Cummins QSB5.9 Troubleshooting
| Engine Model: Cummins QSB5.9 |
| Engine Type: 4-cycle inline 6-cylinder HPCR direct injection liquid-cooled diesel |
| Total Displacement: 359 cu.in (5.9 L) |
| Rated Engine Power: 100-220 Hp (74-164 kW) at 2400 rpm |
| Aspiration Type: Turbocharged |
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| Engine starts hard or won't start |
Fuel filter plugging - Clean or replace the filter.
Air in the fuel system - Air bleeding.
Faulty fuel injection nozzles - Check and replace nozzles if required.
Fuel injection pump is faulty - Repair or change injection pump.
Valve timing is wrong - Use correct valve timing adjustment.
Fuel pipes clogging - Service fuel pipes.
Injection timing is wrong - Set up as recommended.
Piston rings and cylinder are worn - Replace defective components.
| Diesel starts and stalls immediately |
Fuel filter plugging - Change filter element.
Fuel injection pump malfunctioning - Repair or replace injection pump.
Dirty air cleaner - Service air cleaner.
Improper nozzle opening pressure - Adjust according to specifications.
| Engine shuts off suddenly while running |
Fuel injection timing is not adjusted - Adjust fuel injection pump as required.
Clogged fuel filter - Clean or replace the filter.
Engine not warmed up - Warm up to required temperature.
Injection nozzles sticking or clogged - Service or change injection nozzles.
Low idle speed setting is not correct - Adjust low idling as recommended.
Excessive valve clearance - Adjust valve clearance according to specifications.
Fuel injection pump is not operating properly - Change or repair the pump.
| Diesel engine loses power |
Defective injection nozzle - Replace injection nozzles.
Clogged fuel lines or hoses - Fuel hoses and lines must be clean.
Restricted intake air - Clean air cleaner element.
Cylinder head gasket is defective - Cylinder-head gasket replacement required.
Unadjusted injection timing - Adjust injection timing as required.
Faulty fuel injection pump - Repair or replace injection pump.
One of moving engine components is worn - Change or repair damaged parts.
Radiator core is clogged or radiator cap is leaking - Clean radiator or install new cap.
Engine has a lack of coolant - Fill radiator to proper level and check components for faults.
Fan belt is loose or defective - Belt replacement is recommended.
Engine oil level is insufficient - Checking oil level and add if necessary.
Defective cylinder head gasket - Install new cylinder head gasket.
Injection timing is wrong - Use correct injection timing adjustment.
| Oil pressure is insufficient |
Not enough oil in the engine - Check and refill the oil.
Oil pump is worn or damaged - Replace as required.
Oil filter is dirty - Replace or service engine oil filter.
Stuck or defective relief valve - Replace or clean relief valve.
Clearance of crankshaft bearing is excessive - Test and repair or replace worn parts.
Excessive oil clearance of crankpin bearing - Check and replace or repair defective parts.
| Diesel engine using too much oil |
Oil leakage: Gaskets or seals are excessively worn - Install new components.
Crankcase oil too light - Use proper viscosity oil.
Worn or stuck piston rings - Change piston rings.
Valve stems and guides are worn - Valves replacement required.
Pistons or cylinder liners are damaged - Check liners and pistons, install new components as required.
| Abnormal engine knocking or noise |
Engine not warmed up - Warm up engine as required.
Engine oil level is insufficient - Checking oil level and add if necessary.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.
Pistons are broken or worn - Pistons need to be replaced.
Connecting rod is misaligned or worn - Align or replace connecting rod.
Battery voltage is low - Battery needs to be recharged.
Battery is not holding charge - Service battery or change it.
Bad terminals or disconnected battery cables - Connect cables properly or replace terminals.
Battery is discharged or defective - Replace or charge as required.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Battery capacity is low - Battery needs to be recharged.
Damaged starter motor - Replace or repair starter.
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