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Section 12 – Troubleshooting

1. Refer to Drain and Flush Cooling System in Section 5 Contact an Authorized Cummins Repair Facility Be O OO Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 11 CFP33 Series Excessive Coolant Loss Cause Correction Adequate coolant was not added following previous Check the coolant level Refer to Check Coolant Level in maintenance activities Section 5 Add coolant as required and check engine operation If coolant loss persists check for other problems Inspect the engine for coolant leaking from drain cocks or vents Close the leaking drain or vent Add coolant as required and check engine operation Cooling system hose is leaking Inspect the hoses Refer to Check Hose Condition in Section 5 Replace and or tighten loose hose clamps Replace any damaged hoses Refer to Coolant Hose Removal Installation in Section 7 Add coolant as required and check engine operation Pressure cap Cummins Fire Power Part No 11407 Check that the pressure cap does not relieve coolant is malfunctioning or has low pressure rating under normal operating conditions Replace a leaking pressure cap Add coolant as required and check engine operation Mechanical coolant leak Inspect the engine for coolant leaking from manifold expansion and pipe plugs fittings lubricating oil cooler water pump seal cylinder block and other components that have coolant flow Repair leaking component
2. Relay K1 has failed Check de energized continuity at Relay K1 pin 87 to 30 Replace K1 if the circuit is open Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 22 Section 12 Troubleshooting CFP33 Series Auto Start Failure Does not Crank on B NOTE The fire pump engine will not crank automatically when solenoid B is selected at the fire protection system However it does start automatically when solenoid A is selected Cause Correction The electrical connection from the fire protection Test continuity and insulation from ground between the system to Terminal Board TB 10 has failed fire protection system and the engine control panel Locate and repair any electrical fault in the field wiring or in the fire protection system panel The electrical connection from Terminal Board TB 10 Test continuity and insulation from ground between the to Relay K2 has failed TB 10 and Relay K2 Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Relay K2 has failed Check de energized continuity at Relay K2 pin 87 to 30 Replace K1 if the circuit is open Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 23 CFP33 Series Auto Start Failure Does not Crank on A or B NOTE The fire pump engine
3. Section 5 Drain any excess oil Lubricating oil is the wrong grade or type Check the grade and type of oil Refer to Lubricating Oil Recommendations and Specifications in Section 10 If the wrong type or grade of oil is present drain and replace it Refer to Change Lubricating Oil and Filters in Section 7 Engine temperature is too low Troubleshoot as per Coolant Temperature Below Normal Engine Off in this section Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 39 CFP33 Series Engine Cranks Slowly But Does Not Start Cont Starting motor is malfunctioning Replace the starting motor Refer to Starter Motor Assembly Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility ee Drawing No 9774 Section 12 Rev 02 07 Page 12 40 Section 12 Troubleshooting CFP33 Series Engine Difficult to Start or Will Not Start Exhaust Smoke Present NOTE If the engine cranks slowly refer to Engine Cranks Slowly But Does Not Start in this section Fuel tank level is low Fill the fuel tank Fill and bleed the fuel lines to the engine Fuel drain line is restricted Check the fuel drain lines for restriction Clear or replace the fuel lines check valves or tank vents as necessary Fuel filter is clogged Replace the fuel filter Refer to Change Fuel Filter in Section 7 Fuel grade is not correct for the application or the fuel Operate the engine from
4. and B5 9 Series Engines Bulletin Number 3666087 02 If required replace the pressure gauge Refer to Oil Pressure Gauge Removal Installation in Section 7 Check and replace valve Refer to Lubricating Oil Pressure Regulator Main Rifle 007 029 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Drawing No 9774 Section 12 Rev 02 07 Page 12 76 Section 12 Troubleshooting CFP33 Series Lubricating Oil Pressure High Cont Lubricating oil pump installation not correct Verify that the correct lubricating oil pump and o rings are installed Refer to Lubricating Oil Pump 007 031 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 77 CFP33 Series Lubricating Oil Pressure Low Cause Correction Lubricating oil level is below specification Check the oil level Verify the dipstick calibration and the oil pan capacity Fill the system to the specified level Oil level or oil pressure sensor is damaged Replace the oil level or oil pressure sensor Lubricating oil filter is clogged Replace the filter Fuel or coolant is in the lubricating oil Refer to Oil Level Rises symptom tree Regulator or relief valve is not adjusted correctly Adjust the regulator or relief valve Lubr
5. Cause Correction Air intake or exhaust leaks Check for loose or damaged piping connections and missing pipe plugs Check the turbocharger and exhaust manifold mounting Repair any leaks Refer to instructions in Section 7 Check the air intake system for restriction Refer to Check Air Cleaner Service Indicator in Section 5 Replace the air filter as necessary Lubricating oil level above specification Check the oil level Refer to Check Engine Oil Level in Section 5 Drain excess oil and correct the deficiency in maintenance processes Contact an Authorized Cummins Repair Facility a O O Drawing No 9774 Section 12 Rev 02 07 Page 12 72 Section 12 Troubleshooting CFP33 Series Fuel or Lubricating Oil Leaking From Exhaust Manifold Cause Correction Intake air restriction is high Check the air intake system for restriction Refer to Check Air Cleaner Service Indicator in Section 5 Replace the air filter if required Remove the turbocharger drain line and check for restriction Refer to instructions in Section 7 If required clean or replace the drain line Turbocharger oil seal is leaking Check the turbocharger for oil seals and for leaks Refer to the Turbocharger Leaks Engine Oil or Fuel symptom tree in this section Contact an Authorized Cummins Repair Facility o Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 73 CFP33 Series Lubricating Oil Contaminated
6. Crank on A OF B ooooncccconccccconcnnccnnnanonenanconnnnanennnnanneos 12 33 Engine Cranks Normally But Will Not Start No Exhaust Smoke oooocccconoccccoccccocoocococonancononannonnananonnnnnas 12 34 Engine Cranks Slowly But Does Not Stalt ocooccoonocccinnnccccoccoccccoconocconnoronnnanonnnnanronnnnnrrrnnnnnrrrnnnrrrnnnnrrrnnannnrrnnanas 12 38 Engine Difficult to Start or Will Not Start Exhaust Smoke Present c sccccsesseeeeeseeeeseeeeeeseeeeeeseenes 12 40 Engine Acceleration or Response PoOor scccceeseesseeeeeeeeeeeeeeeeeseeeeeseeeeeseeeeeneseneneseesesenssensasaeseeneesseenensongs 12 43 Engine Noise Excessive Mechanical sccccssseecseseecseeeeeeseeeeeseeeeseeeeeseeeeeneeseeneseesaeeeeseeseeneesoesessoenensongs 12 46 Engine Noise Excessive Combustion KlOCKG ccccceeseeeeeseeeeeeeneeeeeneeeseesneeeeesneeeeneneeseoaeeesonsneesenanees 12 48 Engine Runs Rough Af ING uste aaaea aKENo 12 49 Drawing No 9774 Section 12 Rev 02 07 Page 12 2 Section 12 Troubleshooting CFP33 Series Section Contents Cont Page Engine Runs Rough or Misfires Under Load oooncccnnnnicconcccccoccoccccnncnconnnnaronnnnnronnnnnronnnnnnernnnnnronnnarernanannns 12 51 Engine Speed S rges al 16 ui 12 53 Engine speed surges Under Loads a e E ES 12 55 Engine Vibration Excessive at Rated Speed occccononcccconociccoccncoconcnocnnnnncononnnronnnnnnrnrnnnnrrrnnnnrrrnnnnrrrnanarerrnnannnss 12 57 Engine Stops D r
7. Excessive Mechanical Cont Cause Correction Drive belt is squeaking due to insufficient tension or Check and adjust belt tension Refer to Adjust Alternator high loading Drive Belt Tension in Section 7 Intake air flow is restricted Check the air intake system for restriction Refer to Check Air Cleaner Service Indicator in Section 5 Replace the air filter if required Exhaust air flow is restricted Check the exhaust air piping for restriction Remove any restriction Air leakage between the turbocharger and head Tighten the clamp between turbocharger and head Repair leaks between turbocharger and head Turbocharger does not rotate freely Replace the turbocharger Refer to Turbocharger Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 48 Section 12 Troubleshooting CFP33 Series Engine Noise Excessive Combustion Knocks Cause Correction Engine is overloaded Check for added mechanical loading from damaged or defective pump changes in suction head or changes in discharge piping restriction Fuel grade is not correct for the application or the fuel Operate the engine using the correct fuel Refer to quality is poor Fuel Recommendations and Specifications in Section 10 Air in present in the fuel supply to the engine Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel filters as necessary Vent air
8. MANUAL switch at the engine control panel Replace the switch if the switch contacts fail to operate properly Fuel Shutoff Valve FSOV fails to close Press the RESET switch on the engine control panel Alternatively operate the manual override NOTE If the RESET switch did not close the valve an electrical fault to voltage may be present Refer to Drawing 10423 Sheet 1 and Drawing 10423 Sheet 2 in Section 13 If required replace the fuel shutoff valve Refer to Fuel Shutoff Valve FSOV Removal Installation in Section 7 Engine running on fumes drawn into the air intake Identify and isolate the source of the combustible fumes Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 64 Section 12 Troubleshooting CFP33 Series Engine Will Not Shut Off Locally Cause Correction Fuel Shutoff Valve FSOV fails to close Press the RESET switch on the engine control panel Alternatively operate the manual override NOTE If the RESET switch did not close the valve an electrical fault to voltage may be present Refer to Drawing 10423 Sheet 1 and Drawing 10423 Sheet 2 in Section 13 If required replace the fuel shutoff valve Refer to Fuel Shutoff Valve FSOV Removal Installation in Section 7 Engine is running on fumes drawn into the air intake Identify and isolate the source of the combustible fumes Refer to a Cummins Authorized Repair Facility ss
