CFP15E(07)

7-1

7.1 TroubleshootingThe following information is intended as a guide totroubleshooting some common nontechnical equip-ment problems. Many problems can be resolvedusing corrective maintenance, adjustment or minorrepair. Refer to the Vendor supplied literature,electrical schematics and mechanical prints foradditional information.

For engine related issues, refer to Operation andMaintenance Manual, Industrial and Power Genera-tion QSX15 Engines, Bulletin No. 3666423 orcontact the Cummins Customer Assistance Centerat 1-800-DIESELS (1-800-343-7357).

It is beyond the scope of this manual to cover all ofthe various problems that may affect engine perfor-mance.

WARNINGThe status checks should be performed ONLYby a qualified technician. Contact with exposedelectrical components could cause extremepersonal injury or death.

WARNINGBefore equipment operation, ALL guards,covers and protective devices MUST BE inplace and securely fastened. Serious personalinjury could result from contact with exposed ormoving components.

CAUTIONAVOID SERVICING complex components suchas: printed circuit boards, and, ECM's, notspecifically authorized by Cummins Inc. Contacta Cummins Fire Power Customer ServiceDepartment toll free at 1-800-343-7357 beforeperforming any extensive maintenance.

CAUTIONNever climb or stand on the equipment frame,guards, or enclosures. Contact with exposed ormoving components can cause personal injuryor equipment damage.

Section 7 - Troubleshooting

Fire Power Pump EngineDoc. 9779, Rev-10-07

Table of ContentsProblem PageFault Code Chart .........................................................................................................................................7-37.1 Alternator Overcharging with the Engine Running ................................................................................7-47.2 Neither Battery is Charging with the Engine Running ........................................................................... 7-47.3 Only One Battery is Charging with the Engine Running .......................................................................7-57.4 Voltage Indications Differ ....................................................................................................................... 7-57.5 Coolant Contamination .......................................................................................................................... 7-67.6 Excessive Coolant Loss ........................................................................................................................ 7-77.7 Coolant Temperature Above Normal ..................................................................................................... 7-87.8 Coolant Temperature Below Normal (Engine Off) ..............................................................................7-107.9 Raw Water Drain Steaming .................................................................................................................7-117.10 Raw Water Solenoid Valve Fails to Operate .....................................................................................7-117.11 Auto Start Failure - Does not Crank on A or B ..................................................................................7-127.12 Auto Start Failure - Cranks but does not Start ..................................................................................7-127.13 Auto Start Failure – Engine Starts but Crank Terminate Does Not Occur ........................................ 7-137.14 Manual Start Failure from Solenoid Lever - Does not Crank on A or B ............................................ 7-147.15 Manual Start Failure from Control Panel - Does not Crank on A or B .............................................. 7-147.16 Engine Cranks Normally But Will Not Start (No Exhaust Smoke) .....................................................7-157.17 Engine Cranks Slowly But Does Not Start ........................................................................................7-177.18 Engine Stops During Operation .........................................................................................................7-177.19 Engine Will Not Reach Rated Speed (RPM) .....................................................................................7-197.20 Engine Will Not Shut Off Remotely ...................................................................................................7-207.21 Engine Will Not Shut Off Locally .......................................................................................................7-207.22 Fuel Consumption Is Excessive ........................................................................................................7-207.23 Fuel or Lubricating Oil Leaking From Exhaust Manifold ...................................................................7-217.24 Lubricating Oil is Contaminated ........................................................................................................7-217.25 Lubricating Oil Consumption Excessive ............................................................................................7-227.26 Lubricating Oil in the Coolant ............................................................................................................7-237.27 Engine Overspeed Trip ......................................................................................................................7-237.28 Tachometer Does Not Indicate Engine Speed ..................................................................................7-24

FAULT SID(S) CODE PID(P) SPN (LAMP) FMI FMI DESCRIPTION

151 P110 110 Engine Coolant Temperature High – Critical(Yellow) 0 0

214 P175 175 Engine Oil Temperature High - Critical(Yellow) 0 0

235 P111 111 Engine Coolant Level Low - Critical(Yellow) 1 1

259 S017 632 Fuel Shutoff Valve - stuck open(Red) 7 7284 S221 1043 Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low

(Red) 4 4295 P108 108 Ambient Air Pressure Sensor Circuit - data incorrect

(Yellow) 2 2341 S253 630 Engine Control Module – data lost

(Red) 2 2343 S254 629 Engine Control Module - Warning internal hardware failure

(Red) 12 12378 S018 633 Fueling Actuator #1 Circuit - open circuit

(Red) 5 5379 S018 633 Fueling Actuator #1 Circuit - grounded circuit

(Red) 6 6394 S02 0 635 Timing Actuator #1 Circuit - open circuit

(Red) 5 5399 S084 1245 Timing Actuator #2 Circuit - grounded circuit

(Red) 6 6415 P100 100 Engine Oil Pressure Low – Critical

(Yellow) 1 1432 S230 558 Accelerator Pedal Idle Validation Circuit - out of calibration

(Yellow) 13 13449 P094 94 Fuel Pressure High - Warning

(Red) 0 16451 P157 157 Injector Metering Rail #1 Pressure Sensor Circuit - shorted high

