Cummins ISG12 Troubleshooting
| Engine Model: Cummins ISG12 |
| Engine Type: 4-cycle inline 6-cylinder HPCR or XPI fuel injection liquid-cooled diesel |
| Total Displacement: 720 cu.in (11.8 L) |
| Rated Engine Power: 310-490 Hp (231-365 kW) at 2100 rpm |
| Aspiration Type: Turbocharged and aftercooled |
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| Engine difficult to start or won't start |
Fuel filter plugging - Clean or change the filter.
Air in the fuel pipes - Bleed the fuel pipes.
Clogged injection nozzle - Test injection nozzles and change if necessary.
Fuel injection pump is broken - Change pump or rebuild it.
Valve timing is incorrect - Use correct valve timing adjustment.
Restricted fuel pipes - Service or change fuel pipes.
Injection timing is improper - Adjust injection timing as required.
Cylinder or piston rings are worn - Replace defective components.
| Engine starts and then shuts off |
Fuel filter element clogging - Filter maintenance required.
Fuel injection pump is broken - Install a new fuel pump or repair.
Dirty air filter - Service or replace the air filter.
Nozzle opening pressure is not adjusted - Set it correctly.
| Engine shuts off suddenly while running |
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.
Fuel filter element is dirty - Filter maintenance required.
Engine is not preheated - Warm up the engine.
Defective or stuck injection nozzles - Check injection nozzles and replace if required.
Incorrect low idle setting - Correct the settings.
Improper valve clearance - Adjust to proper valve clearance.
Fuel injection pump malfunctioning - Rebuild or change fuel pump.
Clogged injection nozzle - Test injection nozzles and change if necessary.
Dirt in the fuel hoses or lines - Fuel hoses and lines must be clean.
Intake air restriction - Replace air filter element.
Cylinder-head gasket is broken - Change cylinder head gasket.
Wrong injection timing - Adjust according to specifications.
Faulty fuel injection pump - Replace or repair injection pump.
One of moving engine components is worn - Change or repair damaged parts.
Radiator core is dirty or radiator cap is damaged - Clean radiator or change cap.
Low coolant level - Top up coolant fluid and check system for leaks.
Fan belt is broken or worn - Fan belt must be replaced.
Engine oil level is low - Checking oil level and add if necessary.
Defective cylinder head gasket - Gasket should be replaced.
Wrong injection timing - Adjust injection timing as required.
Engine oil insufficient - Fill crankcase to proper oil level.
Worn oil pump - Remove and inspect oil pump.
Oil filter element is dirty - Clean or replace engine oil filter element.
Relief valve is stuck or worn - Replace or service relief valve.
Clearance of crankshaft bearing is excessive - Inspect and change or repair worn components.
Crankpin bearing clearance is excessive - Test and replace or repair worn components.
| High engine oil consumption |
Oil leakage: Seals or gaskets are wearing excessively - Change to repair leaks.
Oil viscosity is incorrect - Fill up with the proper oil viscosity.
Stuck or worn piston rings - Piston rings replacement required.
Valve guides or stems are damaged - Need to replace the valves.
Scored cylinder liners or pistons - Inspect pistons and liners, change as required.
| Engine knocking sound or abnormal noise |
Engine is not preheated - Warm up to required temperature.
Lack of engine oil - Fill the crankcase with engine oil.
Incorrect adjustment of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Piston wear or scoring - Pistons replacement required.
Connecting rod is worn or not aligned - Need to change or align the connecting rod.
Low battery voltage - Low battery charging, charge as required.
Battery won’t hold charge - Service battery or replace it.
Battery cables are disconnected or terminals are faulty - Connect wiring correctly or install new terminals.
Battery is low or faulty - Recharge or replace battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery power is low - Battery is drained, recharge it.
Damaged starter motor - Repair or change starter.
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