9. NOTE If excessive sludge is present in the oilpan refer to Lubricating Oil Sludge in the Crankcase Excessive in this section Cause Correction Bulk oil supply is contaminated Check the bulk oil supply Replace it is necessary Refer to Lubricating Oil Recommendations and Specifications in Section 10 Drain the oil and replace with non contaminated oil Also replace the oil filter Refer to Change Lubricating Oil and Filters in Section 7 Fuel is present in the lubricating oil Refer to the Fuel in Lubricating Oil symptom tree Coolant is present in the lubricating oil Refer to the Coolant in Lubricating Oil symptom tree in this section Metal is present in the lubricating oil Contact an Authorized Cummins Repair Facility Identify unknown lubricating oil contamination Analyze the oil and inspect the filters to identify the contamination Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 74 Section 12 Troubleshooting CFP33 Series Lubricating Oil Consumption Excessive Cause Correction Lubricating oil leak external Inspect the engine for external oil leaks Tighten the capscrews pipe plugs and fittings Replace the gaskets if necessary Intake system is contaminated with dust Remove and clean intake manifold Dipstick is not calibrated correctly Verify the dipstick is correctly marked Breather or breather hose is clogged Clean the breather and br
10. Oil and Filters in Section 7 Coolant temperature is below specification Refer to the Coolant Temperature Below Normal Engine Running symptom tree in this section Crankcase ventilation system is plugged Fuel grade is not correct for the application or the fuel quality is poor Lubricating oil does not meet specifications for operating conditions Drawing No 9774 Section 12 Rev 02 07 Check and clean the crankcase breather and vent tube Refer to Crankcase Breather Tube 003 018 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Operate the engine from a tank of high quality fuel Refer to Fuel Recommendations and Specifications in Section 10 Check the grade and type of oil Refer to Lubricating Oil Recommendations and Specifications in Section 10 If the wrong type or grade of oil is present drain and replace it Refer to Change Lubricating Oil and Filters in Section 7 Verify the correct lubricating oil drain interval Refer to Change Lubricating Oil and Filters in Section 7 Page 12 80 Section 12 Troubleshooting CFP33 Series Lubricating Oil Sludge in the Crankcase Excessive Cont Lubricating oil is contaminated with coolant or fuel Go to the Lubricating Oil Contaminated symptom tree in this section Crankcase pressure is excessive Check for excessive blowby Refer to the Crankcase Gases Blowby Excessive symptom tree in this secti
11. Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Fuel grade is not correct for the application or the fuel Operate the engine with the required fuel Refer to quality is poor Fuel Recommendations and Specifications in Section 10 Drawing No 9774 Section 12 Rev 02 07 Page 12 54 Section 12 Troubleshooting CFP33 Series Engine Speed Surges at Idle Cont Cause Correction The fuel injection pump is malfunctioning Remove the fuel pump Refer to Fuel Injection Pump Removal Installation in Section 7 Calibrate the fuel pump Refer to instructions in Section 7 If required replace the fuel injection pump A fuel supply line restriction exists between the fuel Check the fuel supply line or passage for sharp bends or CIN pump and the injectors restriction Remove ON restrictions A fuel injector is pS Replace the a injector Refer to Fuel r Removal Installation in Section 7 Moisture is pS in the wiring harness connectors et the connectors with Cummins electronic cleaner Part Number 3824510 Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 55 CFP33 Series Engine Speed Surges Under Load Cause Correction Pump suction head or pump discharge head changes Some variation in speed response to load changes is normal Excessive speed changes may occur upon sudden failures in either suction or discharge piping systems Fuel
12. Speed Sensor Removal Installation in Section 7 The tachometer has failed Check the operation of the tachometer with a pulse generator Replace the tachometer is it has failed Refer to Tachometer Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility TT Eef Drawing No 9774 Section 12 Rev 02 07
13. a tank of high quality fuel quality is poor Refer to Fuel Recommendations and Specifications in Section 10 Fuel injection pump is malfunctioning Perform the fuel injection pump test Fuel injection pump timing is not correct Check and adjust the fuel pump timing Refer to Fuel Adjust Fuel Pump in Section 7 Fuel pre filter is clogged Clean the customer supplied fuel pre filter Fuel pump overflow valve is malfunctioning Check the overflow valve Replace if necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 41 CFP33 Series Engine Difficult to Start or Will Not Start Exhaust Smoke Present Cont Fuel suction line is restricted Check the fuel suction line for restriction Fuel connections on the suction side of the fuel lift Tighten all the fuel fittings and connections between the pump are loose fuel tanks and fuel lift pump Fuel suction standpipe in the fuel tank is broken Check and repair the standpipe if necessary Fuel tank air breather hole is clogged Clean the fuel tank breather Fuel lift pump is malfunctioning Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Fuel injectors are plugged Replace the fuel injectors Refer to Fuel Injectors Removal Installation in Section 7 Throttle a misadjusted or damaged co or repair the li
14. from the system Refer to Air in Fuel in Section 7 The fuel injection pump s timing is not correct Check and adjust the fuel injection pump timing Refer to Adjust Fuel Pump in Section 7 The fuel injection pump is failing Replace the fuel injection pump Refer to Fuel Injection Pump Removal Installation in Section 7 Coolant temperature is below specification Refer to the Coolant Temperature Below Normal Engine Running symptom tree in this section Contact a Cummins Authorized Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 49 CFP33 Series Engine Runs Rough at Idle NOTE Operation at idle speed is for maintenance only Cause Correction Engine is cold Allow the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal Engine Running symptom tree Idle speed is set too low Adjust the idle speed Refer to instructions in Section 7 Air is present in the fuel system Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel filters as necessary Vent air from the system Refer to Air in Fuel in Section 7 Fuel filter is becoming plugged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Fuel S S to the engine is inadequate Locate and correct the restriction in fuel flow to the engine The fu
15. level is low in the tank Fill the fuel tank Fill and bleed the fuel lines to the engine Air is in the fuel supply to the engine Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel filters as necessary Vent air from the system Refer to Air in Fuel in Section 7 The fuel filter is plugged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Fuel flow to the engine is not A Locate and correct the restriction in the customer AA fuel lines to the EN The fuel lift pump is SU Check the fuel lift pump for correct A Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Fuel grade is not correct for the application or the fuel Operate the engine with the required fuel Refer to quality is poor Fuel Recommendations and Specifications in Section 10 Drawing No 9774 Section 12 Rev 02 07 Page 12 56 Section 12 Troubleshooting CFP33 Series Engine Speed Surges Under Load Cont Cause Correction The fuel injection pump is malfunctioning Remove the fuel pump Refer to Fuel Injection Pump Removal Installation in Section 7 Calibrate the fuel pump Refer to instructions in Section 7 If required replace the fuel injection pump A fuel supply line restriction exists between the fuel Check the fuel supply line or passage for sharp bends or CIN pump and the i
16. no cables are broken Alternator rotor is not turning Test the alternator mechanically Refer to Alternator Checks and Testing in Section 7 If the alternator shaft does not spin freely because of a bad bearing replace the alternator refer to Alternator Removal Installation in Section 7 If the alternator does not turn because of a bad drive belt replace the drive belt refer to Belt Removal Installation in Section 7 If the alternator does not charge because of poor drive belt tension adjust belt tension refer to Adjust Alternator Drive Belt Tension in Section 7 If the alternator pulley spins freely on the shaft because of a broken key replace the alternator refer to Alternator Removal Installation in Section 7 Battery Isolator input has faulted Test continuity from the alternator to the battery isolator input refer to Drawing 10423 Sheet 2 in Section 13 Repair any open circuit Test continuity through the battery isolator If an internal open circuit is detected replace the battery isolator refer to Battery Isolator Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 6 Section 12 Troubleshooting CFP33 Series Neither Battery is Charging with the Engine Running Cont Cause Correction Alternator excitation is lost Test the alternator electrically Refer to Alternator Checks and Testing in Section 7 If required replace the replaceable diode Refer to Drawi
17. the internal diodes for open circuit or short to ground Refer to the Schematic Electrical Wiring 10423 Sheet 2 Section 13 If required obtain a replacement battery isolator Cummins Part No 8838 Install the battery isolator Refer to Battery Isolator Removal Installation in Section 7 Voltmeter is providing false indication Go to Voltage Indications Differ in this section Contact an Authorized Cummins Repair Facility ST Drawing No 9774 Section 12 Rev 02 07 Page 12 8 Section 12 Troubleshooting CFP33 Series Voltage Indications Differ NOTE The two voltmeters may differ slightly due to calibration differences between the meters Normal differences in battery condition may also cause differences in indication These are normal differences and require no action A voltage difference of more than three or four volts should be investigated Cause Correction One battery is discharged or failing Check battery condition Replace failing battery elements Check wiring for corrosion Ensure good electrical contact Charge discharged batteries by running the engine or with an external battery charger If the battery does not charge with the engine running go to Only One Battery is Charging with the Engine Running Fuse 1 or Fuse 2 is open Refer to Drawing 10423 Check for apparent wire damage or shorts to grounds Sree LIN oeeuont le Replace the failed fuse Refer to Fuse Replacement in Section 7