(Red) 3 3452 P157 157 Injector Metering Rail #1 Pressure Sensor Circuit - shorted low

(Red) 4 4482 P094 94 Fuel Pressure Low - Warning

(Red) 1 18483 P129 1349 Injector Metering Rail #2 Pressure Sensor Circuit - shorted high

(Red) 3 3484 P129 1349 Injector Metering Rail #2 Pressure Sensor Circuit - shorted low

(Red) 4 4485 P129 1349 Injector Metering Rail #2 Pressure High - Warning

(Red) 0 16486 P129 1349 Injector Metering Rail #2 Pressure Low - Warning

(Red) 1 18496 S221 1043 Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage

(Red) 11 11546 P094 94 Fuel Delivery Pressure Sensor Circuit - shorted high

(Red) 3 3547 P094 94 Fuel Delivery Pressure Sensor Circuit- shorted low

(Red) 4 4553 P157 157 Injector Metering Rail #1 Pressure High - warning level

(Red) 1 18559 P157 157 “Unexpectedly low rail pressure was detected on the front three cylinders.“

(Red) 1 18731 S064 723 Engine position signal from the camshaft and crankshaft engine position sensors

(Red) 7 7 do NOT Match up.753 S064 723 Engine position signal from the camshaft and crankshaft engine position sensors

(Red) 2 2 do NOT match up.

7-4


Problem Possible Cause Solution

7.1 Alternator Overchargingwith the Engine Running

NOTE: If the batteries areovercharged while the engine isnot running, troubleshoot thecustomer supplied batterycharging system.

7.2 Neither Battery is Chargingwith the Engine Running

NOTE: If one or both batteries donot charge with the enginestopped, troubleshoot the cus-tomer supplied battery chargingsystem.

NOTE: If only one battery ismaintaining charge, go to OnlyOne Battery is Charging with theEngine Running.

Batteries have failed.

Voltage regulator malfunction.

Battery cables or connections areloose, broken, or corroded(excessive resistance).

Alternator rotor is not rotating.

Battery isolator input has faulted.

Alternator excitation is lost.

Check the condition of thebatteries. Replace any defectivebatteries.

Test the alternator electrically.Contact an Authorized CumminsRepair Facility.

Replace the alternator as neces-sary.

Check the battery cables andconnections. Ensure that allconnections are free of corrosionand that no cables are broken.

Test the alternator mechanically.If the alternator shaft does notspin freely because of a badbearing, replace the alternator.

If the alternator does not turnbecause of a bad drive belt,replace the drive belt. Refer toSection 6 - Maintenance.

If the alternator does not chargebecause of poor drive belttension, adjust belt tension. Referto Section 6 - Maintenance.

If the alternator pulley spinsfreely on the shaft because of abroken key, replace the alterna-tor. Contact an AuthorizedCummins Repair Facility.

Test continuity from the alternatorto the battery isolator input.Repair any open circuit.

Test continuity through thebattery isolator. If an internalopen circuit is detected, replacethe battery isolator.

Test the alternator electrically.Replace the alternator diode asnecessary.

7-5



7.2 Neither Battery is Chargingwith the Engine Running.(Cont'd)

7.3 Only One Battery is Charg-ing with the Engine Running

NOTE: If one or both batteries donot charge with the enginestopped, troubleshoot the cus-tomer supplied battery chargingsystem.

NOTE: If neither battery ismaintaining charge, go to NeitherBattery is Charging with theEngine Running.

7.4 Voltage Indications Differ

NOTE: The two voltmeters maydiffer slightly due to calibrationdifferences between the meters.Normal differences in batterycondition may also cause differ-ences in indication. These arenormal differences and require noaction.

Alternator excitation is lost(Cont'd).

Alternator internal voltageregulator is malfunctioning.

Battery has failed.

Battery cables or connections areloose, broken, or corroded(excessive resistance).

Battery isolator has failed.

Voltmeter is providing falseindication.

One battery is discharged orfailing.

Locate and repair the open circuitor short to ground in the alterna-tor excitation wiring as neces-sary.

Test the alternator electrically. Ifrequired, replace the alternator.Contact an Authorized CumminsRepair Facility.

Check battery charge.

Check the battery cables andconnections. Ensure connectionsclean and that no cables arebroken.

Remove the battery isolator. Testthe internal diodes for opencircuit or short to ground. Re-place the battery isolator asnecessary.

See Voltage Indications Differ inthis section.

Check battery condition. Replacefailing battery elements.

Check wiring for corrosion.Ensure good electrical contact.

Charge discharged batteries byrunning the engine or with anexternal battery charger. If thebattery does not charge with theengine running, go to Only OneBattery is Charging with theEngine Running.

Check for apparent wire damageor shorts to grounds. Replace thefailed fuse.

7-6



7.4 Voltage Indications Differ(Cont'd)

7.5 Coolant Contamination

Breaker 1 or Breaker 2 is tripped.

Open circuit or short to ground inindicator wiring.

Voltmeter has failed.

Coolant is rusty and has debris.

