Fire Pump Drive Engines - Cummins Power Generation

Fire Pump Drive Engines - Cummins Power Generation
Operation and Maintenance Manual
Fire Pump Drive Engines
CFP8E Series
LISTED
Drawing No. 9771, Section 0, Rev. A
Page ii
Foreword
This manual contains information for the correct operation and maintenance of a Cummins Fire Pump engines.
It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and
listings of Cummins Authorized Repair Locations.
Read and follow all safety instructions. Refer to the General Safety Instructions in Section 1.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on
information in effect at the time of printing. Cummins Fire Power, Cummins NPower and Cummins Engine
Company, Inc. reserve the right to make changes at any time without obligation. If any differences are found
between an engine and the information in this manual, contact the local Cummins Authorized Repair Location.
The latest technology and the highest quality components were used to produce this engine. When replacement
parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be
identified by the following trademarks:
NOTE: Warranty information is located in Section 16. Make sure you are familiar with the warranty or warranties
applicable to your engine.
© 2005 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.
Drawing No. 9771, Section 0, Rev. A
Page iii
Index of Sections
Introduction ………………………………………………………………….……………….......................................... 1
Engine Identification …………………………………………………………………………… ................................... 2
Installation and Operation ………………………………………………………….………….. .................................. 3
Maintenance Guidelines ……………………………………………………….…………... ........................................ 4
Maintenance Procedures – Daily …………………………………………………………… ..................................... 5
Maintenance Procedures – Weekly ………………………………………………………......................................... 6
Maintenance Procedures – Every 6 Months or 250 Hours ……………………………. ...................................... 7
Maintenance Procedures – Every 1 Year or 500 Hours ….……………………………........................................ 8
Maintenance Procedures – Every 2 Years or 1,500 Hours …………………………….. ..................................... 9
Maintenance Procedures – Every 4 Years or 3,000 Hours ……………………………. .................................... 10
System Diagrams …………………………………………………………………………... ....................................... 11
Adjustment, Replace and Replacement……………………………............................... ..................................... 12
Service Literature …………………………………………………………………………… ...................................... 13
Service Assistance ………..………………………………………………………………... ...................................... 14
Maintenance Specifications ……………………………………............................................................................ 15
Warranty Information…………………………………………………………………………………….. .................... 16
Troubleshooting …………………………………………………………………………….. ...................................... 17
Assembly Drawings…………………………………………………………………………. ...................................... 18
Drawing No. 9771, Section 0, Rev. A
Page iv
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Drawing No. 9771, Section 0, Rev. A
Section 1 – Introduction
CFP8E Series
Page 1-1
Section 1 – Introduction
Section Contents
Page
To the Owner and Operator .............................................................................................................1-3
About the Manual..............................................................................................................................1-3
How to Use the Manual ....................................................................................................................1-3
Symbols .............................................................................................................................................1-4
Illustrations .......................................................................................................................................1-5
General Safety Instructions .............................................................................................................1-6
General Cleaning Instructions ........................................................................................................1-8
Acronyms and Abbreviations..........................................................................................................1-14
Drawing No. 9771, Section 1, Rev. 0
Page 1-2
Section 1 – Introduction
CFP8E Series
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Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-3
To the Owner and Operator
Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance
schedule recommendations outlined in Maintenance Guidelines in Section 4.
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil, coolant, and filters in the engine as specified in Maintenance Specifications in Section
15.
Cummins Fire Power, Cummins NPower and Cummins Engine Company, Inc use the latest technology and the
highest quality components to produce its engines. Cummins recommends using only genuine Cummins parts.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts
support. If a problem that can not be resolved by a Cummins Authorized Repair Location occurs, follow the
steps outlined in the Service Assistance in Section 14.
About the Manual
This manual contains information needed to operate and maintain an engine correctly as recommended by
Cummins Fire Power, Cummins NPower and Cummins Engine Company, Inc. Additional service literature
(troubleshooting and repair manual) can be ordered by filling out and mailing the Literature Order Form located
in Service Literature in Section 13.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the
U.S. customary in brackets.
Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to the
Symbols subsection in this section for a complete listing of symbols and their definitions.
Each section is preceded by a Section Contents to aid in locating information more quickly.
How to Use the Manual
This manual is organized according to intervals at which maintenance on the engine is to be performed. A table
that states the required intervals and the checks to be made is located in Section 4. Locate the interval at which
maintenance will be performed, then follow the steps given in the referenced section for all the procedures to be
performed. All the procedures done under previous maintenance intervals must be performed, also.
Keep a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or
hours, and which maintenance checks were performed is located in Section 4.
Refer to the Maintenance Specifications in Section 15 for specifications recommended by Cummins Engine
Company, Inc., for your engine. Specifications and torque values for each engine system are given in that
section.
Drawing No. 9771, Section 1, Rev. 0
Page 1-4
Section 1 – Introduction
CFP8E Series
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When
one of the symbols appears, it conveys the meaning define below:
WARNING. Serious personal injury or extensive property damage can result if the
warning instructions are not followed.
CAUTION. Minor personal injury can result or a part, an assembly, or the engine can
be damaged if the caution instructions are not followed.
INSPECTION is required
Refer to another location in this manual or another publication for additional
information.
Indicates a REMOVAL or DISASSEMBLY step.
LUBRICATE the part or assembly.
CLEAN the part or assembly.
TIGHTEN to a specific torque.
Indicates an INSTALLATION or an ASSEMBLY step
PERFORM a mechanical or time MEASUREMENT.
PERFORM an electrical MEASUREMENT.
Indicates that a WRENCH or a TOOL SIZE will be given
Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-5
Illustrations
The illustrations used in this manual are
intended to give an example of a problem, and
to show what to look for and where the problem
can be found.
Some of the illustrations are “generic” and might
not look exactly like the engine or parts used in
your application.
The illustrations can contain symbols to indicate
an action required, and an acceptable or not
acceptable condition.
The illustrations are also intended to show
repair or replacement procedures.
The illustration can differ from your application,
but the procedure given will be the same.
Drawing No. 9771, Section 1, Rev. 0
Page 1-6
Section 1 – Introduction
CFP8E Series
General Safety Instructions
WARNING
Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily
injury or death.
•
Read and understand all of the safety precautions and warnings before performing any repair. This list
contains the general safety precautions that must be followed to provide personal safety. Special safety
precautions are included in the procedures when they apply.
•
Make sure the work area surrounding the product is dry, well lit, ventilated; free from clutter, loose tools,
parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
•
Always wear protective glasses and protective shoes when working.
•
Rotating parts can cause cuts, mutilation or strangulation.
•
Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
•
Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair
work. Put a "Do Not Operate" tag on the controls.
•
Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property
damage, or damage to the fan blade(s) causing premature fan failure.
•
If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
•
Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper
stands to support the product before performing any service work.
•
Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause
personal injury.
•
To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the
correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary.
The lifting hooks must not be side-loaded.
•
Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated
contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water.
In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes.
IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-7
General Safety Instructions (Cont.)
•
Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
•
To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines,
tubes, and compartments.
•
Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts.
•
Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lesser quality if replacements are necessary.
•
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your
functioning.
•
Some state and federal agencies in the United States of America have determined that used engine oil can
be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil. Dispose of waste oil in accordance with applicable requirements.
Drawing No. 9771, Section 1, Rev. 0
Page 1-8
Section 1 – Introduction
CFP8E Series
General Cleaning Instructions
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive
material in oil passages can cause bearing and bushing failures that can progress to major component
damage beyond reuse. This is particularly true of main and rod bearings.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner
beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner
material which can cause early cylinder wear-out or piston ring failures.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal
injury.
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston,
piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal
and result in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger
shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic
beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or
steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate
the tank and any other engine parts cleaned in the tank. Contaminated parts may cause failures from
abrasive wear.
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the
engine can be damaged due to increased parts clearance or inadequate surface finish on parts that
move against other parts.
Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-9
Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they
have to appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to
forming a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface.
Gaskets are designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded
gaskets are those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal
portion forms a metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the
parts are better removed with a blunt-edged scraper on the spots rather than spending time polishing the whole
surface with an air sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to
prevent sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has
been in place a long time, has been overheated or the purpose of the release agent has been defeated by the
application of some sealant. The object however is just to remove the gasket without damaging the surfaces of
the mating parts without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the
carbon build-up above the top ring and in the ring grooves. There is more information on bead blasting and
piston cleaning later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean
metal is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out)
will be destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly.
A medium bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be
just as quick and there will be less damage. Yes, one must look carefully for broken wires after the piston is
removed but the wires are more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If
possible, leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off
along with any attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before
installation. Make sure parts are lubricated with clean oil before installation. They do not need to be oiled all over
but do need oil between moving parts (or a good lube system priming process conducted before cranking the
engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted
again so all that needs happen is remove any loose paint.
Drawing No. 9771, Section 1, Rev. 0
Page 1-10
Section 1 – Introduction
CFP8E Series
Using Abrasive Pads and Abrasive Paper
The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are
all supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive
material in oil passages can cause bearing and bushing failures that can progress to major component
damage beyond reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine
or component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks
or counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially
assembled engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum
oxide particles, silicon carbide, or sand or some other similar hard material. These particles are harder than
most of the parts in the engine. Since they are harder, if they are pressed against softer material they will either
damage the material or become embedded in it. These materials fall off the holding media as the product is
used. If the products are used with power equipment the particles are thrown about the engine. If the particles
fall between two moving parts, damage to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but
larger than the running clearance then damage will occur when the parts move relative to each other (engine
started). While the engine is running and there is oil pressure, particles that are smaller than the bearing
clearance are likely to pass between the parts without damage and be trapped in the oil filter. However, particles
larger than the bearing clearance will remove material from one part and can become embedded in one of the
parts. Once embedded in one part it will abrade the other part until contact is no longer being made between the
two parts. If the damage sufficiently degrades the oil film, the two parts will come into contact resulting in early
wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the
engine as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those
located downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles
and debris with compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean
and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage
the gasket surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member
bonded to the steel). What little sealing material that can adhere is best removed with a blunt-edged scraper or
putty knife. Cleaning gasket surfaces where an edge-molded gasket is used with abrasive pads or paper is
usually a waste of time.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner
beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner
material which can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really
necessary because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and
clean as much of the surface as possible with the tool but clean around the oil hole/opening by hand so as to
prevent contamination of the drilling. Then remove the tape or plug and clean the remaining area carefully and
without the tool. DO NOT use compressed air to blow the debris out of oil drilling on an assembled engine! More
likely than not, the debris can be blown further into the drilling. Using compressed air is fine if both ends of the
drilling are open but that is rarely the case when dealing with an assembled engine.
Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-11
Cleaning Gasket Surfaces
The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the
part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is
used, check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part
of the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air
powered gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons.
See Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to
90 to 95 °C (180 to 200 °F). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best
results. Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's
instructions. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush
or scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When
possible, steam clean the parts before putting them in the cleaning tank.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal
injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These
cleaners should not be heated to temperature in excess of 77 °C (170 °F). The solution begins to break down at
temperatures in excess of 82 °C (180 °F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic
components. They often do not do a good job of removing deposits from the ring groove and are costly to
dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high
alkaline solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further
away from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use
hot high pressure water or steam clean the parts before putting them in the cleaning tank. Removing the
heaviest dirt before placing in the tank will allow the cleaner to work more effectively and the cleaning agent will
last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all
the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The
rust proofing compound must be removed from the parts before assembly or installation on the engine.
Drawing No. 9771, Section 1, Rev. 0
Page 1-12
Section 1 – Introduction
CFP8E Series
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good
method for cleaning the oil drillings and coolant passages.
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.
Do not steam clean the following components:
•
Electrical Components
•
Wiring Harnesses
•
Injectors
•
Fuel Pump
•
Belts and Hoses
•
Bearings (ball or taper roller)
•
Electronic Control Module (ECM)
•
ECM Connectors
Plastic Bead Cleaning
Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part.
Cummins Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine
part. Never use sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the
media manufacturer's recommendations can cause excess dust and can embed in engine parts that can result
in premature failure of components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the use of plastic beads, the operating pressure and cleaning time.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston,
piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal
and result in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger
shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic
beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or
steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate
the tank and any other engine parts cleaned in the tank. Contaminated parts may cause failures from
abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure
any bead blasting media on piston pin bores or aluminum skirts.
Drawing No. 9771, Section 1, Rev. 0
Section 1 – Introduction
CFP8E Series
Page 1-13
Plastic Bead Cleaning (Cont)
Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part
and cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
Bead size: U.S. size Number 16 — 20 for piston cleaning with plastic bead media, Part Number 3822735
Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the
engine can be damaged due to increased parts clearance or inadequate surface finish on parts that
move against other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure
is too high or the blast is being held on one spot too long. The blast operation must not disturb the metal
surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell
blasting produces a great amount of dust particularly when the pressure if the air pressure on the blasting
machine is increased above media manufacturer's recommendation. Cummins Inc. recommends not using
walnut shell media to clean engine parts due to the risk media embedment and subsequent contamination of the
engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too
easily embedded into the material particularly in soft materials and when air pressures greater than media
manufacturer's recommend are used. The glass is an abrasive so when it is in a moving part, that part is
abrading all the parts in contact with it. When higher pressures are used the media is broken and forms a dust of
a very small size that floats easily in the air. This dust is very hard to control in the shop, particularly if only
compressed air (and not hot water) is used to blow the media after it is removed from the blasting cabinet
(blowing the part off inside the cabinet may remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher
pressure washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the
pistons first then use the plastic bead method to safely remove the carbon remaining in the grooves (instead of
running the risk of damaging the surface finish of the groove with a wire wheel or end of a broken piston ring.
Make sure the parts are dry and oil free before bead blasting to prevent clogging the return on the blasting
machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under
the unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at
one-place too long causes the metal to heat up and be moved around. Remember that the spray is not just
hitting the dirt or carbon. If the machining marks on the piston groove or rim have been disturbed then there has
not been enough movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle
across the seat surface and radius rather than straight at them. The object is to remove any carbon build up and
continuing to blast to remove the stain is a waste of time.
Drawing No. 9771, Section 1, Rev. 0
Page 1-14
Section 1 – Introduction
CFP8E Series
Acronyms and Abbreviations
AFC
Amp
API
ASA
ASTM
AWG
C
C.I.D.
CAC
CARB
cc
cm
CPL
cSt
D.
DCA
E.C.S.
ECM
EPA
EPS
F
FSO
FSOS
ft-lb
GAL
H2O
Hg
HP
Air Fuel Control
Ampere
American Petroleum Institute
Air Signal Attenuator
American Society of Testing and Materials
American Wire Gauge
Celsius
Cubic Inch Displacement
Charge Air Cooler
California Air Resources Board
Cubic Centimeter
Centimeter
Control Parts List
Centistokes
Diameter
Diesel Coolant Additive
Emission Control System
Electronic Control Module
Environmental Protection Agency
Engine Position Sensor
Fahrenheit
Fuel Shut-Off
Fuel Shut-Off Switch
Foot-Pound
Gallon (US)
Water
Mercury
Horsepower
in.
in-lb
kg
kPa
l
lb.
lbf.
m
ml
mm
MPa
MPH
MPQ
N
N•m
OEM
oz.
ppm
psi
PTO
qt
RPM
S.A.E.
STC
TDC
US
V
VS
Inch
Inch Pound
Kilograms
Kilopascal
Liter
pound
Pound force
Meter
Milliliter
Millimeter
Megapascal
Miles Per Hour
Miles Per Quart
Newton
Newton-meter
Original Equipment Manufacturer
Ounce
Parts Per Million
Pounds Per Square Inch
Power Takeoff
Quart
Revolutions Per Minute
Society of Automotive Engineers
Step Timing Control
Top Dead Center
United States of America
Volt
Variable Speed
Drawing No. 9771, Section 1, Rev. 0
Section 2 – Engine Identification
CFP8E Series
Page 2-1
Section 2 - Engine Identification
Section Contents
Page
Fire Pump Engines .............................................................................................................................................2-3
Overspeed Switches ..........................................................................................................................................2-3
Operating Speed .................................................................................................................................................2-3
Control System ...................................................................................................................................................2-3
External Engine Components and Views.........................................................................................................2-4
Instrument Panel.................................................................................................................................................2-9
Fire Pump Identification...................................................................................................................................2-10
Fuel Injection Pump Dataplate ........................................................................................................................2-11
ECM Dataplate...................................................................................................................................................2-12
Drawing No. 9771, Section 2, Rev. A
Page 2-2
Section 2 – Engine Identification
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 2, Rev. A
Section 2 - Engine Identification
CFP8E Series
Page 2-3
Fire Pump Engines
Cummins’ complete line of fire pump engines have been approved as packaged units (engine and all
accessories) by Factory Mutual Research and listed by Underwriter’s Laboratories, Inc. and Underwriter’s
Laboratories of Canada. Because of the lengthy and expensive process to design and produce a fire pump
engine that meets these requirements, no deviations are permitted without approval. These engines are to be
used only for fire protection applications.
Overspeed Switches
Each engine is equipped with an overspeed switch which will activate the fuel pump solenoid valve and shut off
the engine when the RPM exceeds a present limit. The overspeed switch senses engine speed during the start
cycle and stops the starting motor cranking cycle. The overspeed switch must be adjusted to the required speed
limit during the in-service inspection.
Operating Speed
All Cummins fire pump engines are shipped from the factory with the operating speed adjusted to the lowest
approved operating speed. Final operating speed adjustment must be made at the time of the in-service
inspection to obtain the required fire pump operating speed specified by the pump manufacturer.
Control System
The function of a fire pump controller is to start the engine. These controllers are more sophisticated than
standard industrial controllers because they include special items for fire pumps. Several options are available:
The automatic start controller can be used for either automatic or manual stop after the fire demand signal is
removed.
Pressure recorders are available to provide a permanent record of water pressure fluctuations and engine
starts.
Sequential starting is available for multiple-pump installations to keep all pumps from starting simultaneously.
NOTE: Fire pump controllers are not supplied by Cummins Fire Power, or Cummins Engine Company, Inc.
Drawing No. 9771, Section 2, Rev. A
Page 2-4
Section 2 – Engine Identification
CFP8E Series
External Engine Components and Views
The following illustrations show the locations of the major external engine components, and other service and
maintenance points. Some external components will be at different locations for different engine models.
Instrument Panel Side
1.
2.
3.
4.
5.
6.
7.
8.
Instrument Panel
Terminal Box
Turbo-boost limiter
Turbocharger
Charge Air Cooler
Fuel Filter
Heat Exchanger
Water Piping for Charge Air Cooler
9.
10.
11.
12.
13.
14.
15.
16.
Fuel Pump
Raw Water Outlet
Raw Water Inlet
Flywheel Housing
Engine Support
Electronic Control Module (ECM)
ECM Switch Holder Box.
Air Cleaner Element
Drawing No. 9771, Section 2, Rev. A
Section 2 - Engine Identification
CFP8E Series
Page 2-5
Turbocharger Side
1.
2.
3.
4.
5.
6.
Top Tank Fill
Exhaust
Turbocharger and Exhaust Shield
Air Cleaner Element
Manual Start Lever
Start Motor
Drawing No. 9771, Section 2, Rev. A
7.
8.
9.
10.
11.
Coolant Heater
Lubricating Oil Filter
Lower Water Hose/Tube
Alternator
Upper Water Hose/Tube
Page 2-6
Section 2 – Engine Identification
CFP8E Series
Front View
Drawing No. 9771, Section 2, Rev. A
Section 2 - Engine Identification
CFP8E Series
Top View
Drawing No. 9771, Section 2, Rev. A
Page 2-7
Page 2-8
Section 2 – Engine Identification
CFP8E Series
Isometric Views
Drawing No. 9771, Section 2, Rev. A
Section 2 - Engine Identification
CFP8E Series
Page 2-9
Instrument Panel
1.
2.
3.
4.
5.
6.
7.
Battery “A” Voltmeter
Battery “B” Voltmeter
Tachometer (with hour-meter)
Water Temperature Gauge
Lubricating Oil Pressure Gauge
Circuit Breaker.
ON/OFF Switch (AUTO/MANUAL)
Drawing No. 9771, Section 2, Rev. A
8.
9.
10.
11.
12.
13.
14.
Overspeed Warning Light
Not used
Overspeed Reset Switch
High Water Temperature Warning Light
Low Oil Pressure Warning Light
Battery A/B Switch
ECM indicators
Page 2-10
Section 2 – Engine Identification
CFP8E Series
Fire Pump Identification
The fire pump dataplate shows specific information about your engine. The engine serial number provides
information for ordering parts and service needs.
NOTE: The fire pump dataplate must not be changed unless approved by Cummins Fire Power.
MFD. DATE:
SERIAL #:
MODEL:
YEAR:
RATED SPEED:
HP OUTPUT:
TYP.
LISTED
INTERNAL COMBUSTION ENGINE
FOR DRIVING CENTRIFUGAL FIRE
PUMP
19ZG
CERTIFIED FOR USE OF SAE DF2
FUEL ONLY PER SAE J313 MAR92
Drawing No. 9771, Section 2, Rev. A
Section 2 - Engine Identification
CFP8E Series
Page 2-11
Fuel Injection Pump
LATER
Drawing No. 9771, Section 2, Rev. A
Page 2-12
Section 2 – Engine Identification
CFP8E Series
ECM Dataplate
The electronic control module (ECM) dataplate shows information about the ECM and how the ECM was
programmed. The dataplate is located on the ECM, above the ECM connectors.
The following information is available on the ECM dataplate:
•
ECM part number (PN)
•
ECM serial number (SN)
•
ECM date code (DC)
•
Engine serial number (ESN)
•
ECM code: Identifies the software in the ECM.
NOTE: Have the ECM code for your engine available when communicating with a Cummins Authorized Repair
Location.
Drawing No. 9771, Section 2, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-1
Section 3 – Installation and Operation
Section Contents
Page
Installation Overview ......................................................................................................... 3-3
Physical Engine Installation ..............................................................................................................................3-3
Fuel Supply Installation .....................................................................................................................................3-4
Fire Pump Installation ........................................................................................................................................3-5
Raw Water Supply Installation ..........................................................................................................................3-5
Battery and Electrical Installation.....................................................................................................................3-8
Signal and Control Installation..........................................................................................................................3-9
Coolant System Preparation ...........................................................................................................................3-10
Lubricating Oil System Preparation ...............................................................................................................3-12
Fuel System Preparation..................................................................................................................................3-13
Pre-Start Inspections........................................................................................................................................3-16
Initial Start .........................................................................................................................................................3-19
Second Start......................................................................................................................................................3-21
Rated Speed Setpoint Adjustment..................................................................................................................3-22
Overspeed Setpoint Adjustment and Testing................................................................................................3-24
Crank Terminate Adjustment and Testing .....................................................................................................3-24
Isolated Acceptance Testing ...........................................................................................................................3-28
Integrated Acceptance Testing .......................................................................................................................3-28
General Operating Information ........................................................................................3-29
Normal Remote Starting Procedure................................................................................................................3-29
Normal Local Starting Procedure ...................................................................................................................3-30
Jumpering the Batteries...................................................................................................................................3-33
Operating the Engine .......................................................................................................................................3-34
Drawing No. 9771, Section 3, Rev. A
Page 3-2
Section 3 – Installation and Operation
CFP8E Series
Emergency Manual Starting Procedures....................................................................................................... 3-35
Starting Procedure - After Extended Shutdown or Oil Change .................................................................. 3-41
Electronic Controlled Fuel System ................................................................................................................ 3-26
Electromagnetic Interference (EMI) ............................................................................................................... 3-26
Emergency Starting With Failed ECM............................................................................................................ 3-34
Emergency Manual Stopping Procedure..........................................................................................................3-x
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 3, Rev. A
Page 3-3
Page 3-4
Section 3 – Installation and Operation
CFP8E Series
Installation Overview
The first part of this section provides instructions for the initial installation, adjustment, and testing of the
Cummins NPower FirePump engine. Appropriate portions of this section should also be used when returning the
engine to operation after overhaul or major maintenance. The second parts details normal operations.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-5
Physical Engine Installation
Location
Refer to Drawing CFP8E_GEN in Section 18 for the general fire pump and engine layout.
Refer to Drawing 8711 in Section 18 for the general fire pump engine power module assembly.
WARNING
Do not operate a diesel engine where there are or can be combustible vapors. These vapors can be
sucked through the air intake system and cause engine acceleration and overspeeding, which can
result in a fire, an explosion, and extensive property damage. Numerous safety devices are available,
such as air intake shutoff devices, to minimize the risk of overspeeding in which an engine, because of
application, might operate in a combustible environment (from a fuel spill or gas leak, for example).
Cummins Engine Company, Inc., does not know how you will use your engine. The equipment owner
and operator, therefore, is responsible for safe operation in a hostile environment. Consult your
Cummins Authorized Repair Location for further information.
Install the fire pump engine in a sheltered environment protected from extremes of weather. Any enclosure must
protect the water supply from freezing. Ensure that the engine and electrical components are not exposed to
significant water dripping or sprays. Avoid installation in a dusty or dirty environment. Provide adequate physical
protection from other physical damage as may be present in the specific location. (Refer to National Fire
Protection Association NFPA20-2003 Chapter 11 for additional installation requirements for installations in the
USA.)
Design the installation to meet the engine’s mounting requirements. Refer to General Engine Data in Section 15.
Install the engine on a stable level foundation that is designed for the load and vibration of pump operation.
Install the engine with ample room for servicing of the engine, the pump, fuel supply, and support systems.
Ensure that the engine location is free of any risk of exposure to combustible vapors.
Drawing No. 9771, Section 3, Rev. A
Page 3-6
Section 3 – Installation and Operation
CFP8E Series
Physical Installation
Use the supplied lifting hooks on the engine to
position the engine.
Provide engine support as required to support
the wet weight specified in General Engine
Data in Section 15.
Position the engine as required for the interface
with the pump, piping, and electrical
connections.
Level the installation with shims as required.
Secure the engine to the support or floor.
Connect the exhaust piping.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-7
Fuel Supply Installation
NOTE: Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for additional installation
requirements for installations in the USA. Ensure that the fuel system is installed in a safe and an effective
manner.
Install an elevated Diesel # 2 fuel tank or other fuel supply arrangement that meets the specifications listed in
Fuel System Specifications in Section 15.
Size the fuel tank for the maximum expected full-load engine operation period with the initial fuel level at the
minimum level for refueling.
Install a 3/8“ NPT (minimum) fuel return line.
Route this line to the bottom of the fuel tank in
order to minimize the return head.
Install a 1/2” NPT (minimum) fuel supply line to
the fire pump engine.
Provide a pre-filter on the fuel line to the fire
engine.
Drawing No. 9771, Section 3, Rev. A
Page 3-8
Section 3 – Installation and Operation
CFP8E Series
Fire Pump Installation
Install the customer supplied fire pump as per the pump manufacturer’s instructions and applicable code
requirements. Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for requirements for
installations in the USA. Ensure that the engine and pump are correctly aligned.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-9
Raw Water Supply Installation
Overview
Raw water is used to cool the engine cooling fluid. Raw water is supplied from the fire pump prior to the pump
discharge flange. It is forced through a cooling loop by fire pump pressure to the heat exchanger. In the heat
exchanger, it flows through the tubes in the bundle and is discharged to an open waste cone. The raw water
supply must be immediately available when the engine is started.
Refer to the Cooling System Flow Diagrams in Section 11 for a simplified block diagram of the cooling weater
system. Refer to Cooling System Specifications in Section 15 for pipe size requirements.
Refer to Drawing 8683 in Section 18 for the optional raw water piping manifold that is available from Cummins
Fire Power.
If the piping supplied by the customer, provide raw water supply piping and components equivalent to that can
be supplied by Cummins FirePower and as shown in Assembly Diagram, Raw Water Piping in Section 11. Refer
to National Fire Protection Association NFPA20-2003 Chapter 11 for installation requirements for installations in
the USA. When choosing the components for the raw water supply and by-pass, care must be taken to ensure
that the internal cross sectional area of the component is at least as large as the recommended pipe size.
When the raw water piping is installed, adjust both pressure regulator setpoints before operating the pump.
Damage to the heat exchanger may occur from improperly regulated raw water supply pressure.
Raw Water Supply & Drain without Cummins Raw Water Manifold
NOTE: Raw water outlet piping from the heat
exchanger should be one pipe size larger than
the supply piping.
NOTE: The velocity of raw water should be as
great as possible without exceeding the
maximum shown on the appropriate engine data
sheet.
NOTE: Failure to comply will result in engine
overheat and failure.
Provide raw water supply to the charge air
cooler water inlet.
Provide an open waste cone raw water drain at
the outlet from of the heat exchanger.
Drawing No. 9771, Section 3, Rev. A
Page 3-10
Section 3 – Installation and Operation
CFP8E Series
Raw Water Supply and Drain with Cummins Raw Water Manifold
NOTE: Raw water outlet piping from the heat
exchanger should be one pipe size larger than
the supply piping.
NOTE: The velocity of raw water should be as
great as possible without exceeding the
maximum shown on the appropriate engine data
sheet.
NOTE: Failure to comply will result in engine
overheat and failure.
Provide raw water supply to the raw water
manifold inlet.
Provide an open waste cone raw water drain at
the outlet from the heat exchanger.
Check Raw Water Pressure Regulator Setpoints
NOTE: Adapt this procedure to the actual
installation if a Cummins raw water manifold is
not supplied.
Temporarily remove raw water inlet piping at
the charge air cooler.
Provide temporary drain piping at the raw water
manifold outlet.
If closed, open the pressure gauge isolation
valve.
NOTE: The normal line has the solenoid valve.
The bypass line does not.
If open, close the normal line inlet valve.
Open the bypass line inlet and outlet valves.
NOTE Temporary water supply pressure
should exceed 414 kPa [60 psig].
Provide temporary water supply piping to the
raw water manifold.
Adjust the bypass pressure regulator for 414
kPa [60 psig] or slightly less.
Close the bypass line inlet valve.
NOTE: Use the correct voltage for unit.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Provide a temporary 12 VDC power source for
the solenoid valve at Pin 13 and Pin 17. Refer
to Drawing 8512 Sheet 1 in Section 18.
Open the normal line inlet and outlet valves.
Adjust the normal pressure regulator for 414
kPa [60 psig] or slightly less.
Remove the power jumper and reconnect the
wiring.
Re-install the raw water piping from the
manifold to the charge air cooler.
Test the pressure regulator setpoints with
water flowing through the heat exchanger. Trim
the setpoints if required.
Remove the temporary water supply to the
manifold.
Re-install the raw water piping at the pump.
Drawing No. 9771, Section 3, Rev. A
Page 3-11
Page 3-12
Section 3 – Installation and Operation
CFP8E Series
Battery and Electrical Installation
Overview
Two redundant sets of batteries must be supplied for the selected operating voltage (12 VDC or 24 VDC).
Batteries must meet the requirement listed in Electrical System Specifications in Section 15.
Batteries may be supplied by Cummins FirePower as an option or may be supplied by the customer.
Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for battery and battery charger
requirements for installations in the USA.
Battery Installation
Install the redundant sets of batteries in a well ventilated or otherwise protected location. Provide adequate
room for servicing or replacing the batteries. Provide protection from extremes of temperature and weather.
Locate the batteries near the engine or increase the size of the conductors as required by applicable codes.
Ensure that the batteries are configured properly for either 12 VDC or 24 VDC operations as appropriate.
Battery Wiring Installation
NOTE: Install the wiring in accordance with applicable codes and specifications.
Install the Loose Wire Kit wires. Refer to Drawing 9767 in Section 18.
If purchased, install the optional battery cable kit (Cummins FirePower Part No. 9609). Otherwise, install
equivalent customer supplied wiring.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-13
Signal and Control Installation
NOTE: Install signal and control wiring at Terminal Board TB. Refer to Drawing 8512 Sheet 1 in Section 18.
Ensure that the fire control system is properly installed and configured as per the manufacturer’s instructions.
Complete the customer-supplied fire pump controller wiring as per the manufacturer’s instructions.
NOTE: Do not connect more than two wires at any point on the fire engine control panel terminal board. If
necessary, add a grounding terminal board at the fire control system.
Connect the control power from the fire pump controller at TB-1 (+) and TB-11 (-). This power source is
necessary for fire pump operations while in the AUTO mode.
Connect the two redundant crank signals from the fire pump controller to TB-9 (Crank Battery A) and to TB-10
(Crank Battery B). Connect the signal ground to TB-11.
Connect the Crank Terminate input to the fire pump controller from TB-2 with signal ground at TB-11. This 12 or
24 VDC signal is present when the engine is running. This signal indicates that the engine has started and that
the crank command from the fire pump controller should stop immediately.
Connect the remote overspeed alarm input to the fire pump controller from TB-3. This 12 or 24 VDC signal is
present when the overspeed switch has operated. If this event occurs, the fire engine will stop. The local RESET
button must be pressed in order to restart the engine.
Connect the Low Oil Pressure alarm input to the fire pump controller from TB-5. This 0 VDC grounded signal is
present when the oil pressure has dropped below the 110 kPa [16 PSIG] setpoint. The engine will continue to
operate but immediate attention is necessary in order to prevent excessive damage to the engine or
catastrophic engine failure.
Connect the High Water Temperature alarm input to the fire pump controller from TB-5. This 0 VDC grounded
signal is present when the engine is running and the coolant temperature has risen above the 93 oC [200 oF]
setpoint. The engine will continue to operate but immediate attention is necessary in order to prevent excessive
damage to the engine or catastrophic engine failure.
If used, provide permanently installed redundant battery charging systems with connections at TB 6 and TB-8
(+) and TB-11 (-). TB-6 (+) and TB-8 (+) and TB-11 (-) should also be used for remote battery voltage
indications at the fire control system or elsewhere.
Ensure electrical continuity and adequate insulation resistance for the installed wiring.
Provide the initial charge on the redundant batteries as per the battery charger’s instructions.
Check that both voltmeters on the local control panel indicate the approximate battery voltage.
Drawing No. 9771, Section 3, Rev. A
Page 3-14
Section 3 – Installation and Operation
CFP8E Series
Coolant System Preparation
Check Cooling System Integrity
NOTE: Refer to Drawing 8709 in Section 18 for
hose arrangement.
Check that all coolant hoses are properly
installed and that the clamps are tight.
Check that the coolant drain petcock is closed.
CAUTION
The valve must be in the ON position to
prevent engine damage.
Check that the coolant filter valve is open. If
required, turn the shutoff to the ON position by
rotating the knob from horizontal to vertical in
the direction shown.
Add Coolant
Remove the pressure cap from the heat
exchanger.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Coolant System Preparation (Cont)
Refer to Cooling System Specifications and
Coolant Recommendations and Specifications
in Section 15.
NOTE: Use a mixture of at least 50 percent
antifreeze and 50 percent water.
NOTE: Close coolant vents when coolant level
reaches the vent.
Add coolant until the coolant level is just below
the fill tube in the coolant heat exchanger.
Check for leaks. Correct any leaks.
Install the pressure cap on the heat exchanger.
Check Raw Water Supply Lineup
CAUTION
The raw water lines to and from the fire
pump must be open, and there must be
sufficient water to the heat exchanger when
the engine has started. Insufficient water
supply will cause overheating, resulting in
engine failure.
Check that the pressure gauge isolation valve
is open.
NOTE: The upper line is the bypass line. The
lower line with the solenoid valve is the normal
line.
Check that the bypass line outlet valve is
closed.
Check that the normal line inlet valve is open.
Check that the normal line outlet valve is open.
Drawing No. 9771, Section 3, Rev. A
Page 3-15
Page 3-16
Section 3 – Installation and Operation
CFP8E Series
Lubricating Oil System Preparation
Add Lubricating Oil
NOTE: For oil requirements, refer to Lubricating
Oil System Specifications and Lubricating Oil
Recommendations and Specifications in Section
15. No change in oil viscosity or type is needed
for new or newly rebuilt engines.
Fill the crankcase with lubricating oil to the “H”
(high) mark on the dipstick.
Prime the Turbocharger
CAUTION
New turbochargers must be pre-lubricated
before startup. Failure to pre-lube the
turbochargers will result in turbocharger
bearing failure.
Remove the air intake filter assembly. Refer to
Intake Air Filter Removal/Installation in Section
12.
Remove the turbocharger oil inlet line from the
turbocharger bearing housing.
NOTE: Rotate the turbine wheel to allow oil to
enter the bearing housing. Any excess oil will
drain through the oil drain line.
