Cummins 6BTAA5.9-G12 Troubleshooting
| Engine Model: Cummins 6BTAA5.9-G12 |
| Engine Type: 4-cycle inline 6-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 359 cu.in (5.9 L) |
| Rated Engine Power: 228-295 Hp (170-220 kW) at 1800 rpm |
| Aspiration Type: Turbocharged and aftercooled |
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| Engine starts hard or doesn't start |
Dirty fuel filter - Replace the filter element.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles are faulty or clogged - Change fuel injection nozzles.
Fuel injection pump malfunction - Replacement or repair required.
Wrong valve timing - Correct or change timing gear.
Fuel pipes clogging - Clean or change fuel pipes.
Incorrect injection timing - Set up as recommended.
Damaged piston rings and cylinder - Replace defective components.
| Engine starts but then stops |
Fuel filter plugged - Replace filter element.
Fuel injection pump is not operating properly - Repair or replace injection pump.
Dirty air cleaner - Clean or replace element.
Nozzle opening pressure is not adjusted - Adjust as required.
| Engine shuts off suddenly while running |
Timing of fuel injection pump is incorrect - Use the correct fuel injection pump timing adjustment.
Fuel filter plugging - Filter maintenance required.
Coolant temperature is low - Warm up the engine.
Stuck or clogged injection nozzle - Repair or change injection nozzles.
| Engine stops while idling |
Incorrectly adjusted low idle speed - Adjust low idling as recommended.
Improper valve clearance - Adjust valve clearance.
Damaged fuel injection pump - Replace or rebuild injection pump.
Fuel injection nozzles are damaged - Clean or change injection nozzles.
Fuel hoses or lines are dirty - Clean fuel system lines and hoses.
Clogged air cleaner - Service air cleaner.
Cylinder head gasket defective - Install a new gasket.
Incorrect injection timing - Set the injection timing correctly.
Fuel injection pump is defective - Rebuild or replace pump.
One of moving engine components has failed - Repair or replace defective components.
Defective radiator cap or clogged radiator fins - Clean radiator or install new cap.
Lack of engine coolant - Top up coolant fluid and check system for leaks.
Loose or damaged fan belt - Change the fan belt.
Not enough engine oil - Checking oil level and add if necessary.
Damaged cylinder-head gasket - Cylinder-head gasket replacement required.
Injection timing is improper - Set up as recommended.
Insufficient engine oil - Need to add oil.
Oil pump is defective - Repair or change.
Clogged oil filter element - Replace or clean engine oil filter element.
Relief valve is stuck or worn - Change or clean relief valve.
Excessive oil clearance of crankshaft bearing - Inspect and change or repair worn components.
Crankpin bearing clearance is excessive - Test and repair or replace worn parts.
| Excessive engine oil consumption |
Oil leakage: Gaskets or seals can be faulty - To repair leaks, replace worn parts.
Crankcase oil too light - Fill up with the correct oil viscosity.
Worn or broken piston rings - Change the piston rings as required.
Damaged valve stems or valve guides - Valves replacement required.
Cylinder liners or pistons are scuffed - Inspect liners and pistons, change as necessary.
| Engine knocking sound or abnormal noise |
Engine is not preheated - Warm up engine as required.
Engine oil insufficient - Fill up the oil to required level.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Pistons are worn or broken - Install new pistons.
Connecting rod is not aligned or defective - Alignment procedure or replacement is required.
Low battery output voltage - Low battery charging, charge as required.
Battery won’t hold charge - Service battery or replace it.
Terminals are faulty or battery cables are disconnected - Check cables and clean or change terminals.
Battery is low or faulty - Battery needs to be recharged or replaced.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery capacity is low - Charge the battery.
Starter motor failure - Repair or install a new starter.
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