Lubricating oil cooler is leaking oilinto the coolant. Coolant beginsto have the texture and color ofchocolate pudding.

If the breaker trips again, locateand correct the overload or repairthe short circuit.

Locate and repair the electricalfault.

Remove wiring at the voltmeterand apply test voltage. Replacethe faulted voltmeter as neces-sary.

Drain and flush the coolingsystem per the instructions inSection 6 - Maintenance.

Replace the coolant water filterper the instructions in Section 6.

Refill with correct mixture ofantifreeze and water per theinstructions in Section 6 - Mainte-nance.


Check the lubricating oil coolerfor coolant leaks and cracks.

Replace the oil cooler gasket orother parts as necessary.

Refill with correct mixture ofantifreeze and water.

If the problem persists, thecylinder block may be cracked orporous. Contact the CumminsAuthorized Repair Facility.

7-7



7.5 Coolant Contamination(Cont'd)

7.6 Excessive Coolant Loss

Coolant Heat Exchanger isleaking raw water into the cool-ant. Coolant volume increasesand pressure is relieved whenthe unit is operating. Antifreezeconcentration decreases.

Coolant is inadvertently contami-nated with unknown liquids.

Adequate coolant was not addedfollowing previous maintenanceactivities.

Inadvertent coolant leak ispresent.

Cooling system hose is leaking.


Perform a pressure test of theraw water side of the heatexchanger. If the heat exchangerleaks, it should be replaced.

Check and adjust raw waterpressure regulator set points.

Check and, if required, replacethe zinc plug.

Refill with correct mixture ofantifreeze and water per theinstructions in Section 6 - Mainte-nance.

Drain and flush the coolingsystem. Refill with correct mixtureof antifreeze and water per theinstructions in Section 6 - Mainte-nance.

Contact an Authorized CumminsRepair Facility.

Check the coolant level. Addcoolant as required and checkengine operation. If coolant losspersists, check for other prob-lems.

Inspect the engine for coolantleaking from drain cocks or vents.Close the leaking drain or vent.Add coolant as required andcheck engine operation.

Check the condition of the hoses.Replace and/or tighten loosehose clamps. Replace anydamaged hoses as necessary.Add coolant as required andcheck engine operation.

7-8



7.6 Excessive Coolant Loss(Cont'd)

7.7 Coolant TemperatureAbove Normal

NOTE: The thermostat’s normaloperating temperature range is82-95° C (180-203° F) The HighWater Temperature lamp on thelocal control panel. The lamp onlyilluminates if the engine isrunning. If the lamp is illuminatedor if temperature is otherwiseexcessive, the engine should bestopped as soon as practical andthe problem corrected.

Pressure cap is malfunctioning orhas low-pressure rating.

Mechanical coolant leak.

Engine is overheating.

Raw water flow is improperlyaligned.

Raw water pressure regulator isimproperly adjusted.

NOTE: Pressure should be about414 kPa [60 psig] or slightly less.

Raw water solenoid has failed.

Check that the pressure cap doesnot relieve coolant under normaloperating conditions. Replace aleaking pressure cap, (CumminsFire Power Part No. 11407). Addcoolant as required and checkengine operation.

Inspect the engine for coolantleaking from manifold, expansionand pipe plugs, fittings, lubricat-ing oil cooler, water pump seal,cylinder block, and other compo-nents that have coolant flow.Repair leaking components. Addcoolant as required and checkengine operation.

Refer to the Coolant TemperatureAbove Normal in this Section.

Check that the raw water mani-fold is aligned for normal flowthrough the solenoid valve(preferred) or bypass flow aroundthe solenoid valve (alternative).Align flow if required.

Check the raw water pressureindication. If pressure is indicatedbut is low, adjust the regulator. Ifpressure is not indicated or isexcessively low, go to raw watersolenoid has failed.

If pressure is excessively lowwhen aligned for normal flow,open the bypass valves. Whenpractical, troubleshoot the rawwater solenoid valve. Refer toRaw Water Solenoid Valve Failsto Operate in this section. If thesolenoid valve operates, replacethe pressure regulator.

7-9



7.7 Coolant TemperatureAbove Normal. (Cont'd)

Raw water solenoid has failed.(Cont'd)

Raw water piping or heat ex-changer is plugged.

Coolant level is below specifica-tion.

Cooling system hose is collapsedor restricted.

Coolant thermostat is malfunc-tioning.

Coolant water pump is malfunc-tioning.

Lubricating oil is contaminatedwith coolant or fuel.

Cooling system hose is col-lapsed, restricted, or leaking.Inspect the hoses.

If pressure is excessively lowwhen aligned for bypass flow,open the normal valves.

Check the raw water strainer forblockage per the instructions inSection 6 - Maintenance. Cleanthe strainer if necessary.

Check the raw water piping forblockage. Clean the piping ifnecessary.

Remove any blockage. Check forflow through the heat exchanger.Replace the heat exchanger asnecessary.

Check the coolant level. Ifcoolant level is excessively low,go to Excessive Coolant Loss inthis section.

Inspect the hoses. Replace anydamaged hoses as necessary.

