Reset the timing.
d. Broken or damaged wiring. d. Repair or replace.
e. Magneto drive assembly broken. e. Replace drive.
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.
Governor inoperative:
a. Insufficient oil:
1. UG-8 low oil level. 1. Add oil.
2. Gasket blocks off oil supply hole (after 2. Re-position or replace gasket.
repair).
3. Water/sludge in oil passages. 3. Clean or replace governor.
b. Binding control linkage:
1. Linkage dirty. 1. Clean.
2. Linkage broken. 2. Repair.
3. Linkage pivot points tight. 3. Re-adjust or replace pivot point bear-
ing surfaces.
c. Electric governor actuator not opening. c. Check wiring and correct.
d. Governor geometry incorrect. d. Correct as necessary.
Poor compression:
a. Worn rings. a. Replace.
b. Leaking valves. b. Recondition seats and valves.
c. Leaking head gaskets. c. Replace.
Camshaft gear not in time with crankshaft gear. Set crankshaft at T.D.C. #1 R.B. Align the
camshaft, idler and crankshaft gear match
marks.
Insufficient fuel supply. Check gas pressure.
Low oil pressure causes engine protection Inspect lubricating oil system and components;
control to shut down engine. correct cause.
High coolant temperature causes engine Inspect cooling system and components; correct
protection control to shut engine down. cause.
Faulty ignition system. Repair or replace components as required.
High intake manifold temperature. Correct cause.
High oil temperature. Correct cause.
Engine overspeed causes engine protection Determine and correct cause.
control 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). a. Remove and clean.
b. Clogged intercooler (air side). b. Remove and clean.