Lubricate the bearings by pouring 59 to 89 ml [2
to 3 oz] of clean engine lubricating oil into the
turbocharger oil supply line fitting.
Tighten the oil supply line.
Torque Value: 24 N•m [18 ft-lb]
Install the air intake filter assembly. Refer to
Intake Air Filter Removal/Installation in Section
12.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Fuel System Preparation
Fill the Fuel Filter
Unscrew the combination fuel filter assembly
and remove it from the engine.
If open, close the water separator drain cock.
Refer to Drain Fuel-Water Separator in
Section 5.
Lubricate the o-ring seal with clean
lubricating oil.
NOTE: Refer to Fuel Recommendations and
Specifications in Section 15 for fuel
requirements.
Fill the fuel element with fuel.
CAUTION
Mechanical over-tightening will distort the
threads, filter element seal or filter can.
Install the filter on the filter head.
Tighten the filter until the gasket contacts the
filter head surface.
Tighten the filter an additional one-half to
three-fourths of a turn, or as specified by the
filter manufacturer.
Drawing No. 9771, Section 3, Rev. A
Page 3-17
Page 3-18
Section 3 – Installation and Operation
CFP8E Series
Fuel System Preparation (Cont)
Fill the Fuel Tank
NOTE: Refer to Fuel Recommendations and
Specifications in Section 15 for fuel
requirements.
Ensure that the fuel tank and piping is clean.
Fill the fuel tank with fuel.
Fill the fuel lines to the engine and fill the fuel
pre-filter.
Tighten all fuel supply line fittings to stop
possible suction leaks.
Bleed the Fuel Lines
Open any fuel isolation valves and bleed any
air from the customer-supplied fuel supply
line to the fire engine.
Bleed the fuel pre-filter of any air.
Tighten the fuel supply line connections in
order to avoid air leakage when the lift pump
draws suction.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-19
Pre-Start Inspections
Perform a visual inspection as follows:
•
Check that there is no apparent damage and that all components are installed.
•
Check that the drive belt is properly installed.
•
Check that all hoses and tubes are properly installed.
•
Check that all electrical connections are properly installed.
•
Check that the fire pump is properly installed as per the pump manufacturer’s instructions, is correctly
aligned, and is free to rotate.
Drawing No. 9771, Section 3, Rev. A
Page 3-20
Section 3 – Installation and Operation
CFP8E Series
Initial Start
NOTE: Pre-lubrication of the engine is not required. The engine will not start until the minimum cranking oil
pressure is detected by the ECM. It can take more cranking time to start the engine after an extended shut down
or oil change.
NOTE: The object of this test is to check that the engine starts and operates normally with oil pressure being
displayed and raw water flow being established to the coolant heat exchanger. Operation at the factory-adjusted
rated speed is also checked.
NOTE: If the engine still will not start,
troubleshoot as per Engine Cranks But Will Not
Start (No Exhaust Smoke) or Engine Difficult to
Start or Will Not Start - Exhaust Smoke Present
in Section 17.
NOTE: When the engine starts, immediately
check that oil pressure is displayed. It should be
on-scale within a few seconds. Stop the engine if
oil pressure is not displayed within about 15
seconds.
NOTE: When the engine starts, immediately
check that raw water flow is established through
the coolant heat exchanger. Raw water flow
should be established immediately but some
delay may occur before the flow exits the heat
exchanger drain connection.
NOTE: Rated speed is displayed on the Field
Setting Tag described in Section 2.
NOTE: Electronically controlled engines should
operate within a few RPM of the rated speed
whether the engine is fully loaded or unloaded. If
it becomes necessary to adjust the engine’s
actual speed to match the rated value, refer to
Rated Speed Setpoint Adjustment in this section.
Start the engine using either the CRANK BATT A
or the CRANK BATT B switch positions.
Check that the engine starts and operates at
rated speed.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Initial Start (Cont)
NOTE: If oil pressure is not present or if the Low
Oil Pressure Light does not go out, stop the
engine and troubleshoot as per Lubricating Oil
Pressure Low in Section 17.
Check that lubricating oil pressure is displayed
within 15 seconds after the engine starts.
NOTE: Raw water should be flowing through the
heat exchanger and water pressure shown on the
local pressure gauge should be no more than
414 kPa (60 psig).
Check that raw water is flowing through the heat
exchanger.
Check that raw water supply pressure is correctly
adjusted.
Operate the engine for 8 to 10 minutes.
Check for leaks, unusual noises, or other
indications of incorrect operation.
Shut off the engine by pressing the AUTO
position on the AUTO/MANUAL rocker switch
and by momentarily pressing the RESET switch.
Check that raw water flow stops automatically
shortly after the engine stops.
Correct any problems found during the inspection
before proceeding.
Check the engine lubricating oil level. Refer to
Check Lubricating Oil Level in Section 5. Top off
if necessary.
Check the coolant heat exchanger’s coolant
level. Refer to Check Coolant Level in Section 5.
Top off if necessary.
Check the raw water strainer. Clean the strainer if
necessary.
Drawing No. 9771, Section 3, Rev. A
Page 3-21
Page 3-22
Section 3 – Installation and Operation
CFP8E Series
Second Start
NOTE: The object of this test is to check that the engine operates normally with coolant temperature being
maintained. Oil pressure is again checked at rated speed.
NOTE: If required, adjust engine operating speed
as per Rated Speed Setpoint Adjustment below.
Start the engine using either the CRANK BATT A
or the CRANK BATT B switch positions.
Check that the engine starts and operates at
about rated speed.
Check that the oil pressure is as specified in
Lubricating Oil System Specifications 276-414
kPa 40-60 psi in Section 15.
NOTE: If oil pressure is not within the rated
range, troubleshoot as per Lubricating Oil
Pressure High or Lubricating Oil Pressure Low in
Section 17.
NOTE: If temperature does not stabilize, stop the
engine and refer to Coolant Temperature Above
Normal or Coolant Temperature Below Normal
(Engine Running) in Troubleshooting Section 17.
Check that engine operating temperature
stabilizes between about 82 and 95 oC [180 and
203 oF].
Stop the engine by pressing the RESET button.
Correct any problems found before proceeding.
Check the engine lubricating oil level. Refer to
Check Lubricating Oil Level in Section 5. Top off
if necessary.
Check the coolant heat exchanger’s coolant
level. Refer to Check Coolant Level in Section 5.
Top off if necessary.
Check the raw water strainer. Clean the strainer if
necessary.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Rated Speed Setpoint Adjustment
NOTE: If required, use this section to adjust the normal operating speed to the nameplate value.
NOTE: Rated speed is displayed on the Field
Setting Tag described in Section 2.
Start the engine.
Observe that the engine starts and accelerates
the currently adjusted speed setpoint.
NOTE: operating speed? Need specific art.
Adjust the speed setpoint to rated speed.
Stop the engine.
Start the engine.
Observe that the engine starts and accelerates to
the rated speed setpoint.
Stop the engine.
Drawing No. 9771, Section 3, Rev. A
Page 3-23
Page 3-24
Section 3 – Installation and Operation
CFP8E Series
Overspeed Setpoint Adjustment and Testing
Overview
Overspeed setpoint adjustment and testing is a repetitive process. Use the Adjustment Procedure to change the
setpoint. Use the Test Procedure to check the setpoint. Repeat the adjustments and checks until the desired
setpoint is demonstrated. When the overspeed setpoint is successfully demonstrated, then check that the
engine operates normally while not being tested
NOTE: The overspeed trip setpoint is displayed
on the Field Setting Tag described in Section 2.
NOTE: The overspeed setpoint must be set at
between 115 and 120% of the engine’s rated
speed.
The speed switch located on the engine’s local
control panel has a TEST button which lowers
the currently adjusted overspeed by 10%. Thus,
an overspeed setpoint of 2112 rpm would be
reduced to (2112 * 0.9 =) 1901 RPM when the
test button is pressed.
Adjust the Speed Switch:
Lower the cover on the engine’s local control
panel.
Disconnect the engine speed sensor signal from
PICK-UP terminals 1 and 2.
Connect a signal generator capable of providing
between 0.25 to 120 VAC RMS signal to the
switch. The signal must be proportional to the
engine’s rated speed.
Provide an overspeed signal at the specified
overspeed switch setting frequency.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Overspeed Setpoint Adjustment and Testing (Cont)
Remove the calibrating screw cover from the
electronic overspeed switch.
NOTE: Turn the small screw on the
potentiometer near the word “OVERSPEED”
clockwise to increase trip speed. Turn it counterclockwise to reduce trip speed.
If the OVERSPEED light is illuminated with the
signal present, perform the following steps:
Reduce the signal frequency.
Press the RESET button.
Turn the potentiometer clockwise to raise the
setpoint.
Increase the signal frequency to setpoint.
With the OVERSPEED light off, slowly turn the
potentiometer counter-clockwise until the light is
just illuminated.
NOTE: Repeat the adjustments as required to
make the finest adjustment practical.
When the setpoint is adjusted, perform the
following steps:
Replace the screw cover at the potentiometer.
Disconnect the signal generator.
Reset the light.
Reconnect the speed sensor input.
Perform the Test Procedure below to check the
effect of the adjustment.
Drawing No. 9771, Section 3, Rev. A
Page 3-25
Page 3-26
Section 3 – Installation and Operation
CFP8E Series
Overspeed Setpoint Adjustment and Testing (Cont)
Test Procedure
NOTE: The overspeed trip setpoint is displayed
on the Field Setting Tag described in Section 2.
Start the engine.
Observe that the engine starts and operates at
about rated speed.
NOTE: Monitor engine speed on the tachometer.
Record the observed engine speed when it trips.
It must trip between 115 and 120% of rated
speed.
NOTE: Do not exceed 120% of rated speed. If
the engine does not trip at or below 120%, stop
the engine and Adjust the Speed Switch.
Adjust the mechanical throttle adjustment to
increase engine speed to the setpoint.
Observe that the engine stops automatically and
that the overspeed trip light is illuminated.
Verify that the engine tripped at a speed between
115 and 120% of rated speed.
Press the RESET button on the speed switch.
Press the RESET switch on the front of the
engine control panel.
Observe that the overspeed light has
extinguished.
NOTE: If required by the local authority, restart
the engine at the current mechanical throttle
setpoint to demonstrate a run-away overspeed
shutdown as specified by Underwriter’s
Laboratory UL 1247.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Overspeed Setpoint Adjustment and Testing (Cont)
Set/Check Normal Operation
Start the engine.
Adjust engine speed for rated value. Refer to
Rated Speed Setpoint Adjustment (CFP83-F10,
F20, F30) or Rated Speed Setpoint Adjustment
(CFP83-F40) in this section.
Stop the engine.
Drawing No. 9771, Section 3, Rev. A
Page 3-27
Page 3-28
Section 3 – Installation and Operation
CFP8E Series
Crank Terminate Adjustment and Testing
NOTE: The crank terminate signal to the remote fire pump controller informs the controller that the engine has
started. This allows the controller to terminate the selected crank signal to the engine. This crank terminate
signal is produced by the overspeed switch in the engine’s local control panel. The setpoint for the crank
terminate signal is adjusted at the factory to a value above normal idling speeds but less than the rated speed.
The setpoint should not require adjustment unless it is necessary to test the switch operation or to replace the
overspeed speed switch.
NOTE: If using this procedure for troubleshooting, perform the test portion prior to making any adjustments.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762) at the
starter. Refer to Drawing 9767 in Section 18.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Crank Terminate Adjustment and Testing (Cont)
Adjust
NOTE: Refer to Drawing 8512 Sheet 1 in Section
18.
Open the engine’s local control panel cover.
Disconnect the GRAY/RED (MPU +) wire from
PICK-UP terminal 1 at the speed switch.
Disconnect the GRAY/BLK (MPU -) wire from
PICK-UP terminal 1 at the speed switch.
Connect a signal or pulse generator to the switch
inputs with the same signal polarity.
Adjust the pulse generator to about 1100 cycles
or pulses per second.
Remove the cover from the speed switch
CRANK/TACH CAL potentiometers.
If, with this signal, the CRANK LED is illuminated
on the speed switch, turn the CRANK
potentiometer E5 clockwise until the LED
extinguishes.
Then, turn the CRANK potentiometer E5 slowly
counterclockwise until the CRANK LED
illuminates.
Replace the cover on the speed switch.
Remove the signal generator.
Connect the GRAY/RED (MPU +) wire at PICKUP terminal 1 at the speed switch.
Connect the GRAY/BLK (MPU -) wire at PICKUP terminal 1 at the speed switch.
Drawing No. 9771, Section 3, Rev. A
Page 3-29
Page 3-30
Section 3 – Installation and Operation
CFP8E Series
Crank Terminate Adjustment and Testing (Cont)
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter. Refer to Drawing 9767 in Section 18.
Test
NOTE: Monitor fire pump controller operations
from the controller. Check for the crank terminate
signal at the input terminals and observe that the
controller removes the crank output to the
engine.
Connect a digital voltmeter at crank terminate
output of the local control panel between TB2 (+)
and TB11 (-). Refer to Drawing 8512 Sheet 1 in
section 18.
NOTE: The engine’s rated speed is displayed on
the Field Setting Tag described in Section 2.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Start the engine from the fire pump controller.
Observe that the engine starts and accelerates to
about rated speed.
Observe that the CRANK terminal LED on the
speed switch is illuminated.
Check that the local digital voltmeter indicates the
12 VDC or 24 VDC signal output voltage.
When testing is done, stop the engine.
Remove the digital voltmeter.
Close the cover on the engine control panel.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-31
Isolated Acceptance Testing
Demonstrate the manual local start, operation, and shutdown of the fire pump from the engine’s local startersolenoid controls. Demonstrate that the engine will operate in the event of blown fuses or other faults in the local
control panel. Demonstrate manual engine speed control. Manual raw water valve operations are required.
Demonstrate the manual local start, operation, and shutdown of the fire pump from the engine’s control panel.
Demonstrate that the engine starts, operates at speed, and stops in the event that the fire pump controller is not
functioning.
Demonstrate the start of the fire pump engine using each battery set separately.
Demonstrate that the fire pump engine alternator operates while the engine is running. Demonstrate that any
customer supplied battery charging systems operate when the engine is not running.
Demonstrate engine startup, operation, and shutdown of the engine with each of the redundant ECM.
Check that engine fault codes are not being set during normal operations.
Drawing No. 9771, Section 3, Rev. A
Page 3-32
Section 3 – Installation and Operation
CFP8E Series
Integrated Acceptance Testing
Demonstrate the start-up, operation, and shutdown of the fire pump engine in response to operations of the
customer-installed fire pump controller. Perform this testing with the testing of the fire pump controller.
Demonstrate that the fire pump controller provides design indications and/or alarms for simulated engine oil
pressure, water temperature, and overspeed faults.
Demonstrate the actual operation of the crank terminate output from the overspeed switch.
Participate in any flushing, pressure testing, flow testing, or capacity testing required for the fire protection
system.
Complete the Cummins Fire Power Start-Up Inspection (SUI) Checklist. This is available on the Cummins
FirePower wed site (www.cumminsfirepower.com/startup).
When these items have been demonstrated, contact operating personnel responsible for fire protection system
that engine is ready for service.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-33
General Operating Information
Cummins fire pumps are tested before being shipped from the factory and are ready to put to work in application
regarding to fire emergencies.
Correct care of your engine will result in longer life, better performance, and more economical operation.
Follow the daily maintenance checks listed in Maintenance Guidelines, Section 4.
Check the water temperature and oil pressure indicators, warning lights, and other gauges daily to make sure
they are operational.
Drawing No. 9771, Section 3, Rev. A
Page 3-34
Section 3 – Installation and Operation
CFP8E Series
Normal Remote Starting Procedure
The fire pump engine starts automatically upon receipt of the start command from the customer installed fire
control panel. The remote command starts the engine when the AUTO/MANUAL rocker switch at the local;
control panel is in the AUTO position. The remote start command consists of either the Crank A or the Crank B
signal. Only one should be selected.
The engine continues to operate as long as the run signal is present. When the run signal is lost, the engine
promptly stops.
When the engine starts, the crank terminate signal is sent to the fire control panel to indicate that the engine is
running. How this is displayed depends upon the fire control panel manufacturer. This indication should be
checked in the event that an automatic start is initiated. If the signal is not present, the engine can be started
locally by using the Emergency Starting Procedure in this section.
The engine may be stopped locally by selecting the manual position on the AUTO/MANUAL rocker switch and
by pressing the local RESET switch.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-35
Normal Local Starting Procedure
Overview
The fire pump engine is started locally for testing and maintenance. Local starts for testing will be performed at
rated speed. That is, the engine starts and promptly ramps up to operating speed. If it is necessary to operate
the engine at idle speed for maintenance or troubleshooting, the engine speed must be manually reduced. After
maintenance or troubleshooting, the speed must be manually reset to the rated value shown on the Field Setting
Tag in see Section 2.
Local Starting Procedure for Testing
CAUTION
To prevent damage to the starter, do not engage the starting motor more than 15 seconds. Wait 15
seconds between each attempt to start (electrical starting motors only).
Drawing No. 9771, Section 3, Rev. A
Page 3-36
Section 3 – Installation and Operation
CFP8E Series
Start the Engine
Press the MANUAL position on the
AUTO/MANUAL rocker switch.
Observe the battery voltages displayed on the
engine control panel. Use the battery with the
highest indicated voltage.
NOTE: Depress the selected switch for up to 15
seconds or until the engine starts. Repeat up to
three times if necessary.
Start the engine using either the CRANK BATT A
or the CRANK BATT B rocker switch positions.
NOTE: If the engine does not start after three
attempts, check the fuel supply system. Absence
of blue or white exhaust smoke during cranking
indicates no fuel is being delivered.
Engine oil pressure must be indicated on the
gauge within 15 seconds after starting.
Stop the Engine
To stop the engine, select the AUTO position on
the AUTO/MANUAL rocker switch and press the
RESET switch.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-37
Local Starting Procedure for Maintenance or Troubleshooting
Engines used in fire pumps or standby service are expected to transition from crank to full load within a short
period of time.
CAUTION
Do not idle the engine for excessively long periods. Long periods of idling (more than 10 minutes) can
damage an engine because combustion chamber temperatures drop so low the fuel will not burn
completely. This will cause carbon to clog the injector spray holes and piston rings, and can cause the
valves to stick. If the engine coolant temperature becomes too low (60°C [140°F]), raw fuel will wash the
lubricating oil off the cylinder walls and dilute the crankcase oil; therefore, all moving parts of the
engine will not receive the correct amount of lubrication.
Adjust the fuel pump as per LATER to get idle
speed.
Manually position the fuel pump at mid throttle
position.
Press the MANUAL position on the
AUTO/MANUAL rocker switch.
CAUTION
To prevent damage to the starter, do not
engage the starting motor more than 15
seconds. Wait 15 seconds between each
attempt to start (electrical starting motors
only).
Start the engine using either the CRANK BATT A
or the CRANK BATT B switch positions.
NOTE: If the engine does not start after three
attempts, check the fuel supply system. Absence
of blue or white exhaust smoke during cranking
indicates no fuel is being delivered.
Engine oil pressure must be indicated on the
gauge within 15 seconds after starting.
Drawing No. 9771, Section 3, Rev. A
Page 3-38
Section 3 – Installation and Operation
CFP8E Series
CAUTION
Do not operate the engine at low idle for long
periods. Long periods at low idle, more than
10 minutes, can damage an engine because
combustion chamber temperatures will
decrease and the fuel will not completely
burn. This will cause carbon to build up
around the injector spray holes and piston
rings, which can cause the valves to stick. To
avoid damage, operate the engine at higher
idle.
When the engine starts, immediately position the
throttle linkage to an idle speed setting of about
700 RPM.
To stop the engine, select the AUTO position on
the AUTO/MANUAL rocker switch and press the
RESET switch.
Adjust the engine to operate at rated speed as
per in this section.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-39
Jumpering the Batteries
NOTE: If a battery charging system is not provided, the engine can be started using known good batteries to
provide a temporary power source. Once the engine is started, disconnect the added batteries and allow the
engine’s alternator to charge the existing batteries. It may take some time to charge the batteries with this
method.
NOTE: For maintainable lead acid batteries as supplied by Cummins N Power, check the state of charge by the
measurement of battery cell specific gravity. Refer to Battery Testing in Section 12 for more information.
WARNING
Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
CAUTION
When using jumper cables to start the
engine, make sure to connect the cables in
parallel: Positive (+) to positive (+) and
ground (-) to ground (-).
The accompanying illustration shows a typical
parallel battery connection. This arrangement,
positive (+) to positive (+), doubles the
cranking amperage.
Use this type of connection to jump start the
engine.
For a 24 VDC system, two or more 12 VDC
batteries are connected in the parallel
connection as shown. If jumpering a 24 VDC
battery setup, another 24 VDC battery pair is
required as the source.
The accompanying illustration shows a typical
series battery connection.
This arrangement, positive (+) to negative (-),
doubles the voltage.
Do not use this type of connection to jump start
the engine using a second 12 VDC battery.
Drawing No. 9771, Section 3, Rev. A
Page 3-40
Section 3 – Installation and Operation
CFP8E Series
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-41
Operating the Engine
Monitor Operating Values Frequently
Monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System
Specifications or Cooling System Specifications in Section 15 for recommended operating pressures and
temperatures. Shut off the engine if any pressure or temperature does not meet the specifications.
Do not exceed a maximum coolant temperature (93°C [220°F]). The pressure cap (or radiator cap) must meet
the minimum pressure of 48 kPa [7 psi].
CAUTION
Continuous operation with low coolant temperature (below 60°C [140°F]) or high coolant temperature
(above 100°C [212°F]) can damage the engine.
Verify raw water coolant pressure and flow.
Monitor Engine Condition Periodically
Most engine failures give an early warning. Look and listen for changes in performance, sound, or engine
appearance that can indicate service or engine repair is needed. Some changes to look for are as follows:
•
Engine misfires
•
Vibration
•
Unusual engine noises
•
Fuel, oil, or coolant leaks
•
Sudden changes in engine operating temperature or oil pressure
•
Excessive smoke
•
Loss of power
•
An increase in oil consumption
•
An increase in fuel consumption
Drawing No. 9771, Section 3, Rev. A
Page 3-42
Section 3 – Installation and Operation
CFP8E Series
Emergency Manual Starting Procedures
Emergency Manual Starting Procedures
Overview
The engine starts automatically in the event of a fire emergency. However, if it fails to start automatically, the
engine can be started locally by either of two means. The Normal Local Starting Procedure in this section can
be used to start the engine if it fails to start because of a failure in the remote fire control system. Operating the
engine with this procedure will automatically control raw water flow.
Additionally, manual means are available to start the engine in the event of some local failures. This procedure
requires the manual operation of the raw water valves and the use of the manual starting lever on either of the
two starting solenoids.
Use the following procedures as specified:
If the red low lube oil pressure light is
illuminated, attempt an Emergency Manual
Mode Electrical Start.
If the red low lube oil pressure light is not
illuminated, attempt an Emergency Manual
Mode Non-Electrical Start.
Also, if the fuel shutoff valve is known to be
faulted, attempt an Emergency Manual Mode
Non-Electrical Start.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Emergency Manual Mode Electrical Start
Starting the Engine
Open both manual valves in the raw water
bypass supply piping.
Press the MANUAL position on the
AUTO/MANUAL rocker switch.
NOTE: Use the lever on either solenoid. If one
does not crank the engine, then use the other.
Depress the lever on the selected solenoid to
start the engine.
When the engine starts, release the lever.
If the engine cranks but does not start, try the
Manual Mode Non-Electrical Start procedure in
this section.
Drawing No. 9771, Section 3, Rev. A
Page 3-43
Page 3-44
Section 3 – Installation and Operation
CFP8E Series
Stopping the Engine
When emergency operation is done, stop the
engine by pressing the AUTO position on the
AUTO/MANUAL rocker switch and then press
the RESTE$T switch..
Emergency Manual Mode Non-Electrical Start
Starting the Engine
Open both manual valves in the raw water
bypass supply piping.
Detach coil of stainless steel wire located on
heat exchanger bracket.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Using stainless steel wire, securely fasten the
fuel pump shutoff valve lever in position shown
to allow engine to run.
To stop engine, release wire and move lever to
stop position (opposite of run).
NOTE: If either crank solenoid lever does not
crank the engine, use the other.
Press down on the crank solenoid lever handle
until the engine starts.
Stopping the Engine
When emergency operation is done, stop the
engine by removing the stainless steel wire
from the fuel pump shutoff valve lever.
If required, push the lever to the stop position.
Be sure to store the wire on the heat
exchanger bracket.
Drawing No. 9771, Section 3, Rev. A
Page 3-45
Page 3-46
Section 3 – Installation and Operation
CFP8E Series
Starting Procedure - After Extended Shutdown or Oil Change
Starting Procedure - After Extended Shutdown or Oil Change
Complete the following steps after each oil change, or after the engine has been shut off for more than 30 days
to make sure the engine receives the correct oil flow through the lubricating oil system:
Bump the engine. Refer to Pre-Lubricate the Engine in this section.
Depending upon the nature of the shutdown, perform other installation checks in this section as appropriate.
Start the engine. Refer to Normal Local Starting Procedure in this section.
If required, vent the fuel system. Refer to Air in Fuel in Section 12.
Follow the Normal Starting Procedure in this section. The engine will run at idle only until the minimum oil
pressure is detected by the ECM.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Page 3-47
Electronic Controlled Fuel System
The engine control system is an electronically operated fuel control system that also provides many operator
and engine or equipment features.
The base functions of the control system include fueling and timing control, limiting the engine speed operating
range between the low- and high-idle set points, and reducing exhaust emissions while optimizing engine
performance.
The control system uses inputs from the operator and its sensors to determine the fueling and timing required to
operate at the desired engine speed.
The electronic control module (ECM) is the control center of the system. It processes all of the inputs and sends
commands to the fuel system and engine control devices.
The ECM performs diagnostic tests on most of its circuits and will activate a fault code if a problem is detected
in one of these circuits. Along with the fault code identifying the problem, a snapshot of engine's operating
parameters at the time of fault activation is also stored in memory.
Some fault codes will cause a diagnostic lamp to activate to signal the driver.
The ECM communicates with service tools through an SAE J1939 datalink.
Some engines and equipment will have J1939 networks on them that link many of the "smart" controllers
together. Engine control devices can temporarily command engine speed or torque to perform one of the
devices' functions.
The control system utilizes a number of sensors to provide information on engine operating parameters. These
sensors include:
•
Coolant temperature sensor
•
Intake air temperature sensor
•
Intake manifold pressure sensor
•
Oil pressure switch
•
Engine speed/position sensor
•
Water-in-fuel sensor
Drawing No. 9771, Section 3, Rev. A
Page 3-48
Section 3 – Installation and Operation
CFP8E Series
Engine Protection System
The engines are equipped with an engine protection system. The system monitors critical engine temperatures
and pressures and will log diagnostic faults when an over or under normal operation condition occurs.
If an out-of-range condition exists and engine de-rate action is to be initiated, the operator will be alerted by an
in-cab WARNING lamp. The WARNING lamp will blink or flash when out-of-range conditions continue to
worsen.
When the red STOP lamp is illuminated, the driver must pull to the side of the work area, when it is safe to do
so, to reduce the possibility of engine damage.
NOTE: Engine power and speed will be gradually reduced depending on the level of severity of the observed
condition. The engine protection system will not shut down the engine unless the engine protection shutdown
feature has been enabled.
Engine Protection Shutdown
This feature automatically shuts off the engine when the temperature, pressure, and coolant level sensors
indicate the engine is operating over or under normal operating conditions.
The red STOP lamp in the cab will flash for 30 seconds prior to shutdown to alert the driver.
Engine Protection Shutdown Override
This feature allows the operator to override a pending engine shutdown.
Prior to engine shutdown, the red STOP lamp will flash for 30 seconds to notify the operator that the engine is
about to shut down.
The operator can override the engine shutdown through use of an OEM switch.
If the engine is not equipped with a clutch switch, then the OEM will provide a dash-mounted switch marked as
the ENGINE PROTECTION SHUTDOWN OVERRIDE switch.
When the operator triggers this switch while the red lamp is flashing, a timer within the ECM will reset and allow
the engine to run for an additional 30 seconds before engine shutdown occurs.
Each time the operator triggers the override switch, the timer within the ECM is reset, thus allowing the engine
to run for an additional 30 seconds.
Diagnostic Fault Codes
The control system can show and record operation anomalies that present themselves as fault codes. These
codes will make troubleshooting easier. The fault codes are recorded in the ECM. They can be read using the
fault lamps in the dash or with the INSITE™ service tool.
NOTE: Not all engine or control system anomalies are shown as fault codes.
There are three types of system codes:
•
Engine electronic control system fault codes
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
•
Engine protection system fault codes
•
Engine maintenance indicator codes
Page 3-49
All fault codes recorded will either be active (fault code is currently active on the engine) or inactive (fault code
was active at some time, but is not active at the moment).
Most of the electronic fault codes will light a lamp when they are active. There are three possible lamps that can
be lit when a fault is active:
The WARNING or CHECK ENGINE lamp is yellow and indicates the need to repair the fault at the first available
opportunity.
The STOP or STOP ENGINE lamp is red and indicates the need to stop the engine as soon as it can be safely
done. The engine should remain shut down until the fault can be repaired.
The MAINTENANCE or FLUID lamp will illuminate when an engine maintenance function needs to be
performed.
NOTE: The names and colors of these lamps can vary by equipment manufacturer.
Some engines will also have a WAIT-TO-START lamp and a WATER-IN-FUEL lamp. The WAIT-TO-START
lamp is illuminated during the preheating time that takes place at key-on during cold-weather starting. To
minimize cranking time during cold-weather starting, the engine should not be cranked until the WAIT-TOSTART lamp has been extinguished.
The WATER-IN-FUEL lamp indicates that the engine's water-in-fuel separator needs to have the water drained
out of it. This task should be performed as soon as possible whenever this lamp is illuminated.
The fault code will flash in the following sequence: First, a WARNING (yellow) lamp will flash. Then there will be
a short 1- or 2-second pause, after which the number of the recorded fault code will flash in STOP (red) lamp.
There will be a 1- or 2-second pause between each number. When the number has finished flashing in red, a
yellow lamp will appear again. The three-digit code will repeat in the same sequence.
The lights flash each fault code out two times before advancing to the next code. To skip to the next fault code
sooner, move the idle speed adjust switch (if equipped) momentarily to the "(+)" position. You can go back to the
previous fault code by momentarily moving the idle speed adjust switch (if equipped) to the "(-)" position. If only
one active fault is recorded, the control system will continuously display the same fault code, even when either
"(+)" or "(-)" switch is depressed.
The explanation and correction of the fault codes are explained in the Troubleshooting and Repair Manual,
Electronic Control System, ISB and QSB5.9 Engines, Bulletin 3666194.
When not using the diagnostic system, turn off the diagnostic switch, or remove the shorting plug. If the
diagnostic switch is left on or the shorting plug in, the electronic control module will not log some faults.
Fault Code Snapshot Data
This data makes up additional fault code information that can be obtained by using the INSITE™ service tool.
The snapshot data records the value or state of the control system sensors and switches at the time a fault
occurred. This data is stored for the first occurrence of the fault, since was last cleared, and for the most recent
occurrence. This data can be very valuable when trying to re-create or determine engine operating conditions at
the time of a fault.
Drawing No. 9771, Section 3, Rev. A
Page 3-50
Section 3 – Installation and Operation
CFP8E Series
Electromagnetic Interference (EMI)
General Information
Some engine applications utilize accessories (CB radios, mobile transmitters, etc.) that generate and use radio
frequency energy that, if not installed and used properly, can cause electromagnetic interference (EMI)
conditions to exist between the accessory and Cummins electronic controlled fuel system. Cummins is not liable
for any performance problems with either the fuel system or the accessory due to EMI. EMI is not considered by
Cummins to be an engine failure and therefore is not warrantable.
System EMI Susceptibility
Your Cummins product has been designed and tested for minimum sensitivity to incoming electromagnetic
energy. Testing has shown that there is no engine performance degradation at relatively high energy levels;
however, if very high energy levels are encountered, then some non-critical diagnostic fault code logging can
occur. The fuel system EMI susceptibility level will protect your engine from most, if not all, electromagnetic
energy-emitting devices that meet the Federal Communications Commission legal requirements.
System EMI Radiation Levels
Your Cummins product has been designed to emit minimum electromagnetic energy. Electronic components are
required to pass various Cummins and industry EMI specifications. Testing has shown that when the engine is
properly installed, it will not interfere with onboard communication equipment or with the vehicle's, equipment's,
or vessel's ability to meet any applicable EMI standards and regulated specifications.
If an interference condition is observed, follow the suggestions below to reduce the amount of interference:
•
Locate the receiving antenna as far away from the engine and as high as possible.
•
Locate the receiving antenna as far away as possible from all metal obstructions (e.g., exhaust stacks)
•
Consult a representative of the accessory supplier in your area to:
•
Calibrate accurately the device for proper frequency, power output, and sensitivity (both base and remote
site devices must be properly calibrated)
•
Obtain antenna reflective energy data measurements to determine the optimum antenna location
•
Obtain optimum antenna type and mounting arrangement for your application
•
Make sure your accessory equipment model is built for maximum filtering to reject incoming electromagnetic
noise.
Drawing No. 9771, Section 3, Rev. A
Section 3 – Installation and Operation
CFP8E Series
Emergency Starting With Failed ECM
Stop the engine.
Switch between ECM “A” and ECM “B”.
Restart the engine.
When practical, replace the failed ECM.
Drawing No. 9771, Section 3, Rev. A
Page 3-51
Page 3-52
Section 3 – Installation and Operation
CFP8E Series
Emergency Manual Stopping Procedure
Drawing No. 9771, Section 3, Rev. A
Section 4 – Maintenance Guidelines
CFP8E Series
Page 4-1
Section 4 - Maintenance Guidelines
Section Contents
Page
Overview ..............................................................................................................................................................4-3
Tool Requirements .............................................................................................................................................4-4
Maintenance Schedule .......................................................................................................................................4-5
Maintenance Record Form.................................................................................................................................4-7
Drawing No. 9771, Section 4, Rev. 0
Page 4-2
Section 4 – Maintenance Guidelines
CFP8E Series
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Drawing No. 9771, Section 4, Rev. 0
Section 4 – Maintenance Guidelines
CFP8E Series
Page 4-3
Overview
Cummins Inc. recommends that the engine be maintained according to the Maintenance Schedule in this
section.
If the engine is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], perform
maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a
dusty environment or if frequent stops are made. Contact your local Cummins Authorized Repair Location for
recommended maintenance intervals.
Some of these maintenance procedures require special tools or must be completed by qualified personnel.
Contact your local Cummins Authorized Repair Location for detailed information.
If your engine is equipped with a component or accessory not manufactured by Cummins Inc., refer to the
component manufacturer's maintenance recommendations.
Use the form provided in this section as a convenient way to record maintenance performed.
Drawing No. 9771, Section 4, Rev. 0
Page 4-4
Section 4 – Maintenance Guidelines
CFP8E Series
Tool Requirements
Most of the maintenance operations described in this manual can be performed with common hand tools (metric
and S.A.E. wrenches, sockets, and screwdrivers).
The following is a list of special service tools required for some maintenance operations:
Tool Part Number
CC-2802
CC-2800
ST-1273
3375045
3375049
3376807
3377161
3822525
3824556
3824591
3824783
3824842
3825157
3825156
Description
Coolant test kit
Refractometer
Pressure gauge
Torque wrench (0 to 175 ft-lb)
Oil filter wrench
Engine coolant and fuel filter wrench
Digital multimeter
Belt Tension Gauge, Click-type (for V-ribbed with 6 to 12 ribs)
Charge air cooler (CAC) pressure kit
Engine barring gear
Torque wrench (0 to 300 in-lb)
M10 Compuchek® fitting
Fuel Injector Connector Puller
Fuel Injector Puller
Contact your nearest Cummins Authorized Repair Location for the required service tools.