18. 07 Section 12 Troubleshooting Page 12 69 CFP33 Series Excessive Black Exhaust Smoke Cont Incorrect injection timing Adjust injection timing Overhead adjustments are not correct Measure and adjust the overhead settings Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 70 Section 12 Troubleshooting CFP33 Series Fuel Consumption Is Excessive Cause Correction Fuel is leaking Check the fuel lines fuel connections and fuel filters for leaks Check the fuel lines to the supply tanks Repair any leaks Poor quality fuel is being used Assure good quality No 2 diesel fuel is being used Refer to Fuel Recommendations and Specifications in Section 10 Intake or exhaust restriction Refer to troubleshooting logic for Exhaust Smoke Excessive Under Load in this section Defective or clogged injection nozzle Replace the defective or clogged injection nozzle Refer to instructions in Section 7 Incorrect injection timing Adjust injection timing Refer to instructions in Section 7 Injection pump is adjusted incorrectly causing Adjust or replace the injection pump Refer to excessive injection instructions in Section 7 Hour meter is not calibrated Check the hour meter Calibrate or replace the hour meter if necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 71 CFP33 Series Fuel Consumption Is Excessive Cont
19. 2 Troubleshooting CFP33 Series Engine Stops During Operation Cause Correction Normal automatic mode shutdown occurs when the No action is required This is a desirable outcome fire protection systems removes the signal power feed to the local control panel In the automatic mode the signal power feed is lost Locate and correct the electrical fault in the fire from the fire protection system to the control panel protection system or the field wiring to the engine control panel Signal power is lost by the operation of the circuit Press the circuit breaker reset button on the engine breaker the engine control panel control panel Locate and correct the electrical fault in engine control panel Refer to Drawing 10423 Sheet 1 in Section 13 An overspeed trip has occurred The overspeed trip Go to Engine Overspeed Trip in this section light is illuminated on the local control panel Remote indications may also be present Alternatively a related overspeed switch failure has occurred The trip indications may not be present The fuel shutoff valve FSOV has failed Check the wiring continuity and insulation from ground for the Fuel Shutoff Switch Refer to Drawing 10423 Sheet 1 and Drawing 10423 Sheet 2 in Section 13 Correct any electrical faults If required replace the FSOV Refer to Fuel Shutoff Valve FSOV Removal Installation in Section 7 Fuel tank level is low Fill the fuel tank Fill and bleed the fuel lines to t
20. Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 65 CFP33 Series Excessive White Exhaust Smoke Cause Correction Engine is operating at low ambient temperature Refer to Cold Weather Operation Bulletin Number 3387266 and the Operation and Maintenance manual Bulletin Number 3666417 for cold weather operating aids and guidelines Air in the fuel system Check for air in the fuel system by installing a clear hose on the suction side of the fuel pump Verify fuel drain is below the fuel level in the tank as air will enter the suction and drain lines if fuel drain is not below fuel level Injectors can also be a source of combustion gases leaking back into the fuel system Fuel grade is not correct for the application or the fuel Operate the engine from a tank of good fuel 40 quality is poor Cetane min above 32 F 45 Cetane min below 32 F Refer to Fuel recommendations and Specifications in the Operation and Maintenance manual Bulletin Number 3666417 Fuel filter is plugged Measure the fuel inlet restriction to the filter head 3 in Hg max Measure the fuel pressure drop across the fuel filter 1 5 in Hg max Max restriction to fuel pump is 4 5 in Ho Air intake system restriction is above specification Check the air intake system for restriction Clean or replace the air filter and inlet piping as necessary Air intake or exhaust leaks Visually inspect the air intake and exhaust syste
21. If the fuse operates again locate and correct the overload or repair the short circuit Open circuit or short to ground in indicator wiring Locate and repair the electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Voltmeter has failed Remove wiring at the voltmeter and apply test voltage If necessary replace the faulted voltmeter Refer to Voltmeter Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 9 CFP33 Series Coolant Contamination Cause Correction Coolant is rusty and has debris Drain and flush the cooling system Refer to Drain and Flush Cooling System in Section 5 If the drained coolant has excessive rust or debris change the coolant more frequently or contact a Cummins Authorized Repair Facility Otherwise refill with correct mixture of antifreeze and water Refer to Drain and Flush Cooling System in Section 5 Lubricating oil cooler is leaking oil into the coolant Drain and flush the cooling system Refer to Drain and Coolant begins to have the texture and color of Flush Cooling System in Section 5 chocolate pudding Check the lubricating oil cooler for coolant leaks and cracks Refer to Lubricating Oil Cooler Removal Installation in Section 7 Replace the oil cooler gasket or other parts Refill with correct mixture of antifreeze and water Refer to Drain and Flush C
22. Section 12 Troubleshooting Page 12 1 CFP33 Series Section 12 Troubleshooting Section Contents Page Troubleshooting Procedures and Techniques cccccsseceeeeeeeeeeeeeeneeeeeeeeeeeeeeeneeseeeeeeseeeeeneeseeneeeeenesenanensags 12 3 Troubleshooting Symptoms Charts ina 12 3 Alternator Overcharging with the Engine RUNNING cccscsseeeeseeeeeeseeseeesensneseeeseeeseesneesseeneessoaneeeseanees 12 4 Neither Battery is Charging with the Engine RUNNINQ nccconcnccccnccnconononcnonnanonnnnnnronnnnaronnnnnnrrnnannrenanarennanannrs 12 5 Only One Battery is Charging with the Engine RUNNINQ cooccccoccncccnnncccononcnnononnanconnnaronnnnanonnnanaronnanarernaannns 12 7 Voltage Indications DIME ozi aaa a etd a aa 12 8 Coolant Contamination cnc ia 12 9 ExXGessive Coolant LOS ie iaa a A ota rie alas 12 11 Coolant Temperature Above Normal c cccccsseccceseecsneesceneeceneeecenseecaneeeceneeeonesecageeeonssesanssesansseeseneesonness 12 13 Coolant Temperature Below Normal Engine Off cccccssssseeeeesseeeeeeneseeeseeeseeseeeseeeneessnensessoaneeseaeneeees 12 17 Coolant Temperature Below Normal Engine Running ococcccoccncononcnncnnnnnncononaconnnnanonnnannronnnnnronnnnnnennnannns 12 18 Raw Water Drain Steaming cccaiscoostice saat wacdurawwaay view aswriuwaun ae cacauesaauet situ seundacuiastauteas ream uacy sums udwecuatianmewcsyenmaneres 12 19 Raw Water Solenoid Valve Fails to Operate oooccconnccc
23. acility Drawing No 9774 Section 12 Rev 02 07 When practical test the electrical operation of the AUTO MANUAL rocker switch Refer to Drawing 10423 Sheet 1 in Section 13 Replace the solenoid if faulted Test continuity and insulation from ground between the AUTO MANUAL rocker switch and the relays Also check the relay connection to ground Locate and repair any electrical fault Refer to Drawing 10423 sheet 1 in Section 13 Open the raw water bypass valves When practical replace Fuse F3 Locate and repair any local electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Test continuity and insulation from ground between Fuse F3 and the overspeed switch s crank circuit Also check the crank circuit output to the CRANK BATT switches Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 If required test and adjust the crank setting Refer to Overspeed Setpoint Adjustment and Testing in Section 3 If required replace the overspeed switch Refer to Overspeed Switch Removal Installation in Section 7 Page 12 34 Section 12 Troubleshooting CFP33 Series Engine Cranks Normally But Will Not Start No Exhaust Smoke No fuel in supply tank Check and replenish fuel supply Check fittings and hose connections and hose conditions Air is in the fuel system Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel
24. anel when CRANK BATT A is selected However it does start when CRANK BATT B is selected Cause Correction The CRANK BATT A switch fails to make contact When practical test the electrical operation of the CRANK BATT A switch Refer to Drawing 10423 Sheet 1 in Section 13 Replace the switch if faulted When practical test the electrical operation of the Relay K1 Refer to Drawing 10423 Sheet 1 in Section 13 Replace the relay if faulted CRANK BATT A switch Relay K1 and the starter Solenoid Also check the solenoid coil connection to ground Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 When practical test the electrical operation of the Solenoid A Refer to Drawing 10423 Sheet 1 in Section 13 Replace the solenoid if faulted Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 32 Section 12 Troubleshooting CFP33 Series Manual Start Failure from Control Panel Does not Crank on B NOTE The fire pump engine will not crank locally from the control panel when CRANK BATT B is selected However it does start when CRANK BATT A is selected Cause Correction The CRANK BATT B switch fails to make contact When practical test the electrical operation of the CRANK BATT B switch Refer to Drawing 10423 Sheet 1 in Section 13 Replace the switch if faulted W