7.00 -- 2 FORM 6296 First Edition


SYMPTOM
Engine stops suddenly (cont’d).
Engine loses power.
FORM 6296 First Edition
PROBABLE CAUSE
Obstructed exhaust manifold.
Piston seizure:
a. Insufficient cooling.
b. Insufficient lubrication.
c. Insufficient ring gap (applicable only im-
mediately after overhaul).
Obstruction in cylinder.
Seizure of bearings main, connecting rod, piston
pin or camshaft.
a. Lack of lubrication.
b. Dirt in oil.
Insufficient fuel:
a. Low gas pressure.
b. Misadjusted wastegate(s) (altitude
compensation).
Air intake system malfunction:
a. Dirty intake air filters.
b. Clogged intercooler.
Air leaks in intake system.
Turbocharger malfunction or failure:
a. Lack of lubrication.
b. Foreign material.
c. Excessive backpressure.
Engine misfiring:
a. Incorrect fuel regulator adjustment.
b. Faulty ignition system.
Ignition system timing incorrect.
Low compression pressure:
a. Leaking head gasket.
b. Leaking exhaust/intake valve.
c. Misadjusted intake and exhaust valves (if
recently overhauled).
d. Worn rings (excessive blow-by).
e. Worn pistons/liner.
f. Cracked piston.
g. Cracked cylinder head.
Excessive exhaust system backpressure.
TROUBLESHOOTING
REMEDY
Locate and remove obstruction.
a. Replace scored piston, sleeve and rings.
Clean and/or fill the cooling system,
including the heat exchangers.
b. Replace scored piston, sleeve and rings.
Clean oil passages, and/or determine
cause.
c. Replace scored piston, sleeve and rings.
Adjust ring gap.
Replace parts.
Replace bearings -- clean up or replace crank-
shaft, camshaft or piston pins, as required.
a. Check oil system; correct cause.
b. Check oil filters.
a. Check gas fuel system.
b. Consult Waukesha factory representa-
tive for correct setting.
a. Remove and clean.
b. Remove and clean.
Bar the engine over by hand
to verify that the cylinders
are clear. Inspect the intake
manifold for accumulations
of oil.
Find and correct as required.
a. Determine cause; repair or replace
turbocharger.
b. Repair or replace turbocharger.
c. Determine and correct cause.
a. Readjust.
b. Repair or replace components as
required.
Re-time.
a. Replace head gasket - inspect for warped
cylinder head and/or crankcase.
Replace if necessary.
b. Recondition seats and valves.
c. Readjust.
d. Replace.
e. Replace as necessary.
f. Replace.
g. Replace.
Correct as required.
7.00 -- 3
TROUBLESHOOTING
SYMPTOM
Engine will not shut down using
normal stopping procedures.
Shut off the gas supply for posi-
tive shutdown of gas engines. In-
spect the intake manifold for accu-
mulations of oil.
Engine will not reach rated speed.
Engine will start but will not reach idle
rpm.
Engine cannot make rapid load
changes.
Engine misfires at light load.
Individual cylinders misfire.
Engine will not run at maximum
power.
Engine detonates.
Emission levels too high.
Low or fluctuating oil pressure.
Shut down
the engine
immediately.
7.00 -- 4
PROBABLE CAUSE REMEDY
Defective ON-OFF switch. Replace.
Overheated combustion chamber deposits Allow engine to cool down before attempting to
cause the engine to run on -- auto ignition. stop.
Engine overloaded. Determine and correct cause.
Insufficient fuel supply. Check fuel supply system.
Restricted air intake. Correct cause.
Governor misadjusted. Readjust.
Ignition not properly timed. Re-time.
Tachometer inaccurate. Calibrate or replace tachometer.
No fuel to the prechamber manifold during start Repair or replace regulator valve.
sequence. Prechamber regulator valve stuck
shut.
Engine misfiring:
a. Fuel system settings incorrect. a. Readjust per fuel system specifications.
b. Faulty ignition system. b. Repair or replace components as
required.
Faulty ignition system. Repair or replace components as required.
Fuel system setting incorrect. Readjust per fuel system specifications.
a. Fuel regulator valve stuck shut. a. Repair or replace regulator.
Prechamber gas admission valve stuck shut. Clean or replace valve.
Faulty ignition system. Repair or replace components as required.
Engine misfiring:
a. Fuel system setting incorrect. a. Readjust per fuel system specifications.
b. Faulty ignition system. b. Repair or replace components as
required.
Engine overloaded. Determine and correct cause of overload.
Incorrect ignition timing. Reset to specification.
Air/fuel ratio too rich. Reset to specification.
Engine misfiring:
a. Faulty ignition system. a. Repair or replace components as
required.
Advanced ignition timing. Reset to specification.
Air/fuel ratio incorrect. Reset to specification.
Engine misfiring:
a. Faulty ignition system. a. Repair or replace components as
required.
Insufficient oil. Add oil as required.
Oil pressure gauge inaccurate. Compare to master gauge. Replace gauge if
necessary.
Oil gauge line plugged or valve shut. Renew gauge line; open valve.
Oil filters plugged. Change elements; clean filter.
Oil pressure regulating valve stuck in open Clean and polish valve.
position.
Oil pressure regulating valve set too low. Readjust oil pressure regulating valve to
309 -- 345 kPa (45 -- 50 psi) at governed speed.
FORM 6296 First Edition