Remove and test the coolantthermostat per the instructions inSection 6 - Maintenance. Re-place the defective thermostat.

Remove and inspect the waterpump. Replace the defectivewater pump. Contact an Autho-rized Cummins Repair Facility.

Check the appearance of the lubri-cating oil. If the color and texture isabnormal, refer to the LubricatingOil Contaminated in this Section.

Replace any damaged hoses asnecessary.

7-10



7.7 Coolant TemperatureAbove Normal (Cont'd)

7.8 Coolant Temperature BelowNormal (Engine Off)

Coolant mixture of antifreeze andwater is not correct.

Lubricating oil level is above orbelow specification.

Coolant temperature sender ismalfunctioning.

Coolant temperature gauge ismalfunctioning.

Coolant temperature switch ismalfunctioning.

The 120 VAC power supply to thecoolant heater is not connected.

The heater’s overload thermostathas operated.



Coolant is not free to circulatethrough the heater.

The coolant heater has failedelectrically.

Electronic fault codes are active.

Coolant thermostat has failedopen.

Verify the concentration ofantifreeze in the coolant. Addantifreeze or water to correct theconcentration.

Check the oil level per theinstructions in Section 6.

Replace the temperature senderas necessary.

Replace the temperature gaugeas necessary.

Remove the temperature switch.Test the temperature switch.Repair or replace the switch, ifnecessary.

Connect the power supply.Correct any electrical faults in thesupply circuit.

Ensure that there is coolant in theheater. Allow time for the auto-matic overload reset to occur.

Replace the temperature sender.

Replace the temperature gauge.

Ensure that the coolant hoses areclear. Repair or replace hoses asnecessary.

Replace the coolant heater.

Refer to the Vendor suppliedliterature or contact an Autho-rized Cummins Repair Facility forFault Codes.

Test operation of the thermostat.Replace the thermostat per theinstructions on Section 6 -Maintenance as necessary.

7-11



7.8 Coolant Temperature BelowNormal (Engine Running)(Cont'd)

7.9 Raw Water Drain Steaming

NOTE: The raw water drain fromthe Coolant Heat Exchanger maysteam if raw water flow is inad-equate when the engine isrunning. It may also steam shortlyafter the engine is stopped. Ifcoolant is leaking into the rawwater drain piping, the steamingmay last for some time while theengine cools. Antifreeze may alsobe observed in the raw waterdrain.

7.10 Raw Water Solenoid ValveFails to Operate

NOTE: The raw water solenoidfailure may fail to open or toclose. The normally closed valvemay fail to open when the enginestarts. This fault will prevent rawwater flow through the normalvalves. Bypass flow should bealigned in this event. The valvemay also fail to close because ofmechanical blockage. In thisevent, the raw water flow fromthe heat exchanger does not stopwhen it should. Depending uponthe fire protection system piping,the open solenoid valve maydrain all water from the fireprotection system piping that ishigher than the engine’s piping.



Raw water flow did not start whenthe engine started.

Engine coolant is leaking into theraw water piping in the coolantheat exchanger.

Solenoid valve fails to closewhen the engine stops.

Solenoid valve fails to energize.

Solenoid fails to open mechani-cally. NOTE: Apply 24 VDC.

Replace the temperature sender.

Replace the temperature gauge.Refer to Section 6 - Maintenance.

Check engine coolant tempera-ture. Go to, Coolant TemperatureAbove Normal in this section.

Remove the coolant heat ex-changer and perform the pres-sure test. Refer to Section 6 -Maintenance. If pressure is notmaintained, replace the heatexchanger.

Replace the solenoid valve.Clean the raw water strainermore frequently. Increase thefrequency of operational testing.

Check electrical continuity andinsulation from ground to thesolenoid. Repair any open orshort circuits in the wiring.

Apply temporary voltage to thesolenoid. If the solenoid fails tooperate, replace it. Contact anAuthorized Cummins RepairFacility.

7-12



7.11 Auto Start Failure - Doesnot Crank on BATT A or B

7.12 Auto Start Failure - Cranksbut does not Start

NOTE: The fire pump engine willcrank automatically when eithersolenoid A or solenoid B isselected at the fire protectionsystem. However, the enginedoes not start. The engine willstart locally. If local startingproblems are identified, go to theapplicable Manual Start Failuretroubleshooting table.

The electrical connection fromthe fire protection system toterminal board has failed.

The electrical connection fromterminal board to relay has failed.

Relay has failed.

The Fire Protection System failsto produce either redundant startsignal to the fire pump.

The overspeed switch as actu-ated. The overspeed lamp isilluminated on the local controlpanel.

Control power from the FireProtection System is not avail-able at local control panel TB-1.

Circuit Breaker CB is open in thelocal control panel.

The AUTO/MANUAL RockerSwitch fails to select AUTOmode.

Test continuity and insulationfrom ground between the fireprotection system and the enginecontrol panel. Locate and repairany electrical fault in the fieldwiring or in the fire protectionsystem panel.

Test continuity and insulationfrom ground between the terminalboard and the relay. Locate andrepair any electrical fault.

Check de-energized continuity atrelay. Replace relay if the circuitis open. Contact an AuthorizedCummins Repair Facility.

