Cummins KTA19-G2 Troubleshooting
| Engine Model: Cummins KTA19-G2 |
| Engine Type: 4-cycle inline 6-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 1159 cu.in (19 L) |
| Rated Engine Power: 490-700 Hp (365-522 kW) at 1800 rpm |
| Aspiration Type: Turbocharged and aftercooled |
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| Engine starts up hard or won't start |
Fuel filter plugging - Change filter element.
Air in the fuel lines - Bleed the fuel lines.
Damaged or dirty injection nozzles - Install a new kit of correctly balanced nozzles.
Damaged fuel injection pump - Repair or change injection pump.
Valve timing is improper - Adjust or replace timing gear.
Fuel pipes clogging - Service or replace fuel pipes.
Injection timing is improper - Set the injection timing correctly.
Piston rings and cylinder are worn - Replace faulty parts.
| Engine stalls after starting |
Fuel filter element is dirty - Clean or replace the filter.
Damaged fuel injection pump - Replacement or repair required.
Air filter element clogged - Replace air filter element.
Incorrect nozzle opening pressure - Adjust as recommended.
| Diesel shuts off while driving |
Timing of fuel injection pump is incorrect - Set up as recommended.
Fuel filter element is dirty - Change filter element.
Engine is not fully warmed up - Engine is not warmed up to the required temperature.
Injection nozzles sticking or clogged - Clean or change injection nozzles.
Incorrectly set low idle speed - Adjust the low idle speed.
Valve out of adjustment - Check and adjust as required.
Fuel injection pump failure - Repair or install a new fuel pump.
Faulty or dirty injection nozzles - Replace injection nozzles.
Restricted fuel lines or hoses - Service fuel lines and hoses.
Air filter plugged - Service or replace the air filter.
Cylinder-head gasket is broken - Install new cylinder head gasket.
Injection timing is wrong - Adjust injection timing as required.
Faulty fuel injection pump - Install a new pump or rebuild.
One of moving engine components is worn - Repair or replace defective components.
Radiator fins are dirty or radiator cap is defective - Install new cap or clean radiator.
Insufficient coolant - Add coolant and check the components of cooling system.
Fan belt is broken or worn - Belt change is required.
Low engine oil level - Need to add engine oil.
Cylinder-head gasket is leaking - Gasket should be replaced.
Injection timing is incorrect - Set up as recommended.
| Insufficient oil pressure |
Insufficient engine oil - Fill crankcase to proper oil level.
Oil pump failure - Repair or change.
Oil filter element is dirty - Clean or replace engine oil filter element.
Worn or dirty relief valve - Replace or clean relief valve.
Excessive crankshaft bearing clearance - Check and replace or repair defective parts.
Excessive crankpin bearing clearance - Inspect and replace or repair faulty parts.
External oil leaks: Seals or gaskets are wearing excessively - Defective components must be replaced.
Oil viscosity is wrong - Use oil of proper viscosity.
Worn or stuck piston rings - Change the piston rings as required.
Valve stems or guides are damaged - Valves need to be changed.
Cylinder liners or pistons are damaged - Inspect liners and pistons, fit new parts as necessary.
Engine not warmed up - Warm up to required temperature.
Low engine oil level - Check and refill engine oil.
Fuel injection pump timing is wrong - Use the correct fuel injection pump timing adjustment.
Piston wear or scoring - Pistons replacement required.
Connecting rod is worn or misaligned - Align or change connecting rod.
Battery power is low - Charge the battery.
Battery is draining quickly - Battery needs service or replacement.
Disconnected wires or corroded battery terminals - Connect cables correctly or replace terminals.
Battery is drained or defective - Need to charge or replace the battery.
Wiring is incorrectly connected or disconnected - Inspect wiring and connect correctly.
Battery capacity is low - Low battery charging, charge as required.
Starter motor failing - Replace or repair starter.
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