Cummins 6BT5.9-G2 Troubleshooting
| Engine Model: Cummins 6BT5.9-G2 |
| Engine Type: 4-cycle inline 6-cylinder direct-injection liquid-cooled diesel |
| Total Displacement: 359 cu.in (5.9 L) |
| Rated Engine Power: 114-201 Hp (85-150 kW) at 2300 rpm |
| Aspiration Type: Turbocharged |
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| Engine hard to start or doesn't start |
Dirty fuel filter - Clean the filter or install new filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are damaged or dirty - Service or change injection nozzles.
Fuel injection pump is not working correctly - Replace injection pump or repair it.
Valve timing is out of adjustment - Correct or change timing gear.
Restricted fuel pipes - Service or change fuel pipes.
Wrong injection timing - Set the injection timing correctly.
Worn piston rings and cylinder - Change defective parts.
| Engine stalls after starting |
Dirty fuel filter - Clean the filter or install new filter element.
Defective fuel injection pump - Repair or replace injection pump.
Air filter is dirty - Clean or change.
Nozzle opening pressure is incorrect - Set it correctly.
| Engine stalls while running |
Fuel injection timing is wrong - Adjust as recommended.
Clogged fuel filter - Clean the filter or install new filter element.
Coolant temperature is low - Warm up to required temperature.
Injection nozzles are jammed or clogged - Clean or replace injection nozzles.
Low idle speed setting is not correct - Adjust low idle speed.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump is broken - Replace or rebuild injection pump.
Clogged injection nozzle - Service or change injection nozzles.
Dirty fuel hoses or lines - Service fuel hoses and lines.
Air filter element clogged - Replace air filter element.
Cylinder head gasket is worn - Install a new gasket.
Wrong injection timing - Check injection timing adjustment.
Fuel injection pump is damaged - Replace or repair injection pump.
Any of moving engine parts is worn - Replace or repair damaged components.
Dirty radiator fins or faulty radiator cap - Install new cap or clean radiator.
Low engine coolant - Top up coolant fluid and check system for leaks.
Fan belt is broken or worn - Belt replacement is recommended.
Engine oil insufficient - Add oil to the engine crankcase.
Worn cylinder head gasket - Cylinder-head gasket replacement required.
Injection timing is incorrect - Use correct injection timing adjustment.
| Insufficient oil pressure |
Low oil level - Add oil as required.
Oil pump is damaged - Install a new pump.
Oil filter clogged - Clean or replace engine oil filter element.
Stuck or worn relief valve - Relief valve need to be replaced or cleaned.
Excessive crankshaft bearing clearance - Inspect and replace or repair faulty components.
Excessive crankpin bearing clearance - Test and repair or replace worn parts.
| Engine consuming too much oil |
Oil leaking: Defective seals or gaskets - Change worn parts according to specifications.
Improper oil viscosity - Use proper viscosity oil.
Worn or stuck piston rings - Piston rings need to be replaced.
Valve guides or stems are damaged - Need to replace the valves.
Scored cylinder liners or pistons - Check liners and pistons, change as required.
Coolant temperature is low - Warm up engine as required.
Engine oil level low - Add oil to the engine crankcase.
Fuel injection pump timing is wrong - Check the fuel injection pump timing adjustment.
Pistons are broken or worn - Pistons replacement required.
Misaligned or defective connecting rod - Need to change or align the connecting rod.
Low battery output - Low battery charging, charge as required.
Battery runs out quickly - Service charging system or replace battery.
Battery cables are disconnected or terminals are faulty - Check wiring connections and replace or clean terminals.
Battery is drained or defective - Recharge or replace battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery output voltage - Low battery charging, charge as required.
Starter motor failing - Repair or replace starter.
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