Cummins 6BTA5.9 Troubleshooting
| Engine Model: Cummins 6BTA5.9 |
| Engine Type: 4-cycle inline 6-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 359 cu.in (5.9 L) |
| Rated Engine Power: 121-201 Hp (90-150 kW) at 2200 rpm |
| Aspiration Type: Turbocharged and aftercooled |
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| Engine difficult to start or will not start |
Fuel filter plugged - Replace the filter element.
Air in the fuel system - Air bleeding.
Clogged or defective injection nozzles - Clean or replace injection nozzles.
Defective fuel injection pump - Replace or repair injection pump.
Improper valve timing - Set the valve timing correctly.
Dirt in the fuel lines or hoses - Clean fuel pipes.
Improper injection timing - Adjust as recommended.
Piston rings and cylinder are worn - Change defective parts.
| Diesel starts but stalls immediately |
Clogged fuel filter - Replace filter element.
Fuel injection pump failure - Install a new fuel pump or repair.
Clogged air filter - Clean or change.
Nozzle opening pressure is incorrect - Adjust as required.
| Engine stalls while running |
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Fuel filter element clogging - Service the filter.
Coolant temperature is low - Engine is not warmed up to the required temperature.
Defective or stuck injection nozzles - Change or repair injection nozzles.
Too low idle RPM - Normalize low idle speed.
Improper valve clearance - Correct valve clearance.
Fuel injection pump malfunction - Change pump or rebuild it.
Clogged or burnt injection nozzle - Clean or change injection nozzles.
Dirt in the fuel lines or hoses - Service fuel lines and hoses.
Air filter element clogged - Replace air filter element.
Blown cylinder head gasket - Replace cylinder head gasket.
Incorrect injection timing - Check injection timing adjustment.
Fuel injection pump malfunctioning - Rebuild or replace pump.
Any of moving engine components is faulty - Repair or replace defective components.
Radiator fins are clogged or radiator cap is faulty - Clean radiator or replace cap.
Engine has a lack of coolant - Add coolant and check the components of cooling system.
Excessive wear of the fan belt - Change as required.
Low engine oil level - Checking oil level and add if necessary.
Cylinder head gasket is defective - Gasket should be replaced.
Wrong injection timing - Adjust as recommended.
| Insufficient oil pressure |
Low crankcase oil level - Check oil level and add oil as required.
Oil pump is damaged - Repair or change.
Clogged oil filter element - Replace or clean engine oil filter element.
Stuck or defective relief valve - Change or clean relief valve.
Clearance of crankshaft bearing is excessive - Test and repair or replace worn parts.
Excessive crankpin bearing clearance - Test and repair or replace worn parts.
| Diesel engine using too much oil |
Oil leaking: Worn seals or gaskets - Change to repair leaks.
Oil viscosity is incorrect - Use oil of correct viscosity.
Worn or stuck piston rings - Replace piston rings.
Worn valve guides and valve stems - Valves need to be changed.
Damaged cylinder liners or pistons - Check pistons and liners, replace as required.
| Engine knocking sound or abnormal noise |
Engine is not fully warmed up - Warm up to required temperature.
Low engine oil level - Fill the crankcase with engine oil.
Wrong setting of fuel injection pump timing - Set up as recommended.
Worn or scored pistons - Pistons replacement required.
Misaligned or defective connecting rod - Align or change connecting rod.
Low battery output - Battery needs to be recharged.
Battery drains quickly - Service charging system or replace battery.
Bad terminals or disconnected battery cables - Check wiring and clean or replace terminals.
Battery is discharged or defective - Charge or replace the battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Low battery output voltage - Low battery charging, charge as required.
Starter motor failure - Repair or replace starter.
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