25. ant as required If coolant level was excessively low go to Excessive Coolant Loss in this section Inspect the hoses Refer to Check Hose Condition in Section 5 Replace any damaged hoses Refer to Coolant Hose Removal Installation in Section 7 Remove and test the coolant thermostat Refer to Coolant Thermostat Removal Installation in Section 7 Replace the thermostat if it is defective Remove and inspect the water pump Refer to Coolant Water Pump Removal Installation in Section 7 Replace the thermostat if it is defective Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 15 CFP33 Series Coolant Temperature Above Normal Cont Cause Correction Lubricating oil is contaminated with coolant or fuel Check the appearance of the lubricating oil If the color and texture is abnormal refer to the Lubricating Oil Contaminated symptom tree Cooling system hose is collapsed restricted or Inspect the hoses Refer to Check Hose Condition in leaking Section 5 Replace any damaged hoses Refer to Coolant Hose Removal Installation in Section 7 Coolant mixture of antifreeze and water is not correct Verify the concentration of antifreeze in the coolant Refer to Check Cooling System Condition in Section 5 Add antifreeze or water to correct the concentration Refer to Coolant Recommendations and Specifications in Section 10 Lubricating oil level is above or below specification Check the
26. ater Solenoid Valve Removal Installation in Section 7 Clean the raw water strainer more frequently Increase the frequency of operational testing Check electrical continuity and insulation from ground to the solenoid Repair any open or short circuits in the wiring NOTE Apply the correct operating voltage either 12 VDC or 24 VDC depending upon the model Apply temporary voltage to the solenoid If the solenoid fails to operate replace it Refer to Raw Water Solenoid Valve Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility pe Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 21 CFP33 Series Auto Start Failure Does not Crank on A NOTE The fire pump engine will not crank automatically when solenoid A is selected at the fire protection system However it does start automatically when solenoid B is selected Cause Correction The electrical connection from the fire protection Test continuity and insulation from ground between the system to Terminal Board TB 9 has failed fire protection system and the engine control panel Locate and repair any electrical fault in the field wiring or in the fire protection system panel The electrical connection from Terminal Board TB 9 to Test continuity and insulation from ground between the Relay K1 has failed TB 9 and Relay K1 Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13
27. bleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 83 CFP33 Series Engine Overspeed Trip NOTE An engine overspeed trip occurs when the engine s speed exceeds the value specified on the Factory setting Tag described in Section 2 The trip isolates the fuel supply to the engine and it stops immediately The trip is indicated on the local control panel and inside the local control panel on the speed switch Additionally a trip output is supplied to the fire protection system for remote display Cause Correction Engine actually operated at too great a speed due to Correct the cause of the load failure catastrophic load failure such as pipe break pump mechanical failure or loss of suction Engine actually operated at too great a speed due to Check rated speed setting as specified on the Factory configuration error setting Tag described in Section 2 Refer to Rated Speed Setpoint Adjustment and Testing in Section 3 Check overspeed speed setting as specified on the Factory Setting Tag described in Section 2 Refer to Overspeed Setpoint Adjustment and Testing in Section Check continuity and insulation from ground for the signal power wiring and ground wiring to the speed switch Refer to Drawing 10423 Sheet 1 in Section 13 Replace defective components an
28. d repair electrical faults If the speed switch fails to operate as per Overspeed Setpoint Adjustment and Testing in Section 3 replace the speed switch Refer to Overspeed Switch Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 84 Section 12 Troubleshooting CFP33 Series Tachometer Does Not Indicate Engine Speed Cause Correction Fuse F4 has opened If required replace Fuse F4 Locate and correct the electrical fault that caused the fuse to operate Refer to Drawing 10423 Sheet 1 in Section 13 An electrical fault exists in the tachometer power and Check continuity and insulation from ground for the grounding circuits power wiring and ground wiring to the tachometer Refer to Drawing 10423 Sheet 1 in Section 13 Replace defective components and repair electrical faults An electrical fault exists in the speed sensor input Check continuity and insulation from ground for the circuit This fault may also cause a failure in the crank speed sensor circuit Refer to Drawing 10423 Sheet 1 terminate signal to the fire protection system in Section 13 Replace defective components and repair electrical faults With the engine running check the signal from the speed sensor with an oscilloscope or pulse counter Replace the speed sensor is it has failed Refer to
29. dicate Engine Speed cccccccsseeeeeeeeeeecseeeeeeeneeeseaseeeseesneeseneneessnenseseaeneesennenes 12 83 Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 3 CFP33 Series Troubleshooting Procedures and Techniques General information This guide describes some typical engine operating problems their causes and some acceptable corrections to those problems Awarnincdd Performing troubleshooting procedures NOT outlined in this in Section can result in equipment damage or personal injury or death Troubleshooting must be performed by trained experienced technicians Consult a Cummins Authorized Repair Location for diagnosis and repair beyond that which is contained in this manual and for symptoms not listed in this in section Before beginning any troubleshooting refer to the General Safety Instructions in Section 1 of this manual Follow the suggestions below for troubleshooting Study the complaint thoroughly before acting Refer to the Engine Identification diagrams in Section 2 the System Diagrams in Section 6 and the Assembly Drawings in Section 13 Do the easiest and most logical things first Find and correct the cause of the complaint Troubleshooting Symptoms Charts AwarnincA Troubleshooting presents the risk of equipment damage personal injury or death Troubleshooting must be performed by trained experienced technicians Use the charts on the following page
30. e tachometer also indicates zero speed An electrical fault is present in the Fire Protection System When practical with the engine running verify speed sensor input to the overspeed switch Refer to Drawing 10423 Sheet 1 in Section 13 If signal is not present go to The speed sensor has failed The tachometer also indicates zero speed in this table Adjust the overspeed switch crank terminate setpoint Refer to Section 3 If required replace the overspeed switch Refer to Overspeed Switch Removal Installation in Section 7 Open the raw water bypass valves When practical replace Fuse F3 Locate and repair any local electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 When practical locate and repair any electrical fault in the speed sensor circuitry Refer to Drawing 10423 Sheet 1 in Section 13 If necessary replace the speed sensor Refer to Speed Sensor Removal Installation in Section 7 When practical test continuity and insulation from ground in the fire protection system and the engine control panel Locate and repair any electrical fault in the fire protection system panel ground between the fire protection system and the engine control panel Locate and repair any electrical fault in the field wiring Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 27 CFP33 Series Auto Start Failure Engine Starts but Crank Terminate does not Occur Cont An elec
31. eather hose Turbocharger compressor or turbine oil seal is leaking Replace the compressor or turbine seal Rear crankshaft seal or seal surface is damaged Repair or replace seal and surface Valve stem guide or seal is damaged Repair or replace the damaged component Worn or broken piston ring or cylinder Replace the worn or broken piston ring or cylinder Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 75 CFP33 Series Lubricating Oil Pressure High Cause Correction Engine is cold Allow the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal Engine Running symptom tree in this section Drain the oil and replace the oil filter Refer to Change Lubricating Oil and Filters in Section 7 Use the correct oil Refer to Lubricating Oil Recommendations and Specifications in Section 10 Replace the oil filter Refer to Change Lubricating Oil and Filters in Section 7 Use the correct oil filter Refer to Lubricating Oil Recommendations and Specifications in Section 10 The pressure gauge is malfunctioning Install a temporary pressure gauge at main oil rifle Compare the indications with the engine running If required replace the pressure sender Refer to Lubricating Oil Pressure Sensor OEM 007 052 in Troubleshooting and Repair Manual B3 9 B4 5
32. efer to Section 3 Replace if necessary Refer to instructions in Section Tachometer is not calibrated Compare the tachometer reading with a handheld tachometer or an electronic service tool reading If out of calibration calibrate the tachometer as necessary at the CAL adjustment on the back of the gauge Refer to Tachometer Calibration in Section 7 Tachometer is malfunctioning Replace the tachometer Refer to Tachometer Removal Installation in Section 7 eo power output is low Refer to the a Acceleration or Response Poor symptom tree in this section Fuel grade is not correct for the application or the fuel Operate the engine with the required fuel Refer to quality is poor Fuel Recommendations and Specifications in Section 10 Fuel filter is clogged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 61 CFP33 Series Engine Will Not Reach Rated Speed RPM Cont Fuel suction line is restricted Check the fuel suction line for restriction Air fuel tube leaking wastegate diaphragm ruptured Tighten the fittings repair plumbing replace wastegate or wastegate plumbing damaged diaphragm Charge air cooler restricted if equipped Inspect the air cooler for internal and external restrictions Replace the restricted cooler if necessary Fuel supply is not adequate Locate and correct the restriction in the cu