Locate and correct the commonmode fault in the Fire ProtectionSystem.

Press the RESET switch on thelocal control panel.

Locate and correct the fault in theFire Protection System or thefield wiring to the local controlpanel as necessary.

Check whether Circuit BreakerCB at the local control panel isopen.

If open, reset the circuit breaker.Locate and correct any electricalfaults in the control panel. Pressthe RESET Switch on the localcontrol panel.

Open Circuit Breaker CB at thelocal control panel and testswitch operation electrically asnecessary.

Replace the switch or repair otherelectrical faults as necessary.When done, close Circuit BreakerCB at the local control panel.

7-13



7.12 Auto Start Failure - Cranksbut does not start (Cont'd)

7.13 Auto Start Failure –Engine Starts but CrankTerminate Does Not Occur

The overspeed switch has failed.

The overspeed switch notcorrectly adjusted or has failed.

Breaker has tripped. The rawwater solenoid valve fails toopen.

The speed sensor has failed. Thetachometer indicates zero RPM.

An electrical fault is present inthe Fire Protection System.

An electrical fault is presentbetween Control Panel and theFire Protection System.

Check power and grounding tothe overspeed switch. Repair anyelectrical faults.

Test and adjust the overspeedsetting. Refer to Overspeed SetPoint Adjustment and Testing inSection 6 - Maintenance. Re-place switch as necessary.

With the engine running, verifyspeed sensor input to theoverspeed switch.

If signal is not present, seeSpeed Sensor Has Failed. Thetachometer also indicates zerospeed.

Adjust the overspeed switchcrank terminate set point. Re-place the overspeed switch asnecessary.

Open the raw water bypassvalves. RESET breaker switch.Locate and repair any localelectrical fault.

Locate and repair any electricalfault in the speed sensor circuitry.Replace the speed sensor asnecessary.

Test continuity and insulationfrom ground between the fireprotection system and the enginecontrol panel. Locate and repairany electrical fault in the fieldwiring.

Test continuity and insulationfrom ground between the fireprotection system and the enginecontrol panel. Locate and repairany electrical fault in the fieldwiring.

7-14



7.14 Manual Start Failure fromSolenoid Lever - Does notCrank on A or B

NOTE: The fire pump engine willnot crank locally when eithersolenoid lever is actuated.

7.15 Manual Start Failure fromControl Panel - Does notCrank on A or B

NOTE: The fire pump engine willnot crank locally from the controlpanel when either CRANK BATTA or CRANK BATT B is selected,however, it does start when asolenoid lever is actuated.

Crank Batter A and B switchesfailed to make contact.

Relay fails in the local manualmode.

Solenoid A or Solenoid B fails toenergize due to electrical fault inthe power or ground circuit.

Solenoid A/B failed to operate.

Starter motor has failed.

An electrical fault is present inthe power or ground circuit forthe starter motor.

Engine is seized.

The MANUAL Mode RockerSwitch contact fails to close.

An electrical fault exists in thesignal power circuit or the groundto the Relays.

Breaker Switch has tripped. Theraw water solenoid valve alsofails to open.

Test electrical operation of CrankBatt A and B Switches. Replacethe faulty switches as necessary.

Test the electrical operation ofthe relay. Replace the relay iffaulted.

Test continuity and insulationfrom ground between the CRANKBATT A/B Switches, Relay, andthe Starter Solenoid. Also, checkthe solenoid coil connection toground. Locate and repair anyelectrical fault.

Test the electrical operation ofthe Solenoid A and Solenoid B.Replace the faulty solenoids asnecessary.

Replace the starter motor.

Test continuity and insulationfrom ground between the batterysplice, the ground connection,and the starter motor. Locate andrepair any electrical fault.

Bar the engine over to break theseizure. Contact an AuthorizedCummins Repair Facility.

Test the electrical operation ofthe AUTO/MANUAL RockerSwitch. Replace the faulty switchas necessary.

Test continuity and insulationfrom ground between the AUTO/MANUAL Rocker Switch and theRelays. Check the relay connec-tion to ground. Locate and repairany electrical fault.

Open the raw water bypassvalves. Locate and repair anylocal electrical fault. RESET theBreaker Switch.

7-15



7.15 Manual Start Failure fromControl Panel - Does notCrank on A or B (Cont'd)

7.16 Engine Cranks NormallyBut Will Not Start (NoExhaust Smoke).

An electrical fault exists in thesignal power circuit or the groundto the overspeed switch’s crankcircuit.

Overspeed switch crank circuitfails to reset with engine shut-down.


Electronic control module (ECM)is locked up.

Battery voltage supply to theelectronic control module (ECM)is low, interrupted, or open.

No fuel in supply tank.

Air is in the fuel system.

Fuel drain line is restricted.

Fuel filter is clogged.

Test continuity and insulationfrom ground between breakerand the overspeed switch’s crankcircuit. Check the crank circuitoutput to the CRANK BATTSwitches. Locate and repair anyelectrical fault.

Test and adjust the crank settingas necessary. Refer toOverspeed Set Point Adjustmentand Testing in Section 6. Replacethe overspeed switch as neces-sary.