SYMPTOM
Low or fluctuating oil pressure.
(cont’d).
Shut down
th engine
the i
immediately.
Low gas/air pressure.
High gas/air pressure.
Low jacket water pressure.
High oil pressure.
Low jacket water temperature.
High jacket water temperature.
FORM 6296 First Edition
TROUBLESHOOTING
PROBABLE CAUSE REMEDY
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(s). Remove and clean screen(s).
Engine is operated at angles that exceed the Operate within maximum safe tilt angles (see
maximum safe tilt specification. Section 1.20 Specifications).
Dirty oil cooler. Clean.
Worn oil pump. Repair or replace pump.
Worn bearings (main, connecting rod and Replace worn bearings.
camshaft).
Cracked or leaking oil piping. Repair or replace piping.
Incorrectly adjusted gas regulator. Readjust.
Insufficient line pressure. Increase line pressure.
Incorrect orifice and/or spring in gas regulator. Replace orifice and/or spring.
Undersize gas regulators. Replace with gas regulators of adequate size.
Undersize piping. Replace with piping of adequate size.
Gas regulators mounted too far from engine. Remount gas regulators as close to carburetors
as possible.
Incorrectly adjusted gas regulator. Readjust.
Incorrect spring in gas regulator. Replace spring.
Excessive line pressure. Reduce line pressure.
Low water level. Fill cooling system.
Air is entering the system through the suction Repair leak; purge air from the system.
side of the jacket water pump.
Wrong pressure cap. Replace.
Gauge inaccurate. Compare to master gauge; replace gauge if
necessary.
Gauge line clogged or valve shut. Replace line; open valve.
Leaking pump seals. Repair pump.
Cracked water-cooled exhaust manifold. Replace manifold.
Incorrectly sized outlet water orifice. Resize per specification.
Misadjusted oil pressure regulating valve. Readjust oil pressure regulating valve to
309 -- 345 kPa (45 -- 50 psi).
Lubricating oil temperature too low. Check/replace oil thermostats.
Lubricating oil of high viscosity. Change to lower viscosity oil as recommended.
Lubricating oil pressure regulating valve stuck in Clean and polish valve.
closed position.
Gauge inaccurate. Compare to master gauge; replace gauge if
necessary.
Inoperative or malfunctioning thermostat(s). Replace thermostatic element or thermostat(s)
(as applicable).
Allow engine to cool.
Gauge inaccurate. Compare to master gauge; replace gauge if
necessary.
Low coolant level. Fill cooling system.
Inoperative or malfunctioning thermostat(s). Replace thermostatic element or thermostats
(as applicable).
Air bound cooling system. Purge air from cooling system.
Engine overloaded. Determine and correct cause.
7.00 -- 5
TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY

High jacket water temperature Poor coolant circulation. Check the entire cooling system, including outlet
(cont’d). water orifice plate sizing.
Worn jacket water pump or seals. Overhaul or replace pump.
Frozen coolant. Completely thaw cooling system before
restarting engine.
Cracked exhaust manifold. Replace manifold.
Incorrect ignition timing. Reset ignition timing.
Cracked head. Replace head.
Cracked sleeve. Replace sleeve.
Low auxiliary water pressure. Gauge inaccurate. Compare to master gauge; replace gauge if
necessary.
Clogged gauge line or the gauge line valve is Replace line or open valve.
shut.
Air is entering the system through the suction Repair leak; purge the system of all air.
side of the water pump.
Worn water pump. Repair or replace.
Clogged heat exchanger or intercooler. Clean heat exchanger/intercooler.
Incorrectly sized auxiliary water circuit orifice Resize per specification.
plate.
High oil consumption. Oil leaks in oil system. Locate and repair leaks.
Improper viscosity. Change to a viscosity recommended for
operating temperatures.
Leaking crankshaft oil seals rear and/or front. Change seals.
Worn valve guides; improperly installed, worn Change head; renew guides, or valve guide
valve stem seals. internal seals.
Stuck/worn piston rings. Renew rings.
Oil contamination. Oil contaminated with water: NOTE: Change oil.
a. Cylinder sleeve cracked or seals leaking. a. Replace sleeve O-rings.
b. Oil cooler leaking. b. Repair or replace oil cooler.
Oil contaminated with dirt:
a. Oil filter bypass valves opening because a. Replace elements.
elements are plugged.
b. Oil filter elements punctured. b. Replace elements.
c. Air intake filters punctured. c. Replace air intake filters.
Excessive vibration. Foundation bolts:
a. Loose. a. Torque to specification.
Stop engine at
once; investi- b. Cracked. b. Replace and torque all bolts to
gate cause. specification.

Unbalanced cylinders; misfiring ignition system. Repair or replace components as required.

Vibration damper:
a. Loose. a. Replace all securing bolts; torque to
specifications.
b. Malfunctioning. b. Replace damper.

