Cummins ISM-400 Troubleshooting
| Engine Model: Cummins ISM-400 |
| Engine Type: 4-cycle 6-cylinder CELECT electronic fuel-injection liquid-cooled diesel |
| Total Displacement: 661 cu.in (10.8 L) |
| Rated Engine Power: 400 Hp (298 kW) at 2000 rpm |
| Aspiration Type: Turbocharged |
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| Engine hard to start or doesn't start |
Fuel filter plugging - Clean or replace the filter.
Air in the fuel pipes - Bleed the fuel pipes.
Fuel injection nozzles are clogged or faulty - Check injection nozzles and replace if required.
Fuel injection pump is not working correctly - Replace or rebuild injection pump.
Valve timing is incorrect - Adjust or replace timing gear.
Fuel pipes clogging - Clean fuel pipes.
Wrong injection timing - Adjust as recommended.
Worn cylinder or piston rings - Replace defective parts.
| Engine starts but stalls suddenly |
Fuel filter plugging - Service the filter.
Fuel injection pump is not operating properly - Change or repair the pump.
Air cleaner is dirty - Carry out maintenance on air filter.
Nozzle opening pressure is improper - Adjust as required.
| Engine stalls during operation |
Fuel injection timing is wrong - Set it up as required.
Fuel filter element is dirty - Change filter element.
Engine is cold - Warm up the engine.
Stuck or burnt injection nozzle - Check injection nozzles and replace if required.
Incorrect low idle setting - Adjustment required.
Improper valve clearance - Adjust valve clearance according to specifications.
Fuel injection pump malfunction - Rebuild or install a new injection pump.
Defective injection nozzle - Clean or replace injection nozzles.
Fuel lines or hoses are clogged - Clean fuel lines and hoses.
Dirty air cleaner - Clean air cleaner element.
Cylinder head gasket is defective - Replace cylinder head gasket.
Injection timing is wrong - Adjust as recommended.
Fuel injection pump is defective - Change pump or rebuild it.
One of moving engine components is worn - Change or repair damaged parts.
Damaged radiator cap or dirty radiator core - Clean radiator or install new cap.
Not enough coolant - Add coolant and check the components of cooling system.
Fan belt is loose or defective - Install new fan belt.
Insufficient engine oil - Check and refill engine oil.
Cylinder head gasket is worn - Replace cylinder head gasket.
Improper injection timing - Use correct injection timing adjustment.
Lack of oil - Add oil as required.
Oil pump malfunction - Remove and inspect oil pump.
Oil filter element clogging - Replace or clean engine oil filter element.
Stuck or defective relief valve - Relief valve need to be replaced or cleaned.
Crankshaft bearing clearance is excessive - Test and replace or repair worn components.
Excessive crankpin bearing clearance - Test and repair or replace worn parts.
| Diesel engine using too much oil |
Oil leaks: Defective seals or gaskets - New components need to be installed.
Improper oil viscosity - Fill up with the correct oil viscosity.
Worn or stuck piston rings - Change the piston rings as required.
Valve guides or stems are damaged - Change the valves.
Cylinder liners or pistons are scuffed - Inspect pistons and liners, replace as required.
| Engine knocking sound or abnormal noise |
Engine is cold - Warm up the engine.
Lack of engine oil - Check and refill engine oil.
Improper fuel injection timing - Set up as recommended.
Piston wear or scoring - Replace the pistons as required.
Connecting rod is worn or misaligned - Align or change connecting rod.
Low battery voltage - Battery is drained, charge it.
Battery does not hold charge - Service battery or change it.
Battery cables are disconnected or terminals are faulty - Check wiring and clean or replace terminals.
Battery is low or faulty - Charge or replace the battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery output voltage - Battery needs to be recharged.
Starter motor failing - Starter should be changed.
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