Refer to the Vendor suppliedliterature or contact an Autho-rized Cummins Repair Facility forFault Codes.

Disconnect the battery cables for30 seconds. Then, reconnect thebattery cables, and start theengine.

Check the battery connections,the fuses, and the battery supplycircuit.

Check and replenish fuel supply.Check fittings and hose connec-tions and hose conditions.

Check for air in the fuel system.Tighten or replace the fuelconnections, fuel lines, fuel tankstand pipe and fuel filters asnecessary. Vent air from thesystem.

Check the fuel drain lines forrestriction. Clear or replace thefuel lines, check valves, or tankvents as necessary.

Replace the fuel filter. Refer toChange Fuel Filter in Section 6 -Maintenance.

7-16



7.16 Engine Cranks NormallyBut Will Not Start (NoExhaust Smoke) (Cont'd)

Fuel grade is not correct for theapplication or the fuel quality ispoor.

Fuel injection pump is malfunc-tioning. Pump timing incorrect.

Fuel tank is empty.

Fuel pump overflow valve ismalfunctioning.

Fuel suction line is restricted.

Fuel connections on the suctionside of the fuel lift pump areloose.

Fuel suction stand pipe in the fueltank is broken.

Fuel supply is not adequate.

Fuel tank air breather is blocked.

Fuel lift pump is malfunctioning.

Injection pump drive shaft ordrive shaft key is damaged.

Fuel injectors are plugged.

Moisture is in the wiring harnessconnectors.

Starter motor rotation is notcorrect or not turning engine.

Operate the engine from a tank ofhigh-quality no. 2 diesel fuel.


Fill the fuel supply tank.

Check the overflow valve.Replace if necessary.

Check the fuel suction line forrestriction.

Tighten all the fuel fittings andconnections between the fueltanks and fuel lift pump.

Check and repair the stand pipe,if necessary.

Locate and correct the restrictionin the customer supplied fuellines to the engine.

Clean the fuel tank breather.

Check the fuel lift pump forcorrect operation. Check thepump output pressure. Replacethe fuel lift pump if necessary.

Repair or replace the injectionpump.

Replace the fuel injectors.

Dry the connectors with Cumminselectronic cleaner, Part Number3824510.

Check the direction of crankshaftrotation. Replace the startermotor as necessary. Contact anAuthorized Cummins RepairFacility.

7-17



7.17 Engine Cranks Slowly ButDoes Not Start

NOTE: Typical engine crankingspeed is 120 RPM. Enginecranking speed can be checkedwith a hand-held tachometer,stroboscope, or electronic servicetool.

7.18 Engine Stops DuringOperation

The battery cable connectionsare loose, broken, or corrodedcreating excessive resistance.

The battery is not properlycharged or has failed.

Lubricating oil level is too high.

Lubricating oil is the wrong gradeor type.

Engine temperature is too low.

Starter motor is malfunctioning.

Normal automatic mode shut-down occurs when the fireprotection systems removes thesignal power feed to the localcontrol panel.

The selected engine controlmodule (ECM) has detected aserious fault condition. TheECM’s STOP light is displayed.

Check the battery cables andconnections. Ensure that connec-tions are clean and tight.

Recharge the battery. If thebattery doers not take thecharge, replace it.

Check the oil level per instruc-tions in Section 6. Drain anyexcess oil.

Check the grade and type of oil.Refer to Lubricating Oil Recom-mendations and Specifications inSection 6.

If the wrong type or grade of oil ispresent, drain and replace it.Refer to Change Lubricating Oiland Filters in Section 6.

Troubleshoot per Coolant Tem-perature Below Normal (EngineOff) in this section.

Replace the starter motor.Contact an Authorized CumminsRepair Facility.

No action required. This is adesirable outcome.

For instructions on how to readactive fault codes, refer toDiagnostic Fault Codes in theVendor supplied literature orcontact a Cummins AuthorizedRepair Facility.

7-18



7.18 Engine Stops DuringOperation (Cont'd)

In the automatic mode, the signalpower feed is lost from the fireprotection system to the controlpanel.

Circuit breaker on control paneltripped.

An overspeed trip has occurred.The overspeed trip lamp illumi-nated on the local control panel.

Power supply or grounding faultexists at the Electronic ControlModule.

The selected ECM has failed.

Fuel tank level is low.

Clogged fuel tank air breatherhole.

Fuel piping to engine is clogged.

The fuel filter is clogged.

Air is trapped in the low pressurefuel lines at the engine.

Fuel lift pump has failed.

Fuel injection pump has failed.

Locate and correct the electricalfault in the fire protection systemor the field wiring to the enginecontrol panel.

Locate and correct the electricalfault in engine control panel.RESET the tripped breaker.

Remote indications may also bepresent. Overspeed switch failurehas occurred. The trip indicationsmay not be present. Go to EngineOverspeed Trip in this section.

Locate and correct the electricalfault in the power supply orgrounding for the ECM.

Select the alternate ECM.Replace the failed ECM. Contactan Authorized Cummins RepairFacility.

Fill the fuel tank. Fill and bleedthe fuel lines to the engine.