33. el lift pump is malfunctioning Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Engine mounts are worn or damaged Check the engine mounts If damaged refer to a Cummins Authorized Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 50 Section 12 Troubleshooting CFP33 Series Engine Runs Rough at Idle Cont Fuel grade is not correct for the application or the fuel Operate the engine on the required fuel Refer to Fuel quality is poor Recommendations and Specifications in Section 10 Fuel pump overflow valve is malfunctioning Check the overflow valve Replace if necessary Fuel injection pump timing is incorrect Check and adjust the injection pump timing Refer to Adjust Fuel Pump in Section 7 Injector is malfunctioning Inspect the injectors Replace the injectors as necessary Refer to Fuel Injectors Removal Installation in Section 7 Fuel injection pump is malfunctioning Remove the fuel injection pump Refer to Fuel Injection Pump Removal Installation in Section 7 Check the calibration of the fuel injection pump Refer to instructions in Section 7 Replace the pump if necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 51 CFP33 Series Engine Runs Rough or Misfires Under Load Cause Correction Engine is cold Al
34. filters as necessary Vent air from the system Refer to Air in Fuel in Section 7 Manual fuel shutoff lever is binding Check to be sure manual shutoff lever is not binding at the injection pump Fuel drain line is restricted Check the fuel drain lines for restriction Clear or replace the fuel lines check valves or tank vents as necessary Fuel filter is clogged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Fuel grade is not correct for the application or the fuel Operate the engine from a tank of high quality fuel quality is poor Refer to Fuel Recommendations and Specifications in Section 10 Fuel injection pump is malfunctioning Perform the fuel injection pump test Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 35 CFP33 Series Engine Cranks Normally But Will Not Start No Exhaust Smoke Cont Fuel injection pump timing is not correct Check and adjust the fuel pump timing Refer to Fuel Adjust Fuel Pump in Section 7 Fuel tank is empty Fill the fuel supply tank Fuel pre filter is clogged Clean the customer supplied fuel pre filter Fuel pump overflow valve is malfunctioning Check the overflow valve Replace if necessary Fuel Shutoff Valve FSOV fails to open If the fuel shutoff valve is not functioning manually override it Refer to Emergency Starting With Failed Fuel Shut Off Solenoid in Section 3 When practical check the wiring
35. for electrical faults Refer to Drawing 10423 Sheet 2 in Section 13 If the wiring is OK replace the Fuel Shutoff Valve Refer o Fuel Shutoff Valve FSOV Removal Installation in Section 7 Fuel suction line is restricted Check the fuel suction line for restriction Fuel connections on the suction side of the fuel lift Tighten all the fuel fittings and connections between the pump are loose fuel tanks and fuel lift pump Drawing No 9774 Section 12 Rev 02 07 Page 12 36 Section 12 Troubleshooting CFP33 Series Engine Cranks Normally But Will Not Start No Exhaust Smoke Cont Fuel suction standpipe in the fuel tank is broken Check and repair the standpipe if necessary Fuel supply is not adequate Check the flow through the filter to locate the source of the restriction Fuel tank air breather hole is clogged Clean the fuel tank breather Fuel lift pump is malfunctioning Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Injection pump driveshaft or driveshaft key is damaged Repair or replace the injection pump Refer to Fuel Injection Pump Removal Installation in Section 7 Fuel injectors are plugged Replace the fuel injectors Refer to Fuel Injectors Removal Installation in Section 7 Throttle linkage misadjusted or damaged Adjust or repair the linkage Refer to instruct
36. for loose or damaged piping connections and missing pipe plugs Check the turbocharger and exhaust manifold mounting If required replace the turbocharger Refer to Turbocharger Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 46 Section 12 Troubleshooting CFP33 Series Engine Noise Excessive Mechanical Cause Correction Lubricating oil is thin or diluted Check the oil level Refer to Check Lubricating Oil Level in Section 7 If the oil level is above the high mark go to Oil Level Rises in this section Lubricating oil pressure is below specification NOTE Oil pressure should range between 69 and 345 kPa 10 to 50 PSI with the engine running Check the oil pressure on the local control panel If the pressure is low refer to the Lubricating Oil Pressure Low symptom tree in this section Inspect the vibration damper Refer to Inspect Vibration Damper in Section 5 If the vibration damper is damaged refer to a Cummins Authorized Repair Facility Inspect the engine mounts If the engine mounts are worn or damaged refer to a Cummins Authorized Repair Facility Check the coolant temperature indication on the local control panel If the high coolant temperature light is illuminated refer to the Coolant Temperature Above Normal symptom tree in this section Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 47 CFP33 Series Engine Noise
37. he engine Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 59 CFP33 Series Engine Stops During Operation Cont Cause Correction Clogged fuel tank air breather hole Clean the fuel tank breather Customer supplied fuel pre filter is clogged Clean the fuel pre filter Fill and bleed the fuel lines to the engine Fuel piping to engine is clogged Clean and repair the fuel piping to the engine The fuel filter is clogged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Air is trapped in the low pressure fuel lines at the Bleed the fuel lines Refer to Air in Fuel in Section 7 engine Fuel lift pump has failed Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Fuel injection pump has failed Replace the fuel injection pump Refer to Fuel Injection Pump Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Page 12 60 Section 12 Troubleshooting CFP33 Series Engine Will Not Reach Rated Speed RPM Load is excessive for engine horsepower rating Reduce the engine load Throttle adjustment is not correct Check the throttle adjustment Refer to Section 3 Fuel shutoff lever mechanical partially engaged Make sure fuel shutoff lever is in the RUN position R
38. heck and tighten oil supply line fitting s if necessary Refer to Turbocharger Oil Supply Line 010 046 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 82 Section 12 Troubleshooting CFP33 Series Crankcase Gases Blowby Excessive NOTE Crankcase gases or blowby may be measured Refer to Crankcase Blowby Measure 014 010 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Cause Correction Cylinder head valve guides are excessively worn Pistons or piston rings are worn damaged or not correct Turbocharger oil seal is leaking Check the valve guides for wear Replace the cylinder head if necessary Refer to Cylinder Head 002 004 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Check the pistons for correct part numbers Refer to Control Parts List CPL Bulletin 3379133 or 4021327 Check the pistons and rings for wear and damage Refer to Piston 001 043 and Piston Rings 001 047 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Check the turbocharger compressor and turbine seals Refer to Turbocharger 010 033 in Trou
39. hen practical test the electrical operation of the Relay K2 Refer to Drawing 10423 Sheet 1 in Section 13 Replace the relay if faulted CRANK BATT B switch Relay K2 and the starter Solenoid Also check the solenoid coil connection to ground Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Solenoid B fails to operate When practical test the electrical operation of the Solenoid B Refer to Drawing 10423 Sheet 1 in Section 13 Replace the solenoid if faulted Contact an Authorized Cummins Repair Facility ee Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting CFP33 Series Page 12 33 Manual Start Failure from Control Panel Does not Crank on A or B NOTE The fire pump engine will not crank locally from the control panel when either CRANK BATT A or CRANK BATT B is selected However it does start when a solenoid lever is actuated Cause Correction The MANUAL mode rocker switch contact fails to close An electrical fault exists in the signal power circuit or the ground to the Relays K1 and K2 Fuse F3 has opened The raw water solenoid valve also fails to open An electrical fault exists in the signal power circuit or the ground to the overspeed switch s crank circuit Overspeed switch crank circuit fails to reset with engine shutdown Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair F
40. icating oil pan strainer is clogged Clean the strainer Lubricating oil suction tube is damaged Repair or replace the suction tube Lubricating oil pump is damaged Replace the oil pump Main or rod bearing is worn or damaged Replace the bearing Contact an Authorized Cummins Repair Facility Be Drawing No 9774 Section 12 Rev 02 07 Page 12 78 Section 12 Troubleshooting CFP33 Series Oil Level Rises NOTE Oil level may increase due to thermal expansion as the engine warms up and then decrease as the engine cools down Slight variations due to temperature changes are normal Cause Correction Excessive oil has been added to the engine Drain the excess oil Refer to Change Lubricating Oil and Filters in Section 7 Fuel is leaking into the oil system Troubleshoot as per Lubricating Oil Contaminated in this section Coolant is leaking into the oil system Troubleshoot as per Lubricating Oil Contaminated in this section Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting CFP33 Series Page 12 79 Lubricating Oil Sludge in the Crankcase Excessive Cause Correction Bulk oil supply is contaminated Check the bulk oil supply Replace it is necessary Refer to Lubricating Oil Recommendations and Specifications in Section 10 Drain the oil and replace with non contaminated oil Also replace the oil filter Refer to Change Lubricating
41. if necessary Fuel suction line is restricted Check the fuel suction line for restriction Drawing No 9774 Section 12 Rev 02 07 Page 12 44 Section 12 Troubleshooting CFP33 Series Engine Acceleration or Response Poor Cont Fuel connections on the suction side of the fuel lift Tighten all the fuel fittings and connections between the pump are loose fuel tanks and fuel lift pump Fuel suction standpipe in the fuel tank is broken Check and repair the standpipe if necessary Fuel tank air breather hole is clogged Clean the fuel tank breather Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Fuel injectors are plugged Replace the fuel injectors Refer to Fuel Injectors Removal Installation in Section 7 Throttle misadjusted or damaged A or repair the linkage Refer to instructions in Section 7 Intake air flow is restricted Check the air intake A for restriction Refer to Check Air Cleaner Service Indicator in Section 7 Replace the air filter if required Exhaust air flow is restricted Check the exhaust air piping for restriction Remove any restriction Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 45 CFP33 Series Engine Acceleration or Response Poor Cont Cause Correction Exhaust air is leaking Check the exhaust piping
