Cummins 6BT5.9-G1 Troubleshooting
| Engine Model: Cummins 6BT5.9-G1 |
| Engine Type: 4-cycle inline 6-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 359 cu.in (5.9 L) |
| Rated Engine Power: 161-221 Hp (120-165 kW) at 1800 rpm |
| Aspiration Type: Turbocharged |
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| Engine difficult to start or won't start |
Fuel filter plugged - Filter maintenance required.
Air in the fuel lines - Bleed the fuel lines.
Fuel injection nozzles fault - If necessary, replace with a new nozzle.
Fuel injection pump is faulty - Replacement or repair required.
Valve timing is improper - Correct or change timing gear.
Restricted fuel pipes - Clean or replace fuel pipes.
Incorrect injection timing - Use correct injection timing adjustment.
Piston rings and cylinder are worn - Change faulty components.
Fuel filter element clogging - Service the filter.
Fuel injection pump malfunctioning - Change or repair the pump.
Clogged air filter element - Change air filter element.
Unadjusted nozzle opening pressure - Set it correctly.
| Diesel shuts off while driving |
Fuel injection timing is wrong - Use the correct fuel injection pump timing adjustment.
Dirty fuel filter - Service the filter.
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Injection nozzles are burnt or jammed - Clean or change injection nozzles.
| Engine stops at low idle speed |
Low idle speed setting is incorrect - Adjust low idling as recommended.
Valve clearance is wrong - Check and adjust as required.
Fuel injection pump is not working correctly - Rebuild or change fuel pump.
Clogged or defective injection nozzles - Test injection nozzles and change if necessary.
Dirty fuel lines or hoses - Clean fuel lines and hoses.
Plugged air cleaner - Replace air filter element.
Cylinder-head gasket is broken - Cylinder-head gasket replacement required.
Injection timing is out of adjustment - Set up as recommended.
Fuel injection pump is faulty - Change or repair the pump.
Any of moving engine parts is worn - Repair or replace defective parts.
Radiator fins are clogged or radiator cap is faulty - Replace cap or clean radiator.
Lack of coolant in cooling system - Add coolant and check the components of cooling system.
Fan belt is worn or faulty - The fan belt needs to be replaced.
Not enough engine oil - Add oil to the engine crankcase.
Cylinder-head gasket is broken - Install a new gasket.
Injection timing is incorrect - Adjust injection timing as required.
Not enough oil in the engine - Fill up the engine oil.
Oil pump failure - Repair or change.
Clogged oil filter - Change or clean engine oil filter element.
Relief valve is seized or worn - Change or service relief valve.
Crankshaft bearing clearance is excessive - Check and change or repair defective parts.
Excessive oil clearance of crankpin bearing - Test and repair or replace worn parts.
| Diesel engine consuming too much oil |
Oil leakage: Worn gaskets or seals - Change to repair leaks.
Improper oil viscosity - Use oil of correct viscosity.
Piston rings are stuck or broken - Change piston rings.
Valve stems or guides are damaged - Valves need to be changed.
Damaged cylinder liners or pistons - Check pistons and liners, install new parts as required.
Coolant temperature is low - Normalize the temperature by warming up the engine.
Not enough engine oil - Fill up the oil to required level.
Timing of fuel injection pump is incorrect - Set it up as required.
Pistons are scored or worn - Pistons replacement required.
Misaligned or defective connecting rod - Align or replace connecting rod.
Battery power is low - Battery is drained, recharge it.
Battery is draining quickly - Service battery or change it.
Disconnected wires or corroded battery terminals - Check cable connections and replace or service terminals.
Battery is low or faulty - Change or recharge battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery capacity - Charge the battery.
Defective starter motor - Replace or repair starter.
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