Clean the fuel tank breather.

Clean and repair engine fuelpiping.

Replace the fuel filter. Refer toChange Fuel Filter in Section 6.

Bleed the fuel lines. Refer to Airin Fuel in Section 6.

Check the fuel lift pump forcorrect operation. Check thepump output pressure. Replacethe fuel lift pump if necessary.Contact an Authorized CumminsRepair Facility.

Replace the fuel injection pump.Contact an Authorized CumminsRepair Facility.

7-19



7.18 Engine stops duringOperation (Cont'd)

7.19 Engine Will Not ReachRated Speed (RPM)


Programmable parameters orselected features are not correct.

Tachometer is not calibrated.Compare the tachometer readingwith a hand held tachometer oran electronic service tool reading.

Engine power output is low.

Fuel filter requires replacement.

Fuel grade not correct for theapplication, or fuel quality is poor.

Fuel suction line is restricted.

Air-fuel tube leaking, waste gatediaphragm ruptured, or wastegate plumbing damaged.

Charge air cooler restricted.

Fuel supply is not adequate.

Stop circuit malfunction in the firepump controller of field wiring.

Refer to the Vendor suppliedliterature or contact an Autho-rized Cummins Repair Facility.

Check the programmable param-eters and the selected featureswith an electronic service tool.Set the parameters and featuresagain if necessary. Refer to aCummins Authorized RepairFacility.

If out of calibration, calibrate thetachometer as necessary at theCAL adjustment on the back ofthe gauge. Refer to the Vendorsupplied literature for additionalinformation. Tachometer ismalfunctioning. Replace thetachometer. Contact an Autho-rized Cummins Repair Facility.

Refer to the Engine Accelerationor Response Poor in this section.

Refer to Change Fuel Filter perthe instructions in Section 6.

Operate the engine with a goodquality no. 2 diesel fuel.

Check the fuel suction line forrestriction.

Tighten the fittings, repair plumb-ing, replace waste gate dia-phragm.

Inspect the air cooler for internaland external restrictions. Replacethe restricted cooler if necessary.

Locate and correct the restrictionin the fuel lines to the engine.

In the AUTO mode, the fire pumpengine stops upon loss of signalpower from the fire pump control-ler. Check stop circuit in FirePump Controller.

7-20



7.20 Engine Will Not Shut OffRemotely

7.21 Engine Will Not Shut OffLocally

7.22 Fuel Consumption IsExcessive

Stop circuit malfunction in the firepump controller of field wiring.


Engine running on fumes drawninto the air intake.

Inadvertent power source ispresent from the fire pumpcontroller.


Engine running on fumes drawninto the air intake.

Fuel is leaking.

Poor-quality fuel is being used.

Defective or clogged injectionnozzle.

Incorrect injection timing.

Correct any faults. Check forshort to voltage on the signalwiring from the fire pump control-ler to the engine control panel.Correct any faults. Check opera-tion of the switch contacts of theAUTO/MANUAL switch at theengine control panel. Replace theswitch if the switch contacts failto operate properly.

Refer to the Vendor suppliedliterature or contact a CumminsAuthorized Repair Facility.

Identify and isolate the source ofthe combustible fumes. Contactan Authorized Cummins RepairFacility.

In the MANUAL Mode, the firepump engine stops when theAUTO/MANUAL Switch isreturned to the AUTO Mode.

Check for inadvertent voltage onthe wiring to terminal board at theengine control panel.

Refer to the Vendor suppliedliterature or contact a CumminsAuthorized Repair Facility.

Identify and isolate the source ofthe combustible fumes.

Check the fuel lines, fuel connec-tions, and fuel filters for leaks.Check the fuel lines to the supplytanks. Repair any leaks.

Assure good-quality no. 2 dieselfuel is being used.

Replace the defective or cloggedinjection nozzle.

Adjust injection timing.

7-21



7.22 Fuel Consumption IsExcessive (Cont'd)

7.23 Fuel or Lubricating OilLeaking From ExhaustManifold

7.24 Lubricating Oil is Con-taminated

Injection pump is adjustedincorrectly causing excessiveinjection.

Air intake or exhaust leaks.

Air intake system restriction isabove specification.

Intake air restriction is high.

Turbocharger drain line is re-stricted.

Turbocharger oil seal is leaking.

Bulk oil supply is contaminated.

Fuel is present in the lubricatingoil.

Coolant is present in the lubricat-ing oil.

Metal is present in the lubricatingoil.

Adjust or replace the injectionpump.

Check for loose or damagedpiping connections and missingpipe plugs. Check the turbo-charger and exhaust manifoldmounting. Repair any leaks.

Check the air intake system forrestriction. Refer to Check AirCleaner Service Indicator inSection 6. Replace the air filteras necessary.

Check the air intake system forrestriction. Refer to Check AirCleaner Service Indicator inSection 6. Replace the air filter ifrequired.

Remove the turbocharger drainline and check for restriction. Ifrequired, clean or replace thedrain line.

Check the turbocharger for oilseals and for leaks. Refer to theTurbocharger Leaks Engine Oilor Fuel symptom tree in thissection.