42. ing Operatoria ai a 12 58 Engine Will Not Reach Rated Speed RPM 00ccccoconccconccccccocccoconcococonconoccnnnocononannonnnnnnrnnnanarennnnnronnnnnrrrnaanarenos 12 60 Engine Will N t Shut Off Remotely cuina cad 12 63 Engine Will Not Shut Off Local oia 12 64 Excessive White Ehau Si SMO O ii a r a a aa A Aaaa 12 65 Excessive Black Exhaust Smoke wivvviciccccesicccswiveccdenevecvenssvecessneesensiceadenssodsnsesteensesswsuwaveecaavendsddvexsdstuasveccanvene 12 68 Fuel Consumption IS EXcessiVO ii a o 12 70 Fuel or Lubricating Oil Leaking From Exhaust Manifold ooocccconnnccconcccccoconoconcnncononcnronnnnanernnnnnronananennnas 12 72 Lubricating Oil COMtAMIN ALC ii E A ai 12 73 Lubricating Oil Consumption EXCESSIVE ooocoonoccccocococonconcononancocnnnnnronnnnnrrrnnnn ren Naa nr rra Ka AA NANGA aA 12 75 Lubricating Oil Pressure High rasa A a 12 76 Lubricating Oil Pressure LOW iii aa 12 77 Ol TS VOI RUS CS orii a e ice seni aaa ces ce taty auoatina E a a 12 78 Lubricating Oil Sludge in the Crankcase Excessive cooooccconcncccooconccnononcocnnnaronnnnancrnnnnnronnnnrrrnnnnnrrnnannrernananenos 12 79 Turbocharger Leaks Engine Oil or Fuel cccsceceeessseeeeeeneeeseeseeeeeeeseeeeeseeeenesseeeeasseesseaneesseeneseoensnessonsnees 12 80 Crankcase Gases Blowby Excessive c c sccccseeseeeeeeeeeeeeeneeeseesneeeeneseeeeeesseeeeaneeeeueseseousaeeseasneessneneessoas 12 81 ENGINE OVErspecd Ti o a de elo tn erect 12 82 Tachometer Does Not In
43. ing Page 12 67 CFP33 Series Excessive White Exhaust Smoke Cont Coolant is leaking into the combustion chamber Check for head gasket leaks cylinder head or block cracks Front gear train is not aligned properly Align the match marks of the idler gear crankshaft gear camshaft gear and fuel pump gears Refer to the Troubleshooting and Repair Manual Bulletin Number 3666418 Internal engine damage Analyze the oil and inspect the filter to locate the area of probable damage Contact an Authorized Cummins Repair Facility ys Drawing No 9774 Section 12 Rev 02 07 Page 12 68 Section 12 Troubleshooting CFP33 Series Excessive Black Exhaust Smoke Engine is being lugged down Increase pump suction head or decrease pump discharge head Clogged air cleaner element Clean or replace the air cleaner element Muffler is crushed or clogged Replace the muffler Refer to the OEM s service manual Air leakage between the turbocharger and head Tighten the clamp between turbocharger and head Repair leaks between turbocharger and head Exhaust leak between turbocharger and exhaust Inspect and change gaskets manifold Turbocharger does not rotate freely Replace the turbocharger Defective or clogged injection nozzle Replace the defective or clogged injection nozzle Injection pump is adjusted incorrectly causing Adjust or replace the injection pump excessive injection Drawing No 9774 Section 12 Rev 02
44. ions in Section 7 Starting motor rotation is not correct Check the direction of crankshaft rotation Refer to instructions in Section 7 Replace the starting motor if necessary Refer to Starter Motor Assembly Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 37 CFP33 Series Engine Cranks Normally But Will Not Start No Exhaust Smoke Cont Cause Correction Starting motor is not turning the engine Replace the starting motor if necessary Refer to Starter Motor Assembly Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Page 12 38 Section 12 Troubleshooting CFP33 Series Engine Cranks Slowly But Does Not Start NOTE Typical engine cranking speed is 120 RPM Engine cranking speed can be checked with a hand held tachometer stroboscope or electronic service tool Cause Correction The batteries are cold Ensure that the batteries are protected from extreme temperatures The battery cables or connections are loose broken or Check the battery cables and connections Ensure corroded creating excessive resistance that connections are clean and tight The battery is not properly charged or has failed Recharge the battery If the battery does not take the charge replace it Lubricating oil level is too high Check the oil level Refer to Check Engine Oil Level in
45. ircuit breaker Locate and correct any electrical faults in the control panel Press the RESET switch on the local control panel The AUTO MANUAL Rocker Switch fails to select When practical open Circuit Breaker CB at the local AUTO mode control panel and test switch operation electrically Refer to Drawing 10423 Sheet 1 in Section 13 If required replace the switch or repair other electrical faults When done close Circuit Breaker CB at the local control panel and reset rocker switch to AUTO mode Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 25 CFP33 Series Auto Start Failure Cranks but does not Start Cont The overspeed switch has failed Check power and grounding to the overspeed switch Refer to Drawing 10423 Sheet 1 in Section 13 Repair any electrical faults If required test and adjust the overspeed setting Refer to Overspeed Setpoint Adjustment and Testing in Section 3 Replace the overspeed switch Refer to Overspeed Switch Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 26 Section 12 Troubleshooting CFP33 Series Auto Start Failure Engine Starts but Crank Terminate does not Occur Cause Correction The overspeed switch not correctly adjusted or has failed Fuse 3 has opened The raw water solenoid valve also fails to open The speed sensor has failed Th
46. low the engine to warm to operating temperature If the engine will not reach operating temperature refer to the Coolant Temperature Below Normal Engine Running symptom tree Air is present in the fuel system Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel filters as necessary Vent air from the system Refer to Air in Fuel in Section 7 Fuel filter is becoming plugged Replace the fuel filter Refer to Change Fuel Filter in Section 7 Fuel supply to the engine is inadequate Locate and correct the restriction in fuel flow to the engine The fuel lift pump is malfunctioning Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Engine mounts are worn or damaged Check the engine mounts If damaged refer to a Cummins Authorized Repair Facility Fuel grade is not correct for the application or the fuel Operate the engine on the required fuel Refer to Fuel quality is poor Recommendations and Specifications in Section 10 Drawing No 9774 Section 12 Rev 02 07 Page 12 52 Section 12 Troubleshooting CFP33 Series Engine Runs Rough or Misfires Under Load Cont Cause Correction Fuel pump overflow valve is malfunctioning Check the overflow valve Replace if necessary Refer to instruction in Section 7 Fuel injec
47. ms for air leaks by looking for cracks listening for high pitch whining or sucking noises or use a soapy solution in the suspect areas Drawing No 9774 Section 12 Rev 02 07 Page 12 66 Section 12 Troubleshooting CFP33 Series Excessive White Exhaust Smoke Cont Cause Correction Fuel drain line restriction is above specification Check the fuel drain lines for restriction 7 5 in Hg max Clear or replace the fuel lines or tank vents as necessary Verify the static injection timing with the value listed on the engine data tag Refer to the Troubleshooting and Repair manual Bulletin Number 3666418 for procedure Turbocharged engines 8 BTDC 1 Adjust the overhead settings Refer to the Troubleshooting and Repair manual Bulletin Number 3666418 Remove the injectors and compare the identification number on the injector with the injector cross reference table 1 Injector is malfunctioning Test the injector opening pressures min 167 bar for used injectors Replace injectors as necessary Refer to the Troubleshooting and Repair manual Bulletin Number 3666418 Fuel injection pump is malfunctioning Replace the fuel pump Refer to the Troubleshooting and Repair manual Bulletin Number 3666418 Raw fuel in the intake manifold external source Check the intake manifold for fuel Locate the fuel sources and repair as necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshoot
48. ng 10423 Sheet 1 in Section 13 If required locate and repair the open circuit or short to ground in the alternator excitation wiring Alternator internal voltage regulator is malfunctioning Test the alternator electrically Refer to Alternator Checks and Testing in Section 7 If required replace the alternator Refer to Alternator Removal Installation Section 7 Battery temperature is above specification Position the batteries away from heat sources Contact an Authorized Cummins Repair Facility OO Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 7 CFP33 Series Only One Battery is Charging with the Engine Running NOTE If one or both batteries do not charge with the engine stopped troubleshoot the customer supplied battery charging system NOTE If neither battery is maintaining charge go to Neither Battery is Charging with the Engine Running Cause Correction Battery has failed Test battery condition Refer to Battery Testing in Section 7 If the battery has failed replace the failed battery units Refer to Battery Removal Installation in Section Battery cables or connections are loose broken or Check the battery cables and connections Ensure corroded excessive resistance that all connections are free of corrosion and that no cables are broken Battery isolator has failed Remove the battery isolator Refer to Battery Isolator Removal Installation in Section 7 Test
49. njectors restriction Remove ON restrictions A fuel injector is pS Replace the a injector Refer to Fuel r Removal Installation in Section 7 Moisture is pS in the wiring harness connectors et the connectors with Cummins electronic cleaner Part Number 3824510 Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 57 CFP33 Series Engine Vibration Excessive at Rated Speed Engine runs rough or is misfiring Refer to the Engine Runs Rough or Misfires Under Load symptom tree in this section Fuel injection pump is adjusted incorrectly Adjust or replace the injection pump Refer to Adjust Fuel Pump and or Fuel Injection Pump Removal Installation in Section 7 Inspect the engine mounts Refer to Check Engine Mounting Bolts in Section 5 Replace the engine mounts as needed Refer to a Cummins Authorized Repair Facility Inspect the vibration damper Refer to Inspect Vibration Damper in Section 5 Replace if necessary Refer to a Cummins Authorized Repair Facility Check if the alternator is vibrating excessively Replace the alternator if necessary Refer to Alternator Removal Installation in Section 7 Water pump bearing is worn or damaged Check if the water pump is vibrating excessively Replace the pump if necessary Refer to Water Pump Removal Installation in Section 7 Contact a Cummins Authorized Repair Facility o Drawing No 9774 Section 12 Rev 02 07 Page 12 58 Section 1