Sockets
10 mm
12 mm
13 mm
15 mm
17 mm
18 mm
19 mm
22 mm
27 mm
Wrenches
8 mm
13 mm
15 mm
19 mm
22 mm
24 mm
17 mm (open end)
Other
Engine Barring Gear, Part No. 3377371
Allen Wrench (8 mm)
Breaker Bar (3/8-in drive)
Flat Screwdriver
Ratchet (3/8-in drive)
Ratchet (1/2-in drive)
Filter Wrenches (75 to 80 mm, 90 to 95 mm, and 118 to 131 mm)
Pliers
Torque Wrench
T-Bar Puller (75 mm)
Drawing No. 9771, Section 4, Rev. 0
Section 4 – Maintenance Guidelines
CFP8E Series
Page 4-5
Maintenance Schedule
Daily or Refueling (See Section 5)
Perform the following maintenance activities each day or at each refueling, whichever comes first:
•
Air Intake Filter and Piping
•
Check Coolant Level
•
Check Crankcase Breather Tube
•
Check Engine Oil Level
•
Drain Fuel-Water Separator
NOTE 1: Must use a heavy-duty year-around antifreeze that meets the chemical composition of GM6038M. The
change interval is 500 hours or 1 year, whichever comes first.
Weekly (See Section 6)
Perform the following additional maintenance activities weekly:
•
Bleed Fuel Tanks
•
Clean Raw Water Strainers
•
Check Battery Condition
•
Test Run Engine
Every 250 Hours or 6 Months (See Section 7)
Perform the following additional maintenance activities every 250 hours or every six months, whichever comes
first:
•
Check Engine Coolant Heater
•
Check Hose Condition
•
General Information
•
Inspect Heat Exchanger Zinc Plug
•
Check Engine Mounting Bolts
•
Check Turbochargers Mounting Nuts
•
Inspect Electrical Components
•
Check Cooling System Condition
•
Check Air Cleaner Service Indicator
•
Inspect Air Intake System Piping
•
Change Lubricating Oil and Filters
•
Change Fuel Filter (Spin-on Type)
•
Clean Charge Air Cooler
Drawing No. 9771, Section 4, Rev. 0
Page 4-6
Section 4 – Maintenance Guidelines
CFP8E Series
Maintenance Schedule (Cont)
Every 500 Hours or 1 Year (See Section 8)
Perform the following additional maintenance activities every 500 hours or every year, whichever comes first:
•
Drain and Flush Cooling System
•
Change Coolant Filter
•
Vent Fuel Supply Lines
•
Vent Injection Pump
NOTE 1: Must use a heavy-duty year-around antifreeze that meets the chemical composition of GM6038M. The
change interval is 500 hours or 1 year, whichever comes first.
Every 1500 Hours or 2 Years (See Section 9)
Perform the following additional maintenance activities every 1500 hours or every two years, whichever comes
first:
•
Check Overspeed Switch Operation
•
Check Drive Belt, Tensioner Bearing and Belt Tension
•
Check Valve Lash Clearance
NOTE 1: Initial valve lash clearance adjustment; subsequent adjustments must be performed at 1500-hour or 2year intervals, whichever comes first.
Every 3000 Hours or 4 Years (See Section 10)
Perform the following additional maintenance activities every 3000 hours or every four years, whichever comes
first:
•
Inspect Turbocharger
•
Inspect Viscous Damper
•
Inspect Water Pump
Drawing No. 9771, Section 4, Rev. 0
Section 4 – Maintenance Guidelines
CFP8E Series
Page 4-7
Maintenance Record Form
Maintenance Record
Engine Serial No.
Owner's Name
Date
Engine Model
Equipment Name/Number
Hours or Time
Interval
Drawing No. 9771, Section 4, Rev. 0
Actual Hours
Check
Performed
Performed By
Comments
Page 4-8
Section 4 – Maintenance Guidelines
CFP8E Series
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Drawing No. 9771, Section 4, Rev. 0
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Page 5-1
Section 5 – Maintenance Procedures –Daily
Section Contents
Page
Overview ..............................................................................................................................................................5-3
Check Air Intake Filter and Piping ....................................................................................................................5-3
Check Coolant Level ..........................................................................................................................................5-4
Check Crankcase Breather Tube ......................................................................................................................5-5
Check Lubricating Oil Level ..............................................................................................................................5-5
Drain Fuel-Water Separator ...............................................................................................................................5-6
Inspect Charge Air Cooler Piping .....................................................................................................................5-7
Check Coolant Heat Exchanger Piping ............................................................................................................5-8
Check Coolant Heater Piping ............................................................................................................................5-8
Drawing No. 9771, Section 5, Rev. A
Page 5-2
Section 5 – Maintenance Procedures – Daily
CFP8E Series
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Drawing No. 9771, Section 5, Rev. A
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Page 5-3
Overview
General Information
Preventative maintenance begins with day-to-day awareness of the engine and its system.
On a daily basis, inspect the engine for the following issues:
•
Leaks
•
Loose or damaged parts
•
Worn or damaged belts
•
Any change in engine appearance
•
Odor of fuel
Correct any problems as per the instructions in this manual.
Perform the specific checks in this section only after the engine has been stopped. Do not perform this section if
the fire pump is in operation.
Check Air Intake Filter and Piping
Visually inspect the air intake filter and piping
daily for wear points and damage to piping,
loose clamps, or punctures.
Replace damaged air filter or pipes, and tighten
loose clamps, as necessary, to prevent the air
system from leaking. Refer to Adjustment,
Repair and Replacement in Section 12 for
replacement procedures.
Check for corrosion under the clamps and
hoses of the intake system piping. Corrosion
can allow corrosive products and dirt to enter
the intake system.
Disassemble and clean, as required. Refer to
Adjustment, Repair and Replacement in Section
12 for replacement procedures.
Torque loosened clamps.
Torque Value: 8 N●m [72 in-lb]
Drawing No. 9771, Section 5, Rev. A
Page 5-4
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Check Coolant Level
WARNING
Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
CAUTION
Never use a sealing additive to stop leaks in the cooling system. This can result in cooling system
plugging and inadequate coolant flow, causing the engine to overheat.
CAUTION
Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to
below 50°C [120°F] before adding coolant.
Press down, unscrew and remove the pressure
cap.
NOTE: Coolant level should be just below the
bottom of the fill neck. It must be above the raw
water tubes.
Check coolant level.
NOTE: Make up coolant added to the engine
must be mixed with the correct proportions of
antifreeze, supplemental coolant additive (if
recommended by Cummins), and water to avoid
engine damage.
Coolant specifications can be found in Coolant
Recommendations and Specifications in
Section 15.
If required, prepare a coolant solution.
Fill the cooling system with coolant to the
bottom of the fill neck in the coolant heat
exchanger.
When done, press down and screw in the
pressure cap.
Drawing No. 9771, Section 5, Rev. A
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Page 5-5
Check Crankcase Breather Tube
Inspect the breather tube for sludge, debris, or
ice in the tube.
If the breather tube is obstructed or blocked,
clean it.
Check Lubricating Oil Level
CAUTION
Never operate the engine with oil level below the L (low) mark or above the H (high) mark. Poor engine
performance or engine damage can occur.
NOTE: Wait at least 15 minutes after shutting off
the engine to check the oil level. This allows
time for the oil to drain into the oil pan.
Check the oil level on the dipstick.
NOTE: If the lube oil is excessively high,
troubleshoot as per Oil Level Rises in Section
17.
If the lube oil level is greater than the high mark,
drain the excessive oil. Refer to Drain Oil in
Change Lubricating Oil and Filters in Section 7.
If the lube oil level is below the low mark, add
oil. Refer to Fill Oil in Change Lubricating Oil
and Filters in Section 7.
NOTE: If the lube oil is excessively low,
troubleshoot as per Lubricating Oil Consumption
Excessive in Section 17.
Oil Capacity (Low to High Mark Oil): 3.8 liters
[4 U.S. qt]
For additional lubricating oil recommendations
and oil pan capacity information, refer to
Lubricating Oil Recommendations and
Specifications and Lubricating Oil System
Specifications in Section 15.
Drawing No. 9771, Section 5, Rev. A
Page 5-6
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Drain Fuel-Water Separator
Cummins Inc. requires a fuel-water separator or fuel filter be installed in the fuel supply system. Drain the water
and sediment from the separator daily.
WARNING
Drain the water-fuel separator into a container and dispose of in accordance with local environmental
regulations. If more than
NOTE: If more than 59 ml (2 oz) is drained,
refilling of the filter is required to prevent hard
starting.
Use your hand to open the drain valve. Turn the
valve counterclockwise approximately 3½ turns
until the valve drops down 25.4 mm [1 in] and
draining occurs.
Drain the filter sump until clear fuel is visible.
CAUTION
When closing the drain valve, do not overtighten the valve. Over-tightening can
damage the threads.
Close the valve by lifting the valve and turning it
clockwise until it is hand-tight.
If required, refill the filter. Refer to Change Fuel
Filter in Section 7 for removal and installation
instructions.
Drawing No. 9771, Section 5, Rev. A
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Inspect Charge Air Cooler Piping
Inspect the charge air piping and hoses daily for
holes, cracks, or loose connections.
Tighten the hose clamps, if necessary.
Refer to the manufacturer's specifications for the
correct torque value.
Inspect the charge air cooler for dirt and debris
blocking the fins.
Check for cracks, holes, or other damage.
If damage is found, refer to the .
Inspect the intake piping daily for wear points
and damage to piping, loose clamps, or
punctures that can damage the engine.
Replace damaged pipes and tighten loose
clamps as necessary to prevent the air system
from leaking.
Torque Value: 8 N•m [72 in-lb]
Check for corrosion under the clamps and
hoses of the intake system piping. Corrosion
can allow corrosive products and dirt to enter
the intake system. Disassemble and clean as
required.
Drawing No. 9771, Section 5, Rev. A
Page 5-7
Page 5-8
Section 5 – Maintenance Procedures – Daily
CFP8E Series
Check Coolant Heat Exchanger Piping
Visually inspect the coolant heat exchanger and
piping daily for wear points and damage to
piping, loose clamps, or punctures.
Replace damaged tubes, clamps, or pipes, and
tighten loose clamps, as necessary, to prevent
the coolant system from leaking. Refer to
Adjustment, Repair and Replacement in Section
12 for replacement procedures.
Check Coolant Heater Piping
Visually inspect the coolant heat exchanger and
piping daily for wear points and damage to
piping, loose clamps, or punctures.
Replace damaged tubes, clamps, or pipes, and
tighten loose clamps, as necessary, to prevent
the coolant system from leaking. Refer to
Adjustment, Repair and Replacement in Section
12 for replacement procedures.
Drawing No. 9771, Section 5, Rev. A
Section 6 – Weekly Maintenance
CFP8E Series
Page 6-1
Section 6 - Maintenance Procedures – Weekly
Section Contents
Page
General Information............................................................................................................................................6-3
Bleed Fuel Tanks ................................................................................................................................................6-3
Clean Raw Water Strainers ................................................................................................................................6-3
Check Battery Condition....................................................................................................................................6-3
Test Run Engine .................................................................................................................................................6-4
Drawing No. 9771, Section 6, Rev. 0
Page 6-2
Section 6 – Weekly Maintenance
CFP08E Series
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Drawing No. 9771, Section 6, Rev. 0
Section 6 – Weekly Maintenance
CFP08E Series
Page 6-3
General Information
With the engine not running, perform the daily maintenance checks plus the following:
Bleed Fuel Tanks
Loosen the fuel tank drain plug or open the
drain valve.
Drain approximately 1 cup of fuel to remove
water and sediment.
Close the drain valve or tighten the drain plug.
Dispose of the waste fuel in accordance with
applicable requirements.
Clean Raw Water Strainers
For each raw water strainer, remove the plug.
Inspect and remove any debris.
Install the strainer plugs.
Unless otherwise directed, ensure that the
bypass line valves are closed and the normal
line valves are open.
Check Battery Condition
Inspect the condition of the batteries.
Follow the manufacturer’s recommendations for
inspection and maintenance procedures.
Drawing No. 9771, Section 6, Rev. 0
Page 6-4
Section 6 – Weekly Maintenance
CFP08E Series
Test Run Engine
Start Test Run
Select the MANUAL position on the
AUTO/MANUAL Switch.
Press the CRANK A or CRANK B switch.
Check Unusual Engine Noise
Run the engine no less than 30 minutes to attain
normal running temperature.
During the weekly maintenance check, listen for
any unusual engine noise which can indicate
that service is required.
Check running indications
Observe that the engine is operating at test
speed as follows:
Check oil pressure
Check coolant temperature
Check that both battery voltmeters indicate 12
VDC or 24V DC depending upon the
application.
Drawing No. 9771, Section 6, Rev. 0
Section 6 – Weekly Maintenance
CFP08E Series
Check that the inlet air restriction indicator has
not popped-up.
Check that the ECM Stop signal is not present
Check that the ECM Idle signal is not present
End Test Run
Select the AUTO position on the
AUTO/MANUAL Switch.
Drawing No. 9771, Section 6, Rev. 0
Page 6-5
Page 6-6
Section 6 – Weekly Maintenance
CFP08E Series
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Drawing No. 9771, Section 6, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Page 7-1
Section 7 - Maintenance Procedures Every 6 Months or 250
Hours
Section Contents
Page
General Information............................................................................................................................................7-3
Check Hose Condition .......................................................................................................................................7-3
Check Engine Coolant Heater ...........................................................................................................................7-3
Inspect Heat Exchanger Zinc Plug....................................................................................................................7-3
Inspect Electrical Components .........................................................................................................................7-4
Check Turbochargers Mounting Nuts ..............................................................................................................7-4
Check Engine Mounting Bolts...........................................................................................................................7-4
Check Cooling System Condition.....................................................................................................................7-5
Check Air Cleaner Service Indicator.................................................................................................................7-6
Inspect Air Intake System Piping ......................................................................................................................7-6
Change Lubricating Oil and Filters...................................................................................................................7-7
Change Fuel Filter (Spin-on Type) ..................................................................................................................7-12
Clean Charge Air Cooler ..................................................................................................................................7-13
Drawing No. 9771, Section 7, Rev. 0
Page 7-2
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
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Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Page 7-3
General Information
All checks or inspections listed under daily or previous maintenance intervals must also be performed at this
time, in addition to those listed under this maintenance interval.
Check Hose Condition
Inspect the lubricating, fuel, and cooling system
hoses and hose connection for leaks or
deterioration. Particles of deteriorated hose can
be carried through the cooling system and slow
or partially stop circulation.
Check Engine Coolant Heater
NOTE: Do not perform this inspection procedure
until 24 hours after shutting off the engine.
The engine coolant heater must maintain an
engine coolant temperature or 49 °C (120 °F) or
above. The engine block must be warm to the
touch in the water jacket areas.
If the heater does not appear to be working
correctly, contact a Cummins Authorized Repair
Location.
Inspect Heat Exchanger Zinc Plug
Remove the zinc plug.
Inspect the plug. If it has eroded over 50
percent, replace the plug.
Drawing No. 9771, Section 7, Rev. 0
Page 7-4
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Inspect Electrical Components
Clean and tighten any loose electrical
connections.
Follow the manufacturer’s recommended
procedures for servicing the electrical
components and batteries.
Check Turbochargers Mounting Nuts
Check the turbocharger mounting nuts. Tighten
the mounting nuts.
Torque Value: 65 N•m (50 ft-lb)
Check Engine Mounting Bolts
Check the torque on the engine mounting nuts
and bolts. Tighten any that are loose.
Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Check Cooling System Condition
WARNING
Check the coolant level only when the engine is
stopped. Wait until the coolant temperature is
below 50 °C (120 °F) before removing the
pressure cap. Failure to do so can cause
personal injury from heated coolant spray.
Check the antifreeze concentration.
Use a mixture of 50-percent water and 50percent ethylene glycol-base antifreeze to
protect the engine to -37°C [-34°F] year-around.
Antifreeze is essential in any climate. It
broadens the operating temperature range by
lowering the coolant freezing point and raising
its boiling point.
The corrosion inhibitors also protect the cooling
system components from corrosion and provide
longer component life.
Drawing No. 9771, Section 7, Rev. 0
Page 7-5
Page 7-6
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Check Air Cleaner Service Indicator
CAUTION
Never operate the engine without an air cleaner. Unfiltered foreign objects could cause engine damage.
Maximum intake air restriction is 762 mm H2O [30.0 in H2O] for turbocharged engines.
Turbocharged engines must be operated at rated RPM and full load to check maximum intake air restriction.
Replace the air cleaner element when the restriction reaches the maximum allowable limit, or clean according to
the manufacturer's recommendations.
NOTE: Follow the manufacturer's instructions
when cleaning or replacing the air cleaner
element.
Check the air cleaner service indicator, if
equipped.
Change the filter element when the red indicator
flag (2) is at the raised position in the window
(1).
After the air cleaner has been serviced, push
the button (3) to reset the service indicator.
NOTE: Never operate the engine without an air
cleaner. Intake air must be filtered to prevent dirt
and debris from entering the engine and causing
premature wear.
Inspect Air Intake System Piping
Inspect the intake piping for cracked hoses,
loose clamps, or punctures that can allow dirt
and debris to enter the engine.
Tighten or replace parts as necessary to make
sure the air intake system does not leak.
Check for corrosion of the intake system piping
under the clamps and hoses. Corrosion can
allow corrosive products and dirt to enter the
intake system.
Disassemble and clean as required.
Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Change Lubricating Oil and Filters
Lubricating Oil and Filter Change Interval
Engine oil becomes contaminated and essential
oil additives are depleted with use. The amount
of contamination is related to the total amount of
fuel and oil consumed.
The oil change interval for turbocharged engines
is every 6 months or 250 hours.
Change the oil and the filters to remove the
contaminants suspended in the oil.
NOTE: If the lubricating oil is drained from the
oil pan to make an engine repair, new oil must
be used. Do not use oil after it has been drained
from the oil pan.
Laboratory and field tests have determined that,
when using the recommended quality oils and
filters, a turbocharged engine in good condition
and equipped with a by-pass oil filter can
consume 255 U.S. gallons of fuel for each U.S.
gallon of oil in the oil system before the
maximum level of oil contamination is reached.
NOTE: Cummins Engine Co. Inc, does not
recommend exceeding 25,000 miles and/or 600
hours on oil change intervals.
Drawing No. 9771, Section 7, Rev. 0
Page 7-7
Page 7-8
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Drain
CAUTION
Avoid prolonged and repeated skin contact
with used engine oils. Such prolonged and
repeated contact can cause skin disorders
or other bodily injury. Wash thoroughly after
contact. Keep out of reach of children.
NOTE: If the engine is in service, the oil drain
interval of 250 hours or 3 months must be
observed.
PROTECT THE ENVIRONMENT: Handling and
disposal of used engine oil is subject to federal,
state, and local laws and regulations. Use
authorized waste disposal facilities, including
civic amenity sites and garages providing
authorized facilities for receipt of used oil. If in
doubt, contact state and local environmental
authorities or the Environmental Protection
Agency for guidance as to proper handling and
disposal of used engine oil.
Change the oil and filters to remove the
contaminants suspended in the oil.
NOTE: Drain the oil only when it is hot and the
contaminants are in suspension.
CAUTION
Hot oil can cause personal injury.
Operate the engine until the water temperature
reaches 60°C [140°F].
Shut the engine off.
NOTE: Use a container that can hold at least 20
liters [15 qt] of oil.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil
and suspended contaminates are removed from
the engine.
Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Remove
Clean the area around the lubricating oil filter
head. Remove the filter. Clean the gasket
surface of the filter head.
NOTE: The o-ring can stick on the filter head.
Make sure it is removed before installing the
new filter.
Install
Apply a light film of lubricating oil to the gasket
sealing surface before installing the filters.
CAUTION
Mechanical over tightening can distort the
threads or damage the filter element seal.
Install the filter as specified by the filter
manufacturer.
Drawing No. 9771, Section 7, Rev. 0
Page 7-9
Page 7-10
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Check and clean the oil drain plug threads and
sealing surface.
Install the oil drain plug.
Torque Value: 50 N•m [37 ft-lb]
NOTE: Use a high-quality 15W-40 multiviscosity
lubricating oil, such as Cummins Premium
Blue®, or its equivalent, in Cummins engines.
Choose the correct lubricating oil for your
operating climate as outlined in Section 15.
Fill the engine with clean oil to the proper level.
NOTE: Capacities assume standard pan. Total
system assumes standard pan plus filter.
Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Operate the engine at idle to inspect for leaks at
the filters and the drain plug.
Stop the engine.
Wait approximately 15 minutes to let the oil
drain from the upper parts of the engine.
Check the oil level again.
Add oil as necessary to bring the oil level to the
H (high) mark on the dipstick.
Drawing No. 9771, Section 7, Rev. 0
Page 7-11
Page 7-12
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Change Fuel Filter (Spin-on Type)
Remove
NOTE: Close any OEM fuel valves (if equipped)
to prevent fuel from draining or siphoning.
Clean the area around the fuel filter head.
Remove the filters. Clean the gasket surface of
the filter head.
Replace the o-ring.
Install
Fill the new filter(s) with clean fuel, and lubricate
the o-ring seal with clean lubricating oil.
Fuel-water separator - used in single-filter
applications.
CAUTION
Mechanical over-tightening will distort the
threads, filter element seal or filter can.
Install the filter as specified by the filter
manufacturer.
Drawing No. 9771, Section 7, Rev. 0
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
Clean Charge Air Cooler
If the engine experiences a turbocharger
failure or any other occasion where oil or
debris is put into the charge air cooler, the
charge air cooler must be cleaned.
Remove charge air cooler from the engine.
Refer to the manufacturer's instructions.
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
avoid personal injury.
CAUTION
Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air
cooler will result.
Flush the charge air cooler internally with
solvent in the opposite direction of normal
airflow.
Shake the charge air cooler and lightly tap on
the end tanks with a rubber mallet to dislodge
trapped debris.
Continue flushing until all debris or oil is
removed.
Drawing No. 9771, Section 7, Rev. 0
Page 7-13
Page 7-14
Section 7 - Maintenance Procedures Every 6 Months or 250 hours
CFP8E Series
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
After the charge air cooler has been thoroughly
cleaned of all oil and debris with solvent, wash
the charge air cooler internally with hot, soapy
water to remove the remaining solvent.
Rinse thoroughly with clean water.
Blow compressed air into the charge air cooler
in the opposite direction of normal airflow until
the charge air cooler is dry internally.
Refer to the engine manufacturer's instructions
for installation procedures.
Drawing No. 9771, Section 7, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Page 8-1
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
Section Contents
Page
General Information............................................................................................................................................8-3
Drain and Flush Cooling System ......................................................................................................................8-3
Change Coolant Filter ........................................................................................................................................8-8
Vent Fuel Supply Lines ....................................................................................................................................8-10
Vent Injection Pump .........................................................................................................................................8-12
Drawing No. 9771, Section 8, Rev. 0
Page 8-2
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 8, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Page 8-3
General Information
All checks or inspections listed under daily or previous maintenance intervals must also be performed at this
time, in addition to those listed under this maintenance interval.
Drain and Flush Cooling System
Cleaning and Checking
The cooling system must be clean to work
correctly.
Drain the system and flush with clean water.
If the system shows mineral buildup, scale, rust
or oil, clean with a heavy duty engine coolant
cleaner and follow the manufacturer’s
directions.
Drain
CAUTION
Avoid prolonged and repeated skin contact
with used antifreeze. Such prolonged,
repeated contact can cause skin disorders
or other bodily injury.
CAUTION
Wait until the temperature is below 50°C
[120°F] before removing the coolant system
pressure cap. Failure to do so can cause
personal injury from heated coolant spray.
Avoid excessive contact - wash thoroughly after
contact.
Keep out of reach of children.
Protect the environment: Handling and
disposing of used antifreeze can be subject to
federal, state, and local laws and regulations.
Use authorized waste disposal facilities,
including civic amenity sites and garages
providing authorized facilities for the receipt of
used antifreeze. If in doubt, contact local
authorities or the EPA for guidance as to proper
handling of used antifreeze.
Drawing No. 9771, Section 8, Rev. 0
Page 8-4
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Drain the cooling system by opening the drain
valve on the radiator and removing the plug in
the bottom of the water inlet.
A drain pan with a capacity of 20 liters [5 gal]
will be adequate in most applications.
Check for damaged hoses and loose or
damaged hose clamps.
Replace as required.
Check the radiator for leaks, damage, and
buildup of dirt.
Clean and repair as required.
Flush
CAUTION
During filling, air must be vented from the
engine coolant passages. The air vents
through the “jiggle pin” openings to the top
heat exchanger hose and out the fill
opening. Additional venting is provided for
engines equipped with an after cooler. Open
the petcock during filling.
NOTE: Adequate venting is provided for a fill
rate of 10 liters/minute [2.6 gal/min].
Drawing No. 9771, Section 8, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
NOTE: Do not install the heat exchanger cap.
The engine is to be operated without the cap
for this process.
Fill the system with a mixture of sodium
carbonate and water (or a commercially
available equivalent).
NOTE: Use 0.5 kg [1.0 lb] of sodium carbonate
for every 23 liters [6 gal] of water.
Operate the engine for 5 minutes with the
coolant temperature above 82°C [180°F].
Shut the engine off, and drain the cooling
system.
Fill the cooling system with clean water.
NOTE: Be sure to vent the engine and
aftercooler for complete filling.
NOTE: Do not install the radiator cap or the
new coolant filter.
Drawing No. 9771, Section 8, Rev. 0
Page 8-5
Page 8-6
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Operate the engine for 5 minutes with the
coolant temperature above 82°C [180°F].
Shut the engine off.
Drain the cooling system.
NOTE: If the water being drained is still dirty,
the system must be flushed again until the
water is clean.
Fill
CAUTION
The system must be filled properly to
prevent air locks. During filling, air must be
vented from the engine coolant passages.
The system has a design fill rate of 10
liters/minute [2.8 gal/min].
CAUTION
Never use water alone for coolant. Damage
from corrosion can be the result of using
water alone for coolant.
Use a mixture of 50-percent water and 50percent ethylene glycol antifreeze to fill the
cooling system.
Coolant Capacity (Engine Only): 4.50 liters
[1.19 US Gal]
Drawing No. 9771, Section 8, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
WARNING
Before removing the pressure cap, wait until
the coolant temperature is below 50°C
[120°F]. Failure to do so can cause personal
injury from heated coolant spray.
Install the pressure cap.
Operate the engine until it reaches a
temperature of 82°C [180°F], and check for
coolant leaks.
Check the coolant level again to make sure the
system is full of coolant, or that the coolant
level has risen to the hot level in the recovery
bottle on the system, if so equipped.
Drawing No. 9771, Section 8, Rev. 0
Page 8-7
Page 8-8
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Change Coolant Filter
Remove
WARNING
Wait until the coolant temperature is below
50°C [122°F] before removing the pressure
cap. Remove the coolant system pressure
cap and close the shutoff valve before
removing the coolant filter. Failure to do so
can result in personal injury from heated
coolant spray.
Turn the shutoff valve to the OFF position by
rotating the knob from vertical to horizontal in
the direction shown.
Remove and discard the coolant filter.
Clean
Clean the gasket surface.
Drawing No. 9771, Section 8, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Install
CAUTION
Do not allow oil to get into the filter. Oil will
damage the DCA.
CAUTION
Mechanical over-tightening can distort the
threads or damage the filter head.
Apply a thin film of lubricating oil to the gasket
sealing surface before installing the new
coolant filter.
Install the coolant filter on the filter head.
Tighten the filter until the gasket contacts the
filter head surface.
Tighten the coolant filter an additional 1/2 to 3/4
of a turn, or as specified by the filter
manufacturer.
CAUTION
The valve must be in the ON position to
prevent engine damage.
Turn the shutoff to the ON position by rotating
the knob from horizontal to vertical in the
direction shown.
Test Run
Install the coolant system pressure cap.
Operate the engine.
Check for coolant leaks.
After the air has been purged from the system,
check the coolant level again.
Drawing No. 9771, Section 8, Rev. 0
Page 8-9
Page 8-10
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Vent Fuel Supply Lines
General Information
Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air
introduced by changing the filters or injection pump supply line will be vented automatically if the fuel filter is
changed in accordance with the instructions. No manual bleeding of fuel lines is required.
NOTE: Manual bleeding is required if any of the following is true:
•
The fuel filter is not filled prior to installation
•
The injection pump is replaced
•
High-pressure fuel line connections are loosened or lines replaced
•
Engine is initially started or started after an extended period of no engine operation
•
Vehicle fuel tank has run empty
Low Pressure Fuel Line(s)
Open the vent screw.
Allow fuel to drain until the fuel flowing from the
fitting is free of air.
Tighten the vent screw.
Torque value: 8 N•m (6ft-lb).
The low pressure fuel lines are bled by
pumping the hand lever on the filter head.
High Pressure Fuel Line(s)
WARNING
The pressure of the fuel in the line is
sufficient to penetrate the skin and cause
serious bodily harm.
Venting is accomplished by loosening one or
more fittings at the injectors and cranking the
engine to allow entrapped air to bleed from the
lines.
Drawing No. 9771, Section 8, Rev. 0
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
WARNING
Do not bleed a hot engine as this could
cause fuel to spill onto a hot exhaust
manifold creating a danger of fire.
With the engine at idle, vent one line at the time
until the engine runs smoothly.
Retighten Line Fittings
Tighten the line fittings and check for leaks.
Torque Value: 22 N•m [16 ft-lb]
Drawing No. 9771, Section 8, Rev. 0
Page 8-11
Page 8-12
Section 8 - Maintenance Procedures Every 1 Year or 500 Hours
CFP8E Series
Vent Injection Pump
WARNING
The pressure of the fuel in the line is
sufficient to penetrate the skin and cause
serious personal injury. Wear gloves and
protective clothing.
Loosen the fittings at the injectors, and crank
the engine to allow entrapped air to bleed from
the lines. Tighten the fittings.
WARNING
It is necessary to put the engine in the run
position. Because the engine could start, be
sure to follow all the safety precautions.
Use the normal engine starting procedure.
Start the engine and vent one line at a time
until the engine runs smoothly.
NOTE: Do not engage the starter for more than
30 seconds each time when it is used to vent
the system: Wait 2 minutes between
engagements.
Drawing No. 9771, Section 8, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Page 9-1
Section 9 - Maintenance Procedures Every 2 Years or 1500 Hours
Section Contents
Page
General Information............................................................................................................................................9-3
Check Overspeed Switch Operation.................................................................................................................9-3
Check Drive Belt, Tensioner Bearing and Belt Tension .................................................................................9-4
Check Valve Lash Clearance ...........................................................................................................................9-10
Drawing No. 9771, Section 9, Rev. 0
Page 9-2
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Page 9-3
General Information
All checks or inspections listed under daily or previous maintenance intervals must also be performed at this
time, in addition to those listed under this maintenance interval, except for valve lash adjustment.
Check Overspeed Switch Operation
Check the overspeed switch for operation.
Refer to Operating Instructions in Section 1 for
settings.
Drawing No. 9771, Section 9, Rev. 0
Page 9-4
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Check Drive Belt, Tensioner Bearing and Belt Tension
Inspect
Remove the belt guard.
Remove the drive belt.
Visually inspect the belt.
Check the belt for intersecting cracks.
Transverse (across the belt width) cracks are
acceptable. Longitudinal (direction of belt
length) cracks that intersect with transverse
cracks are not acceptable.
Replace the belt if it is frayed or has pieces of
material missing.
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Check the tensioner bearing.
The tensioner pulley should spin freely with no
rough spots detected under hand pressure.
Replace tensioner or bearing if defective.
Install the drive belt.
Torque Value: Tension Limit: 360 to 490 N•m
[266 to 361 ft-lb].
Drawing No. 9771, Section 9, Rev. 0
Page 9-5
Page 9-6
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Check the location of the drive belt on the belt
tensioner pulley. The belt should be centered
on, or centered close to the middle of, the
pulley. Unaligned belts, either too far forward or
backward, can cause belt wear, belt roll-off
failures, or increase uneven tensioner bushing
wear.
Use the Cummins belt tensioner gauge, Part
No. ST-1293, to measure the tension in the
drive belt. This needs to be in the range of 360
to 490 N•m [266 to 361 ft-lb] for the C Series.
Check the tensioner arm, pulley, and stops for
cracks. If any cracks are noticed, the tensioner
must be replaced.
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
With the belt on, verify that neither tensioner
arm stops are in contact with the spring casing
stop. If either stop is touching, the drive belt
must be replaced. After replacing the belt, if the
tensioner arm stops are still in contact with the
spring casing stop, replace the tensioner.
Remove the drive belt, and check the torque of
the tensioner capscrew. After checking the
torque, use a breaker bar with a 3/8-inch ratchet
to rotate the tensioner slowly away from the
area of belt contact. If the arm rotates with any
roughness or hesitancy, replace the tensioner.
Torque Value: B and C Series engines 43
N•m [32 ft-lb]
Check the belt for damage. Transverse (across
the belt width) cracks are acceptable.
Longitudinal (direction of the belt length) cracks
that intersect with transverse cracks are not
acceptable.
If the belt is frayed or has any piece of material
missing, the belt is unacceptable and needs to
be replaced.
Drawing No. 9771, Section 9, Rev. 0
Page 9-7
Page 9-8
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
With the belt removed, verify that the tensioner
arm stop is in contact with the spring case stop.
If these two are not touching, the tensioner must
be replaced.
With the belt removed, check to be sure that the
tensioner pulley rotates freely.
Measure the clearance between the tensioner
spring case and the tensioner arm to verify
tensioner wear-out and uneven bearing wear.
If the clearance exceeds 3 mm [0.12 in] at any
point, the tensioner failed and must be replaced
as a complete assembly.
Experience has revealed that tensioners
generally will show a larger clearance gap near
the lower portion of the spring case, resulting in
the upper portion rubbing against the tensioner
arm.
Always replace the belt when a tensioner is
replaced.
1. Tensioner cap
2. Tensioner arm
3. Spring case
4. Tensioner pulley
5. Clearance gap
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Inspect the tensioner for evidence of the
tensioner arm contacting the tensioner cap.
If there is evidence of the two areas making
contact, the pivot tube bushing has failed and
the tensioner must be replaced.
Drawing No. 9771, Section 9, Rev. 0
Page 9-9
Page 9-10
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Check Valve Lash Clearance
Adjust
Remove the air crossover tube from the engine
if equipped.
Disconnect the support clamps, hose clamp,
and wastegate sensing line.
Remove the crankcase vent tube and any other
parts that would prevent removal of the valve
cover.
Remove valve cover.
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Locate top dead center for cylinder No. 1 by
rotating the crankshaft slowly while pressing on
the engine timing pin.
The barring gear inserts into the flywheel
housing and engages the flywheel ring gear.
The engine can then be rotated by hand using a
1/2-inch ratchet or breaker bar.
When the engine timing pin engages the hole in
the camshaft gear, cylinder No. 1 is at top dead
center on the compression stroke.
CAUTION
Be sure to disengage the engine timing pin
after locating top dead center to prevent
damage to the engine timing pin.
Intake clearance: 0.30 mm [0.012 in].
Exhaust clearance: 0.61 mm [0.024 in].
Check/set valves with engine cold - below 60°C
[140°F].
NOTE: The clearance is correct when some
resistance is “felt” when the feeler gauge is
slipped between the valve stem and the rocker
lever.
Drawing No. 9771, Section 9, Rev. 0
Page 9-11
Page 9-12
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Locate top dead center for cylinder No. 1.
Check/adjust the valves indicated for STEP A
(I = intake; E = exhaust).
After tightening the rocker lever locknut, check
the valve clearance to make sure the valve
clearance has not changed.
Torque Value: 24 N•m [212 in-lb]
CAUTION
Be sure the engine timing pin is disengaged
to prevent damage to the engine timing pin.
Mark vibration damper and rotate the
crankshaft 360 degrees.
Set the valves indicated for STEP B.
After tightening the rocker lever locknut, check
the valve clearance to make sure the valve
clearance has not changed.
Torque Value: 24 N•m [212 in-lb]
Drawing No. 9771, Section 9, Rev. 0
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
NOTE: If the seal is not damaged, it can be
used again.
If the seal is damaged, install a new seal.
Install the rubber seal into the groove in the
valve cover.
Start the installation at the overlap area shown
in the illustration.
Do not stretch the rubber seal.
If the seal has more overlap than shown in the
illustration, trim the length to provide the
correct overlap.
Install new sealing o-rings on the capscrews.
Install the valve cover and wastegate sensing
tube.
Torque Value: 24 N•m [212 in-lb]
Install the crankcase vent tube, and secure with
the support clamps and hose clamp.
Torque Values:
A = 24 N•m [212 in-lb].
B = 43 N•m [32 in-lb].
