Cummins K38 Troubleshooting
| Engine Model: Cummins K38 |
| Engine Type: 4-cycle 12-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 2319 cu.in (38 L) |
| Rated Engine Power: 900-1500 Hp (671-1119 kW) at 2000 rpm |
| Aspiration Type: Turbocharged and aftercooled |
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| Engine starts hard or won't start |
Fuel filter element is dirty - Change the filter element.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles fault - Service or change injection nozzles.
Fuel injection pump is damaged - Replace or repair injection pump.
Improper valve timing - Correct or replace timing gear.
Fuel pipes are plugged - Clean fuel pipes.
Incorrect injection timing - Use correct injection timing adjustment.
Excessive wear of piston rings and cylinder - Replace defective components.
| Diesel starts and suddenly stops |
Fuel filter element is clogged - Replace the filter element.
Fuel injection pump malfunction - Repair or install new pump.
Air cleaner is dirty - Change air filter element.
Improper nozzle opening pressure - Set up as recommended.
| Engine stops suddenly during operation |
Fuel injection timing is not adjusted - Adjust as recommended.
Fuel filter element is dirty - Change filter element.
Engine is not warmed up to the required temperature - Warm up engine as required.
Injection nozzles are stuck or clogged - Change or repair injection nozzles.
| Engine stops while idling |
Wrong adjustment of low idle speed - Normalize low idle speed.
The valve clearance is not adjusted - Check and adjust.
Defective fuel injection pump - Replacement or repair required.
Fuel injection nozzles are faulty or clogged - Install a new kit of correctly balanced nozzles.
Dirt in the fuel hoses or lines - Service fuel lines and hoses.
Air filter clogged - Replace air filter element.
Cylinder-head gasket is leaking - Cylinder-head gasket replacement required.
Wrong injection timing - Adjust as recommended.
Fuel injection pump failure - Repair or install new pump.
One of moving engine parts is faulty - Change or repair damaged parts.
Dirty radiator core or defective radiator cap - Clean radiator or install new cap.
Insufficient coolant - Fill radiator to proper level and check components for faults.
Fan belt is loose or defective - Replace the fan belt.
Insufficient engine oil - Fill up the engine oil.
Damaged cylinder-head gasket - Change cylinder head gasket.
Unadjusted injection timing - Adjust as recommended.
| Insufficient oil pressure |
Insufficient engine oil - Add oil as required.
Oil pump failure - Replace as required.
Oil filter clogged - Change or clean engine oil filter element.
Relief valve is defective or dirty - Replace or service relief valve.
Clearance of crankshaft bearing is excessive - Inspect and replace or repair faulty parts.
Excessive oil clearance of crankpin bearing - Inspect and replace or repair faulty components.
| Excessive oil consumption |
Oil leaks: Worn gaskets or seals - To repair leaks, replace worn parts.
Crankcase oil too light - Fill up with the correct oil viscosity.
Stuck or defective piston rings - Install new piston rings.
Valve stems and guides are worn - Valves must be replaced.
Cylinder liners or pistons are scuffed - Check liners and pistons, replace as required.
| Abnormal engine noise or knocking |
Engine not warmed up - Normalize the temperature by warming up the engine.
Not enough engine oil - Fill up the engine oil.
Improper fuel injection timing - Adjust as recommended.
Pistons are worn or scored - Pistons need to be replaced.
Misaligned or defective connecting rod - Need to align or replace the connecting rod.
Low battery voltage - Low battery charging, charge as required.
Battery drains quickly - Service or change the battery.
Disconnected wires or corroded battery terminals - Connect wiring properly or install new terminals.
Battery is discharged or worn - Replace or charge as required.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery voltage is low - Charge the battery.
Faulty starter motor - Starter should be replaced.
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