50. nkage Refer to instructions in Section 7 Intake air flow is restricted Check the air intake A for restriction Refer to Check Air Cleaner Service Indicator in Section 5 Replace the air filter if required Drawing No 9774 Section 12 Rev 02 07 Page 12 42 Section 12 Troubleshooting CFP33 Series Engine Difficult to Start or Will Not Start Exhaust Smoke Present Cont Exhaust air flow is restricted Check the exhaust air piping for restriction Remove any restriction Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 43 CFP33 Series Engine Acceleration or Response Poor Cause Correction Fuel drain line is restricted Check the fuel drain lines for restriction Clear or replace the fuel lines check valves or tank vents as necessary Fuel filter is clogged Replace the fuel filter Refer to Change Fuel Filter in Section 7 Fuel grade is not correct for the application or the fuel Operate the engine from a tank of high quality fuel quality is poor Refer to Fuel Recommendations and Specifications in Section 10 Fuel injection pump is malfunctioning Perform the fuel injection pump test Fuel injection pump timing is not correct Check and adjust the fuel pump timing Refer to Fuel Adjust Fuel Pump in Section 7 Fuel pre filter is clogged Clean the customer supplied fuel pre filter Fuel pump overflow valve is malfunctioning Check the overflow valve Replace
51. ococicoccccocacoconacoconaconnnncnnnnncnonanonnnnrennnnrennnrenanarennannnnnan 12 20 Auto Start Failure Does not Crank on A ooooonndcconcncccooconoccnconcononcncononnnnrrnnnnrrrnnnn nera nrrrnnnnrrrnnnnrrrnannnrrrnanarennas 12 21 Auto Start Failure Does not Crank on B ooonncccononccccococcccncnncononcnnononnnnnnnnnnrrnnnnnrrrnnnnrrrnnnnrrrnnnnnrrnannnrrrnanarennas 12 22 Auto Start Failure Does not Crank on A or B ooccccononccccocccconocococonnononnnnnnronnnnnrennnnnnronannrernnnnnrrrnannrernnanarennas 12 23 Auto Start Failure Cranks but does not Start oocccconnocccconnccccoccncoconcanocnnnnconnnnnnonnnnnnronnnnnrnrnnnnrrnnnnnrrrnnanarennas 12 24 Auto Start Failure Engine Starts but Crank Terminate does not Occur c onocccocncccncociconococnnnconcancnnnononanos 12 26 Manual Start Failure from Solenoid Lever Does not Crank on A cooonncccconcccoconcncoconcnonnnnanonenanaronnnnanennnanns 12 28 Manual Start Failure from Solenoid Lever Does not Crank on B oooooccccoccccccoccccoconcnonnnnnnonnnannronnananennnanns 12 29 Manual Start Failure from Solenoid Lever Does not Crank on A or B oooodoccononccconccccconcanconnnannonanarennanannos 12 30 Manual Start Failure from Control Panel Does not Crank on A ooocconnncccnncccccnccococoncanonnnnanonnnnnnrnnananennnannns 12 31 Manual Start Failure from Control Panel Does not Crank on B occonnncccnnocccconcncoconcanonencnncnnnanarenanarennnnanes 12 32 Manual Start Failure from Control Panel Does not
52. oil level Refer to Check Engine Oil Level in Section 5 Add or drain oil if necessary Coolant temperature sender is malfunctioning Replace the temperature sender Refer to Coolant Temperature Sender Removal Installation in Section 7 Coolant temperature gauge is malfunctioning Replace the temperature gauge Refer to Coolant Temperature Gauge Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 16 Section 12 Troubleshooting CFP33 Series Coolant Temperature Above Normal Cont Cause Correction Coolant temperature switch is malfunctioning Remove the temperature switch Refer to Coolant Temperature Switch Removal Installation in Section 7 Test the temperature switch Repair or replace the switch if necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 17 CFP33 Series Coolant Temperature Below Normal R on The 120 VAC power supply to the coolant heater is Connect the power AA Correct any electrical faults not connected in the ON circuit The heater s overload thermostat has A Ensure that there is coolant in the heater Allow time for the automatic overload reset to occur Coolant temperature sender is pS ee the temperature sender Refer to Coolant Temperature Sender Removal Installation in Section 7 Coolant temperature gauge is malfunctioning Replace the temperature gauge Refer to Coolant A A Removal Installation in Section 7 Co
53. olant is not free to circulate 3 the heater Ensure that the coolant hoses are clear Refer to Coolant Hose Removal Installation in Section 7 The coolant heater has failed E A the coolant heater Refer to Coolant Heater Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 18 Section 12 Troubleshooting CFP33 Series Coolant Temperature Below Normal Engine Running Cause Correction Coolant thermostat has failed open Test operation of the thermostat Refer to Coolant Thermostat Tests in Section 7 If necessary replace the thermostat Refer to Coolant Thermostat Removal Installation in Section 7 Coolant temperature sender is malfunctioning Replace the temperature sender Refer to Coolant Temperature Sender Removal Installation in Section 7 Coolant temperature gauge is malfunctioning Replace the temperature gauge Refer to Coolant Temperature Gauge Removal Installation in Section 7 Contact an Authorized Cummins Repair Facility OO Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 19 CFP33 Series Raw Water Drain Steaming NOTE The raw water drain from the Coolant Heat Exchanger may steam if raw water flow is inadequate when the engine is running It may also steam shortly after the engine is stopped If coolant is leaking into the raw water drain piping the steaming may last for some time while the engine cools Antifreeze may also be observed in
54. on Closed crankcase ventilation hoses are leaking or Inspect the closed crankcase ventilation system hoses damaged and connections for leaks obstruction or damage Refer to Closed Crankcase Ventilation Hoses 003 024 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Close crankcase ventilation valve is leaking or Inspect the closed crankcase ventilation valve for malfunctioning obstruction or damage Refer to Closed Crankcase Ventilation Valve 003 023 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Refer to a Cummins Authorized Repair Facility es Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 81 CFP33 Series Turbocharger Leaks Engine Oil or Fuel Engine is operating for extended periods under light or Operate the engine at idle speed for maintenance no load conditions slobbering activities only Lubricating oil or fuel is entering the turbocharger Check the turbocharger for oil or fuel in the piping Refer to Turbocharger 010 033 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 Remove the turbocharger drain line and check for restriction Clean or replace the drain line Refer to Turbocharger Oil Drain Line 010 045 in Troubleshooting and Repair Manual B3 9 B4 5 and B5 9 Series Engines Bulletin Number 3666087 02 C
55. ooling System in Section 5 If the problem persists the cylinder block may be cracked or porous Refer to a Cummins Authorized Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 10 Coolant Contamination Cont Section 12 Troubleshooting CFP33 Series Cause Correction Coolant Heat Exchanger is leaking raw water into the coolant Coolant volume increases and pressure is relieved when the unit is operating Antifreeze concentration decreases Coolant is inadvertently contaminated with unknown liquids Drain and flush the cooling system Refer to Drain and Flush Cooling System in Section 5 Remove Coolant Heat Exchanger Refer to Coolant Heat Exchanger Removal Installation in Section 7 Perform a pressure test of the raw water side of the heat exchanger Refer to Coolant Heat Exchanger Removal Installation in Section 7 If the heat exchanger leaks it should be replaced Install a known good Coolant Heat Exchanger Refer to Coolant Heat Exchanger Removal Installation in Section 7 Check and adjust raw water pressure regulator setpoints Refer to Raw Water Piping Lineup and Configuration in Section 3 Check and if required replace the Zinc Plug Refer to Inspect Heat Exchanger Zinc Plug in Section 5 Refill with correct mixture of antifreeze and water Refer to Drain and Flush Cooling System in Section 5 Drain and flush the cooling system Refill with correct mixture of antifreeze and water
56. s Add coolant as required and check engine operation Drawing No 9774 Section 12 Rev 02 07 Page 12 12 Section 12 Troubleshooting CFP33 Series Excessive Coolant Loss Cont Engine is overheating Refer to the Coolant Temperature Above Normal symptom tree Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 13 CFP33 Series Coolant Temperature Above Normal NOTE The thermostat s normal operating temperature range is 82 95 C 180 203 F The High Water Temperature lamp on the local control panel see Instrument Panel in Section 2 illuminates at 93 92 94 C 200 198 202 F The lamp will only illuminate if the engine is running If the lamp is illuminated or if temperature is otherwise excessive the engine should be stopped as soon as practical and the problem corrected Cause Correction Raw water flow is improperly aligned Check that the raw water manifold is aligned for normal flow through the solenoid valve preferred or bypass flow around the solenoid valve alternative Refer to Drawing 8682 in Section 13 Align flow if required Raw water pressure regulator is improperly adjusted NOTE Pressure should be about 414 kPa 60 psig or slightly less Check the raw water pressure indication If pressure is indicated but is low adjust the regulator Refer to Check Raw Water Pressure Regulator Setpoints in Section 3 If pressure is not indicated or is exce