Drawing No. 9771, Section 9, Rev. 0
Page 9-13
Page 9-14
Section 9 – Maintenance Procedures Every 2 Years or 1500 Hours
CFP8E Series
Install the air crossover tube and any other
parts previously removed to gain access to the
valve cover.
Drawing No. 9771, Section 9, Rev. 0
Section 10 – Maintenance Procedures Every 4 Years or 3000 Hours
CFP8E Series
Page 10-1
Section 10 - Maintenance Procedures Every 4 Years or 3000
Hours
Section Contents
Page
General Information..........................................................................................................................................10-3
Inspect Turbocharger.......................................................................................................................................10-3
Inspect Viscous Damper ..................................................................................................................................10-4
Inspect Water Pump .........................................................................................................................................10-4
Drawing No. 9771, Section 10, Rev. 0
Page 10-2
Section 10 – Maintenance Procedures Every 4 Years or 3000 Hours
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 10, Rev. 0
Section 10 – Maintenance Procedures Every 4 Years or 3000 Hours
CFP8E Series
Page 10-3
General Information
All checks or inspections listed under daily or previous maintenance intervals must also be performed at this
time, in addition to those listed under this maintenance interval.
Inspect Turbocharger
Remove the air intake and the exhaust piping.
Look for damaged or cracked compressor or
turbine blades.
Check to see that the turbocharger shaft spins
freely.
NOTE: If visual inspections or dimensional
checks indicate a problem, contact a Cummins
Authorized Location for Assistance.
The turbocharger must be removed for
replacement or rebuild if the clearances are
beyond the limits.
Install the air intake and the exhaust piping.
Drawing No. 9771, Section 10, Rev. 0
Page 10-4
Section 10 – Maintenance Procedures Every 4 Years or 3000 Hours
CFP8E Series
Inspect Viscous Damper
Check the damper for evidence of fluid loss,
dents, and wobble.
Visually inspect the vibration damper thickness
for any deformation or raising of the damper
front cover plate.
If any variations or deformations are detected,
refer to the Troubleshooting and Repair Manual
for detailed inspection procedures.
Inspect Water Pump
Inspect the water pump for drive pulley wobble
and grease or water leakage around the water
pump shaft.
Replace with a new or rebuilt, pre-lubricated unit
as necessary.
Refer to the Troubleshooting and Repair Manual
for more information.
Drawing No. 9771, Section 10, Rev. 0
Section 11 – System Diagrams
CFP8E Series
Page 11-1
Section 11 - System Diagrams
Section Contents
Page
Overview ............................................................................................................................................................11-3
Flow Diagram, Air Intake System....................................................................................................................11-4
Flow Diagram, Cooling System .......................................................................................................................11-5
Flow Diagram, Exhaust System ....................................................................................................................11-10
Flow Diagram, Fuel System ...........................................................................................................................11-11
Fuel System Operation...................................................................................................................................11-12
Flow Diagram, Lubricating Oil System.........................................................................................................11-13
Assembly Diagram, Raw Water Piping.........................................................................................................11-16
Drawing No. 9771, Section 11, Rev. A
Page 11-2
Section 11 – System Diagrams
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-3
Overview
The following drawings show the flow through the engine systems. Although parts can change between different
applications and installations, the flow remains the same. The systems shown are as follows:
•
Fuel system
•
Lubricating oil system
•
Coolant system
•
Intake air system
•
Exhaust system
•
Raw Water Piping
Knowledge of the engine systems can help in troubleshooting, service, and general maintenance of your engine.
Drawing No. 9771, Section 11, Rev. A
Page 11-4
Section 11 – System Diagrams
CFP8E Series
Flow Diagram, Air Intake System
1.
Intake air inlet to turbocharger
4.
Intake manifold - integral part of cylinder head
2.
Turbocharger air to charge air cooler
5.
Intake valve
3.
Charge air cooler
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-5
Flow Diagram, Cooling System
Drawing No. 9771, Section 11, Rev. A
Page 11-6
Section 11 – System Diagrams
CFP8E Series
Flow Diagram, Cooling System (Cont)
1.
Coolant inlet
4.
Coolant flow past oil cooler
2.
Water pump impeller
5.
Upper coolant manifold
3.
Coolant flow to oil cooler
6.
Coolant flow to cylinder head
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-7
Flow Diagram, Cooling System (Cont)
1.
Flow from upper coolant manifold
3.
Cylinder head gasket
2.
Flow to liner cavity
4.
Coolant flow orifice
Drawing No. 9771, Section 11, Rev. A
Page 11-8
Section 11 – System Diagrams
CFP8E Series
Flow Diagram, Cooling System (Cont)
1.
Flow past cylinder liners
2.
Lower coolant manifold
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-9
Flow Diagram, Cooling System (Cont)
1.
Thermostats
5.
Partial coolant flow to radiator
2.
Flow to water pump inlet
6.
Restricted flow to bypass
3.
Bypass passage
7.
Flow to heat exchanger
4.
Flow from lower coolant manifold
8.
Bypass closed.
Drawing No. 9771, Section 11, Rev. A
Page 11-10
Section 11 – System Diagrams
CFP8E Series
Flow Diagram, Exhaust System
1.
Exhaust valve
3.
Dual entry to turbocharger
2.
Exhaust manifold - pulse type
4.
Turbocharger exhaust outlet.
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-11
Flow Diagram, Fuel System
1.
Fuel from supply tank
8.
Robert Bosch PES.A injection pump
2.
Pre-filter or screen
9.
Robert Bosch PES.P injection pump
3.
Fuel transfer pump
10.
Fuel drain manifold
4.
Fuel/water separator
11.
High-pressure fuel lines
5.
Fuel filter-Low-pressure supply line
12.
Robert Bosch, 7-mm closed-nozzle, hole-type
injectors
6.
Turboboost control line
13.
Fuel return to supply tank.
7.
Robert Bosch® PES.MW injection pump
Drawing No. 9771, Section 11, Rev. A
Page 11-12
Section 11 – System Diagrams
CFP8E Series
Fuel System Operation
The function of the fuel system is to inject a
metered quantity of clean atomized fuel into
the engine cylinders at a precise time near the
end of the compression stroke. The
components of the fuel system contribute to
the delivery of fuel to the cylinders.
The fuel transfer pump is mechanically driven
by a plunger running against a special lobe on
the camshaft. The fuel transfer pump contains
a pumping piston and check valves to control
the flow of fuel and bleed back during engine
shutdown.
1. Fuel injection pump
2. High-pressure fuel lines
3. Injectors
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-13
Flow Diagram, Lubricating Oil System
1.
Lubrication oil filter
3.
Turbocharger lubricating oil drain
2.
Turbocharger lubricating oil supply
4.
To main lubricating oil rifle
Drawing No. 9771, Section 11, Rev. A
Page 11-14
Section 11 – System Diagrams
CFP8E Series
Flow Diagram, Lubricating Oil System (Cont)
1.
From lubricating oil cooler
4.
To piston cooling nozzle
2.
Main lubricating oil rifle
5.
From main lubricating oil rifle
3.
To camshaft
6.
To connecting rod bearing
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-15
Flow Diagram, Lubricating Oil System (Cont)
1.
From cam bushings
4.
Rocker lever shaft
2.
Transfer slot
5.
Rocker lever bore
3.
Rocker lever support
6.
Rocker lever
Drawing No. 9771, Section 11, Rev. A
Page 11-16
Section 11 – System Diagrams
CFP8E Series
Assembly Diagram, Raw Water Piping
Raw water is used to cool the engine coolant and is supplied from the fire pump prior to the pump discharge
flange. It is forced through a cooling loop by fire pump pressure to the engine heat exchanger. Then it is
discharged to an open waste cone.
The following raw water manifold is available as an option (Cummins N Power Part No. 8683). If supplied by the
customer, National Fire Protection Association (NFPA) Pamphlet No. 20 lists the components that are required.
Refer to the Cooling System Specifications in Section 15 for process requirements. Refer to Raw Water Piping,
Lineup, and Configuration in Section 3.
1.
Supply Pressure Gauge
7.
Normal Inlet Valve
2.
Supply Pressure Gauge Isolation Valve
8.
Normal Strainer
3.
Bypass Outlet Valve
9.
Normal Pressure Regulator
4.
Bypass Pressure Regulator
10.
Solenoid Operated Valve
5.
Bypass Strainer
11.
Normal Outlet Valve
6.
Bypass Inlet Valve
12.
1” supply to the heat exchanger
Drawing No. 9771, Section 11, Rev. A
Section 11 – System Diagrams
CFP8E Series
Page 11-17
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 11, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Page 12-1
Section 12 – Adjustment, Repair and Replacement
Section Contents
Page
Overview ............................................................................................................................................................12-5
Belts
Belt Guard Removal/Installation .....................................................................................................................12-7
Belt Removal/Installation ...............................................................................................................................12-11
Automatic Belt Tensioner Removal/Installation ..........................................................................................12-12
Coolant
Coolant Heat Exchanger Removal/Installation ............................................................................................12-13
Coolant Heater Removal/Installation ............................................................................................................12-21
Coolant Hose Removal/Installation ..............................................................................................................12-26
Raw Water Pressure Regulator Removal/Installation.................................................................................12-35
Raw Water Solenoid Valve Removal/Installation.........................................................................................12-39
Water Temperature Gauge Removal/Installation ........................................................................................12-43
Coolant Temperature Sender Removal/Installation ....................................................................................12-45
Coolant Temperature Switch Removal/Installation.....................................................................................12-47
Coolant Thermostat Removal/Installation....................................................................................................12-49
Coolant Thermostat Tests .............................................................................................................................12-53
Coolant Water Pump Removal/Installation ..................................................................................................12-56
Coolant Filter Assembly Removal/Installation ............................................................................................12-59
Electrical
Alternator Checks and Testing .....................................................................................................................12-63
Alternator Removal/Installation ....................................................................................................................12-66
Alternator Bracket Removal/Installation ......................................................................................................12-68
Battery Isolator Removal/Installation ...........................................................................................................12-69
Engine Harness Removal/Installation ..........................................................................................................12-72
Voltmeter Removal/Installation .....................................................................................................................12-74
Battery Testing................................................................................................................................................12-76
Battery Removal/Installation .........................................................................................................................12-81
Check Battery Cables and Connections ......................................................................................................12-85
Starter Motor Assembly Removal/Installation .............................................................................................12-86
Crank Solenoid Assembly Removal/Installation .........................................................................................12-89
Control Panel Fuse Replacement .................................................................................................................12-92
Drawing No. 9771, Section 12, Rev. A
Page 12-14
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Section Contents (Cont)
Page
Exhaust
Exhaust Manifold Removal/Installation ....................................................................................................... 12-95
Exhaust Restriction Measurement............................................................................................................... 12-97
Exhaust Shield Removal/Installation ........................................................................................................... 12-98
Fuel
CAPS Fuel System Overview...................................................................................................................... 12-101
Fuel Pump Delivery Valve Removal/Installation ....................................................................................... 12-104
Fuel Pump Gear Pump Check..................................................................................................................... 12-107
Fuel Pump Gear Pump Removal/Installation ............................................................................................ 12-110
Adjust Fuel Pump Timing............................................................................................................................ 12-112
Fuel Lift Pump Check .................................................................................................................................. 12-114
Fuel Lift Pump Removal/Installation.......................................................................................................... 12-117
CAPS Fuel Injection Pump Rotor Removal/Installation........................................................................... 12-121
Injection Control Valve Removal/Installation............................................................................................ 12-123
Pumping Control Valve Tests ..................................................................................................................... 12-129
Rate Shape Snubber Removal/Installation................................................................................................ 12-131
Fuel Pump Distributor Inlet Fitting............................................................................................................. 12-134
Fuel Pump Accumulator Module................................................................................................................ 12-138
Fuel Pump Distributor and Injection Control Valve Module.................................................................... 12-145
Fuel Pump Cam Housing Module............................................................................................................... 12-151
Fuel Pump Gear Pump Module Check....................................................................................................... 12-157
Fuel Pump Gear Pump Module Removal/Installation .............................................................................. 12-158
Fuel Pump Rate Shape Tube ...................................................................................................................... 12-162
Fuel Pump Head Outlet Fitting ................................................................................................................... 12-165
Fuel Pump Head Checks ............................................................................................................................. 12-168
Fuel Pump Head Removal/Installation....................................................................................................... 12-171
Fuel Pump Actuator Housing ..................................................................................................................... 12-177
Fuel Injection Pump Removal/Installation................................................................................................. 12-179
Fuel Cooled ECM Cooling Plate Removal/Installation ............................................................................. 12-184
Measure Fuel Drain Line Restriction ......................................................................................................... 12-188
Fuel Drain Lines Removal/Installation....................................................................................................... 12-190
Spin-On Type Fuel Filter ............................................................................................................................. 12-192
Measure Fuel Inlet Restriction.................................................................................................................... 12-195
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Page 12-3
Section Contents (Cont)
Page
Low Pressure Fuel Supply Lines Removal/Installation ............................................................................12-197
Fuel Injectors Removal/Installation ............................................................................................................12-201
High Pressure Injector Supply Lines Removal/Installation......................................................................12-208
Head Mounted Fuel Connector ...................................................................................................................12-211
Fuel Pump Air Bleed Line ............................................................................................................................12-213
Fuel Rail .........................................................................................................................................................12-218
Fuel Pressure Relief Valve...........................................................................................................................12-220
Fuel Rail High Pressure Fitting ...................................................................................................................12-224
Air in Fuel ......................................................................................................................................................12-226
Fuel Filter Head Bracket Removal/Installation ..........................................................................................12-231
Fuel Pump Removal/Installation .................................................................................................................12-234
Intake Air
Intake Air Filter Removal/Installation .........................................................................................................12-239
Air Crossover Removal/Installation............................................................................................................12-240
Air Inlet Connection Removal/Installation .................................................................................................12-242
Air Leaks, Air Intake and Exhaust Systems...............................................................................................12-243
Air Intake Restriction Removal/Installation ...............................................................................................12-250
Turbocharger Checks...................................................................................................................................12-252
Turbocharger Removal/Installation ............................................................................................................12-257
Turbocharger Oil Drain Line Removal/Installation....................................................................................12-263
Turbocharger Oil Supply Line Removal/Installation.................................................................................12-265
Turbocharger Wastegate Actuator Checks................................................................................................12-267
Turbocharger Wastegate Actuator Removal/Installation .........................................................................12-269
Turbocharger Wastegate Valve Body Inspection......................................................................................12-273
Measure Intake Manifold Pressure .............................................................................................................12-275
Air Intake Connection Removal/Installation ..............................................................................................12-276
Air Intake Manifold Cover Removal/Installation ........................................................................................12-278
Charge Air Cooler (CAC) Removal and Installation ..................................................................................12-281
Clean the Charge Air Cooler........................................................................................................................12-282
Inspect Charge Air Cooler (CAC) ................................................................................................................12-284
Charge Air Cooler Pressure Test ................................................................................................................12-285
Charge Air Cooler Leak Test .......................................................................................................................12-287
Charge Air Cooler (CAC) Temperature Differential Test ..........................................................................12-289
Drawing No. 9771, Section 12, Rev. A
Page 12-14
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Section Contents (Cont)
Page
Oil
Fill and Drain Lubricating Oil...................................................................................................................... 12-291
Lubricating Oil Cooler Removal/Installation ............................................................................................. 12-294
Lubricating Oil Dipstick Tube Removal/Installation................................................................................. 12-298
Lubricating Oil Dipstick Calibration........................................................................................................... 12-300
Lubricating Oil Filter Removal/Installation................................................................................................ 12-302
Lubricating Oil Bypass Valve Removal/Installation ................................................................................. 12-304
Lubricating Oil Filter Head Removal/Installation...................................................................................... 12-307
Lubricating Oil High Pressure Relief Valve Removal/Installation........................................................... 12-309
Lubricating Oil Pan Removal/Installation.................................................................................................. 12-310
Lubricating Oil Pressure Regulator Removal/Installation ....................................................................... 12-314
Lubricating Oil Pump Removal/Installation .............................................................................................. 12-317
Lubricating Oil Suction Tube Removal/Installation ................................................................................. 12-323
Lubricating Oil and Filter Analysis ............................................................................................................ 12-326
Oil Pressure Switch Removal/Installation ................................................................................................. 12-328
Oil Pressure Sender Removal/Installation ................................................................................................ 12-329
Oil Pressure Gauge Removal/Installation ................................................................................................. 12-330
Speed
Speed Sensor Removal/Installation........................................................................................................... 12-331
Tachometer Removal/Installation .............................................................................................................. 12-332
Overspeed Switch Removal/Installation.................................................................................................... 12-333
Tachometer Calibration............................................................................................................................... 12-334
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Page 12-5
Section Contents (Cont)
Page
ECM
Primary ECM Removal/Installation .............................................................................................................12-335
Secondary ECM Removal/Installation ........................................................................................................12-336
ECM Harness Removal/Installation ............................................................................................................12-337
ECM Engine Speed Sensor..........................................................................................................................12-338
ECM Engine Position Sensor ......................................................................................................................12-339
ECM Oil Pressure Sensor ............................................................................................................................12-340
ECM Boost Pressure Sensor .......................................................................................................................12-341
ECM Coolant Temperature Sensor .............................................................................................................12-342
ECM Fuel Pressure Sensor..........................................................................................................................12-343
ECM Fuel Temperature Sensor ...................................................................................................................12-344
ECM Ambient Air Pressure Sensor.............................................................................................................12-345
ECM Air Temperature Sensor......................................................................................................................12-346
Drawing No. 9771, Section 12, Rev. A
Page 12-14
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Overview
Coverage
This section of this manual addresses the Adjustment, Repair, and Replacement of Cummins NPower Fire
Pump Engine components. Work this manual with the associated base engine troubleshooting and repair
manuals.
Base engine components are addressed in Cummins Manual No. 4021418, ISC, QSC8.3, ISL, and QSL9
Troubleshooting and Repair Manual.
The electronic engine control module and associated components are addressed in Cummins Manual No.
3666271, ISC, ISCe, ISL, QSC8.3, and QSL9 Electronic Control System Troubleshooting and Repair Manual.
Refer to Service Literature Section 13 for additional information about these manuals.
Requirements
Satisfy all code requirements or local regulations necessary to remove the fire pump from service. This may
require contacting the local fire department or other authority.
Obtain the required tools and supplies for the intended service. If fluids are to be drained, get appropriate
containers. Dispose of any waste fluids or removed components in accordance with applicable environmental
requirements.
Ensure that the area is prepared for the intended service.
When work is completed, ensure that the fire pump is operational and correctly aligned for service. As required,
notify the local fire department or other authority.
Maintenance must be performed by trained, experienced technicians. Refer to Service Assistance Section 14 for
qualified service assistance.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-7
Belt Guard Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect or isolate the coolant heater power
supply.
Disconnect and insulate the Contactor to
Starter Cable (Cummins Fire Power Part No
9762) from the starter (Refer to Drawing 9767
in Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-8
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Belt Guard Removal/Installation (Cont)
Ensure that the engine and engine coolant is
cool in order to avoid burns.
Remove the engine coolant pressure cap.
Drain the engine coolant system. Refer to
Drain and Flush Coolant System in Section 8.
Remove the Lower Engine Coolant and Fill
Hose from the heat exchanger.
Remove
Remove the three bolts and the belt guard.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Belt Guard Removal/Installation (Cont)
Install
NOTE: Install only Cummins approved
replacement belt guard (Cummins Fire Power
Part No. 9820) or equivalent.
When other work is completed, install the belt
guard using the three bolts.
Torque as per Capscrew Markings and Torque
Values in Section 15.
Close coolant drain valve.
Refill the engine coolant. Refer to Drain and
Flush Coolant System in Section 8.
Install the coolant system pressure cap.
Reconnect the coolant heater power supply.
Drawing No. 9771, Section 12, Rev. A
Page 12-9
Page 12-10
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Belt Guard Removal/Installation (Cont)
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
NOTE: Start the engine and do a quick check
for leaks. If any coolant leaks are observed,
stop the engine, repair the leak, check coolant
level, then restart the engine.
Start the engine. Refer to Normal Local
Starting Procedure in Section 3.
Check for and repair any coolant leaks.
Ensure that repairs are completed
satisfactorily.
Stop the engine.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Belt Removal/Installation
Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard Removal /
Installation in this section.
Remove
NOTE: The belt tensioner is spring-loaded and
must be pivoted away from the drive belt.
Pivoting in the wrong direction can result in
damage to the belt tensioner.
Lift the tensioner to remove the drive belt.
Install
NOTE: The belt tensioner is spring-loaded and
must be pivoted away from the drive belt.
Pivoting in the wrong direction can result in
damage to the belt tensioner.
Service Tip: If difficulty is experienced
installing the drive belt (i.e., the belt seems too
short), position the belt over the grooved
pulleys first then while holding the tensioner up,
slide the belt over the water pump pulley.
NOTE: Install only Cummins approved
replacement v-ribbed belts (Cummins Part No.
3289135) or equivalent.
Lift and hold the belt tensioner. Install the drive
belt and release the tensioner.
Follow-Up
When work is completed, install the Belt Guard
and do the listed follow up steps. Refer to Belt
Guard Removal/Installation in this section.
Check that the drive belt operates without
unusual noises.
Drawing No. 9771, Section 12, Rev. A
Page 12-11
Page 12-12
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Automatic Belt Tensioner Removal/Installation
Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard
Removal/Installation in this section.
Remove the Drive Belt. Refer to Belt Removal/
Installation in this section.
Remove
Remove the belt tensioner from the bracket.
Install
NOTE: Install only Cummins approved
replacement belt tensioner (Cummins Part No.
3936213) or equivalent.
Install the belt tensioner and cap screw.
Torque Value: 43 N•m [32 ft-lb]
Follow-Up
When work is completed, install the Drive Belt.
Refer to Belt Removal/Installation in this
section.
When work is completed, install the Belt Guard
and do the listed follow up steps. Refer to Belt
Guard Removal/Installation in this section.
Check that the drive belt operates without
unusual noises.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-13
Coolant Heat Exchanger Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect or isolate the coolant heater power
supply.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762) from
the starter (Refer to Drawing 9767 in Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-14
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
Ensure that the engine and engine coolant is cool
in order to avoid burns.
Remove the engine coolant pressure cap.
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 8.
Remove the Upper Engine Coolant Hose from
the heat exchanger.
Remove the Lower Engine Coolant and Fill Hose
from the heat exchanger.
Close the Raw Water Manifold Bypass Line
Outlet Isolation Valve.
Close the Raw Water Manifold Normal Line
Outlet Isolation Valve.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
Remove the 1” NPT raw water inlet piping from
the charge air cooler to the heat exchanger.
(Refer to Drawing 9595 in Section 18 for raw
water supply piping details.)
Also, remove any customer-supplied raw water
outlet fittings. Save these components for reuse.
Pressure Test
NOTE: This test is required if internal leakage in
the heat exchanger is suspected. It may be
performed prior to the removal from the engine.
NOTE: Use teflon tape or other pipe sealant
when installing the test setup in order to prevent
leaks.
Install a 1-1/4” NPT pipe plug at the raw water
outlet of the heat exchanger.
Install a pressure test setup with 700 kPa [100
psi] pressure gauge at the 1” NPT raw water inlet
to the heat exchanger.
NOTE: There should be no detectable decrease
in the pressure reading for the duration of the
test.
Apply air pressure at 621 kPa [90 psig].
Isolate the pressure source and monitor the
pressure gauge for 5 minutes.
After testing, release the pressure.
Remove the pipe plug and the test setup.
If leakage is detected, the heat exchanger must
be replaced.
Drawing No. 9771, Section 12, Rev. A
Page 12-15
Page 12-16
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
Remove
Provide temporary support for the coolant heat
exchanger in order to avoid dropping it.
Remove the four back sets of nuts, washers, and
bolts at the heat exchanger mounting clamps.
Remove the heat exchanger and clamps from the
engine.
Disassemble
If required for replacement, remove the two front
sets of nuts and bolts at the coolant heat
exchanger clamps.
If required for replacement, remove the zinc plug
and other pipe fittings from the heat exchanger.
Assemble
NOTE: Use teflon or other pipe sealant when
installing threaded pipe fittings.
If missing, install the zinc plug (Cummins Fire
Power Part No. 9750) and brass fitting (Cummins
Fire Power Part No. 9751) in the bottom of the
heat exchanger.
If missing, install the pipe fittings removed from
the original heat exchanger. Refer to Drawing
8944 in Section 18 for component information.
If removed, position the two clamps on the heat
exchanger and install the two front sets of nuts
and bolts at the coolant heat exchanger clamps.
Do not tighten at this time. Refer to Drawing 8944
in Section 18 for component information.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
Install
Provide support for the coolant heat exchanger in
order to avoid dropping it.
Position the heat exchanger and clamps on the
engine’s mounting bracket and start the four
bolts.
Start the nut and washers on the four bolts.
Align the heat exchanger with the required hose
connections and tighten the four back sets of
clamp fasteners.
Tighten the two front sets of clamp fasteners.
Follow-Up
Install the Upper Engine Coolant Hose at the
heat exchanger.
Install the Lower Engine Coolant and Fill Hose at
the heat exchanger.
Install the 1” NPT raw water inlet piping from the
charge air cooler to the heat exchanger. (Refer to
Drawing 9595 in Section 18 for raw water supply
piping details.)
Also, install any customer-supplied raw water
outlet fittings.
Drawing No. 9771, Section 12, Rev. A
Page 12-17
Page 12-18
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
Close coolant drain valve.
Refill the engine coolant. Refer to Drain and
Flush Coolant System in Section 8.
Install the coolant system pressure cap.
Reconnect the coolant heater power supply.
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
NOTE: Start the engine and do a quick check for
leaks. If any coolant leaks are observed, stop the
engine, repair the leak, check coolant level, then
restart the engine. If no leaks are present,
promptly establish raw water flow through the
heat exchanger.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for and repair any coolant leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
CAUTION
When establishing raw water flow, ensure that
the raw water pressure does not exceed 414
kPa (60 psig) at the heat exchanger. Adjust
the pressure regulators as required.
Slowly open the Raw Water Manifold Bypass
Line Outlet Isolation Valve.
Observe raw water flow through the heat
exchanger.
Adjust the bypass pressure regulator if required.
Close the Raw Water Manifold Bypass Line
Outlet Isolation Valve.
CAUTION
When establishing raw water flow, ensure that
the raw water pressure does not exceed 414
kPa (60 psig) at the heat exchanger. Adjust
the pressure regulators as required.
Slowly open the Raw Water Manifold Normal
Line Outlet Isolation Valve.
Observe raw water flow through the heat
exchanger.
Adjust the normal pressure regulator if required.
NOTE: If temperature does not stabilize, stop the
engine and refer to Coolant Temperature Above
Normal or Coolant Temperature Below Normal
(Engine Running) in Troubleshooting Section 17.
Check that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
200 oF].
Check that no coolant hoses are collapsed.
When temperature has stabilized, stop the
engine.
Ensure that repairs are completed satisfactorily.
Drawing No. 9771, Section 12, Rev. A
Page 12-19
Page 12-20
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heat Exchanger Removal/Installation (Cont)
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
Check the coolant level. Refer to Check Coolant
Level in Section 5. Add coolant if necessary.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-21
Coolant Heater Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect or isolate the coolant heater power
supply.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-22
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heater Removal/Installation (Cont)
Ensure that the engine and engine coolant is
cool in order to avoid burns.
Remove the engine coolant pressure cap.
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 8.
NOTE: Collect the remainder of the coolant in
the heater hoses.
NOTE: Refer to Drawing 8941 in Section 18 for
detailed component information.
Remove the Upper Coolant Heater Hose.
Remove the Lower Coolant Heater Hose.
Remove
Remove the two capscrews, washers, bracket,
and coolant heater. Refer to Drawing 8941 in
Section 18 for detailed component information.
If required, remove the nuts, bolts, washers and
mounting bracket from the coolant heater.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heater Removal/Installation (Cont)
Install
If missing, install the nuts, bolts, washers and
mounting bracket on the coolant heater. Refer
to Drawing 8941 in Section 18 for detailed
component information.
Position the coolant heater and mounting
bracket and start the two bolts with washers.
Torque the two bolts on the mounting bracket
as per Capscrew Markings and Torque Values
in Section 15.
Follow-Up
NOTE: Refer to Drawing 8941 in Section 18 for
detailed component information.
Install the Upper Coolant Heater Hose.
Install the Lower Coolant Heater Hose.
Close the coolant drain valve.
Drawing No. 9771, Section 12, Rev. A
Page 12-23
Page 12-24
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heater Removal/Installation (Cont)
Refill the engine coolant. Refer to Drain and
Flush Coolant System in Section 8.
Install the coolant system pressure cap.
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
NOTE: Start the engine and do a quick check
for leaks. If any coolant leaks are observed,
stop the engine, repair the leak, check coolant
level, then restart the engine.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for and repair any coolant leaks.
Stop the engine.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or
steam can cause personal injury.
Check the coolant level. Refer to Check Coolant
Level in Section 5. Add coolant if necessary.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Heater Removal/Installation (Cont)
Reconnect the coolant heater power supply.
Observe that the coolant temperature cools
down but stabilizes.
Check that the engine block remains warm to
the touch.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-25
Page 12-26
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation
Identify hose clamps and add manufacturer’s torque value.
NOTE: This section addresses all coolant tubes and hoses. Only remove those coolant hoses that are
necessary. It is not required to remove both ends of the hose for the replacement of other components. Use the
following sections as applicable:
•
Prepare
•
Remove the Upper Engine Coolant Hose
•
Remove the Lower Engine Coolant and Fill Hoses
•
Remove the Upper Coolant Heater Hose
•
Remove the Lower Coolant Heater Hose
•
Remove the Coolant Vent Hose
•
Inspect
•
Install the Upper Engine Coolant Hose
•
Install the Lower Engine Coolant and Fill Hoses
•
Install the Upper Coolant Heater Hose
•
Install the Lower Coolant Heater Hose
•
Install the Coolant Vent Hose
•
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-27
Coolant Hose Removal/Installation (Cont)
Prepare
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect or isolate the coolant heater power
supply.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762) from
the starter (Refer to Drawing 9767 in Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-28
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Ensure that the engine and engine coolant is cool
in order to avoid burns.
Remove the engine coolant pressure cap.
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 8.
Remove the Upper Engine Coolant Hose
NOTE: Refer to Assembly Drawing 8944 in
Section 18 for detailed construction.
Loosen the hose clamp at the heat exchanger.
Loosen the hose clamp at the engine.
Pull the hose from the heat exchanger and
engine.
Remove the Lower Engine Coolant and Fill
Hoses
NOTE: Refer to Assembly Drawing 8944 in
Section 18 for detailed construction.
Remove the nuts and U-bolt supporting the lower
engine coolant hose.
Loosen the fill hose clamp at the heat exchanger.
Loosen the engine coolant hose clamp at the
heat exchanger.
Loosen the engine coolant hose clamp at the
engine.
Pull the hoses from the heat exchanger and
engine.
If required for replacement, disassemble the
components.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Remove the Upper Coolant Heater Hose
NOTE: Refer to Assembly Drawing 8941 in
Section 18 for detailed construction.
NOTE: Be prepared to collect the residual
coolant that may drain from the hose.
Loosen the hose clamp at the engine.
Loosen the hose clamp at the coolant heater.
Pull the hose and tubing from the connections.
Disassemble additional components if this is
required for inspection or repairs.
Remove the Lower Coolant Heater Hose
NOTE: Refer to Assembly Drawing 8941 in
Section 18 for detailed construction.
NOTE: Be prepared to collect the residual
coolant that may drain from the hose.
Loosen the hose clamp at the engine.
Loosen the hose clamp at the coolant heater.
Pull the hose and tubing from the connections.
Disassemble additional components if this is
required for inspection or repairs.
Remove the Coolant Vent Hose
NOTE: Refer to Assembly Drawing 9543 in
Section 18 for detailed construction.
Loosen the flair fitting at the coolant heat
exchanger.
Loosen the flair fitting at the engine.
Pull the hose from the connections.
Drawing No. 9771, Section 12, Rev. A
Page 12-29
Page 12-30
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Inspect
NOTE: Inspect the cooling system hoses and
hose connection for leaks or deterioration.
Particles of deteriorated hose can be carried
through the cooling system and slow or partially
stop circulation.
Inspect the hoses and hose connections.
Replace any hoses or clamps that are damaged.
Install the Upper Engine Coolant Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8944 in
Section 18 for detailed construction.
Position the hose clamps on the hose.
Push the hose onto the heat exchanger and
engine connections.
Tighten the hose clamp at the heat exchanger.
Tighten the hose clamp at the engine.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Install the Lower Engine Coolant and Fill
Hoses
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8944 in
Section 18 for detailed construction.
Position the hose clamps on the hoses.
Push the hose on the connections at the heat
exchanger and engine.
Position and tighten the lower engine coolant
hose clamp at the engine.
Position and tighten the lower engine coolant
hose clamp at the heat exchanger.
Position and tighten the upper fill hose clamp at
the heat exchanger.
Install the nuts and U-bolt supporting the lower
hose. Tighten the capscrew as per Capscrews
Markings and Torque Values in Section 15.
Install the Upper Coolant Heater Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8941 in
Section 18 for detailed construction.
Position the hose clamps on the hoses.
Push the hose on the connections at the coolant
heater and the engine.
Position and tighten the lower engine coolant
hose clamp at the engine.
Position and tighten the lower engine coolant
hose clamp at the coolant heater.
Drawing No. 9771, Section 12, Rev. A
Page 12-31
Page 12-32
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Install the Lower Coolant Heater Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8941 in
Section 18 for detailed construction.
Position the hose clamps on the hoses.
Push the hose on the connections at the coolant
heater and the engine.
Position and tighten the lower engine coolant
hose clamp at the engine.
Position and tighten the lower engine coolant
hose clamp at the coolant heater.
Install the Coolant Vent Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 9543 in
Section 18 for detailed construction.
Connect the hose flair connector at the heat
exchanger.
Connect the hose flair connector at the engine
coolant vent connection.
Follow-Up
Close the coolant drain valve.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
Refill the engine coolant. Refer to Drain and
Flush Coolant System in Section 8.
Install the coolant system pressure cap.
Reconnect the coolant heater power supply.
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
NOTE: Start the engine and do a quick check for
leaks. If any coolant leaks are observed, stop the
engine, repair the leak, check coolant level, then
restart the engine.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for and repair any coolant leaks.
Check that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
200 oF].
Check that no coolant hoses are collapsed.
When temperature has stabilized, stop the
engine.
Ensure that repairs are completed satisfactorily.
Drawing No. 9771, Section 12, Rev. A
Page 12-33
Page 12-34
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Hose Removal/Installation (Cont)
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
Check the coolant level. Refer to Check Coolant
Level in Section 5. Add coolant if necessary.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-35
Raw Water Pressure Regulator Removal/Installation
NOTE: This section applies only to pressure regulators supplied by Cummins Fire Power. These procedures
should be modified for alternative piping or components as supplied by the customer.
NOTE: This section applies to both the normal and bypass lines. Use the appropriate sections as follows:
•
Prepare (Bypass Line)
•
Prepare (Normal Line)
•
Remove (Bypass Line)
•
Remove (Normal Line)
•
Install (Bypass Line)
•
Install (Normal Line)
•
Follow-Up (Bypass Line)
•
Follow-Up (Normal Line)
Prepare (Bypass Line)
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Close the Raw Water Manifold Bypass Line
Inlet Isolation Valve.
Close the Raw Water Manifold Bypass Line
Outlet Isolation Valve.
Prepare (Normal Line)
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Close the Raw Water Manifold Normal Line
Inlet Isolation Valve
Close the Raw Water Manifold Normal Line
Outlet Isolation Valve.
Drawing No. 9771, Section 12, Rev. A
Page 12-36
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Pressure Regulator Removal/Installation (Cont)
Remove (Bypass Line)
Loosen the pipe union upstream of the pressure
regulator.
Unscrew the pressure regulator from the outlet
isolation valve.
As required, remove the pipe nipples from the
pressure regulator.
Remove (Normal Line)
Loosen the pipe union downstream of the
pressure regulator.
Unscrew the pressure regulator from the
solenoid valve.
As required, remove the pipe nipples from the
pressure regulator.
Install (Bypass Line)
When the pressure regulator is repaired or
replaced, prepare it for installation.
NOTE: Use pipe dope or silicon sealant on
threaded fittings.
As required, install the pipe nipples on the
pressure regulator. Tighten with a pipe wrench
or equivalent.