Crankshaft:
a. Broken. a. Conduct a complete investigation of en-
tire engine for damage.
b. Main bearing nuts loose. b. Determine the reason for loosening; in-
vestigate the entire lower crankcase
before torquing the bolts to specification
and running the engine.

7.00 -- 6 FORM 6296 First Edition


SYMPTOM
Excessive vibration (cont’d).
High oil temperature.
Knocking or unusual noises.
Excessive fuel consumption.
TURBOCHARGER: Excessive noise
or vibration.
GOVERNOR -- UG-8: Engine hunts
or surges.
FORM 6296 First Edition
TROUBLESHOOTING
PROBABLE CAUSE REMEDY
b. Crankshaft nut loose. b. Determine the reason for loosening; in-
vestigate the entire lower crankcase
before torquing the nut to specification
and running the engine.
b. Crankshaft counterweight loose. b. Determine the reason for loosening; in-
vestigate the entire lower crankcase
before torquing the counterweight to
specification and running the engine.
Loose flywheel. Determine cause and correct.
Gauge inaccurate. Compare to master gauge; replace gauge if
necessary.
Engine overloaded. Determine and correct cause.
Insufficient cooling:
a. Low auxiliary water pressure. a. See “Low Auxiliary Water Pressure”
causes.
b. Dirty oil cooler. b. Clean or replace.
c. Defective oil cooler thermostatic control. c. Repair or replace.
Dirty jacket water heat exchanger or radiator. Clean or replace.
Low lubricating oil pressure. See “Low Lubricating Oil Pressure” causes.
Low octane fuel. Adjust timing for the fuel used.
Engine overloaded. Determine and correct cause.
Overly advanced ignition timing. Re-time.
Excessive valve clearance. Adjust to specification.
Sticking valves or rocker arms. Free up or replace.
Damaged or excessively worn accessory drives. Repair or replace components as required.
Loose bearings (failed). Replace bearings.
Loose piston pins (failed). Replace piston pins and/or pin bushings as
required.
Excessive crankshaft end play. Replace main bearing thrust rings.
Misfitted or excessively worn timing gears. Replace.
Leaks in fuel system. Repair as required.
Faulty ignition system. Repair or replace components.
Retarded ignition timing. Set timing to specifications.
Engine overloaded. Determine and correct cause.
Lean air/fuel ratio. Set to specifications.
Poor compression. Determine cause(s) and repair.
Low oil pressure. Improper bearing lubrication. Provide required oil pressure. Clean or replace
Load engine before warm oil is supplied to the oil line. If trouble persists, overhaul turbocharger.
turbocharger.
Dirty impeller/turbine. Clean.
Damaged impeller/turbine. Replace as necessary.
Leak in engine intake or exhaust manifold. Tighten loose connections or replace manifold
gaskets as necessary.
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.
7.00 -- 7
TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE REMEDY

GOVERNOR -- UG-8: Engine hunts Binding in engine linkage. Repair and realign linkage.
or surges (cont’d).
(cont’d)
Governor worn or not correctly adjusted. Repair and adjust governor.
GOVERNOR -- UG-8: Terminal Rough engine drive. a. Inspect for rough gear teeth.
shaft/engine
h ft/ i linkage
li k jiggles.
ji l
b. Check backlash of gears.
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.
GOVERNOR -- UG-8: Engine g is slow Compensation adjustment incorrect. Readjust compensation.
t respond
to d tto speed
d or load
l d changes.
h
Engine overloaded. Reduce load.
Restricted fuel supply. Clean fuel supply line and filters.
GOVERNOR -- UG-8: Engine
g will not Butterfly valves will not open far enough. a. Adjust engine-to-governor fuel linkage.
pick
i k up rated
t d load.
l d
b. Adjust load limiting device.
Restricted fuel supply. Clean fuel supply line and filters.
Speed adjustment of the governor is restricted. a. Check the maximum speed limit adjust-
ment on dial control governor.
b. Inspect speed adjusting linkage for inter-
ference on lever control governor.

7.00 -- 8 FORM 6296 First Edition