Check the oil supply. Replace itis necessary. Drain the oil andreplace with non-contaminatedoil. Also, replace the oil filter.Refer to Change Lubricating Oiland Filters in Section 6.

Refer to the Fuel in LubricatingOil in this section.

Refer to the Coolant in Lubricat-ing Oil symptom tree in thissection.


7-22



7.25 Lubricating Oil Consump-tion Excessive

Verify the oil consumption rate.

External engine leak is present.

Crankcase ventilation system isplugged.

Turbocharger oil seal is leaking.

Lubricating oil cooler is leaking.

Lubricating oil does not meetspecifications for operatingconditions.

Lubricating oil drain interval isexcessive.

Piston, cylinder liner, or pistonrings are worn or damaged.

Piston rings are not seatedcorrectly (after an engine rebuildor piston installation).

Check the amount of oil addedversus the operating hours.

Inspect the engine and itscomponents for seal, gasket,tappet cover, oil cooler, or draincocks leaks. Repair or correctany leaks.

Check and clean the crank casebreather and vent tube per theinstructions in Section 6.

Check the turbocharger compres-sor and turbine seals. Contact anAuthorized Cummins RepairFacility.

Check for lubricating oil in thecoolant. Refer to the LubricatingOil in the Coolant in this section.Contact an Authorized CumminsRepair Facility.

Change the oil and filters per theinstructions in Section 6.

Verify the correct lubricating oildrain interval. Refer to ChangeLubricating Oil and Filters inSection 6.

Check for air intake system leaks.Contact an Authorized CumminsRepair Facility.

Check blowby. If blowby isexcessive, check the piston ringsfor correct seating. Contact anAuthorized Cummins RepairFacility.

7-23



7.26 Lubricating Oil in theCoolant

7.27 Engine Overspeed Trip

NOTE: An engine overspeed tripoccurs when the engine’s speedexceeds the value specified onthe Factory Setting Tag de-scribed in Section 2. The tripisolates the fuel supply to theengine and it stops immediately.The trip is indicated on the localcontrol panel and inside the localcontrol panel on the speedswitch. Additionally, a trip outputis supplied to the fire protectionsystem for remote display.

Bulk coolant supply is contami-nated.

Lubricating oil cooler is malfunc-tioning.

Cylinder head gasket damagedor leaking.

Cylinder head is cracked orporous.

Cylinder block is cracked orporous.

Engine operated at too great aspeed due to catastrophic loadfailure such as pipe break, pumpmechanical failure, or loss ofsuction.

Engine actually operated at toogreat a speed due to configura-tion error.

Overspeed switch is set at toolow a set point.

Check the coolant expansiontank per the instructions inSection 6. Drain the coolant andreplace with non-contaminatedcoolant. Refer to Drain and FlushCooling System in Section 6.Replace the coolant filter. Referto Change Coolant Filter inSection 6.

Check the oil cooler. Contact anAuthorized Cummins RepairFacility.


Remove intake manifold. Re-move exhaust manifold. Checkfor evidence of coolant leak. Ifnecessary, operate engine atidle. Pressure-test the cylinderhead. Contact an AuthorizedCummins Repair Facility.

Remove the oil pan. Pressure-test the cooling system to checkfor leaks. Contact an AuthorizedCummins Repair Facility.

Correct the cause of the loadfailure. Contact a CumminsAuthorized Repair Facility.

Check rated speed setting asspecified on the Factory SettingTag. Refer to Rated Speed SetPoint Adjustment and Testing inSection 6.

Check overspeed speed settingas specified on the FactorySetting Tag. Refer to OverspeedSet Point Adjustment and Testingin Section 6.

7-24



Speed switch wiring failure hasoccurred.

Speed switch failure has oc-curred.

An electrical fault exists in thetachometer power and groundingcircuits.

An electrical fault exists in thespeed sensor input circuit.

The speed sensor has failed.

The tachometer has failed.

Check continuity and insulationfrom ground for the signal powerwiring and ground wiring to thespeed switch. Replace defectivecomponents and repair electricalfaults.

If the speed switch fails tooperate as per Overspeed SetPoint Adjustment and Testing inSection 6, replace the speedswitch. Contact an AuthorizedCummins Repair Facility.

Check continuity and insulationfrom ground for the power wiringand ground wiring to the tachom-eter. Contact an AuthorizedCummins Repair Facility. Re-place defective components andrepair electrical faults.

This fault may also cause afailure in the crank terminatesignal to the fire protectionsystem. Check continuity andinsulation from ground for thespeed sensor circuit. Contact anAuthorized Cummins RepairFacility. Replace defectivecomponents and repair electricalfaults.

With the engine running, checkthe signal from the speed sensorwith an oscilloscope or pulsecounter. Replace the speedsensor is it has failed. Contact anAuthorized Cummins RepairFacility.

Check the operation of thetachometer with a pulse genera-tor. Replace the tachometer is ithas failed. Contact an AuthorizedCummins Repair Facility.

7.27 Engine Overspeed Trip(Cont'd)

7.28 Tachometer Does NotIndicate Engine Speed

CFP15E(07)

Documents

Transcript of CFP15E(07)