Screw the pressure regulator onto the outlet
isolation valve.
Align and connect the pipe union. Tighten with a
pipe wrench or equivalent.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Pressure Regulator Removal/Installation (Cont)
Install (Normal Line)
When the pressure regulator is repaired or
replaced, prepare it for installation.
NOTE: Use pipe dope or silicon sealant on
threaded fittings.
As required, install the pipe nipples on the
pressure regulator. Tighten with a pipe wrench
or equivalent.
Screw the pressure regulator onto the solenoid
valve.
Align and connect the pipe union. Tighten with a
pipe wrench or equivalent.
Follow-Up (Bypass Line)
Check the pressure regulator setpoint (refer to
Section 3).
If required, open the Raw Water Manifold
Bypass Line Inlet Isolation Valve.
If required, open the Raw Water Manifold
Bypass Line Outlet Isolation Valve.
Verify that raw water flow is established through
the heat exchanger.
When flow is verified, close the bypass line
outlet valve.
Ensure that the normal line inlet and outlet
valves are both open.
Ensure that the pressure gauge isolation valve
is open.
Ensure that repairs are completed satisfactorily.
Place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Page 12-37
Page 12-38
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Pressure Regulator Removal/Installation (Cont)
Follow-Up (Normal Line)
Check the pressure regulator setpoint (refer to
Section 3).
If required, open the Raw Water Manifold
Normal Line Inlet Isolation Valve.
If required, open the Raw Water Manifold
Normal Line Outlet Isolation Valve.
As required, close the bypass line outlet valve.
Ensure that the pressure gauge isolation valve
is open.
Start the engine to operate the raw water
solenoid valve. (Refer to Section 3),
Verify that raw water flow is established through
the heat exchanger.
When flow is verified, stop the engine.
Observe that raw water flow stops.
Ensure that repairs are completed satisfactorily.
Place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Solenoid Valve Removal/Installation
NOTE: This section applies to solenoid valves supplied by Cummins Fire Power.
Prepare
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the positive battery cables from both
batteries.
Disconnect any customer supplied battery
chargers.
Close the Raw Water Manifold Normal Line
Inlet Isolation Valve.
Close the Raw Water Manifold Normal Line
Outlet Isolation Valve.
Remove
NOTE: Minimize the loss of wire when cutting
the splices.
NOTE: Tag each end of the wire before making
the cut.
Cut the butt-splices at the connection between
the two solenoid valve pigtail wires and the fire
pump electrical harness.
Loosen the union fitting between the solenoid
valve and the pressure regulator.
Unscrew the solenoid valve from the outlet
isolation valve or inlet nipple.
Remove the solenoid valve.
If appropriate for replacement, remove the pipe
fittings from the solenoid valve.
Drawing No. 9771, Section 12, Rev. A
Page 12-39
Page 12-40
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Install
NOTE: Install only Cummins approved
replacement solenoid valves [Cummins Fire
Power Part No. 8210G14-12VDC (12 VDC) or
8210G14-24VDC (24 VDC)].
NOTE: Use thread sealant when making
threaded plumbing connections.
If removed, install the inlet and outlet fittings on
the solenoid valve.
Position the solenoid valve and start threading it
into the outlet valve or onto the outlet valve
nipple.
Thread the valve until it is tight and so that the
electrical housing is facing up.
Align and tighten the union connection.
NOTE: Use termination techniques that meet all
local requirements. Cummins recommends
crimped and insulated butt splices.
NOTE: The solenoid valve’s green pigtail lead is
not used. The other two leads are not polarity
dependent.
Splice the two solenoid pigtail leads to the fire
pump harness solenoid leads.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Follow-Up
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Connect the positive battery cables at both
batteries,
Open the Raw Water Manifold Normal Line Inlet
Isolation Valve.
Open the Raw Water Manifold Normal Line
Outlet Isolation Valve.
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that raw water flow starts when the
engine starts.
Drawing No. 9771, Section 12, Rev. A
Page 12-41
Page 12-42
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Stop the engine.
Check that raw water flow stops shortly after the
engine stops.
If raw water flow does not start when the engine
starts, refer to Coolant Temperature Above
Normal in Troubleshooting Section 17.
If raw water flow does not stop shortly after the
engine stops, refer to in Troubleshooting
Section 17.
If operation is correct, place the
AUTO/MANUAL Switch at the local panel in the
AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Water Temperature Gauge Removal/Installation
Prepare
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the positive battery cables from both
batteries.
Disconnect any customer supplied battery
chargers.
Remove
Use a nut driver or equivalent to remove the
control panel’s mounting bolt.
Pull the control panel out from the enclosure so
that it is supported by the piano hinge on the
bottom.
NOTE: Check and tag all wires with location
tags prior to removal.
Remove the two dark blue [METER +] wires
from the [I] terminal on the gauge.
Remove the single black ground wire from the
[G] terminal on the gauge.
Remove the single [WTG] wire from the [S]
terminal on the gauge.
NOTE: Catch the gauge as the meter bracket is
removed.
Remove the two nuts and the meter bracket
from the back of the panel.
Remove the gauge from the panel.
Drawing No. 9771, Section 12, Rev. A
Page 12-43
Page 12-44
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Water Temperature Gauge Removal/Installation (Cont)
Install
Position the gauge in the panel. Orient it for
ease of reading.
Position the meter bracket on the gauge’s
mounting studs. Start the nuts.
Tighten the nuts hand tight plus a full turn.
Connect the two dark blue [METER +] wires on
the [I] terminal on the gauge.
Connect the single black ground wire on the [G]
terminal on the gauge.
Connect the single [WTG] wire on the [S]
terminal on the gauge.
Raise the control panel and install the panel
mounting bolt.
Follow-Up
Reconnect the batteries and any battery
chargers.
Observe that the [WATER TEMP] gauge
indicates a reasonable value for ambient
cooling water temperature.
If the gauge does indicate correctly, place the
AUTO/MANUAL Switch at the local panel in the
AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Temperature Sender Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from pets and
children. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap. Heated coolant spray or steam can
cause personal injury.
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 8.
Remove
Disconnect the temperature sensor wiring.
Remove the temperature sensor.
Install
NOTE: Apply liquid teflon sealant to the threads
when installing the temperature sensor.
Install the temperature sensor.
Torque Value:
•
(Cast Iron) 50 N•m [37 ft-lb]
•
(Aluminum) 30 N•m [22 ft-lb]
Reconnect the wiring.
Drawing No. 9771, Section 12, Rev. A
Page 12-45
Page 12-46
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Temperature Sender Removal/Installation (Cont)
Follow-Up
Fill coolant to proper level. Refer to Drain and
Flush Cooling System in Section 8.
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
199 oF].
If temperature does not stabilize in the desired
range, stop the engine and refer to refer to
Coolant Temperature Above Normal or Coolant
Temperature Below Normal (Engine Running)
in Troubleshooting Section 17.
If operation is correct, stop the engine and
place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Temperature Switch Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from pets and
children. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap. Heated coolant spray or steam can
cause personal injury.
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 8.
Remove
Disconnect the temperature switch wiring.
Remove the temperature switch.
Install
Apply liquid teflon sealant to the threads when
installing the temperature switch.
Install the temperature switch.
Torque Value:
•
(Cast Iron) 50 N•m [37 ft-lb]
•
(Aluminum) 30 N•m [22 ft-lb]
Reconnect the wiring.
Drawing No. 9771, Section 12, Rev. A
Page 12-47
Page 12-48
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Temperature Switch Removal/Installation (Cont)
Follow-Up
Fill coolant to proper level. Refer to Drain and
Flush Cooling System in Section 8.
Operate the engine. Refer to Operating
Instructions in Section 3.
Check that the High Water Temperature Light
on the control panel does not illuminate.
Check for leaks. Repair any leaks.
Observe that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
199 oF].
Stop the engine.
If operation is correct, place the
AUTO/MANUAL Switch at the local panel in the
AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Thermostat Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children and
pets. If not reused, dispose of in accordance
with local environmental regulations.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
CAUTION
Always use the correct thermostat, and never
operate the engine without a thermostat
installed. The engine can overheat if operated
without a thermostat because the path of
least resistance for the coolant is through the
bypass to the pump inlet. An incorrect
thermostat can cause the engine to overheat
or run too cold.
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 8.
Disconnect the coolant hose. Refer to Remove
Upper Engine Coolant Hose in this section.
Remove
Remove the two mounting capscrews and the
water outlet connection.
Remove the thermostat and both the upper and
lower seals.
Drawing No. 9771, Section 12, Rev. A
Page 12-49
Page 12-50
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Thermostat Removal/Installation (Cont)
Clean
NOTE: Do not let any debris fall into the
thermostat cavity when cleaning the gasket
surfaces. Stuff a clean rag in the hole.
Clean the mating surfaces on the water outlet
connection and on the engine with a putty knife
and clean cloth.
Inspect for Reuse
Inspect the thermostat for obvious damage such
as obstructions caused by debris, broken springs,
or stuck or missing vent pins.
Make sure the thermostat is clean and free from
corrosion.
NOTE: Do not allow the thermostat or
thermometer to touch the side of the container.
NOTE: The fully open distance between the
thermostat flange and housing is 9.4 mm [0.370
in].
Suspend the thermostat and a 100°C [212°F]
thermometer in a container of water.
Heat the water slowly so the wax element in the
thermostat has sufficient time to react to the
rising water temperature.
Check the thermostat as follows:
Requirements
•
Starts to open within ±1°C [±2°F] of 82°C
[180°F].
•
Fully open within ±1°C [±2°F] of 93°C
[199°F].
If the thermostat does not operate within the
required range, it must be replaced.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Thermostat Removal/Installation (Cont)
Install
CAUTION
Always use the correct thermostat, and never
operate the engine without a thermostat
installed. The engine can overheat if operated
without a thermostat because the path of
least resistance for the coolant is through the
bypass to the pump inlet. An incorrect
thermostat can cause the engine to overheat
or run too cold.
If used, remove the rag from the hole in the
engine block.
NOTE: Make sure that the top and bottom seals
are in place.
Install the thermostat (Cummins Part No.
3940632) and two new thermostat seals
(Cummins Part No. 145581) into the thermostat
housing.
Install the water outlet connection (thermostat
housing).
Install the two capscrews.
Torque Value: 24 N•m [18 ft-lb]
Install the water outlet hose. Refer to Install
Upper Engine Coolant Hose in this section.
Drawing No. 9771, Section 12, Rev. A
Page 12-51
Page 12-52
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Follow-Up
Fill the cooling system. Refer to Drain and Flush
Cooling System in Section 8.
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
199 oF]. If temperature does not stabilize, stop
the engine and refer to Coolant Temperature
Above Normal or Coolant Temperature Below
Normal (Engine Running) in Troubleshooting
Section 17.
If operation is correct, place the AUTO/MANUAL
Switch at the local panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-53
Coolant Thermostat Tests
The thermostat controls the coolant temperature. When the coolant temperature is below operating temperature,
coolant is bypassed to the inlet of the water pump. When the coolant temperature reaches the operating range,
the thermostat opens, sealing off the bypass, and forcing coolant to flow to the radiator. The thermostat begins
opening at 82°C [180°F].
CAUTION
Never operate the engine without a thermostat. Without a thermostat, the path of least resistance for the
coolant is through the bypass to the pump inlet. This will cause the engine to overheat.
An incorrect or malfunctioning thermostat can cause the engine to run too hot or too cold.
Coolant Thermostat Leak Test
The engine thermostat and thermostat seal
must operate properly in order for the engine to
operate in the most efficient heat range.
Overheating or overcooling will shorten engine
life.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
accordance with local environmental
regulations.
Allow the engine to cool well below 83 oC [181
o
F].
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 8.
Loosen the hose clamp on the Upper Engine
Coolant Hose.
Remove the hose from the thermostat housing.
Drawing No. 9771, Section 12, Rev. A
Page 12-54
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Thermostat Tests (Cont)
Use INSITE™ to monitor the coolant
temperature. Install a thermocouple or
temperature gauge that is known to be accurate,
in the cylinder block on the engine side of the
thermostat.
Install a hose of the same size on the
thermostat housing outlet long enough to reach
a remote, dry container used to collect coolant.
Install and tighten a hose clamp on the housing
outlet.
Place the other end of the hose in a dry
container.
CAUTION
Always vent the engine and aftercooler
during filling to remove air from the coolant
system, or overheating will result.
Refill the cooling system. Refer to Drain and
Flush Cooling System in Section 8.
NOTE: The engine coolant temperature must be
below the thermostat opening temperature of 82
o
C [180 oF] to perform this test.
Operate the engine at rated rpm for 1 minute.
Refer to Operating Instructions in Section 3.
Shut off the engine.
NOTE: The amount of coolant collected must
not be more than 100 cc [3.3 fl oz].
Measure the amount of coolant collected in the
container.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Thermostat Tests (Cont)
If more than 100 cc [3.3 fl oz] of coolant is
collected, the thermostat is leaking and must be
replaced. Refer to Coolant Thermostat
Removal/Installation in this section.
If leakage is not present, then continue to
perform the Coolant Thermostat Function Test
below.
Coolant Thermostat Function Test
Start the engine and allow the engine to
approach operating temperature.
Monitor the water temperature with an electronic
service tool or a gauge.
Monitor the operation of the thermostat.
Thermostat Initial Opening Temperature:
•
MIN: 81 oC [178 oF]
•
MAX: 83 oC [182 oF]
Stop the engine when the coolant starts to flow.
If the coolant does not start flowing into the
container during the initial opening temperature
range, the thermostat must be replaced. Refer
to Coolant Thermostat Removal/Installation in
this section.
Follow-Up
Remove any test instruments.
Install the heat exchanger hose and tighten
hose clamp.
Return any coolant to the engine.
If operation is correct, place the AUTO/MANUAL
Switch at the local panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Page 12-55
Page 12-56
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Water Pump Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children and
pets. If not reused, dispose of in accordance
with local environmental regulations.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50C [120F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Drain engine coolant as required for the intended
service. Refer to Drain and Flush Coolant System
in Section 8.
If installed, remove the Belt Guard. Refer to Belt
Guard Removal/Installation in this section.
If installed, remove the Drive Belt. Refer to Belt
Removal/Installation in this section.
Remove
Remove the three water pump capscrews and
the water pump.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Water Pump Removal/Installation (Cont)
Clean and Inspect for Reuse
Clean the o-ring sealing surface on the water
pump housing.
Inspect the water pump housing and impeller for
cracks or damage.
NOTE: A streak or chemical buildup at the weep
hole is not justification for water pump
replacement. If a steady flow of coolant or oil is
observed, replace the water pump with a new or
rebuilt unit.
Inspect the water pump weep hole for an
indication of a steady leak.
NOTE: A small screwdriver or a small tool can
be used to remove any debris.
Inspect the weep hole to make sure it is open. A
plugged weep hole can cause the water pump
to fail.
If the water pump has failed, replace it with a
new unit (Cummins Part No. 3286293 or
3973114) with new O-Ring (Cummins Part No.
3940386).
Install
Install a new o-ring (Cummins Part No.
3940386) into the groove in the water pump.
Drawing No. 9771, Section 12, Rev. A
Page 12-57
Page 12-58
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Water Pump Removal/Installation (Cont)
Install the water pump and three water pump
mounting capscrews.
Tighten the water pump mounting capscrews.
Torque Value: 24 N•m [212 in-lb]
Follow-Up
Install the Drive Belt. Refer to Belt
Removal/Installation in this section.
Install the Belt Guard. Refer to Belt Guard
Removal/Installation in this section.
Close the coolant drain valves.
Refill engine coolant as required Refer to Drain
and Flush Coolant System in Section 8.
NOTE: Perform the appropriate actions in Initial
Start-Up (see Section 3).
Perform a test run. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that the alternator is charging.
Check that engine operating temperature
stabilizes between about 82 and 93 oC [180 and
199 oF]. If temperature does not stabilize, stop
the engine and refer to Coolant Temperature
Above Normal or Coolant Temperature Below
Normal (Engine Running) in Troubleshooting
Section 17.
Stop the engine.
Ensure that repairs are completed satisfactorily.
Place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-59
Coolant Filter Assembly Removal/Installation
Prepare
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762) from
the starter (Refer to Drawing 9767 in Section 18).
Remove the coolant system pressure cap.
Turn the shutoff valve to the OFF position by
rotating the knob from vertical to horizontal in the
direction shown.
Drawing No. 9771, Section 12, Rev. A
Page 12-60
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Filter Assembly Removal/Installation (Cont)
Remove
WARNING
A small amount of coolant can leak when
servicing the coolant filter with the shutoff
valve in the OFF position. To reduce the
possibility of personal injury, avoid contact
with hot coolant.
Remove and discard the coolant filter.
Clean the filter housing with a dry clean rag.
Install
CAUTION
Do not allow oil to get into the filter.
Apply a thin film of lubricating oil to the gasket
sealing surface before installing the new coolant
filter.
CAUTION
Mechanical over-tightening can distort the
threads or damage the filter head.
Install the coolant filter on the filter head. Tighten
the filter until the gasket contacts the filter head
surface.
Tighten the coolant filter an additional 1/2 to 3/4
of a turn, or as specified by the filter
manufacturer.
CAUTION
The valve must be in the ON position to
prevent engine damage.
Turn the shutoff to the ON position by rotating the
knob from horizontal to vertical in the direction
shown.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Coolant Filter Assembly Removal/Installation (Cont)
Follow-Up
Install the coolant system pressure cap.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for and repair any coolant leaks.
After the air has been purged from the system,
stop the engine.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
Check the coolant level. Refer to Check Coolant
Level in Section 5. Add coolant if necessary.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-61
Page 12-62
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
This Page Intentionally Left Blank
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Checks and Testing
Alternator Wiring Integrity Check
NOTE: Refer to Drawing 8512 Sheet 1, Drawing
8512 Sheet 2, and Drawing 9767 in Section 18
for schematic details.
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the battery compartment
before servicing the batteries.
WARNING
To reduce the possibility of arcing, remove
the negative (-) battery cable first and attach
the negative (-) battery cable last.
Check the battery and all wiring connections for
damage. Refer to Battery Cables and
Connections in this section.
Check all connections for tightness and
cleanliness. Include both the slip connectors at
the alternator and connections at the battery.
NOTE: Continuity should be in the single digit
Ohms or less. Resistance to ground should be
in the mega-Ohm range. Refer to any applicable
customer criteria.
Using a digital multimeter or other test
equipment, check for continuity between
terminals. Check also the insulation resistance
to ground.
Correct any electrical faults.
Alternator Mechanical Check
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Visually check the drive belt and alternator
pulley to be sure the alternator is rotating.
Note any unusual noises such as from belt
whine or alternator mechanical fault.
Stop the engine.
Correct any mechanical failures.
Drawing No. 9771, Section 12, Rev. A
Page 12-63
Page 12-64
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Checks and Testing (Cont)
Alternator Voltage Output Test
CAUTION
Batteries must have been satisfactorily load
tested and must be charged with a resting
voltage of more than 12.4 Volts for this
testing.
CAUTION
Batteries must have been satisfactorily load
tested and must be charged with a resting
voltage of more than 12.4 Volts for this
testing.
NOTE: Conduct this testing at normal shop
temperature.
NOTE: Voltage should not exceed 15.5 V (for a
12 VDC system) or 31 V (for a 24 VDC system).
Start the engine and operate at rated speed.
Refer to Normal Local Starting Procedure in
Section 3.
Measure the alternator voltage output to the
batteries with digital multimeter, Cummins Part
Number 3377161.
Stop the engine.
Replace the alternator if the voltage exceeds
specification. Refer to Alternator
Removal/Installation in this section.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Checks and Testing (Cont)
Alternator Amperage Output Test
NOTE: Conduct this testing at normal shop
temperature.
NOTE: Refer to Electrical Specifications in
Section 15 for the minimum required alternator
output. Use the value listed for the system
voltage.
Connect a carbon pile load in parallel across the
battery terminals. Refer to Jumpering the
Batteries in Section 3 for how to make a parallel
connection.
Connect a clamp-on (induction) ammeter across
the alternator output cable.
Start the engine and operate at rated speed.
Refer to Normal Local Starting Procedure in
Section 3.
Adjust the carbon pile for maximum indication.
Note the amperage indicated on the ammeter.
Stop the engine.
Remove the test equipment.
Replace the alternator if the output is not 90% or
more of the specification value. Refer to
Alternator Removal/Installation in this section.
Drawing No. 9771, Section 12, Rev. A
Page 12-65
Page 12-66
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Removal/Installation
Prepare
Remove the belt guard. Refer to Belt Guard
Removal/Installation in this section.
Remove the drive belt. Refer to Belt
Removal/Installation in this section.
NOTE: Refer to Drawing 8513 Sheet 1 in
Section 18 for wiring harness information.
NOTE: Ensure that the connectors are clearly
tagged for the correct reconnection.
Disconnect the engine wiring harness
connectors from the alternator.
Remove
Remove the alternator link capscrew.
Remove the alternator mounting capscrew.
Remove the alternator.
NOTE: If the alternator bracket must also be
removed, go to Alternator Bracket
Removal/Installation in this section.
Install
Ensure that the alternator bracket is installed.
Refer to Alternator Bracket Removal/Installation
in this section.
Install the alternator and alternator capscrews in
the reverse order of removal.
Torque Value: 43 N•m [32 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Removal/Installation (Cont)
Install the alternator link capscrew.
Torque Value: 24 N•m [18 ft-lb]
Follow-Up
NOTE: Refer to Drawing 8513 Sheet 1 in
Section 18 for wiring harness information.
Connect the engine wiring harness connectors
to the alternator.
Install the drive belt. Refer to Belt
Removal/Installation in this section.
Install the belt guard. Refer to Belt Guard
Removal/Installation in this section.
Drawing No. 9771, Section 12, Rev. A
Page 12-67
Page 12-68
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Alternator Bracket Removal/Installation
Prepare
Remove the alternator. Refer to Alternator
Removal/Installation in this section.
Remove
Remove the alternator bracket mounting
capscrews and bracket.
Install
Install the mounting bracket and bracket
mounting capscrews.
Torque Value: 24 N•m [18 ft-lb]
Follow-Up
Install the alternator. Refer to Alternator
Removal/Installation in this section.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Isolator Removal/Installation
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
disconnecting the battery cable clamps.
Disconnect the negative battery cable from
Battery A.
Disconnect the negative battery cable from
Battery B.
Remove
NOTE: Ensure that all battery isolator wires are
clearly tagged for reconnection. Also note the
orientation of the existing isolator.
Drawing No. 9771, Section 12, Rev. A
Page 12-69
Page 12-70
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Isolator Removal/Installation (Cont)
Disconnect the battery cable from terminal 1.
Disconnect the battery cable from terminal 2.
Disconnect the alternator cable from terminal A.
Disconnect the alternator excitation cable from
terminal E.
Remove the four mounting nuts and the battery
isolator
Install
Align and position the battery isolator on the four
mounting studs.
Install the four mounting nuts.
Connect the battery cable at terminal 1.
Connect the battery cable at terminal 2.
Connect the alternator cable at terminal A.
Connect the alternator excitation cable at
terminal E.
Ensure that all four rubber caps are in position.
Follow-Up
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
connecting the battery cable clamps.
Connect the negative battery cable at Battery A.
Connect the negative battery cable at Battery B.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Isolator Removal/Installation (Cont)
NOTE: Refer to Drawing 8512 Sheet 2 for
schematic details. Measure voltages at the
most convenient location.
With the engine off, verify the following voltages
at the battery isolator terminals to ground:
•
Terminal 1 indicates battery voltage.
•
Terminal 2 indicates the other battery
voltage.
•
Terminal E indicates no voltage.
Start the engine. Refer to Normal Local Starting
Procedure in Section e3.
With the engine running, verify the following
voltages at the battery isolator terminals to
ground:
•
Terminal 1 indicates battery voltage.
•
Terminal 2 indicates the other battery
voltage.
•
Terminal E indicates battery voltage.
•
Terminal A indicates about 1 volt higher
than battery voltage.
Stop the engine.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-71
Page 12-72
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Engine Harness Removal/Installation
NOTE: There are two harness assemblies on this fire pump engine. This section addresses the engine harness
connected to the control panel. The ECM harness is addressed in ECM Harness Removal/Installation also in
this section.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
disconnecting the battery cable clamps.
Disconnect the negative battery cable from
Battery A.
Disconnect the negative battery cable from
Battery B.
Remove
NOTE: Refer to Drawing 8513 Sheet 1 in
Section 18 for a depiction of the engine wiring
harness.
NOTE: Ensure that each terminal is properly
labeled for ease of reconnection.
Disconnect the harness connection at each
terminal.
Install
NOTE: Refer to Drawing 8513 Sheet 1 in
Section 18 for a depiction of the engine wiring
harness.
Connect the harness connection at each
terminal.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Engine Harness Removal/Installation (Cont)
Follow-Up
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
connecting the battery cable clamps.
Connect the negative battery cable at Battery A.
Connect the negative battery cable at Battery B.
NOTE: Refer to Second Start in Section 3 for
the suggested checks.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Observe that the engine starts with no unusual
noises or vibrations.
Verify that the engine reaches operating
temperature.
Stop the engine.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-73
Page 12-74
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Voltmeter Removal/Installation
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
NOTE: Refer to Control Panel Fuse
Replacement in this section for fuse location
information.
Remove the electrical fuse from the fuse block
as follows:
•
For Voltmeter A, remove Fuse F1
•
For Voltmeter B, remove Fuse F2
Remove
NOTE: Refer to Drawing 8512 Sheet 1 in
Section 18 for electrical schematic details.
Open the local control panel.
NOTE: Ensure that the wires are clearly tagged
for reconnection.
Loosen the nuts on the stud and remove the
wires.
Remove the nuts on the mounting bracket and
remove the voltmeter from the panel.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Voltmeter Removal/Installation (Cont)
Install
Orient the voltmeter in the cutout in the
electrical panel.
Position the mounting bracket on the gauge.
Install the mounting nuts.
Reconnect the electrical wires on the studs in
the same positions as they were originally
installed.
Tighten the nuts on the studs.
Follow-up
Reinstall the electrical fuse in the fuse block.
When the batteries are functional and charged,
reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-75
Page 12-76
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Testing
WARNING
Batteries can emit explosive gases. To avoid injury, always ventilate the compartment before servicing
the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-)
battery cable last.
WARNING
Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always
provide a strong tank of soda water as a neutralizing agent when servicing the batteries. Wear goggles
and protective clothing to avoid serious burns.
NOTE: This section is for conventional batteries only. Maintenance-free batteries may be supplied by the
customer. These are sealed and do not require the addition of water. Also, specific gravity cannot be checked. If
the batteries are not supplied by Cummins Fire Power, follow the battery manufacturer’s recommendations for
testing and servicing their batteries.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Testing (Cont)
Check Electrolyte Level
Remove all cell covers for both sets of batteries.
Check the electrolyte level in each cell of each
battery.
NOTE: Cummins recommends the use of a selfleveling filler. If a syringe type filler is used, use
care to prevent overflow or splashing of acid
from the cell.
CAUTION
Do not overfill the cell. Fill only to the level
indication.
CAUTION
If a syringe type filler is used, use care to
prevent overflow or splashing of acid from
the cell.
As required, fill each battery cell with distilled
water.
Install all cell covers for both sets of batteries.
If water was added, recharge the battery prior to
checking specific gravity.
Drawing No. 9771, Section 12, Rev. A
Page 12-77
Page 12-78
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Testing (Cont)
Check Specific Gravity
NOTE: If water has been added to a dry cell,
recharge the battery to mix the added water
with the existing battery electrolyte. This will
prevent incorrect readings.
NOTE: The battery must be more than about ¼
charged before the hydrometer readings can be
accurate. Accurate readings may require
several hours of charging for a fully discharged
battery.
Use a hydrometer to measure the specific
gravity of each cell.
State of Charge and Specific Gravity*
% Charged
Non-Tropical
Tropical
100%
1.265
1.225
75%
1.225
1.185
50%
1.190
1.150
25%
1.155
1.115
0%
1.120
1.080
* At 26.7 oC [80 oF]
Check the battery fluid column in the
refractometer to determine the state of charge
of each battery cell.
NOTE: Evaluate the state of charge in respect
to the local requirements. A cold location will
require a greater specific gravity than a hot
climate for the necessary cranking amperes.
If charge is low, charge the batteries. Refer to
Battery and Electrical Installation in Section 3.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Testing (Cont)
Check Battery Output
CAUTION
Do not connect battery charging cables to
any electronic control system part. This can
damage the electronic control system parts.
NOTE: Use the inductive charging-cranking
systems analyzer, Cummins Part Number
3377193, to test the output amperage of either
maintenance-free or conventional vent cap
batteries. Follow the instructions provided with
the test equipment.
NOTE: The required battery output in cold
cranking amperes is provided in Electrical
System Specifications kin Section 15. Use the
listed value for the system voltage.
Test both sets of batteries.
NOTE: For customer supplied batteries, refer to
the manufacturer's literature for charging
instructions.
If the output amperage is low, charge the
battery. Refer to Battery and Electrical
Installation in Section 3.
Replace the battery if it will not charge to the
manufacturer's specifications or will not
maintain a charge.
Follow-up
When the batteries are functional and charged,
reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-79
Page 12-80
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Testing (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-81
Battery Removal/Installation
WARNING
Batteries can emit explosive gases. To avoid injury, always ventilate the compartment before servicing
the batteries.
WARNING
Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always
provide a strong tank of soda water as a neutralizing agent when servicing the batteries. Wear goggles
and protective clothing to avoid serious burns.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
Clear and ventilate the battery storage area.
Collect the necessary tools and safety
equipment.
Drawing No. 9771, Section 12, Rev. A
Page 12-82
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Removal/Installation (Cont)
Remove
NOTE: Use the correct battery tools. Use end
wrenches to loosen the battery clamps. Use a
battery cable puller to remove tight cable
clamps from the battery terminal. Use a battery
carrier to lift and carry the battery.
Remove any battery support hardware.
WARNING
To reduce the possibility of arcing, remove
the negative (-) battery cable first.
Loosen the battery cable clamps.
Remove the negative battery cable first.
Remove the positive battery cable first.
WARNING
Do not tip the battery and spill the acid.
Using a battery carrier, lift and remove the
battery.
If disposing of the battery, dispose of it in
accordance with all applicable environmental
regulations.
Clean
NOTE: Use the correct battery tools. Use a
terminal cleaning brush for the battery terminal.
Use a putty knife and wire brush to remove dirt
and corrosion from the battery body and any
support.
Clean the battery posts to remove all corrosion
and to expose the metal.
Remove any other corrosion or debris from the
battery body or battery support.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Removal/Installation (Cont)
Install
NOTE: Use the correct battery tools. Use a
battery cable clamp spreader to install tight
cable clamps on the battery terminal. Use end
wrenches to tighten the battery clamps
WARNING
Do not tip the battery and spill the acid.
Using a battery carrier, carry and position the
battery.
WARNING
To reduce the possibility of arcing, attach
the negative (-) battery cable last.
Spread the positive cable clamp and position
the clamp on the post.
Tighten the positive cable clamp.
Spread the negative cable clamp and position
the clamp on the post.
Tighten the negative cable clamp.
Install any battery support hardware.
Follow-Up
If new batteries are installed, charge the
batteries. Refer to Battery and Electrical
Installation in Section 3.
When the batteries are charged, reconnect the
Contactor to Starter Cable (Cummins Fire
Power Part No 9762) at the starter (Refer to
Drawing 9767 in Section 18).
Drawing No. 9771, Section 12, Rev. A
Page 12-83
Page 12-84
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Battery Removal/Installation (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Check Battery Cables and Connections
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries.
WARNING
To reduce the possibility of arcing, remove
the negative (-) battery cable first and attach
the negative (-) battery cable last.
NOTE: There are two possible heavy-duty
battery connections:
•
Battery terminal and clamp
•
Threaded battery terminal and nut
Remove and inspect the battery cables and
connections for cracks or corrosion.
Replace broken terminals, connectors, or
cables.
If the connections are corroded, use a battery
brush or wire brush to clean the connections
until shiny.
Alternatively, if a brush won’t do the job, use an
acid neutralizing solution to remove the
corrosion.
Brush or wipe all residue or debris from the
terminals.
NOTE: Coat the terminals with a high
temperature grease to prevent corrosion.
Install the cables and tighten the battery
connections.
Drawing No. 9771, Section 12, Rev. A
Page 12-85
Page 12-86
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Starter Motor Assembly Removal/Installation
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
Remove the grounding strap from the starter, if
used.
Remove
Disconnect the ground cable from the battery.
Identify each electrical wire with a tag indicating
location.
Remove the battery cable from the solenoid.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Starter Motor Removal/Installation (Cont)
Remove the starting motor and spacer.
Install
Install the starter motor in the reverse order of
removal.
Torque Value: 43 N•m [32 ft-lb]
Follow-Up
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) at the
starter (Refer to Drawing 9767 in Section 18).
Install the grounding strap to the starter, if used.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Observe that the engine starts with no unusual
noises or vibrations.
Stop the engine.
Drawing No. 9771, Section 12, Rev. A
Page 12-87
Page 12-88
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Starter Motor Removal/Installation (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Page 12-89
Crank Solenoid Assembly Removal/Installation
NOTE: Use this procedure to remove and install either or both of the crank solenoid assemblies. The crank
solenoid assembly sub-components are not serviceable parts as supplied by Cummins Fire Power.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
disconnecting the battery cable clamps.
Disconnect the negative battery cable from
Battery A.
Disconnect the negative battery cable from
Battery B.
Remove
NOTE: Refer to Drawing 8512 Sheet 1 in
Section 18 for schematic information related to
the crank solenoid assemblies.
NOTE: Ensure that the wires are clearly
identified for ease of reconnection.
NOTE: Observe the location of flat and lock
washers for ease of reconnection.
NOTE: Save the nuts, bolts, flat washers, and
lock washers for reuse.
Disconnect all electrical connectors from the
solenoid’s four terminal studs.
Loosen the four sets of mounting nuts, bolts,
and washers.
Remove the crank solenoid and fasteners from
the engine.
Drawing No. 9771, Section 12, Rev. A
Page 12-90
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Crank Solenoid Assembly Removal/Installation (Cont)
Install
NOTE: Install the correct component. For 12
VDC systems, use Cummins NPower Part No
8824. For 24 VDC systems, use Cummins
NPower Part No 8846.
Position the four bolts through the mounting
holes.
Position the crank solenoid on the bolts, add the
lock washers, and start the nuts.
Tighten the four mounting nuts.
NOTE: Refer to Drawing 8512 Sheet 1 in
Section 18 for crank solenoid schematic
information.
Position the flat washers, cable lugs, lock
washers, and nuts on the studs in the same
order as was removed.
Tighten the nuts on the studs.
With power still disconnected, verify that the
lever handle on the crank solenoid operates
freely.
Follow-Up
NOTE: Refer to Battery Removal/Installation in
this section for detailed instructions for
reconnecting the battery cable clamps.
Connect the negative battery cable from Battery
A.
Connect the negative battery cable from Battery
B.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Crank Solenoid Assembly Removal/Installation (Cont)
Demonstrate Local Electrical Start
NOTE: If Crank Solenoid A was replaced, start
the engine using CRANK BATT A. Alternatively;
use B if B was replaced.
Start the engine electrically from the local
control panel.
Verify that the engine starts normally with no
unusual indications.
Stop the engine.
Demonstrate Local Manual Start
NOTE: If Crank Solenoid A was replaced, start
the engine using CRANK BATT A. Alternatively;
use B if B was replaced.
Start the engine manually from the crank
solenoid lever handle.
Verify that the engine starts normally with no
unusual indications.
Stop the engine.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Page 12-91
Page 12-92
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Control Panel Fuse Replacement
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762)
from the starter (Refer to Drawing 9767 in
Section 18).
Remove
Open the fire pump engine’s local control panel.
Loosen the cover screw and remove the fuse
block cover.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Control Panel Fuse Replacement (Cont)
NOTE: The fuses are ATO/ATC ¼” blade type
automotive fuses. The 20 Amp fuses (Fuse 1, 2,
and 3) are colored yellow. The five amp fuse is
colored tan.
NOTE: Refer to Drawing 8512 Sheet 1 in
Section 18 for schematic details.
NOTE: The fuses are ordered from top to
bottom as follows:
•
5 A Fuse F4 (Control Panel Indications)
•
20 A Fuse F1 (Battery A)
•
20 A Fuse F2 (Battery B)
•
20 A Fuse F3 (Crank Circuit)
Select the fuse for testing or replacement.