57. s of this section to aid in diagnosing specific engine symptoms Read each row of blocks from top to bottom Follow through the chart to identify the corrective action Drawing No 9774 Section 12 Rev 02 07 Page 12 4 Section 12 Troubleshooting CFP33 Series Alternator Overcharging with the Engine Running NOTE If the batteries are overcharged while the engine is not running troubleshoot the customer supplied battery charging system Cause Correction Batteries have failed Check the condition of the batteries Replace any defective batteries The internal voltage regulator in the alternator is Test the alternator electrically Refer to Alternator malfunctioning Checks and Testing in Section 7 If required replace the alternator Refer to Alternator Removal Installation Section 7 Contact an Authorized Cummins Repair Facility Se Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 5 CFP33 Series Neither Battery is Charging with the Engine Running NOTE If one or both batteries do not charge with the engine stopped troubleshoot the customer supplied battery charging system NOTE If only one battery is maintaining charge go to Only One Battery is Charging with the Engine Running Cause Correction Battery cables or connections are loose broken or Check the battery cables and connections Ensure that corroded excessive resistance all connections are free of corrosion and that
58. ssively low go to Raw water solenoid has failed in this table Raw water solenoid has failed If pressure is excessively low when aligned for normal flow open the bypass valves Then when practical troubleshoot the raw water solenoid valve Refer to Raw Water Solenoid Valve Fails to Operate in this section If the solenoid valve operates replace the pressure regulator Refer to Raw Water Pressure Regulator Removal Installation in Section 7 If pressure is excessively low when aligned for bypass flow open the normal valves Then when practical replace the pressure regulator Refer to Raw Water Pressure Regulator Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 14 Section 12 Troubleshooting CFP33 Series Coolant Temperature Above Normal Cont Cause Correction Raw water piping or heat exchanger is plugged Check the raw water strainer for blockage Refer to Drawing 8682 in Section 13 Clean the strainer if necessary Check the Cummins supplied raw water piping for blockage Refer to Drawing 8682 and Drawing 9636 in Section 13 Clean the piping if necessary Check the customer supplied raw water piping for blockage Remove any blockage Check for flow through the heat exchanger If necessary replace the heat exchanger Refer to Coolant Heat Exchanger Removal Installation in Section T Check the coolant level Refer to Check Coolant Level in Section 5 Add cool
59. stomer supplied fuel lines to the engine Exhaust back pressure too high NOTE The maximum allowable exhaust back pressure is specified in Exhaust System Specifications in Section 10 Measure the exhaust back pressure Correct the problem is it is above specification Check the fuel lift pump for correct operation Check the pump output pressure Replace the fuel lift pump if necessary Refer to Fuel Lift Pump Removal Installation in Section 7 Drawing No 9774 Section 12 Rev 02 07 Page 12 62 Section 12 Troubleshooting CFP33 Series Engine Will Not Reach Rated Speed RPM Cont Fuel injection pump is malfunctioning Remove the fuel pump Refer to Fuel Injection Pump Removal Installation in Section 7 Calibrate the fuel pump If required replace the fuel injection pump Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 63 CFP33 Series Engine Will Not Shut Off Remotely Cause Correction Stop circuit malfunction in the fire pump controller of NOTE In the AUTO mode the fire pump engine stops field wiring upon loss of signal power from the fire pump controller Check the engine stop circuit in the fire pump controller Correct any faults Check for short to voltage on the signal wiring from the fire pump controller to the engine control panel Correct any faults Check operation of the switch contacts of the AUTO
60. the raw water drain Raw water flow did not start when the engine started Check engine coolant temperature Go to Coolant Temperature Above Normal in this section Engine coolant is leaking into the raw water piping in When practical remove the coolant heat exchanger the coolant heat exchanger and perform the pressure test Refer to Coolant Heat Exchanger Removal Installation in Section 7 If pressure is not maintained replace the heat exchanger Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 20 Section 12 Troubleshooting CFP33 Series Raw Water Solenoid Valve Fails to Operate NOTE The raw water solenoid failure may fail to open or to close The normally closed valve may fail to open when the engine starts This fault will prevent raw water flow through the normal valves Bypass flow should be aligned in this event The valve may also fail to close because of mechanical blockage In this event the raw water flow from the heat exchanger does not stop when it should Depending upon the fire protection system piping the open solenoid valve may drain all water from the fire protection system piping that is higher than the engine s piping Cause Correction Solenoid valve fails to close when the engine stops Solenoid fails to open mechanically Replace the solenoid valve Refer to Raw W
61. tion pump timing is incorrect Check and adjust the injection pump timing Refer to Adjust Fuel Pump in Section 7 Inspect the injectors Replace the injectors as necessary Refer to Fuel Injectors Removal Installation in Section 7 Fuel injection pump is malfunctioning Remove the fuel injection pump Refer to Fuel Injection Pump Removal Installation in Section 7 Check the calibration of the fuel injection pump Refer to instructions in Section 7 Replace the pump if necessary Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 53 CFP33 Series Engine Speed Surges at Idle NOTE Operation at idle speed is for maintenance only Fuel level is low in the tank Fill the fuel tank Fill and bleed the fuel lines to the engine Engine idle speed is set too low Adjust the idle speed Refer to instructions in Section 7 Air is in the fuel supply to the engine Check for air in the fuel system Tighten or replace the fuel connections fuel lines fuel tank standpipe and fuel filters as necessary Vent air from the system Refer to Air in Fuel in Section 7 The fuel filter is plugged Replace the fuel filter Refer to Change Fuel Filter in Section 5 Fuel flow to the engine is not adequate Locate and correct the restriction in the customer supplied fuel lines to the engine The fuel lift pump is malfunctioning Check the fuel lift pump for correct operation Check the pump output pressure
62. trical fault is present in the control panel When practical test continuity and insulation from between Fuse F3 and TB 2 ground between Fuse F3 and TB 2 Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 28 Section 12 Troubleshooting CFP33 Series Manual Start Failure from Solenoid Lever Does not Crank on A NOTE The fire pump engine will not crank locally from the solenoid lever when solenoid A is actuated However it does start when solenoid B is actuated Battery A is discharged or has failed Recharge or replace the battery ground between Battery A and the starter motor Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Remove and test Solenoid A lever and switch operation Refer to Crank Solenoid Assembly Removal Installation in Section 7 If required replace Solenoid A Contact an Authorized Cummins Repair Facility ee Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 29 CFP33 Series Manual Start Failure from Solenoid Lever Does not Crank on B NOTE The fire pump engine will not crank locally from the solenoid lever when solenoid B is actuated However it does start when solenoid A is actuated Battery B is discharged or has failed Recharge or replace the battery An electrical fault is present be
63. tween Battery B and the When practical test continuity and insulation from starter motor ground between Battery B and the starter motor Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Remove and test Solenoid B lever and switch operation Refer to Crank Solenoid Assembly Removal Installation in Section 7 If required replace Solenoid B Contact an Authorized Cummins Repair Facility an Authorized Cummins Repair Contact an Authorized Cummins Repair Facility Drawing No 9774 Section 12 Rev 02 07 Page 12 30 Section 12 Troubleshooting CFP33 Series Manual Start Failure from Solenoid Lever Does not Crank on A or B NOTE The fire pump engine will not crank locally when either solenoid lever is actuated Starter motor has failed Replace the starter motor Refer to Starter Motor Removal Installation in Section 7 An electrical fault is present in the power or ground Test continuity and insulation from ground between the circuit for the starter motor battery splice the ground connection and the starter motor Locate and repair any electrical fault Refer to Drawing 10423 Sheet 1 in Section 13 Contact an Authorized Cummins Repair Facility A Drawing No 9774 Section 12 Rev 02 07 Section 12 Troubleshooting Page 12 31 CFP33 Series Manual Start Failure from Control Panel Does not Crank on A NOTE The fire pump engine will not crank locally from the control p
64. will not crank automatically when either solenoid A or solenoid B is selected at the fire protection system However it does crank and start when started locally If local starting problems are identified go to the applicable Manual Start Failure troubleshooting table Cause Correction The Fire Protection System fails to produce either Locate and correct the common mode fault in the Fire redundant start signal to the fire pump Protection System Drawing No 9774 Section 12 Rev 02 07 Page 12 24 Section 12 Troubleshooting CFP33 Series Auto Start Failure Cranks but does not Start NOTE The fire pump engine will crank automatically when either solenoid A or solenoid B is selected at the fire protection system However the engine does not start The engine will start locally If local starting problems are identified go to the applicable Manual Start Failure troubleshooting table The overspeed switch as actuated The overspeed Press the RESET switch on the local control panel lamp is illuminated on the local control panel Control power from the Fire Protection System is not When practical locate and correct the fault in the Fire available at local control panel TB1 Protection System or the field wiring to the local control panel Circuit Breaker CB is open in the local control panel Check whether Circuit Breaker CB at the local control panel is open Refer to Drawing 10423 Sheet 1 in Section 13 If open reset the c

Section 12 – Troubleshooting

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Section 12 &ndash; Troubleshooting

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Section 12 – Troubleshooting