Pull the fuse from the fuse block.
Check for continuity either visually or with an
ohmmeter.
Check for short circuits to ground on any fuse
circuit that had an open circuited fuse. Correct
any faults.
If necessary, remove, test, or replace the
engine harness. Refer to Engine Harness
Removal/Installation in this section.
Install
Replace any fuse with an open circuit. Place the
new fuse into the fuse block and press it in until
the fuse is properly inserted.
Install the fuse block cover and tighten the
cover screw,
Close the control panel.
Drawing No. 9771, Section 12, Rev. A
Page 12-93
Page 12-94
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Control Panel Fuse Replacement (Cont)
Follow-Up
Reconnect the Contactor to Starter Cable
(Cummins Fire Power Part No 9762) from the
starter (Refer to Drawing 9767 in Section 18).
NOTE: If Fuse 1 or Fuse 2 was replaced, start
the engine using CRANK BATT A or CRANK
BATT B respectively.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Observe that the engine starts with no unusual
indications.
Observe that engine speed is indicated.
Observe that raw water flow has started.
Stop the engine.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Exhaust Manifold Removal/Installation
Prepare
Remove the heat shield.
Remove the air intake piping from the
turbocharger.
Remove the air outlet piping from the
turbocharger.
Remove the exhaust outlet piping from the
turbocharger.
Remove the turbocharger.
Remove
Refer to Exhaust Manifold, Dry (45-011-007) in
ISC, QSC8.3, ISL, and QSL9 Troubleshooting
and Repair Manual, Bulletin Number 4021418.
Clean
Refer to Exhaust Manifold, Dry (45-011-007) in
ISC, QSC8.3, ISL, and QSL9 Troubleshooting
and Repair Manual, Bulletin Number 4021418.
Drawing No. 9771, Section 12, Rev. A
Page 12-95
Page 12-96
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Exhaust Manifold Removal/Installation (Cont)
Install
Refer to Exhaust Manifold, Dry (45-011-007) in
ISC, QSC8.3, ISL, and QSL9 Troubleshooting
and Repair Manual, Bulletin Number 4021418.
Follow-Up
Install the turbocharger.
Install the exhaust outlet piping at the
turbocharger.
Install the air outlet piping at the turbocharger.
Install the air intake piping at the turbocharger.
Install the heat shield.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Exhaust Restriction Measurement
Measure
NOTE: The maximum acceptable exhaust
restriction is listed in Exhaust System
Specifications in Section 15.
NOTE: A new pressure tap in the customersupplied exhaust piping may be required.
Install pressure gauge, Cummins Part Number
ST-1273, in the exhaust piping at the connection
to the fire pump.
Operate the engine at rated speed and load.
Refer to Normal Local Starting Procedure in
Section 3.
Observe the exhaust restriction.
Stop the engine. Refer to Normal Local Starting
Procedure in Section 3.
Remove the pressure gauge and plug the
pressure tap.
If the backpressure exceeds specification,
modify the exhaust piping accordingly.
Drawing No. 9771, Section 12, Rev. A
Page 12-97
Page 12-98
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Exhaust Shield Removal/Installation
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect and insulate the Contactor to Starter
Cable (Cummins Fire Power Part No 9762) from
the starter (Refer to Drawing 9767 in Section
18).
Remove
Remove the exhaust shield and fasteners. Refer
to Drawing 9515 in Section 18.
Need fastener info
Install
Install the exhaust shield and fasteners. Refer to
Drawing 9515 in Section 18.
Need fastener info
Torque Values?
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Exhaust Shield Removal/Installation (Cont)
Follow-Up
If work is completed, reconnect the Contactor to
Starter Cable (Cummins Fire Power Part No
9762) at the starter (Refer to Drawing 9767 in
Section 18).
If functional components were removed,
repaired, or replaced, perform the appropriate
installation checks and engine starts as listed in
Section 3. Verify that the components operate
properly.
If testing is completed, place the
AUTO/MANUAL rocker switch in the AUTO
position.
Drawing No. 9771, Section 12, Rev. A
Page 12-99
Page 12-100
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
This Page Intentionally Left Blank
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAPS Fuel System Overview
The CAPS fuel system is a distributor-type
injection system. CAPS stands for Cummins
Accumulator Pump System. An accumulator is
used to store pressurized fuel for the injection
event. There are four components that provide
or receive input to the electronic control module
(ECM). There are two pumping control valves
(1) that are controlled by the ECM. These
valves control the pressure in the accumulator.
The accumulator fuel pressure/temperature (2)
sensor is located on the accumulator and
provides the ECM with pressure and
temperature information. The injection control
valve (3) is also controlled by the ECM and
regulates fuel injected into the cylinder.
The CAPS injection pump can be divided into
six distinct units/modules. They are the gear
pump, cam housing, accumulator, rate shape
tube, injection control valve (ICV), and
distributor. Fuel flows through the modules in
the following order:
gear pump - 5
cam housing - 6
accumulator - 1
rate shape tube - 2
injector control valve (ICV) - 3
distributor - 4.
A lift pump is used for priming the pump at
start-up. The lift pump runs for approximately
30 seconds after key-on. Once the engine is
started, the gear pump is able to maintain
prime without any assistance from the lift
pump.
Drawing No. 9771, Section 12, Rev. A
Page 12-101
Page 12-102
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
The gear pump supplies fuel to the pumping
plungers through internal drillings in the cam
housing. The gear pump also supplies fuel to
the distributor for lubrication. The fuel pressure
is regulated to approximately 160 psi at rated
engine rpm. The gear pump has an internal
filter to catch any debris generated
downstream of the main, external fuel filter.
The pump camshaft is driven off the engine
camshaft; therefore, pump rpm is one-half
engine rpm. The gear pump is driven by the
pump camshaft through an internal coupling.
The gear pump shaft then turns the distributor
rotor through a second internal coupling.
Each of the two pumping plungers is driven by
a three lobed camshaft (3). The camshaft is
located in the cam housing module by tapered
roller bearings. The bearings that support the
camshaft, as well as the tappets (2), rollers (1),
and camshaft itself are lubricated with engine
oil. These are the only components in the
pump lubricated with engine oil.
A pumping control valve (2) is located above
each pumping plunger (1). The supply fuel from
the gear pump flows around the plunger of this
normally open valve into the chamber above
the plunger. The volume above each pumping
plunger is filled, by the gear pump, as the
plungers travel downward. As the plunger
starts to move upward, the fuel is pushed
backward into the gear pump. When the
pumping control valve closes, the fuel is
pushed into the accumulator and then held by
check valves. The time when the pumping
control valve is energized (closed) is based on
engine speed, accumulator pressure, and
throttle position. A 0- to 24,000-psi pressure
sensor is located in the accumulator. The
pressure sensor provides direct feedback to
the ECM, so the desired accumulator pressure
is maintained. This pressure sensor also has
temperature sensing capabilities built into it.
Fuel moves from the accumulator to the
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
distributor and through the rate shape tube (3).
Fuel is delivered to the injection control valve
(1) by the rate shape tube and through a
drilling in the distributor (2). The ICV controls
both fueling and timing. The injection control
valve contains an inner pin and outer valve.
The outer valve is moved by magnetic force
generated inside the ICV by a current from the
ECM. The inner pin is moved by spring force
and fuel pressure. When the two pins are in the
closed position, no fuel flows through the
control valve. The position of these internal
parts controls fuel flow to the distributor rotor
(3) and to the drain (4). The injection control
valve opens and closes once for each injection
event.
The distributor (1) directs the fuel to the correct
injector using the rotor. The drain fuel from the
ICV is routed through the ICV pressure
regulator (4) and is returned to the tank.
The position of the rotor directs the fuel to one
of six drillings in the distributor housing. These
drillings communicate the fuel to six fuel pump
delivery valves (3). There is one injector line
per delivery valve. The injection line carries the
fuel to the injector.
Drawing No. 9771, Section 12, Rev. A
Page 12-103
Page 12-104
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Delivery Valve Removal/Installation
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Thoroughly steam-clean the distributor outlet
fitting and fuel pump area.
Dry with compressed air.
Remove the high-pressure fuel supply lines.
Refer to Procedure 006-051.
Remove
Remove the distributor outlet fitting and the seal
disk.
NOTE: A tool like the one shown here can be
made from a 1/8 in or 3/16 in Allen wrench. Use
it to remove the seal disc. Refer to Procedure
005-084 for instruction on how to make the tool.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
NOTE: The outlet fitting valve and seat are a
matched set; do not “mix and match” valves and
seats with other outlet fitting assemblies.
If either the outlet fitting valve or seat is
damaged, the entire outlet fitting assembly must
be replaced. Also, the seal washers must
always be replaced.
Clean and Inspect for Reuse
Check for broken parts, debris, or sticking of the
outlet fitting valve. Replace the outlet fitting
assembly if any parts are damaged. Always
replace the seal washer.
Use QD contact cleaner, Part Number 3824510,
to clean the delivery valve port in the distributor.
Drawing No. 9771, Section 12, Rev. A
Page 12-105
Page 12-106
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install a new seal washer into the distributor
outlet fitting hole. Make sure the washer is fully
seated in the bottom of the hole.
Install the outlet fitting assembly hand tight.
Tighten the outlet fitting assemblies.
Torque Value: 81 N•m [60 ft-lb]
Follow-Up
Install the high-pressure fuel supply lines. Refer
to Procedure 006-051.
Operate the engine and inspect for fuel leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Gear Pump Check
Initial Check
The gear pump shaft incorporates a double
seal. The first seals oil in the fuel pump cam
housing; the second seals fuel in the gear
pump. If either seal fails, a leak will drip from
the weep hole. The weep hole is located near
the gear pump mounting flange on the inboard
side (toward the engine block).
A gear pump gasket seals oil at the gear pump
to cam housing interface.
Measuring gear pump pressure with the engine
cranking (useful if engine will not start).
Install a pressure gauge at the on engine fuel
filter head (M10 x 1.5 Compuchek® fitting, Part
Number3824842).
Monitor the gear pump pressure while the
engine is cranking.
Measurements Gear Pump Pressure at
Cranking (minimum): 69 kPa [10 psi]
If the gear pump pressure is lower than 69 kPa
[10 psi] during cranking, make sure that the
engine cranking speed is at least 150 rpm.
Make sure that the lift pump pressure during
cranking is at least 35 kPa [5 psi]. Refer to
Procedure 005-045.
Drawing No. 9771, Section 12, Rev. A
Page 12-107
Page 12-108
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Construction of Banjo Pressure Gauge
Adapter
A banjo-style pressure gauge adapter can be
used to measure pressure or vacuum at any
point in the low-pressure fuel system where a
banjo bolt exists at a fuel line.
The ISC and ISL engines with high-pressure
common rail fuel systems use M12 x 7/16-inch
banjo bolt connection. This tool can be used for
measurement of drain line restriction (pressure)
at the fuel drain manifold.
Make a banjo bolt flow adapter tool by drilling
and tapping the hex face of an M12 x 7/16-inch
banjo bolt, Part Number 3903035 or similar
banjo bolt.
Drill and tap the banjo bolt to the size of
Compuchek® fitting (or other hose union) being
used (example 1/8-inch NPT Compuchek®
fitting, Part Number 3377244, or M10
Compuchek® fitting, Part Number 3824842).
Assemble the banjo pressure gauge adapter as
follows.
Install the Compuchek® fitting, or other type
fitting, in the hexagon face of the banjo bolt.
Attach a hose or pressure gauge to the banjo
pressure adapter.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Measuring Gear Pump Pressure at Rated
Condition
Install a M10 x 1.5 Compuchek® fitting, Part
Number 3824842, at the diagnostic port on the
outlet of the fuel filter head.
Construct a “T” adapter fitting using one quickdisconnects, Part Number 3376859, and two
1/8-inch NPT Compuchek® fitting, Part Number
3042618.
Install a 0.043-inch orificed diagnostic fuel line
(Part Number 3164621) at the outlet of the fuel
filter head. Run the fuel hose back to the fuel
tank.
Install a 0 to 1034 kPa [0 to 150 psi] pressure
gauge at the “T” adapter fitting.
Operate the engine at high idle and observe the
gear pump pressure.
Measurements Minimum Gear Pump
Pressure 483 kPa [70 psi]
If the gear pump pressure is low, check for
excessive inlet vacuum. Refer to Procedure
006-020.
Drawing No. 9771, Section 12, Rev. A
Page 12-109
Page 12-110
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Gear Pump Removal/Installation
Prepare
Clean the fuel, oil and debris from the gear
pump.
Remove the fuel supply lines from the gear
pump. Refer to Procedure 006-024.
Remove
Remove the four bolts that hold the gear pump
to the fuel pump.
Remove the drive coupling if it remains attached
to the rear of the fuel pump camshaft.
Remove the gear pump gasket.
Clean and Inspect for Reuse
Inspect the drive coupling for wear. If worn, the
drive coupling must be replaced.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install the drive coupling into the back of the
high-pressure pump camshaft.
Insert the mounting bolts through the gear pump
flange.
Install a new gasket onto the bolts.
Index the gear pump input shaft to engage the
drive coupling and install the gear pump.
Install the four gear pump bolts and tighten.
Torque Value: 34 N•m [25 ft-lb]
Follow-Up
Install the fuel supply lines. Refer to Procedure
006-024.
Drawing No. 9771, Section 12, Rev. A
Page 12-111
Page 12-112
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Adjust Fuel Pump Timing
Prepare
Remove the gear cover. Refer to Procedure
001-031.
Remove the fuel pump camshaft nut. Refer to
Procedure 005-016 or 005-229.
Inspect for Reuse
Check that the fuel pump camshaft alignment
dowel is present in the fuel pump drive gear
keyway. If the alignment dowel is not visible,
remove the injection pump, determine the cause
of misalignment, and repair or replace any
damaged components.
Fuel pump gear keyway
Fuel pump timing dowel pin
Fuel pump camshaft
Fuel pump gear
If this inspection is being performed due to a
performance complaint, and the problem first
occurred after gear train removal and
replacement then check the timing of the
camshaft gear to the crankshaft gear and the
camshaft gear to the fuel pump drive gear.
Refer to Procedure 001-012.
If the engine camshaft gear is mistimed in
relation to the crankshaft gear, intake and
exhaust valve events will not be optimized. Also,
for CAPS injection pump fuel systems, the
primary speed sensor reads the tonewheel on
the camshaft gear and fuel injection timing will
be incorrect.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install and tighten the injection pump camshaft
nut. Refer to Procedure 005-016 or 005-229.
Install the front gear cover. Refer to Procedure
001-031.
Drawing No. 9771, Section 12, Rev. A
Page 12-113
Page 12-114
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Lift Pump Check
Initial Check
Block Mounted Lift Pump
A malfunctioning electric fuel lift pump can
cause slow engine starts or may result in an
engine failing to start. The fuel lift pump can be
cleaned and repaired to a limited extent.
The lift pump will operate for 30 to 60 seconds
when the key is switched ON. The lift pump will
also operate while the engine is cranking.
The lift pump is contained in an assembly that
includes fuel supply and drain manifolds. These
manifolds provide for OEM connection of fuel
supply and return hoses. The fuel supply
manifold also contains M10 STORM fittings
which allow for pressure and vacuum
measurement of the fuel supply at the electric lift
pump.
A bypass check valve in the fuel supply manifold
ensures that the system is primed by the lift
pump. This check valve opens under vacuum
created by the fuel injection pump once the
engine is started. High vacuum measured
between the electric lift pump and the fuel filter
may indicate that this check valve has become
plugged.
The output of the fuel lift pump can be checked
through the following test:
Measure the output pressure using a pressure
gauge at the lift pump outlet port.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
The lift pump check valve restriction can be
determined using the following test:
Install a 0 to 762 mm Hg [0 to 30 in Hg] vacuum
gauge at the inlet and outlet M10 STORM ports
on the electric lift pump head
Operate the engine at rated power condition
Record the inlet restriction at the inlet and outlet
of the lift pump.
Refer to Procedure 006-020.
Maximum Fuel Lift Pump Inlet Restriction:
102 mm-hg 4 in-hg
Initial Check
ECM Cooling Plate Mounted Lift Pump
A malfunctioning electric fuel lift pump can
cause slow engine starts or may result in an
engine failing to start. The fuel lift pump can be
cleaned and repaired to a limited extent.
The lift pump will operate for 30 to 60 seconds
when the key is switched ON. The lift pump will
also operate while the engine is cranking.
A lift pump is mounted to the back of the ECM
cooling plate.
A bypass check valve in the ECM cooling plate
ensures that the system is primed by the lift
pump. This check valve opens under vacuum
created by the gear pump once the engine is
started. High vacuum measured between the
electric lift pump and the gear pump may
indicate that this check valve has become
plugged.
The ECM cooling plate check valve is integral
with the lower (outlet) fitting of the ECM cooling
plate.
Drawing No. 9771, Section 12, Rev. A
Page 12-115
Page 12-116
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
The output of the fuel lift pump can be checked
through the following test:
Measure the output pressure using a pressure
gauge at the inlet to the high-pressure pump
gear pump assembly.
Install a pressure gauge at the inlet port of the
high-pressure pump gear pump.
Turn the key switch ON and measure the lift
pump pressure using a pressure gauge at the
gear pump inlet.
NOTE: At initial key-on, the lift pump will run for
30 seconds then stop.
Measurements
Minimum Pressure 34 kPa [5 psi]
NOTE: If the lift pump pressure is low while the
lift pump runs, make sure that the ECM cooling
plate check valve is not blocked open.
NOTE: If the lift pump pressure is low while the
lift pump runs, make sure that fuel is primed. For
example, following fuel filter replacement it is
necessary to cycle the fuel lift pump three or
four times before air is purged.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Lift Pump Removal/Installation
Prepare
Block Mounted Lift Pump
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the negative (-) battery cable first.
NOTE: Thoroughly clean fittings and
components before removal. Make sure that the
debris, water, steam or cleaning solution does
not reach inside the fuel system.
Remove the fuel lift pump inlet and outlet fuel
lines. Refer to Procedure 006-024.
Disconnect the fuel pump power lead.
Drawing No. 9771, Section 12, Rev. A
Page 12-117
Page 12-118
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Prepare
ECM Cooling Plate Mounted Lift Pump
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the negative (-) battery cable first.
Disconnect the electric fuel priming pump from
the engine wiring harness.
NOTE: Thoroughly clean fittings and
components before removal. Make sure that the
debris, water, steam or cleaning solution does
not reach inside the fuel system.
Remove the fuel supply lines. Refer to
Procedure 006-024.
Remove the ECM cooling plate. Refer to
Procedure 006-006.
Remove
Block Mounted Lift Pump
Remove the three capscrews and the electric lift
pump from the engine block.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
ECM Cooling Plate Mounted Lift Pump
Remove the electric lift pump from the ECM
cooling plate.
Install
Block Mounted Lift Pump
Install the fuel lift pump to block using the three
mounting capscrews.
Tighten the capscrews.
Torque Value: 12 N•m [106 in-lb]
Install
ECM Cooling Plate Mounted Lift Pump
Install the electric lift pump to the ECM cooling
plate.
Tighten the mounting capscrews.
Torque Value: 10 N•m [89 in-lb]
NOTE: The ECM cooling plate check valve must
be free of debris and installed into the lower
ECM cooling plate port (outlet port).
NOTE: Hold the fuel lines as shown so that they
can not come into contact with each other or the
engine block.
Drawing No. 9771, Section 12, Rev. A
Page 12-119
Page 12-120
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Block Mounted Lift Pump
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Connect the power lead to the fuel lift pump.
Install all removed fuel lines. Refer to Procedure
006-024.
Connect the battery, negative (-) cable last.
Follow-Up
ECM Cooling Plate Mounted Lift Pump
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Install the ECM cooling plate to the engine
block. Refer to Procedure 006-006.
Install all fuel lines. Refer to Procedure 006-024.
Connect the battery, negative (-) cable last.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAPS Fuel Injection Pump Rotor Removal/Installation
Prepare
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturers recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Steam clean the fuel injection pump and the
engine in the vicinity of the fuel pump.
Dry with compressed air. Pay special attention
to the distributor area.
Remove
CAUTION
The rotor can slide out during the removal
of the distributor plug. If the rotor is
dropped, the entire distributor module must
be replaced. Do not attempt to start the
engine with the distributor plug removed.
Doing so can cause the rotor to be ejected
from the distributor, causing damage to the
rotor.
ISL Only: Remove the air bleed line. Refer to
Procedure 006-056.
Remove the distributor plug, being sure the
rotor does not fall out.
Drawing No. 9771, Section 12, Rev. A
Page 12-121
Page 12-122
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Check the position of the notch on the rotor. It
must line up with the alignment mark (A) on the
outside of the distributor (when the engine is
barred to TDC for the number 1 cylinder). If the
alignment is correct, the rotor is properly timed
to the engine.
If a mechanical problem exists, indicated by
misalignment of the rotor, the entire fuel pump
will have to be replaced; refer to Procedure
005-016.
Clean the rotor bore with QD contact cleaner,
Part Number 3824510.
Install
Use Lubriplate™ 105, or equivalent, between
the drive coupling and the rotor to prevent it
from falling off during assembly.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAUTION
The rotor must be properly timed to the fuel
pump camshaft. Improper assembly will
cause the rotor to be 180 degrees out of
time.
Insert the rotor and coupling into the distributor
module completely.
Lightly rotate the rotor with finger-pressure until
it drops into the slot in the drive coupling.
When properly engaged, the notch in the rotor
will align with the hole in the distributor while
the engine is at Number cylinder TDC.
If the rotor will not engage, remove the rotor
and drive coupling and try again. Do not tighten
the rotor cap if the coupling will not engage.
If not properly timed, remove the rotor and drive
coupling and repeat the previous step. Make
sure the fuel pump camshaft dowel pin is
pointing toward the top of the fuel pump before
installing.
Install the distributor plug and torque.
Torque Value: 14 N•m [10 ft-lb]
NOTE: Be sure the rotor is fully engaged before
replacing the plug.
ISL Only: Install the air bleed line. Refer to
Procedure 006-056.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-123
Page 12-124
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Injection Control Valve Removal/Installation
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Fault codes can occur if steam sprays
directly on the electrical connections on top
of the accumulator block.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove the fuel injection pump accumulator.
Refer to Procedure 005-085.
Remove
Unplug the engine wiring harness from the
injection control valve connector.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove the injection control valve drain line.
Remove the six injection control valve mounting
screws.
Remove the injection control valve from the
distributor module.
Do not misplace parts during disassembly.
Secure the six bolts, sealing plate, and both
crush tubes into a parts bag. The parts are to be
returned with the core.
Clean and Inspect for Reuse
Clean the mounting surface of the distributor
module and injection control valve.
Use QD contact cleaner, Part Number 3824510.
Spray or wipe debris away from the three
distributor module drillings. Do not allow debris
to enter the distributor module drillings.
Inspect the distributor module sealing face for
cracks, indentations, and damage.
Replace the distributor module if damage is
found.
Install
Install guide pins, Part Number 3165166, in the
upper left and lower right corner of the
distributor module.
Install the o-rings into the sealing plate using
Lubriplate™ to hold them in place.
Slide the sealing plate down over the guide pins.
The o-rings must be securely seated in the
sealing plate before proceeding.
Insert crush tubes into the sealing plate.
Check the position of the crush tubes. They
must sit flush on the distributor module and
must not be installed at an angle.
Drawing No. 9771, Section 12, Rev. A
Page 12-125
Page 12-126
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the injection control valve on top of the
distributor module using guide pins.
Check that the o-rings are still in their grooves.
Install four bolts through the injection control
valve and tighten finger tight.
Remove the two guide pins.
Install the two remaining bolts, finger tight,
through the injection control valve.
CAUTION
Bolts must be torqued as described or the
injection control valve/distributor module
will not function properly. Use a high-quality,
calibrated torque wrench.
Torque bolts in sequence for each pass for six
passes. Refer to the accompanying illustration
for the torque sequence.
Pass
Torque Value
1.
1.8 N•m [16 in-lb]
2.
3.6 N•m [32 in-lb]
3.
5.6 N•m [50 in-lb]
4.
5.6 N•m [50 in-lb]
5.
5.6 N•m [50 in-lb]
6.
5.6 N•m [50 in-lb]
Install the injection control valve drain line.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Click Test
Use INSITE™, with the keyswitch in the ON
position, to run the control valve click test.
Select Injection Control Valve to initiate the test.
A click will be heard until None is selected on
the Control Valve Click Test screen.
If no click is heard, troubleshoot any active fault
codes.
The click test will need to be performed after
any repairs are made to clear the fault codes.
Drawing No. 9771, Section 12, Rev. A
Page 12-127
Page 12-128
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the fuel injection pump accumulator.
Refer to Procedure 005-085.
Install the air bleed line. Refer to Procedure
006-056.
Install the drive gear cover.
Connect the fuel pressure sensor and the fuel
temperature sensors to the engine harness.
Connect the pumping control valve connector to
the engine harness.
Connect the stator connector to the engine
harness.
Click test the injection control valve stator to
check for proper operation. Refer to Click Test
in this procedure.
Start the engine and check for fuel leaks or
active fault codes.
Recheck for fuel leaks or active fault codes.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Pumping Control Valve Tests
Prepare
Click Test
Use INSITE™, with the keyswitch in the ON
position, to run the control valve click test.
Select the Pumping Control Valve to be tested
to initiate the test. Select either front control
valve or rear control valve.
A “click” will be heard until the other pumping
control valve is selected, or None is selected on
the Control Valve Click Test screen.
If no “click” is heard, troubleshoot any active
fault codes.
NOTE: The click test will need to be performed
after any repairs are made to clear the fault
codes.
Cutout Test
The plunger cutout test can be used to check
performance of the front and rear pumping
plungers.
NOTE: When performing this test, the engine
load must be the same when each pumping
plunger is cut out.
Use INSITE™, with the engine running at idle,
to perform this test.
Drawing No. 9771, Section 12, Rev. A
Page 12-129
Page 12-130
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Select the pumping control valve to be cut out.
Select the monitor button and monitor valve
close angle, engine speed, and accumulator
pressure while the selected plunger is cut out.
Record valve close angle, engine speed, and
accumulator pressure after the engine
stabilizes.
After testing with one pumping control valve
disabled, select “None” so that the engine will
run with both valves enabled. Switching directly
from “Front” to “Rear” or “Rear” to “Front” will
cause the engine to misfire or hesitate.
Cut out the other pumping control valve, and
record valve close angle, engine speed, and
accumulator pressure after the engine
stabilizes.
Compare the results when the rear pumping
control valve is cut out, against the results when
the front pumping control valve is cut out.
If the engine dies when one of the pumping
control valves is cut out, replace the
accumulator. Refer to procedure 005-085.
NOTE: The valve close angle must not vary
more than 15 degrees crank angle.
If the valve close angle varies more than 15
degrees between the front and rear valves then
replace the accumulator module. Refer to
Procedure 005-085.
NOTE: Troubleshoot any active fault codes
before replacing the pump.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Rate Shape Snubber Removal/Installation
Prepare
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Thoroughly steam-clean the rate shape tube
and fuel pump area.
Dry with compressed air.
Remove the rate shape tube assembly. Refer to
Procedure 005-090.
Remove
Remove the rate shape snubber assembly.
Use a center punch to pry the seal disc from the
accumulator.
Drawing No. 9771, Section 12, Rev. A
Page 12-131
Page 12-132
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect for Reuse
The parts in the assembly are as shown:
1. Snubber valve seat
2. Spring
3. Rate shape snubber body
4. Seal disc
5. Snubber valve
6. Spring post.
Replace the snubber assembly if the snubber
spring is broken.
Do not reuse snubber seal discs.
Early design snubber valves are not reusable.
Part Number 3800351, first snubber valve
assembly released for CAPS (one groove, not
reusable)
Part Number 3800764, second snubber valve
assembly released for CAPS (two grooves, not
reusable)
Part Number 4010544, current snubber valve
assembly released for CAPS (no grooves, may
be reused); always replace the seal disk.
Install
Clean the bore for the distributor outlet fitting
with QD cleaner prior to installation of the new
snubber assembly.
Install a new seal disc into the accumulator.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Apply lubricating oil to the face of the snubber
seat and to the face and threads of the snubber
fitting.
Install the snubber assembly.
Torque Value: 14 N•m [124 in-lb]
Rotate 80 degrees
Follow-Up
Install the rate shape tube assembly. Refer to
Procedure 005-090.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-133
Page 12-134
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Distributor Inlet Fitting
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Thoroughly steam-clean the distributor outlet
fitting and fuel pump area.
Dry with compressed air.
Remove the rate shape tube assembly. Refer to
Procedure 005-090.
Remove
Remove the distributor inlet fitting and the seal
disc.
NOTE: A tool like the one shown in this
procedure can be made from a 1/8-inch or 3/16inch Allen wrench. Use it to remove the seal
disc.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Two (2) types of inlet fittings and sealing
washers may be in use. A flat washer will be
installed in most new pumps and a piloted
washer will be installed in some ReCon®
pumps. The piloted washer is provided in
service kits to aid installation.
Different removal techniques are necessary
based on the type of sealing washer being
removed.
Removal of “piloted seal washer”
Using a plastic hammer, tap a spiral easy out
into the center hole of the sealing washer. Turn
the easy out counterclockwise to dislodge the
washer.
Removal of a “flat washer”
The flat sealing washer is swaged into the inlet
fitting bore during installation. A special tool can
be made to aid in its removal by grinding the
short leg of a 1/8-inch or 3/16-inch Allen wrench
so that the wrench is no longer than 13-mm
[1/2-in] long (measured from the outside of the
long leg). This tool acts as a mini heal bar to pry
out the sealing washer without damaging the
back of the hole.
Drawing No. 9771, Section 12, Rev. A
Page 12-135
Page 12-136
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Pry out the old sealing washer using the
modified Allen wrench.
Quite a bit of force is required to remove the
sealing washer.
Clean and Inspect for Reuse
CAUTION
Any debris left in this fitting during
assembly will run through the fuel pump.
Damage the to fuel pump can occur.
Using QD contact cleaner, Part Number
3824510, clean the inlet fitting bore from the
bottom of the bore outward.
Install
CAUTION
Any dirt trapped in this fitting during
assembly will run through the fuel pump.
Damage to the fuel pump can occur.
Use clean grease to retain the sealing washer to
the inlet fitting while it is being installed into the
bore. Use Lubriplate™ 105, or equivalent.
Install sealing washer into counterbore in the
inlet fitting.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install a new inlet fitting.
Tighten the fitting after sealing washer is seated
correctly.
Torque Value: 5.7 N•m [50 in-lb]
Rotate 120 degrees clockwise
Follow-Up
Install the rate shape tube assembly. Refer to
Procedure 005-090.
Start the engine and check for fuel leaks at the
rate shape tube connections.
Road-test the vehicle. Recheck for fuel leaks or
active fault codes.
Drawing No. 9771, Section 12, Rev. A
Page 12-137
Page 12-138
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Accumulator Module
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Make sure that steam does not spray
directly on the electrical connections on
the top of the accumulator block, or fault
codes will possibly occur.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove
Remove the fuel pump drive gear cover.
Locate top dead center for cylinder number 1
by barring the engine slowly until the line on
the pump gear lines up with the line on the
gear cover.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove the rate shape tube assembly. Refer
to Procedure 005-090.
Remove the air bleed line. Refer to Procedure
006-056.
Remove the fuel pump upper support bracket.
Disconnect the 4-pin Deutsch connector for
the pumping control valves.
Disconnect the pressure and temperature
sensors.
NOTE: The pressure sensor connector has a
potted pigtail connector. This sensor can only
be disconnected at the engine harness end of
the pigtail harness.
Drawing No. 9771, Section 12, Rev. A
Page 12-139
Page 12-140
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
WARNING
The accumulator module weighs 11 kg [25
lb] and is free to move once the capscrews
are removed. Do not drop; personal injury
can occur.
CAUTION
Do not use air tools. The use of air tools
will possibly damage the fuel pump.
Remove two of the four capscrews that are
located diagonally from one another.
Remove the last two capscrews. Alternately
loosen the capscrew to avoid binding. Loosen
each capscrew about one turn at a time.
WARNING
The accumulator module weighs 11 kg [25
lb] and is free to move once the capscrews
are removed. Do not drop; personal injury
can occur.
Remove the accumulator module.
Use as much care as possible to avoid
dislodging the springs from the bottom of the
accumulator.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
If the springs are dislodged, the ceramic
plungers can fall out. The plungers are
matched to each bore.
Reseat the springs fully onto plunger barrels.
Do not interchange the plungers.
NOTE: Before replacing a ceramic plunger,
special care needs to be taken to clean it.
Use QD contact cleaner, Part Number
3824510, to clean the plunger.
Remove the oil seal ring and fuel passage orings.
Clean and Inspect for Reuse
Clean the small fuel passage using the plastic
tube provided with the contact cleaner.
Use QD contact cleaner, Part Number
3824510.
Drawing No. 9771, Section 12, Rev. A
Page 12-141
Page 12-142
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean the o-ring groove and mounting surface
on the cam housing and the accumulator.
Make sure the top of the tappets in the cam
housing are clean. Wipe out debris with a
clean towel.
Check the tappets for proper alignment.
The tappets have a slot on the side that
engages a pin on the engine side of the cam
housing. The pin keeps the roller aligned with
the camshaft. Make sure the tappet assembly
is properly aligned. Make sure the tappet
guide pins and guide pin grooves are not worn
excessively.
With the tappets removed, the tappet rollers
and camshaft can be inspected. Linear
scratches on the cam and rollers is expected;
pitting on the nose of the camshaft is not.
Install
Install a new oil ring seal and fuel passage oring.
Apply Lubriplate™ 105, or equivalent, to the oring grooves to hold the o-rings in place.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAUTION
The ceramic plungers can fall out when
removing the plastic caps or old springs.
Do not interchange the plungers. If they fall
out, use QD contact cleaner, Part Number
3824510, to clean the plungers thoroughly
before replacing them.
If replacing the accumulator module with a new
one, remove the springs from the old
accumulator module.
Fully install the springs on the plunger barrels
of the new accumulator module.
NOTE: The use of two 10-mm x 80-mm studs
will aid in the installation.
Install the accumulator module.
NOTE: Use care to avoid dislodging the
springs on the accumulator and the o-rings on
the cam housing.
CAUTION
Do not use air tools. The use of air tools will
possibly damage the fuel pump.
Install two of the four capscrews.
Draw the accumulator module down evenly.
Only turn each capscrew about one turn at a
time.
Make sure the o-rings are still in their grooves
before the accumulator is fully tightened to the
cam housing. Use a mirror if necessary.
Drawing No. 9771, Section 12, Rev. A
Page 12-143
Page 12-144
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install remaining two capscrews.
Tighten the four capscrews.
Torque Value: 68 N•m [50 ft-lb]
Install the upper support bracket.
Tighten the capscrews.
Torque Value: 44 N•m [32 ft-lb]
Follow-Up
Finishing Steps
Install rate shape tube assembly. Refer to
Procedure 005-090.
Install the air bleed line. Refer to Procedure
006-056.
Install the drive gear cover.
Connect the fuel pressure sensor and the fuel
temperature sensors to the engine harness.
Connect the pumping control valve connector to
the engine harness.
Start the engine and check for fuel leaks or
active fault codes.
Road-test the vehicle.
Recheck for fuel leaks or active fault codes.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Page 12-145
Fuel Pump Distributor and Injection Control Valve Module
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Fault codes can occur if steam sprays
directly on the electrical connections on
top of the accumulator block.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove the air bleed line. Refer to Procedure
006-056.
Remove the fuel pump from the engine, if
necessary. Refer to Procedure 005-016.
Mount the fuel pump in the vise ring. Orient
the pump with the distributor facing upward to
aid in disassembly.
Remove the rate shape tube assembly. Refer
to Procedure 005-090.
Drawing No. 9771, Section 12, Rev. A
Page 12-146
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
CAUTION
The capscrews also fasten the gear pump
module. The gear pump is free to move
after the capscrews are removed.
Loosen but do not remove the distributor
plug.
Remove the four mounting capscrews on the
distributor.
Remove the injection control valve/distributor
module.
Remove the drive coupling.
Discard the two o-rings.
Place the injection control valve/distributor
module on a clean bench vise.
Remove the injection control valve from the
distributor module and install the injection
control valve on the new distributor module.
Refer to Procedure 005-078.
NOTE: Injection control valves built before
January 2001 are not reusable. If removing
an injection control valve built before January
2001, use the appropriate injection control
valve kit to complete the repair.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Inspect coupling and gear pump shaft ends
for excessive wear. Wear may be found on
the inside corners of the coupling groove;
such wear is not common.
A polished surface is acceptable.
Replace the gear pump module if wear is
visible.
Replace the gear pump module if the gear
pump driveshaft is damaged.
NOTE: A distributor rotor seizure can cause
damage to the gear pump. If rotor seizure is
suspected, inspect the gear pump. Refer to
Procedure 005-089.
Install
Install the drive coupling.
Center the coupling on the gear pump shaft.
Apply Lubriplate™ 105, or equivalent, to the
coupling to keep it from sliding in the shaft
groove during assembly.
Drawing No. 9771, Section 12, Rev. A
Page 12-147
Page 12-148
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install new o-rings.
Apply Lubriplate™ 105, or equivalent, to the
o-rings to keep them from falling out during
assembly.
The dowel pin must be facing up toward the
top of the pump.
If the shaft needs to be rotated, install the fuel
pump drive nut onto the shaft to provide a
means for rotating the shaft.
CAUTION
The rotor can slide out once the
distributor plug is removed.
CAUTION
Do not drop the rotor. Damaging the rotor
will necessitate replacement of the entire
distributor module.
Remove the large plug from the end of the
distributor.
Do not remove the rotor.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the distributor module.
Lightly rotate the rotor with finger pressure
until it drops into the slot in the drive coupling.
When properly engaged, the notch in the
rotor will align with the hole in the distributor
(when the engine is at top dead center for
number 1 cylinder).
Do not pinch the o-rings.
Install the four distributor capscrews.
Tighten the capscrews.
Torque Value: 48 N•m [35 ft-lb]
CAUTION
The rotor must be properly timed to the
fuel pump camshaft. Improper assembly
will cause the rotor to be 180 degrees out
of time.
If not properly timed, reinstall the drive
coupling and rotor. Refer to Procedure 005072.
Drawing No. 9771, Section 12, Rev. A
Page 12-149
Page 12-150
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install a new o-ring on the distributor plug.
Install the large plug at the end of the
distributor.
Tighten the distributor plug.
Torque Value: 14 N•m [120 in-lb]
Follow-Up
Install the rate shape tube assembly. Refer to
Procedure 005-090.
Install the fuel pump on the engine. Refer to
Procedure 005-016.
Install the air bleed line. Refer to Procedure
006-056.
Run the injection control valve click test using
INSITE™. Refer to Procedure 005-078.
Start the engine and check for fuel leaks or
active fault codes.
Road-test the vehicle for at least one mile.
Recheck for fuel leaks or active fault codes.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Cam Housing Module
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Make sure that steam does not spray
directly on the electrical connections on the
top of the accumulator block, or fault codes
will possibly occur.
Thoroughly steam-clean the entire fuel pump.
Dry the pump with compressed air.
Bar the engine to TDC.
Drawing No. 9771, Section 12, Rev. A
Page 12-151
Page 12-152
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
CAPS Fuel System
Remove the air bleed line (1). Refer to
Procedure 006-056.
Remove the fuel pump from the engine. Refer
to Procedure 005-016.
Mount the fuel pump to the mounting plate, Part
Number 3162897, and orient the fuel pump with
the distributor facing upward to aid in
disassembly.
Remove the rate shape tube assembly. Refer to
Procedure 005-090.
Remove the accumulator module. Refer to
Procedure 005-085.
Remove the distributor module. Refer to
Procedure 005-086.
Remove the gear pump module. Refer to
Procedure 005-089.
Clean and Inspect for Reuse
Clean the mounting surfaces of the cam
housing.
Use QD contact cleaner, Part Number
3824510.
Inspect the camshaft coupling interface for
wear. If the camshaft is worn excessively,
replace the cam housing module.
CAUTION
If the tappets are removed, be sure to install
them in the same bore they were removed
from.
Remove the roller tappets from the cam
housing bores.
Inspect the roller surfaces for pitting and wear.
Make sure the roller rotates freely and
smoothly.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Replace the cam housing module if the rollers
are worn.
NOTE: It is normal to see lines (scratches) worn
in the direction of roller travel. The cam housing
or tappets should be replaced if the rollers are
pitted.
Examine the tappets guide pin slots. If the
guide pin slot is worn more than 25-percent of
its original width, the tappet must be replaced.
Inspect the guide pins. If the guide pins are
worn or if oil leaks at the cam housing guide pin
press fit, the cam housing must be replaced.
Inspect the camshaft lobes for pitting and wear.
Replace the cam housing if there is any pitting
or wear.
Inspect for raised burrs in the tappet bore.
Replace the cam housing if raised burrs are
present. Scratching or polishing is normal.
Inspect the tappet bores for scuffing or wear
leading into the housing.
Polishing will occur in vertical bands at many
places around the inside of the bores.
Polish in the bores is acceptable.
Replace the cam housing if there is severe
tappet guide pin wear (more than 25-percent of
tappet pin is worn).
Drawing No. 9771, Section 12, Rev. A
Page 12-153
Page 12-154
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Using fingers, make sure the camshaft turns
freely. The bearings must turn smoothly and
freely during rotation.
Replace the cam housing if the bearings are
tight or rough.
Check the camshaft for end-play.
MAX Camshaft End-Play 0.05 mm [0.002 in]
Inspect the oil feed and pump mounting o-ring.
Install
CAPS Fuel System
Make sure the timing dowel pin in the camshaft
points toward the top of the fuel pump.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricate the tappets and camshaft lobes with
clean 15W-40 engine oil.
Install the roller tappets into the cam housing.
Be sure that the tappets guide grooves are
oriented correctly onto the tappet guide pins.
Also, be sure that the tappet assemblies are
installed in their original bores.
Check the tappets for proper alignment.
The tappets have a slot on the side that
engages a pin on the engine side of the cam
housing. The pin keeps the roller aligned with
the camshaft. Make sure the tappet is properly
aligned.
CAUTION
The ceramic plungers will possibly fall out
when removing the springs. Do not
interchange the plungers or change their
upwards orientation. If the plungers are
removed, use QD contact cleaner, Part
Number 3824510, to clean them before
replacing.
NOTE: When assembling the fuel injection
pump, take care to keep the ceramic pumping
plungers in their original orientation in the
accumulator module.
If not already done, install the spring and tappet
retainers onto the accumulator or fuel pump
barrel assemblies.
Install the gear pump module. Refer to
Procedure 005-089.
Install the distributor module. Refer to
Procedure 005-086.
Install the accumulator module. Refer to
Procedure 005-085.
Install the rate shape tube assembly. Refer to
Procedure 005-090.
Install the fuel pump onto the engine. Refer to
Procedure 005-016.
Install the air bleed line. Refer to Procedure
005-056.
Drawing No. 9771, Section 12, Rev. A
Page 12-155
Page 12-156
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Start the engine and check for fuel leaks or
active fault codes.
Perform repeat throttle snaps to create
increased accumulator or fuel rail pressure.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Gear Pump Module Check
Initial Check
Measure the outlet pressure at the diagnostic
fitting on the CAPS pump at a rated flow
condition and compare to the following chart.
Engine Speed (rpm)
Gear Pump Pressure kPa [psi]
Engine Speed (rpm)
Gear Pump
Pressure kPa [psi]
200
14 [2]
700
138 [20]
1300
379 [55]
2200
827 [120]
Drawing No. 9771, Section 12, Rev. A
Page 12-157
Page 12-158
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Gear Pump Module Removal/Installation
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris or
dirt can cause personal injury.
CAUTION
Make sure that steam does not spray
directly on the electrical connections on the
top of the accumulator block, or fault codes
will possibly occur.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove the air bleed line. Refer to Procedure
006-056.
Remove the fuel pump from the engine. Refer
to Procedure 005-016.
Mount the fuel pump in a vise ring. Orient the
pump with the distributor facing upward to aid in
disassembly.
Remove the rate shape tube. Refer to
Procedure 005-090.
Remove the distributor module. Refer to
Procedure 005-086.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
Remove the gear pump module.
NOTE: Do not remove the two capscrews. The
gear pump will slide off the dowel pins once the
distributor is removed.
Clean and Inspect for Reuse
Clean the mounting surfaces of the gear pump
and cam housing.
Use QD contact cleaner, Part Number 3824510.
Inspect the drive coupling and shaft ends for
excessive wear.
A polished surface is acceptable.
Replace the coupling if wear is visible.
Drawing No. 9771, Section 12, Rev. A
Page 12-159
Page 12-160
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
CAUTION
The larger o-rings on either end of the gear
pump differ in size. The longer o-ring goes
to the side facing the cam housing.
Install new o-rings.
Apply Lubriplate™ 105, or equivalent, to the orings to keep them from falling out during
assembly.
Install the drive coupling.
Center the coupling in the shaft.
Align the gear pump shaft with drive the
coupling and install the gear pump module.
Make sure the o-rings are not pinched.
Make sure the timing dowel pin is facing toward
the top of the fuel pump.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the distributor module. Refer to
Procedure 005-086.
Install the rate shape tube. Refer to Procedure
005-090.
Install the fuel pump on the engine. Refer to
Procedure 005-016.
Install the air bleed line. Refer to Procedure
006-056.
Start the engine and check for fuel leaks or
active fault codes.
Road-test the vehicle for at least one mile.
Recheck for fuel leaks or active fault codes.
Drawing No. 9771, Section 12, Rev. A
Page 12-161
Page 12-162
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Rate Shape Tube
Prepare
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Make sure that direct steam spray stream
does not contact the electrical connections
on the top of the accumulator block; fault
codes will possibly occur.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove
Loosen the two rate shape tube nuts (1).
Remove the two bracket capscrews (2).
Remove the rate shape tube assembly.
Do not loosen or remove the isolator capscrews
(3).
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Clean the ends of the rate shape tube.
Clean out the rate shape tube with contact
cleaner if debris is suspected of entering the
tube.
Flush any dirt from the snubber fitting and
distributor inlet fitting.
Use QD contact cleaner, Part Number
3824510.
Inspect isolators for signs of wear or cracks.
Replace the rate shape tube assembly if any
isolator is worn, cracked, or missing.
Inspect the ends of the rate shape tube for
damage.
Drawing No. 9771, Section 12, Rev. A
Page 12-163
Page 12-164
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install the rate shape tube assembly using the
following steps:
Install the tube nuts (1) and capscrews (2)
finger tight
Tighten the rate shape tube nuts (1)
Torque Value: 46 N•m [34 ft-lb]
Tighten the two bracket capscrews (2).
Capscrew 41 N•m [30 ft-lb]
Thermistor Adapter 34 N•m [25 ft-lb]
NOTE: If any force is required to flex the rate
shape tube in order to start the tube nuts, the
rate shape tube must be replaced with a new
tube.
NOTE: Make sure the harness clip is installed
between the bracket and capscrew, not
between the bracket and accumulator.
Follow-Up
Start the engine and check for fuel leaks at the
rate shape tube connections.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Head Outlet Fitting
Prepare
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris or
dirt can cause personal injury.
Thoroughly clean the entire fuel pump.
Dry the fuel pump with compressed air.
Remove the high-pressure fuel line from the fuel
pump actuator housing. Refer to Procedure 006051.
Remove the fuel drain line from the actuator
housing. Refer to Procedure 006-013.
Remove the fuel supply line from the fuel pump
actuator housing. Refer to Procedure 006-024.
Remove the fuel pump actuator housing from
the high-pressure fuel pump. Refer to Procedure
005-228.
Remove
Remove the fuel pump head outlet fitting and
the seal washer from the threaded hole in the
back of the high-pressure pump head.
NOTE: It is necessary to remove the seal
washer with the aid of a tapered punch. Insert a
tapered punch into the center of the seal washer
and work the seal out from the bore in the back
of the high-pressure pump head.
Drawing No. 9771, Section 12, Rev. A
Page 12-165
Page 12-166
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Clean the threaded hole in the high-pressure
pump head with QD contact cleaner, Part
Number 3824510.
Inspect the threads and cavity in the highpressure pump head for burrs or debris.
Inspect the seal washer end of the outlet fitting.
There should be a polished crown that is free of
nicks or inclusions. If the crown is damaged or
severely flattened, the male union must be
replaced.
Clean any burrs with a wire brush then flush the
bore clean.
Install
NOTE: This joint is designed to seal in excess of
179,264 kPa [26,000 psi]. Seal washers must
not be reused.
Install a new seal washer onto the outlet fitting.
The seal washer should pilot into the outlet
fitting. A small amount of very clean grease,
such as Lubriplate™, will help in keeping the
seal attached to the outlet fitting during
installation.
Torque Value: 5.6 N•m [50 in-lb]
Rotate 120 degrees
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the fuel pump actuator housing to the
high-pressure fuel pump. Refer to Procedure
005-228.
Install the high-pressure fuel line to the fuel
pump actuator housing. Refer to Procedure
006-051.
Install the fuel drain line to the actuator housing.
Refer to Procedure 006-013.
Install the fuel supply line to the fuel pump
actuator housing. Refer to Procedure 006-024.
Operate the engine and check for leaks.
Perform several throttle snaps so that increased
fuel rail pressure may be developed.
Drawing No. 9771, Section 12, Rev. A
Page 12-167
Page 12-168
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Head Checks
Initial Check
This test utilizes a flow adapter fitting. The
purpose of the flow adapter fitting is to route
the drain flow of the fuel pump only into a
collection device so that leakage may be
measured.
This tool, Part Number 3164618, can be
purchased or constructed according to the
procedures in Procedure 006-026.
Test Setup
Remove the banjo bolt from the fuel pump
drain line at the fuel drain manifold.
Install a banjo flow adapter fitting at the fuel
drain manifold and route a hose from this
adapter to a bucket or the vehicle's fuel tanks.
The pump drain line connects at the center
connection point on the fuel drain manifold.
Alternate Test Setup
If the drain manifold is not easily accessed, a
M14 banjo may be attached at the pump head
drain port with a fuel hose that is routed to the
collection container.
In this setup a bolt, nut, and washers are
needed to prevent drain flow from flowing
backwards and leaking from the unused drain
line.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAUTION
The high-pressure leakage test in the
INSITE™ electronic service tool will cause
the engine to operate at elevated pressures
while the engine idles. The engine noise will
change when this test is being performed
due to the higher fuel injection pressures.
Safety glasses should be worn while
working near the running engine. Fuel lines
should not be adjusted while performing
this test.
Close the engine cover(s) while performing
these tests.
Test (Engine Will Not Start)
Turn the keyswitch ON and allow the lift pump
to complete its cycle. Afterward the cycle is
completed, begin cranking the engine until fuel
exits the drain line.
When fuel begins to exit the drain line, route
the drain flow to a graduated cylinder and
continue cranking for 30 seconds.
Maximum Volume of Fuel During Cranking: 200
cc [7 oz] in 30 seconds
If 200 cc [7 oz] pump head drain flow is
collected in less than 30 seconds of cranking,
the pump head has failed and must be
replaced.
Drawing No. 9771, Section 12, Rev. A
Page 12-169
Page 12-170
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Test (Engine Will Start)
If the engine will start, perform the highpressure leakage test using Cummins
INSITE™ electronic service tool.
Connect the INSITE™ electronic service tool.
Start the engine and allow the engine to idle
with fuel flowing into a collection device.
Begin the high-pressure leakage test using
INSITE™.
Measure the time necessary to collect 300 cc
[10 oz] of fuel pump head drain flow while
performing the high-pressure leakage test.
Use a graduated cylinder for this
measurement.
Maximum Volume of Fuel During HighPressure Leakage Test: 300 cc [10 oz] in 30
seconds
If 300 cc [10 oz] pump head drain flow is
collected in less than 30 seconds, the pump
head has failed and must be replaced.
This specification is valid for engines operating
on diesel fuels. Low fuel viscosity will increase
the leakage rate; for example, kerosene or
aviation fuels will result in excessive leakage.
Verify the fuel type before replacing a fuel
pump head for excessive leakage.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Head Removal/Installation
Prepare
Remove the high-pressure fuel line from the
high-pressure pump. Refer to Procedure 006051.
Remove the fuel drain line from the fuel pump
actuator housing. Refer to Procedure 006-013.
Remove the fuel supply line from the fuel pump
actuator housing. Refer to Procedure 006-024.
Disconnect the wire harness from the fuel
pump actuator.
Remove the fuel pump actuator housing. Refer
to Procedure 005-228
Remove
Remove the fuel pump drive gear cover.
Locate top dead center for cylinder number 1
by barring the engine slowly until the line on the
pump gear lines up with the line on the gear
cover.
CAUTION
Do not use air tool. The use of air tools will
possibly damage the fuel pump.
Remove the upper support bracket.
Remove two of the four capscrews that are
located diagonally from one another.
Drawing No. 9771, Section 12, Rev. A
Page 12-171
Page 12-172
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove the last two capscrews. Alternately
loosen the capscrew to avoid binding. Loosen
each capscrew about one turn at a time.
Carefully lift the fuel pump head from the cam
housing, being careful to keep the tappet
springs attached to the pump head, and place
the head on a clean surface.
Clean and Inspect for Reuse
Remove the springs and spring retainers from
the barrel retainers.
Make certain to keep track of which spring
came from the front and rear. It is
recommended that these parts be installed in
the same order even if a new high-pressure
pump head is installed.
CAUTION
Do not remove the barrel retainers. Damage
to the pump head and barrel retainers will
result.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
If the plungers are pressed fully upward, the
fluid above the plunger and the inlet check
valve seal can hold it in place.
Special care must be taken to be sure these
parts are kept extremely clean if removed.
Cover the cam housing with a clean shop towel
while the head is removed.
Do not use cleaning agents, other than contact
cleaner, on pump components.
CAUTION
Each plunger must be installed in the same
orientation and in the same barrel, or
engine damage can result. Marking the
bottoms of the plungers with a felt tip
marker will help to ensure that correct
orientation is maintained.
If the plungers are removed, inspect the
plungers. Slight discoloration can be evident.
Deep scoring must not be evident. If scoring or
scratches exist that can be felt, the fuel pump
head must be replaced.
While the fuel pump head is removed, inspect
the cam housing. The tappets can be removed
using an o-ring pick as the removal tool.
Drawing No. 9771, Section 12, Rev. A
Page 12-173
Page 12-174
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect the tappet guide pins and tappet guide
pin grooves for excessive wear. If more than
25-percent guide pin or groove wear is
observed, the fuel pump must be replaced.
With the cam housing tappets removed, inspect
the camshaft for wear. If excessive pitting on
the nose of the camshaft is observed, the fuel
pump must be replaced.
Inspect the tappet rollers for wear. If excessive
pitting on the rollers is observed, the tappet(s)
must be replaced.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
If damage to the camshaft, tappets, or cam
housing is observed, it is possible the fuel
pump is not receiving adequate lubricating oil.
When replacing the fuel pump, inspect the gear
housing to make sure no blockages exist in the
oil supply to the fuel pump.
Install
Install the tappets in their original tappet bores.
Be certain the tappets are installed in their
original locations.
Be certain that the tappet guide pins engage
the guide the guide pin grooves.
Install new fuel pump head o-rings onto the
cam housing.
If installing a new or rebuilt pump head, install
the new tappet springs and retainers provided
with the pump head.
Place the high-pressure pump head onto the
high-pressure pump cam housing.
Draw the high-pressure pump head down by
alternately tightening the four high-pressure
pump head bolts until the head just contacts
the cam housing.
Tighten the four high-pressure pump head bolts
to their final torque.
Torque Value: 68 N•m [50 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Page 12-175
Page 12-176
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Connect the upper support bracket to the highpressure pump head in the following order:
Connect the upper support bracket bolts to the
high-pressure pump head and tighten finger
tight.
Connect the upper support bracket bolts to the
cylinder head and tighten to their final torque.
Support Bracket to Cylinder Head 43 N•m
[32 ft-lb]
Tighten the bolts that attach to the highpressure pump head to their final torque.
Support Bracket to Pump Head 43 N•m [32
ft-lb]
Follow-Up
Install the fuel pump actuator housing. Refer to
Procedure 005-228.
Connect the high-pressure fuel supply line.
Refer to Procedure 006-051.
Connect the fuel drain line from the fuel pump
actuator housing. Refer to Procedure 006-013.
Connect the fuel supply line from the fuel pump
actuator housing. Refer to Procedure 006-024.
Connect the engine harness to the fuel pump
actuator.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Actuator Housing
Prepare
Disconnect the wire harness from the fuel pump
actuator.
Disconnect the fuel supply line from the fuel
pump actuator housing. Refer to Procedure 006024.
Disconnect the high-pressure fuel line from the
fuel pump actuator housing. Refer to Procedure
006-051.
Disconnect the fuel drain from the fuel pump
actuator housing. Refer to Procedure 006-013.
Remove
Remove the three bolts that hold the fuel pump
actuator housing to the high-pressure fuel pump
head.
Remove the fuel pump actuator housing and the
gasket.
Clean and Inspect for Reuse
Inspect the fuel pump actuator housing gasket.
Do not reuse the gasket if the material is
damaged, cracked, or torn.
Be sure that the mounting surfaces of the highpressure pump head and the fuel control valve
adapter block are clean. Use contact cleaner to
clean these surfaces.
Drawing No. 9771, Section 12, Rev. A
Page 12-177
Page 12-178
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Insert the three mounting bolts through the fuel
pump actuator housing.
Install the gasket over the bolts. The gasket
must be installed dry.
Install the actuator housing.
Tighten the mounting bolts.
Torque Value: 34 N•m [25 ft-lb]
Follow-Up
Connect the high-pressure fuel line to the fuel
pump. Refer to Procedure 006-051.
Connect the fuel supply line to the fuel pump.
Refer to Procedure 006-024.
Connect the fuel drain line to the fuel pump.
Refer to Procedure 006-013.
Connect the wire harness to the fuel pump
actuator.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Injection Pump Removal/Installation
Prepare
Disconnect the injection pump supply line. Refer
to Procedure 006-024.
Remove the injector supply lines. Refer to
Procedure 006-051.
Disconnect the fuel drain line. Refer to
Procedure 006-013.
Disconnect the pumping control valve 4-pin
Deutsch connector.
Disconnect the injection control valve 4-pin
Deutsch connector.
Disconnect the accumulator pressure sensor.
Disconnect the accumulator temperature
sensor.
Remove
Remove the injection pump upper support
bracket.
Remove the injection pump tail support bracket.
Remove the fuel pump gear access plug.
Drawing No. 9771, Section 12, Rev. A
Page 12-179
Page 12-180
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Locate top dead center for cylinder number 1 by
barring engine slowly until the line on the pump
gear lines up with the line on the gear cover.
Remove the fuel pump drive gear retaining nut
and washer.
Pull the fuel injection pump drive gear loose
from the pump driveshaft.
Remove the four mounting nuts.
Remove the fuel injection pump.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
The fuel pump driveshaft key must not be
sheared.
If the key is sheared, the cam housing module
of fuel pump must be replaced and the drive
gear must be replaced.
Check that the locating dowel is installed in the
cam housing.
Install
Be sure the engine is at number 1 cylinder top
dead center. The fuel pump gear timing mark
should align with the top dead center mark on
the gear housing.
Clean the fuel injection pump drive shaft with an
evaporative cleaner.
Clean the fuel pump gear inside diameter with
an evaporative cleaner.
The fuel pump drive gear inside diameter and
the drive shaft outside diameter must be clean
and dry before installing the gear.
Make sure the fuel injection pump is at its top
dead center position.
The fuel injection pump is at number 1 cylinder
top dead center when the dowel pin in the shaft
(A) is perpendicular to the top of the
accumulator.
Be sure that the dowel is installed in the pump
driveshaft.
Drawing No. 9771, Section 12, Rev. A
Page 12-181
Page 12-182
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Make sure the o-ring seals for the oil feed orifice
(A) and pilot (B) are correctly installed and are
not damaged.
Lubricate the mounting flange with cleaner.
The fuel pump drive gear inside diameter and
the shaft outside diameter must be clean and
dry before installing the gear.
Slide the fuel injector pump shaft through the
drive gear and position the fuel injection pump
flange onto the mounting studs.
Make sure the dowel pin in the shaft (A) lines up
with the keyway in the fuel injection pump gear.
Make sure the dowel pin in the fuel injection
pump flange lines up with the hole in the gear
housing.
Install the mounting nuts.
Install the fuel injection pump upper support
bracket.
Install the fuel injection pump tail support
bracket.
Fuel Pump Mounting Nuts: 44 N•m [32 ft-lb]
Fuel Pump Support Brackets (8.8 or 9.8
capscrews): 44 N•m [32 ft-lb]
Fuel Pump Support Brackets (10.9
capscrews): 65 N•m [48 ft-lb]
Tighten the fuel injection pump drive gear nut.
Torque Value: 108 N•m [132 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the gear cover access cap hand tight.
Connect the injection pump supply line. Refer to
Procedure 006-024.
Connect the injector supply lines. Refer to
Procedure 006-051.
Connect the fuel drain line. Refer to Procedure
006-013.
Connect the pumping control valve 4-pin
Deutsch connector.
Connect the injection control valve 4-pin
Deutsch connector.
Connect the accumulator pressure sensor to
the engine harness.
Connect the accumulator temperature sensor to
the engine harness.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-183
Page 12-184
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Cooled ECM Cooling Plate Removal/Installation
Initial Check
The ECM cooling plate assembly provides a
vibration isolated mounting location for the
ECM. The cooling plate also provides ECM
cooling and incorporates the fuel lift pump. A
check valve at the outlet port in the ECM
cooling plate makes sure that the fuel system is
primed while the fuel lift pump is running.
Check the ECM cooling plate for damaged
vibration isolators, loose capscrews, or fuel
leaks.
Make sure that the ground strap is properly
installed. A missing or poorly connected ground
strap may cause intermittent engine
performance problems.
The ground strap must be connected between
the head of the ECM mounting bolt and the
ECM.
The ground strap must be connected to an
unpainted block surface that is free of corrosion.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Prepare
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the negative (-) battery cable first.
Disconnect the harness connections from the
ECM.
Disconnect the ECM ground strap.
Disconnect the engine harness from the electric
fuel priming pump.
Disconnect the fuel supply lines from the ECM
cooling plate. Remove the suction fuel lines, if
necessary.
Remove the ECM from the cooling plate. Refer
to Procedure 019-031 in Troubleshooting and
Repair Manual, CM850 Electronic Control
System, ISC, QSC8.3, ISL and QSL9 Engines,
Bulletin
Remove
Remove the ECM cooling plate capscrews and
the ECM cooling plate form the engine block.
NOTE: The electric fuel priming pump and
priming pump fuel lines will be attached to the
ECM cooling plate while the cooling plate is
being removed.
Drawing No. 9771, Section 12, Rev. A
Page 12-185
Page 12-186
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Disassemble
Remove the following components from the
ECM cooling plate:
Male banjo quick disconnect fitting
Male banjo check valve fitting
Fuel lift pump supply lines
Fuel lift pump brackets
Fuel lift pump.
Inspect for Reuse
Inspect the ECM cooling plate for leaks (note
that the fuel passages are contained in a tube
that is cast into the cooling plate).
Replace any damaged vibration isolators.
Inspect for leaks in the electric fuel supply pump
priming circuit; look for cracked fuel tubes,
damaged o-rings or damaged seal washers.
Inspect the check valve for debris or damage.
Assemble
Install the electric fuel priming pump. Refer to
Procedure 005-045.
Install the fuel priming circuit fuel lines. Refer to
Procedure 005-045.
Be sure the lines are supported while tightening
the banjo screws. The lines must not be
permitted to bind.
Be sure the ECM check valve is installed into
the bottom (outlet) fitting of the ECM cooling
plate.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install the ECM cooling plate assembly on the
engine block. Tighten the capscrews.
Torque Value: 24 N•m [18 ft-lb ]
Follow-Up
CAUTION
Failure to properly install the ECM ground
strap may cause intermittent engine
symptoms including intermittent engine
stalls. One end of the ground strap must be
installed between the ECM housing and the
head of the bottom most ECM mounting
capscrew. The other end of the ground strap
must be tightly bolted to an unpainted block
surface that is free from corrosion.
NOTE: Be sure the vibrations isolators are
installed correctly. The isolators fit in a single
direction into the chamfered locators.
Install the ECM on the ECM cooling plate. Refer
to Procedure 019-031 in Troubleshooting and
Repair Manual, CM850 Electronic Control
System, ISC, QSC8.3, ISL and QSL9 Engines,
Bulletin 4021416.
Install the fuel supply lines. Refer to 006-024.
Cycle the keyswitch a few times to allow the
system to prime.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-187
Page 12-188
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Measure Fuel Drain Line Restriction
Prepare
Obtain or construct a M12 banjo pressure
gauge tool.
A banjo-style pressure gauge adapter may be
used to measure pressure or vacuum at any
point in the low-pressure fuel system where a
banjo bolt exists at a fuel line.
The ISC and ISL engines with high-pressure
common rail fuel systems use M12 x 1.5 banjo
bolt connections. This tool may be used for
measurement of drain line restriction (pressure)
at the fuel drain manifold.
Make a banjo bolt pressure gauge tool by
drilling and tapping the hex face of a M12 x 1.5
banjo bolt, Part Number 3903035, or equivalent.
Drill and tap the banjo bolt to the size of
Compuchek® fitting, or other hose union, being
used (example 1/8-inch NPT Compuchek®
fitting, Part Number 3377244, or M10
Compuchek® fitting, Part Number 3824842).
Assemble the banjo pressure gauge adapter.
Install the Compuchek® or other type fitting in
the hex face of the banjo bolt.
Attach a hose or pressure gauge to the banjo
pressure adapter.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the M12 banjo pressure gauge adapter in
place of the injector drain line banjo at the fuel
drain manifold (Cummins Common Rail fuel
systems).
Install the M12 banjo pressure gauge adapter in
place of the banjo bolt that attaches the injector
drain line to the electric lift pump drain manifold
(CAPS fuel systems).
Install a 0 to 762 mm Hg [0 to 30 in Hg]
pressure gauge at the M12 banjo pressure
gauge adapter.
Measure
Operate the engine at rated speed and no load.
Observe the reading on the gauge.
Maximum Fuel Drain Line Pressure 254.0 mmhg [10.0 in-hg]
If the drain line pressure is out of specification,
check for bends or kinks in the drain lines. Look
for places where the OEM fuel lines may be
pinched by wire ties or p-clips. Check for block
fuel tank vents.
Follow-Up
Remove all test fittings and reinstall drain lines.
Refer to Procedure 006-013.
Drawing No. 9771, Section 12, Rev. A
Page 12-189
Page 12-190
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Drain Lines Removal/Installation
Prepare
Remove
CAPS Fuel System
There are two drain lines on the engine:
The fuel injection pump drain line routes fuel
from the fuel injection pump to the fuel lift pump
drain manifold. This line has a p-clip brace that
attaches to the cylinder head.
The injector drain line which routes fuel from the
rear of the cylinder head to the fuel lift pump
drain manifold.
These lines are removed by removing the banjo
bolts and sealing washers.
Inspect for Reuse
Inspect the lines for damage.
Inspect the banjo seal washers for damage.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
CAPS Fuel System
Connect the fuel drain line at the fuel pump
banjo fitting at the rear of the cylinder head and
at the lift pump. Use two (2) wrenches when
installing the drain line at the fuel pump return.
Style One (1) 24 N•m [18 ft-lb ]
Style Two (2) 24 N•m [18 ft-lb ]
Refer to Procedure 006-056 for the air bleeding
installation procedure.
Install and tighten the clamp capscrews.
M12 Banjo Bolts 24 N•m [18 ft-lb]
P-Clip Capscrew 24 N•m [18 ft-lb]
Follow-Up
Operate the engine under a load and check for
leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-191
Page 12-192
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Spin-On Type Fuel Filter
General Information
CAPS Fuel System
The CAPS fuel system requires the use of a
single fuel filter. The filter must have the
following characteristics:
water-separating
10-micron rating
water-in-fuel sensor
water-drain valve
engine mounted or chassis mounted.
Fleetguard® FS1022 meets these requirements.
Prepare
Remove
Disconnect the wiring harness from the waterin-fuel sensor, if equipped.
Disconnect the wiring harness from the fuel
heater, if equipped.
Loosen and remove the fuel filter.
Make sure the seal ring does not stick to the
filter head.
Remove the ring with an o-ring pick, if
necessary.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
CAPS Fuel System
CAUTION
Mechanical over-tightening can distort the
threads as well as damage the filter element
seal or filter canister.
Do not fill the fuel filter with fuel before
installation; instead, prime the fuel system using
the fuel lift pump.
Be sure the center seal ring is installed onto the
filter spud.
Install the filter as specified by the filter
manufacturer.
Connect the water-in-fuel sensor and the fuel
heater, if equipped.
Prime
WARNING
Do not open the high-pressure fuel system
with the engine running. Engine operation
causes high fuel pressure. High-pressure
fuel spray can cause serious injury or death.
Cycle the keyswitch and allow the lift pump to
run. The lift pump will run for 30 seconds.
Afterwards, turn the keyswitch off and back on
again allowing the lift pump to run again.
Allow the lift pump to run for three or four 30second cycles before attempting to start the
engine.
Drawing No. 9771, Section 12, Rev. A
Page 12-193
Page 12-194
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Operate the fuel lift pump to help prime the fuel
system. Turn the keyswitch to RUN, but do not
attempt to start the engine. This will cause the
ECM to operate the fuel lift pump through a
priming cycle which lasts at least 30 seconds.
Cycle the lift pump several times by keying off,
waiting 10 seconds and keying back on again.
Once the engine is started, slowly increase the
engine speed while air is purged from the fuel
plumbing.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Measure Fuel Inlet Restriction
Prepare
Set-Up
Obtain a 0.043-inch orificed diagnostic fuel line,
Part Number 3164621. This tool can also be
constructed. Refer to Procedure 006-003.
Obtain a container suitable for collection of fuel
that exits the diagnostic fuel line. A 5-gallon
bucket is recommended.
Install a 1/8-inch NPT Compuchek® diagnostic
fitting, Part Number 3042618, at the inlet to the
fuel injection pump (Cummins Accumulator
Pump System only).
Attach the 0.043-inch orificed diagnostic fuel
line at the fuel injection pump cam housing
Compuchek® fitting. Route this hose into a
collection container or into the fuel tank.
Attach a 0 to 762 mm Hg [0 to 30 in Hg]
vacuum gauge at the gear pump inlet
Compuchek® port.
Measure
Operate the engine at idle and measure the
inlet vacuum.
Maximum Fuel Inlet Restriction (CAPS Fuel
Systems)
At OEM connection 102.0 mm Hg [4.0 in Hg]
At inlet to fuel gear pump (dirty filter) 254.0 mm
Hg [10.0 in Hg]
Maximum Fuel Inlet Restriction (Cummins
Common Rail Fuel System)
At OEM connection (dirty filter) loaded
condition 203.2 mm Hg [8.0 in Hg]
At inlet to fuel gear pump (dirty filter) loaded
condition 304.8 mm Hg [10.0 in Hg]
Drawing No. 9771, Section 12, Rev. A
Page 12-195
Page 12-196
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
If the inlet restriction is excessive, look for the
root cause:
Suction side fuel filters plugged
Fuel heater valves are restricted
ECM cooling plate plugged
ECM cooling plate check valve restriction
OEM fuel lines pinched or restricted
Fuel tank stand pipes restricted.
NOTE: Do not leave Compuchek® fittings
installed on the suction side of the gear pump.
A Compuchek® fitting on the suction side of
the gear pump can allow air to enter the fuel
flow resulting in performance problems.
Disconnect all diagnostic test fittings and
reinstall all plugs.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Low Pressure Fuel Supply Lines Removal/Installation
Initial Check
Inspect all fuel supply lines and fittings. Look
for cracks in the lines or leaking fittings.
Inspect the straight thread o-ring metric hose
fitting. Make sure that the lock nuts tighten
against the o-ring rather than bottom out
against the end of the fitting's threads
(example: Cummins Accumulator Pump
System fuel pump inlet and Cummins
Accumulator Pump System fuel filter head).
Inspect the quick-disconnect style fittings for
damaged o-ring connections or broken locking
tangs.
Remove
Remove the fuel supply lines.
For quick disconnect style fuel lines, remove
the clasp from the fuel line brace. This will allow
the lines to move so they can be disconnected.
Drawing No. 9771, Section 12, Rev. A
Page 12-197
Page 12-198
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Loosen all quick disconnect lines from the
brace.
To remove the gear pump outlet line, the gear
pump inlet line must be removed first.
Remove the quick disconnect style fuel lines by
pressing in the locking tangs on both sides of
the quick disconnect fitting.
To aid removal, a screwdriver may be inserted
between the fuel line end and quick disconnect
male union. After pressing the opposing locking
tangs, twisting the flat blade of the screwdriver
helps to remove the fuel line.
If fuel leaks or suction side air entry is
suspected, remove the fuel hoses or quick
disconnect fittings.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect for Reuse
Inspect for burrs or debris on metal connectors
that may cause leaks.
On straight thread o-ring metric connectors, be
certain the o-rings are not frayed or cut.
On quick disconnect style fittings, be certain the
o-rings are not frayed or cut, and that the lock
tangs are not damaged.
Inspect the banjo seal washers. Replace and
damaged washers.
Install
Install the fuel supply lines.
Number 10 Flare Fitting: 37 N•m [27 ft-lb]
M12 Quick Disconnect Union: 24 N•m [18 ftlb]
Install the quick disconnect fuel lines (Cummins
Common Rail Fuel Systems only).
Install the quick disconnect fittings.
Torque Value 24 N•m [18 ft-lb]
Make sure that the quick disconnect style fuel
lines clasp onto the quick disconnect fittings.
Make sure the lines are routed and connected
correctly. If the lines are connected incorrectly,
the engine will not run.
For quick-disconnect style lines used with the
Cummins Common Rail Fuel System, fuel lines
are routed in the following order:
OEM connection to the upper fitting at the ECM
cooling plate
Lower ECM cooling plate fitting to the upper
gear pump fitting
Lower gear pump fitting to the 2-micron fuel
filter inlet
2-micron fuel filter outlet to the fuel pump fuel
Drawing No. 9771, Section 12, Rev. A
Page 12-199
Page 12-200
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
control actuator housing.
The fuel supply line brace holds the fuel lines in
the following order:
The inside line connects the upper gear pump
fitting to the lower ECM cooling plate fitting
The middle line connects the 2-micron filter
outlet to the fuel pump fuel control actuator
housing
The outside line connects the lower gear pump
fitting to the 2-micron filter inlet.
Install the fuel line brace clasp (quick
disconnect style fuel lines only) and the brace,
if necessary.
Fuel Line Brace 24 N•m [18 ft-lb]
Fuel Line Brace Clasp 24 N•m [18 ft-lb]
Follow-Up
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Injectors Removal/Installation
Preparatory Steps
CAPS Fuel System
CAUTION
Attempting to remove the injector without
first removing the fuel connector will cause
damage to the injector body and/or fuel
connector.
Remove the rocker lever cover. Refer to
Procedure 003-011.
Remove the engine brake, if equipped. Refer to
Procedure 020-004.
Remove the fuel connector. Refer to Procedure
006-052.
Remove
CAPS Fuel System
Remove the injector hold-down bolt that is
nearest the exhaust manifold side of the
engine.
Remove the injector hold-down.
Remove the high-pressure fuel connector.
Refer to Procedure 006-051.
Using the injector puller, Part No. 3825156, pull
the injector out of the head.
Alternatively, a rocker cover capscrew can be
installed into the top of the injector and used to
pull the injector from the cylinder head.
Be sure that the injector seal washer is
removed from the injector bore.
Drawing No. 9771, Section 12, Rev. A
Page 12-201
Page 12-202
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Test
Mechanical Injectors
WARNING
While testing the injectors, keep hands and
body parts away from the injector nozzle.
Fuel coming from the injector is under
extreme pressure and can cause serious
injury by penetrating the skin.
Install the injectors on an injector test stand.
Open the bypass valve for the pressure gauge
so the spray pattern can be checked.
Use injector test fixture, Part Number 3162269,
with the injector nozzle test, Part Number
3376946.
Operate the test stand lever quickly several
times to check the spray pattern of the injectors.
Verify that the correct number of plumes are
present for the number of holes in the injector.
Also pay close attention to the size and shape
of each plume. If possible, compare the spray
pattern to that of a new injector with the same
assembly number.
NOTE: The injector spray pattern is an
excellent indicator of the nozzle hole condition.
Check each plume carefully. It is possible that
only a single hole has been damaged resulting
in degraded engine performance.
Close the bypass valve for the pressure gauge
and operate the test stand lever to check the
nozzle opening pressure. There must be a
good crisp pop when the nozzle opens and the
pressure must be within specification for the
assembly number. Refer to the Master Repair
Manual, Injection Pumps and Injectors,
Midrange Engines, Bulletin 3666037-05 or later.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
If the nozzle opening pressure is excessively
low and/or the nozzle sprays excessive fuel, the
injector needle can be sticking. The needle can
be stuck due to poor lubrication or debris.
Sometimes it is possible to unstick an injector
needle by using the injector test stand. Open
the bypass valve for the pressure gauge and
operate the test stand lever rapidly for 10 to 20
strokes.
Recheck the nozzle opening pressure and
spray pattern to see if the injector has returned
to normal operation.
If the injector is still out of specification, replace
the injector.
Check the injector for drip and/or excessive
leak down. Close the bypass valve for the
pressure gauge and build pressure to within 10
bars of the opening pressure of the nozzle.
A drop of fuel must not form within 15 seconds.
Disassemble
Mechanical Injectors
Place the injector in the injector clamp and
remove the nozzle retaining nut.
NOTE: Injectors covered under warranty by the
manufacturer must not be repaired. Refer to the
manufacturer's warranty instructions.
Remove the nozzle, intermediate plate, spring,
and shims from the injector.
Drawing No. 9771, Section 12, Rev. A
Page 12-203
Page 12-204
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Verify the injector sealing washer is the correct
thickness. The incorrect sealing washer can
cause high pressure fuel leaks, and/or
performance problems due to incorrect injector
protrusion.
Refer to the injector part number for correct
sealing washer shim thickness.
NOTE: All ISC and ISL engines which use
mechanical (“POP”) style injectors use a 1.5
mm [0.06 in] injector seal washer.
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
avoid personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
CAUTION
Do not use a steel wire brush or glass
beading to clean the injectors. This will
damage the nozzle holes and cause
performance problems.
Clean injector tip and body with safety solvent
and soft clean rag.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect the o-ring for damage.
Look for burrs on the inlet to the injector.
Check the nozzle holes for any signs of
damage such as hole erosion or hole plugging.
Spray safety solvent on the injector body and
inspect the fuel inlet passage for small cracks
which can allow high pressure fuel to leak to the
injector drain passage.
Assemble
Mechanical Injectors
Clean the injector internal components with
clean diesel fuel and a clean rag. Make sure
there is no debris in the internal parts of the
injector.
Install shims necessary to modify the nozzle
opening pressure. More shims raise the nozzle
opening pressure, less shims lower the nozzle
opening pressure.
Drawing No. 9771, Section 12, Rev. A
Page 12-205
Page 12-206
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the spring, button, intermediate plate,
and nozzle/needle.
Make sure that the intermediate plate is in the
correct orientation with the supply hole on the
plate lining up with the supply hole on the
holder.
Install the retaining nut finger tight. Place the
injector in the injector clamp and tighten the
retaining nut. Install the sealing washer and
body o-ring.
Torque Value: 47 N•m [35 ft-lb]
Install
CAPS Fuel System
Make sure that the injector bore is clean and
that only one (1) sealing washer is installed on
the injector nozzle.
Lubricate the injector o-ring with clean engine
oil.
Place the injector in the head in the proper
orientation.
Place the injector hold-down clamp on top of
the injector and make sure that the injector is
fully seated in the injector bore.
Install the injector hold-down and tighten.
Torque Value: 10 N•m [89 in-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
CAPS Fuel System
Install the fuel connector. Refer to Procedure
006-052.
Install the rocker lever cover. Refer to
Procedure 003-011.
Install the high pressure fuel lines. Refer to
Procedure 006-051.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-207
Page 12-208
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
High Pressure Injector Supply Lines Removal/Installation
Initial Check
CAPS Fuel System
Inspect the lines for cracks, chafing, or leaks.
Make sure that the lines are tightened to the
proper specification.
Check the fuel pump connection.
Torque Value: 24 N•m [18 ft-lb]
Check the cylinder head connection.
Torque Value: 38 N•m [28 ft-lb]
Initial Check
Cummins Common Rail Fuel System
Check the fuel pump connection.
Torque Value: 38 N•m [28 ft-lb]
Check the cylinder head connection.
Torque Value: 38 N•m [28 ft-lb]
Check the fuel rail connection.
Torque Value: 38 N•m [28 ft-lb]
Prepare
Remove
CAPS Fuel System
Remove the fuel line from the injection pump.
NOTE: Use two (2) wrenches to prevent the
outlet fitting from turning.
Remove the fuel line clamp capscrews from the
intake cover. This must be done before injection
lines can be pulled loose from cylinder head.
Remove the fuel line from the cylinder head.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
Cummins Common Rail Fuel System
If necessary, remove the air intake connection
or turbo control actuator.
Loosen the fuel line at the fuel rail and the fuel
connector or high-pressure pump outlet fitting.
Remove the high-pressure fuel line.
Clean and Inspect for Reuse
Check the ferrules of the lines for any signs of
burrs or foreign material.
Inspect the sealing surface on the cone for
severe deformation that would prohibit reuse.
Check for cracks and deformation.
Install
CAPS Fuel System
Before installing the injector supply lines, make
sure that the fuel connector is fully and properly
seated against the injector. Refer to Procedure
006-052.
Drawing No. 9771, Section 12, Rev. A
Page 12-209
Page 12-210
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the fuel lines in the reverse order of
removal.
Check the fuel pump connection.
Torque Value: 24 N•m [18 ft-lb]
Check the cylinder head connection.
Torque Value: 38 N•m [28 ft-lb]
Operate the engine and check for leaks.
Install
Cummins Common Rail Fuel System
Before installing the injector supply lines, make
sure that the fuel connector is fully and properly
seated against the injector. Refer to Procedure
006-052.
For Cummins Common Rail Fuel Systems, be
certain that the high-pressure connector
retaining nut is tightened. Refer to Procedure
006-052.
Install the fuel lines in the reverse order of
removal.
Check the fuel pump connection.
Torque Value: 38 N•m [28 ft-lb]
Check the cylinder head connection.
Torque Value: 38 N•m [28 ft-lb]
Check the fuel rail connection.
Torque Value: 38 N•m [28 ft-lb]
Operate the engine and check for leaks.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Head Mounted Fuel Connector
Prepare
Remove
CAPS Fuel System
Remove injector supply line. Refer to Procedure
006-051.
Use fuel connector puller, Part Number
3825157, to remove the fuel connector from the
cylinder head.
Inspect for Reuse
A new high-pressure connector must be
installed if a new injector is being installed.
Inspect the fuel connector. Look for burrs or
deformation around the inlet and outlet sides of
the connector.
Check the edge filter for signs of plugging or
material contamination. Do not reuse a highpressure fuel connector debris is present.
Check the o-ring for tearing or deterioration.
Inspect the outlet sealing surface of the highpressure connector for wear, an uneven seating
surface, or signs of leakage.
When a high-pressure fuel leak is present, small
lines or cuts in the connector will be eroded into
the seating surface.
The high-pressure connector and injector must
be replaced when this failure is observed.
Drawing No. 9771, Section 12, Rev. A
Page 12-211
Page 12-212
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
CAPS Fuel System
Oil the fuel connector o-ring with clean engine
oil.
Carefully push the fuel connector into the head
until it stops against the injector. Be certain the
injector is fully seated in the injector bore before
installing the fuel connector. Refer to Procedure
006-026.
Install the high-pressure fuel lines. Refer to
Procedure 006-051.
Operate the engine and check for leaks.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Air Bleed Line
Prepare
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
Do not use the air bleed line as a handle or
step. Doing this may result in cracks or
damaged air bleed line that will cause fuel
leaks. Make sure that steam does not spray
directly on the electrical connections on the
top of the accumulator block or fault codes
will possibly occur.
Thoroughly steam-clean the entire fuel pump.
Dry the fuel pump with compressed air.
Drawing No. 9771, Section 12, Rev. A
Page 12-213
Page 12-214
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
ISC and QSC8.3 With CAPS Injection Pump
WARNING
To reduce the possibility of an air bleed line
leak due to a broken air bleed line, use two
wrenches during removal and installation.
Failure to do so may result in a cracked fuel
line. In certain applications, with the fuel
tank above the head of the engine, this will
result in fuel draining from the fuel tank.
NOTE: There are three styles of air bleed lines.
Identify your style and use the appropriate
procedures that follow.
Style One (1):
Remove the banjo capscrew at the injection
control valve drain fitting of the fuel pump. Use
two wrenches to prevent the line from being
bent.
Style Two (2):
Remove the banjo capscrew at the injection
control valve drain fitting of the fuel pump.
Remove the hollow banjo fitting holding the air
bleed line. Use two wrenches to prevent the line
from being bent.
Remove the banjo capscrew at the air bleed
fitting on top of the fuel pump. It is located on
the accumulator module next to the two
pumping control valves.
Use two wrenches to prevent the air bleed fitting
from turning.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ISL and QSL9 With CAPS Injection Pump
Remove the banjo bolt from the injection control
valve drain fitting and the distributor plug.
Remove the banjo capscrew at the air bleed
fitting on top of the fuel pump. It is located on
the accumulator module next to the two
pumping control valves.
Use two wrenches to prevent the air bleed fitting
from turning.
Inspect for Reuse
Inspect the lines for pinches, bends, or
damaged connectors.
Drawing No. 9771, Section 12, Rev. A
Page 12-215
Page 12-216
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
ISC and QSC8.3 With CAPS Injection Pump
WARNING
To reduce the possibility of an air bleed line
leak due to a broken air bleed line, use two
wrenches during removal and installation.
Failure to do so may result in a cracked fuel
line. In certain applications, with the fuel
tank above the head of the engine, this will
result in fuel draining from the fuel tank.
Install the banjo capscrew at the air bleed fitting
on top of the fuel pump. Use two wrenches to
prevent the line from being bent.
Torque Value: 8 N•m [70 in-lb]
NOTE: Use new sealing washers.
Style One (1):
Install the banjo capscrew drain fitting on the
fuel pump at the injection control valve. Use two
wrenches to prevent the line from being bent.
Torque Value: 8 N•m [70 in-lb]
NOTE: Use new sealing washers.
Style Two (2):
Install the hollow banjo fitting at the injection
control valve drain fitting to secure the air bleed
line. Use two wrenches to prevent the line from
being bent.
Torque Value:24 N•m [18 ft-lb]
Install banjo capscrew. Use two wrenches to
prevent the line from being bent.
Torque Value:24 N•m [18 ft-lb]
NOTE: Use new sealing washers.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ISL and QSL9 With CAPS Injection Pump
Install the banjo capscrew at the air bleed fitting
on top of the fuel pump. Use two wrenches to
prevent the air bleed fitting from turning.
Install the banjo capscrew in the injection control
valve drain fitting and the distributor plug.
Torque Value: 8 N•m [70 in-lb]
NOTE: Use new sealing washers.
Follow-Up
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-217
Page 12-218
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Rail
Initial Check
WARNING
The pressure within the fuel rail is
extremely high. High pressure can
penetrate the skin. Stand clear of the engine
while it is running.
WARNING
The fuel pump high-pressure fuel lines and
fuel rail contain very high-pressure fuel. To
avoid the possibility of personal injury and
property damage, never loosen any fittings
while the engine is running.
Inspect the fuel pressure sensor, high-pressure
fuel line connections, and male unions for
leaks.
Prepare
Disconnect the fuel pressure sensor from the
engine wiring harness. Refer to Procedure 019043 in Troubleshooting and Repair Manual,
CM850 Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
Remove
Remove the high-pressure fuel lines from the
fuel rail. Refer to Procedure 006-051.
Remove the fuel drain line from the fuel rail
pressure relief valve. Refer to Procedure 006013.
Remove the capscrews that secure the fuel rail
to the cylinder head. Remove the fuel rail
assembly.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install the fuel rail assembly. Follow the proper
sequence to make sure that high-pressure fuel
lines are properly aligned.
Install the fuel rail assembly capscrews fingertight.
Install the high-pressure fuel lines finger-tight.
Tighten the fuel rail assembly capscrews.
Torque Value: 43 N•m [32 ft-lb]
Tighten the high-pressure fuel lines. Refer to
Procedure 006-051.
Follow-Up
Install the fuel drain line to the fuel pressure
relief valve. Refer to Procedure 006-013.
Install the fuel pressure sensor to the engine
wiring harness. Refer to Procedure 019-043 in
Troubleshooting and Repair Manual, CM850
Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-219
Page 12-220
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pressure Relief Valve
Initial Check
WARNING
The pressure within the fuel rail is extremely
high. High-pressure can penetrate the skin.
Stand clear of the engine while it is running.
WARNING
The fuel pump high-pressure fuel lines and
fuel rail contain very high pressure fuel. To
avoid the possibility of personal injury,
never loosen any fittings while the engine is
running.
Operate the engine and check for external fuel
leaks.
Check for a fuel rail pressure relief valve that
leaks excessive fuel to drain.
Measurement of fuel rail pressure relief valve
leakage requires use of a fuel return hose, Part
Number 3164618. If necessary this tool can be
constructed. Refer to Procedure 006-026. The
tool is used to isolate the leakage from just the
fuel rail pressure relief valve so that it can be
measured into a graduated cylinder.
NOTE: If Fault Code 449 or 2311 is active, do
not replace the fuel rail pressure relief valve
without first determining the cause of the fault
condition. Refer to the appropriate
troubleshooting tree(s).
Remove the M12 banjo bolt that connects the
fuel rail pressure relief valve drain line to the fuel
drain manifold.
Install a fuel return hose, Part Number 3164618,
at the fuel drain manifold.
Route the fuel return hose into a collection
device.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Alternatively, fuel rail pressure relief valve
leakage measurement tool, Part Number
4164617, can be installed at the fuel rail
pressure relief valve.
Test
Start the engine and allow the engine to idle.
Measure the leakage.
Specification:
Less than 30 drops per minute must drain from
the fuel rail pressure relief valve while the
engine runs at idle.
CAUTION
Fuel is at high pressure during this test.
After connecting the test fitting, close the
engine cover and stand clear of highpressure fuel lines.
While the engine is running at idle, use the
INSITE™ High Pressure Leak Test to create
higher fuel rail pressure. INSITE™ will
command 1500 BAR fuel rail pressure while the
engine is at idle during this test.
Specification:
Less than 30 drops of fuel per minute must
drain from the fuel rail pressure relief valve.
If fuel rail pressure relief valve leakage is
excessive, it must be replaced. However, make
certain that Fault Code 449 or 2311 is not active
indicating that a system failure is causing the
fuel rail pressure relief valve to open.
Drawing No. 9771, Section 12, Rev. A
Page 12-221
Page 12-222
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove the fuel return hose and install the fuel
drain line banjo bolt. Refer to Procedure 006013.
Operate the engine and check for leaks.
Remove
Remove the fuel drain line from the fuel rail
pressure relief valve. Refer to Procedure 006013.
Remove the fuel pressure relief valve adapter
and copper seal washer.
Remove the fuel pressure relief valve.
Inspect for Reuse
If the fuel pressure relief valve exhibits
excessive leakage to drain, it must not be
reused.
Inspect the high-pressure seal surface on the
fuel pressure relief valve and also in the fuel rail
for damage. Do not reuse components if the
high-pressure seal joint is damaged.
Inspect the copper seal washer and adapter
fitting for damage.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Install the fuel pressure relief valve with
Lubriplate™ on the threads.
Torque Value: 100 N•m [74 ft-lb]
If the reducer has been removed from the fuel
rail pressure relief valve, install the reducer with
a new copper seal washer.
Torque Value: 37 N•m [27 ft-lb]
Follow-Up
Install the fuel drain line to the fuel pressure
relief valve. Refer to Procedure 006-013.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-223
Page 12-224
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Rail High Pressure Fitting
Initial Check
Operate the engine and check for external
leaks.
Remove
Remove the high-pressure fitting only if a leak
is detected.
Install
Flush the outlet fitting using contact cleaner.
Apply Lubriplate™ to the high-pressure fitting
threads.
Install the high-pressure fitting.
Torque Value: 100 N•m [74 ft-lb]
Reinstall the high-pressure fuel line. Refer to
Procedure 006-051.
Operate the engine and check for leaks. If a
leak occurs after replacing the fitting, replace
the rail.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-225
Page 12-226
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Air in Fuel
Prepare
Setup
Obtain a 1.09 mm [0.043 in] orificed diagnostic
fuel line, Part Number 3164621. This tool can
also be constructed following the steps below.
Obtain a container suitable for collection of fuel
that exits the diagnostic fuel line (a five gallon
bucket is recommended).
Construct a sight tube (CAPS fuel systems
only) using the following steps.
Construct a 1.09 mm [0.043 in] orificed
diagnostic fuel line.
NOTE: This tool is available for purchase, Part
Number 3164621.
A 0.043-inch orifice diagnostic fuel line is used
in procedures to create rated flow through the
low pressure fuel system without the need to
operate the engine under load.
Tap a female quick connect, Part Number
3376859.
Tap size: 8-36 national fine (U.S.)
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Clean the female quick connect, Part Number
3376859, with compressed air.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Assemble a 1.09 mm [0.043 in] injector orifice,
Part Number 3045018, with washer, to the
female quick connect, Part Number 3376859.
NOTE: To obtain correct flow, use a 1.09 mm
[0.043 in] injector orifice, Part Number 3045018.
Attach the orifice to an appropriate length (it
must reach from the fuel pump to the fuel tank)
of 1/4-inch, or larger, tubing.
NOTE: It is recommended that this tool be
marked and identified as having a 1.09 mm
[0.043 in] orifice installed. This is to ensure that
there is no confusion when using this tool in the
future.
Construct a sight tube (CAPS fuel systems
only):
Assemble two (one male and one female, 7/814 thread barb-tite fittings and hose clamps to a
61 cm [2 ft] long number-10 clear hose
approved for use with diesel fuel.
Drawing No. 9771, Section 12, Rev. A
Page 12-227
Page 12-228
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Measure
CAPS Fuel System
Attach the 1.09 mm [0.043 in] diagnostic fuel
line at the fuel injection pump's diagnostic
fitting.
Run the outlet of the diagnostic fuel line into the
fuel collection container (or the vehicles fuel
tank).
Install the sight glass between the fuel filter
head and the fuel injection pump inlet.
Run the engine from idle to high idle several
times to purge the air induced while installing
the diagnostic fuel line.
Run the engine up to high idle while another
technician checks for air in the system.
NOTE: A small amount of air in the inlet line is
acceptable. Ignore any air that is observed in
the tube running back to the fuel tank.
Afterwards, operate the engine at idle and
observe any air in the fuel supply. If air is
observed, isolate the air to the following
components:
Fuel filter assembly
Fuel heater
Fuel lift pump assembly
OEM fuel plumbing
Fuel tank stand-pipe
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Cummins Common Rail Fuel System
NOTE: A symptom of air-in-fuel for the ISC and
ISL engine equipped with a Cummins Common
Rail Fuel System is an audible surge associated
with fuel system pressure fluctuations due to air
in the fuel supply.
The following test method will simulate rated
fuel flow through the system so that air in fuel
problems may be diagnosed.
Install a Compuchek® fitting, Part Number
3824842, at the inlet to the 2 um fuel filter and
attach the 1.09 mm [0.043 in] diagnostic fuel
line.
Route the outlet of the 0.043-inch diagnostic
fuel line into a collection device of suitable size
(a 5-gallon bucket is recommended).
Start the engine and run the engine from idle to
high idle several times to purge the air induced
while installing the diagnostic fuel line.
Observe the fuel flow exiting the diagnostic fuel
line while the engine runs at idle.
A few bubbles exiting the line is expected. A
foamy appearance is indication of a leak that
allows air to enter, a severe inlet restriction that
causes cavitation, or a system that is not yet
primed. If fuel inlet restriction (refer to
Procedure 006-020) is not excessive, the
source of air entry should be isolated to one of
the following:
Suction fuel lines
ECM cooling plate assembly
OEM fuel lines
Suction-side fuel filter assemblies
Stand-pipe(s) in the fuel tank(s)
Drawing No. 9771, Section 12, Rev. A
Page 12-229
Page 12-230
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow Up
Remove all test fuel lines and install the low
pressure fuel lines. Refer to Procedure 006024.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Filter Head Bracket Removal/Installation
Prepare
Remove the fuel filter. Refer to Procedure 006015.
Remove the fuel supply lines from the filter
head. Refer to Procedure 006-024.
Remove
Remove the four (4) capscrews retaining the
filter head.
Remove the filter head bracket from the
engine.
Disassemble
Fuel heater equipped engines have a filter
spud that can be removed for the purpose of
removing the fuel heater.
Remove the fuel heater and filter spud, if
equipped.
Drawing No. 9771, Section 12, Rev. A
Page 12-231
Page 12-232
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
Inspect the filter head for cracks, passage
blockage, material or debris on the sealing
surfaces.
Clean any loctite from the filter adapter threads.
Assemble
Apply Loctite™ 277, or equivalent, to the filter
adapter threads that are engaging the filter
head.
Assemble the filter head.
Install the filter adapter and fuel heater (if
equipped).
Torque Value: 27 N•m [20 in-lb]
Install
Install the bracket and filter head. Tighten the
retaining capscrews.
Torque Value: 43 N•m [32 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the fuel filter. Refer to Procedure 006015.
Install the fuel supply lines. Refer to Procedure
006-024.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-233
Page 12-234
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fuel Pump Removal/Installation
Prepare
Remove the fuel supply lines from the fuel
pump. Refer to Procedure 006-024.
Remove the fuel drain line from the fuel pump.
Refer to Procedure 006-013.
Disconnect the engine harness from the fuel
pump actuator.
Remove the fuel pump gear access cover.
Remove
Remove the fuel pump upper support bracket.
Locate top dead center for cylinder Number 1
by barring the engine until the line on the fuel
pump gear aligns with the front cover mark for
top dead center.
Remove the fuel pump gear nut and washer.
Pull the fuel injection pump drive gear loose
from the pump drive shaft. This can be done
using Cummins Gear Puller, Part Number
3824469.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove the four mounting nuts that hold the
fuel pump to the gear housing.
Remove the fuel pump.
Inspect for Reuse
The dowel pin in the fuel pump driveshaft must
not be sheared.
If the dowel is sheared, the cam housing or fuel
pump must be replaced and the drive gear must
be replaced.
Be sure that the pilot o-ring is not cut or
damaged.
Be sure that the pump oil supply o-ring is not
damaged.
Drawing No. 9771, Section 12, Rev. A
Page 12-235
Page 12-236
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Be sure that the engine is at Number 1 cylinder
top dead center. The fuel pump gear timing
mark should align with the top dead center
mark on the front cover.
Lubricate the pilot o-ring with clean engine oil.
Clean the nose of the camshaft with an
evaporative cleaner.
Clean the fuel pump gear inside diameter with
an evaporative cleaner.
The fuel pump drive gear inside diameter and
the drive shaft outside diameter must be clean
and dry before installing the gear.
Slide the fuel injection pump shaft through the
drive gear and position the fuel injection pump
flange onto the mounting studs.
Make sure the dowel pin in the drive shaft lines
up with the keyway in the fuel injection pump
gear.
Installation Sequence:
Install the pump mounting nuts (leave loose).
Install the support bracket bolts (leave loose).
Tighten the pump mounting nuts.
Torque Value: 44 N•m [32 ft-lb]
Tighten the support bracket bolts.
Torque Value: 65 N•m [48 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Tighten the fuel injection pump drive gear nut.
Torque Value: 180 N•m [132 ft-lb]
Follow-Up
Install the access cover in the front cover.
Install the fuel supply lines to the fuel pump.
Refer to Procedure 006-024.
Install the fuel drain line to the fuel pump. Refer
to Procedure 006-013.
Connect the wire harness to the fuel pump
actuator.
Drawing No. 9771, Section 12, Rev. A
Page 12-237
Page 12-238
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
This Page Intentionally Left Blank
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Intake Air Filter Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-239
Page 12-240
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Crossover Removal/Installation
Prepare
Remove
Loosen the hose clamps, and position the
crossover tube so that it can be removed.
Remove the tube.
Inspect for Reuse
Check the crossover tube for cracks, holes, and
worn sections. Replace with a new hose and
clamps if necessary.
Install
Install the crossover tube and clamps in the
reverse order of removal.
Tighten the clamps.
Torque Value: 5 N•m [44 in-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-241
Page 12-242
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Inlet Connection Removal/Installation
Prepare
Remove
Loosen air inlet clamps.
Remove the air inlet connection.
Install
Install the air inlet connection.
Tighten air inlet clamps.
Run engine and check for leaks.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Leaks, Air Intake and Exhaust Systems
Initial Check
Leaks in the intake air system are most
commonly identified by:
Inspection of piping for cracked or loose
clamps.
Applying a solution of soapy water in the
suspected area and inspecting for bubbles.
Listening for a high-pitched whining or sucking
sound in the suspected area.
CAUTION
Engine intake air must be filtered to prevent
dirt and debris from entering the engine. If
intake air piping is damaged or loose,
unfiltered air will enter the engine and cause
premature wear.
Inspect the inlet air piping for cracked hoses
and damaged or loose clamps.
Operate the engine at high idle, and use a
solution of soapy water to spot intake air leaks.
If an air leak exists, the soap bubbles will be
drawn in with the air.
Drawing No. 9771, Section 12, Rev. A
Page 12-243
Page 12-244
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Replace damaged pipes and tighten loose
clamps to make sure the air inlet system does
not leak.
Check for corrosion of the inlet system piping
under the clamps and hoses. Corrosion can
allow corrosive products and dirt to enter the
intake system.
Disassemble and clean as required.
Pressure Side Intake System
Leaks in the intake system will reduce the
amount of air to the cylinders during engine
operation and decrease engine performance.
Operate the engine at full throttle and rated rpm
with maximum load.
Listen for a high-pitched whistling sound from
the turbocharger, nearby piping, and
connections.
Apply a soapy water solution to sealing
surfaces and inspect for bubbles. Bubbles can
be easily detected.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Leaks can also be found at the turbocharger
outlet connection.
Inspect for damage, replace sealing o-ring, and
tighten loose clamps.
Any Charge Air Cooler Tubing or
Connecting Hoses
Inspect the hose and tubing for damage.
Tighten loose clamps.
Refer to the equipment manufacturer's
specifications for the correct torque value.
Air Intake Connection
Inspect for damage.
If necessary, replace the gasket or tighten loose
clamps. Refer to Procedure 010-080.
Drawing No. 9771, Section 12, Rev. A
Page 12-245
Page 12-246
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Intake Manifold
Inspect for damage.
Replace the gasket, if necessary. Refer to
Procedure 010-108.
Wastegate Capsule/Plumbing
Inspect for damage.
Variable Geometry Turbocharger Actuator
Plumbing
Inspect for cracks and/or air leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Compressor Housing Sealing Surface
Inspect for damage.
Clean surface.
Exhaust System
Leaks in the exhaust system will cause the
turbocharger to operate at a lower speed,
reducing the amount of air going to the
cylinders during engine operation.
Operate the engine at full throttle and rated rpm
with maximum load.
Leaks can be identified by noise, soapy water,
or discoloration caused by the escaping hot
gases.
Drawing No. 9771, Section 12, Rev. A
Page 12-247
Page 12-248
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Inspect the exhaust manifold gaskets for leaks.
Inspect the turbocharger mounting gaskets for
leaks.
Inspect the turbine housing sealing surface for
leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Operate the engine at full throttle and rated rpm
with maximum load.
Listen and inspect again for leaks.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-249
Page 12-250
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Intake Restriction Removal/Installation
Prepare
Measure
Install a vacuum gauge or water manometer in
the intake air piping.
The gauge adapter must be installed at a 90degree angle to the airflow in a straight section
of pipe, one pipe diameter before the
turbocharger.
Operate the engine at full throttle and rated rpm
with maximum load.
Record the data on the gauge or manometer.
MAX Inlet Air Restriction63.5 cm H2O [[25.0
in H2O]
If restriction exceeds specifications, replace or
clean the air filter element. Refer to the
equipment manufacturer's instructions.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Inspect the intake piping for damage. Refer to
the equipment manufacturer's repair
instructions.
Remove the test equipment.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-251
Page 12-252
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Checks
Prepare
Initial Check
Remove the intake pipe from the turbocharger.
See the Remove step in this procedure.
Inspect the turbocharger compressor impeller
blades for damage.
Replace the turbocharger if damage is found.
See the Remove and Install steps in this
procedure.
If the compressor impeller is damaged, inspect
the intake piping and filter element for damage.
Repair any damage before operating the
engine.
Remove the exhaust pipe from the
turbocharger. See the Remove step in this
procedure.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage is found.
See the Remove and Install steps in this
procedure.
Axial Clearance Check
Use dial depth gauge, Part Number ST-537.
Push the rotor assembly away from the gauge.
Set the gauge on zero.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Push the rotor assembly toward the gauge and
record the reading.
Axial Clearance
Minimum 0.025 mm [0.001 in]
Maximum 0.127 mm [0.005 in]
Replace the turbocharger if the clearance does
not meet the specifications. See the Remove
and Install steps in this procedure.
Radial Clearance Check
Use a wire-type feeler gauge to measure the
clearance between the turbocharger
compressor wheel and turbocharger
compressor housing.
Gently push the compressor wheel toward the
compressor housing and gauge.
Record the clearance.
With the feeler gauge in the same location,
gently push the turbocharger compressor wheel
away from the turbocharger compressor
housing and measure the clearance between
the compressor wheel and housing.
Subtract the smaller clearance from the larger
clearance. This is the radial bearing clearance.
Wastegate Radial Bearing Clearance
MIN 0.330 mm [0.013 in]
MAX 0.508 mm [0.020 in]
For variable geometry turbocharger check the
radial movement of the rotor system by pushing
the turbocharger compressor wheel toward the
wall of the compressor cover with light finger
pressure. The turbocharger passes inspection if
the wheel does not contact the compressor
cover wall.
Repeat the procedure on the turbocharger
turbine wheel.
Replace the turbocharger if the radial bearing
clearance does not meet specifications. See the
Drawing No. 9771, Section 12, Rev. A
Page 12-253
Page 12-254
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Remove and Install steps in this procedure.
Leak Check
Inspect the turbocharger compressor intake and
discharge for oil.
If oil is present in the compressor intake as well
as in the discharge, check upstream in the
turbocharger for the source of the oil.
If oil is present only in the discharge side, install
the air intake and charge air cooler piping.
Refer to the OEM service manual.
Check for intake restriction. Refer to Procedure
010-031.
If no intake restriction is found, replace the
turbocharger. See the Remove and Install steps
in this procedure.
NOTE: If the engine experiences a turbocharger
failure or any other occasion where oil is put
into the charge air system, the charge air
system must be inspected and cleaned. Refer
to Procedure 010-027.
Add 1 unit of fluorescent tracer, Part Number
3376891, to each 38 liters [10.0 gal] of engine
lubricating oil.
Operate the engine at low idle for 10 minutes.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Shut off the engine.
Allow the turbocharger to cool.
Remove the exhaust pipe from the turbine
housing. See the Remove step in this
procedure.
Use a high-intensity black light, Part Number
3163339, to inspect the turbine outlet for leaks.
A yellow glow indicates an oil leak. A dark blue
glow indicates fuel in the oil.
If oil is found on the turbine housing, remove
the oil drain line and check for restrictions.
Refer to Procedure 010-045.
Clear any restrictions found.
Install the turbocharger drain line. Refer to
Procedure 010-045.
Drawing No. 9771, Section 12, Rev. A
Page 12-255
Page 12-256
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
If the oil drain line was not restricted, remove
the turbocharger. See the Remove and Install
steps in this procedure.
Use a high-intensity black light, Part Number
3163339, to inspect the turbine inlet for leaks.
A yellow glow indicates an oil leak from the
engine.
If a yellow glow is not seen in the turbine inlet,
replace the turbocharger. See the Remove and
Install steps in this procedure.
Install the exhaust pipe to the turbocharger
turbine outlet and tighten the clamp. See the
Install step in this procedure.
Install the intake pipe to the turbocharger
compressor inlet and tighten the clamp. See the
Install step in this procedure.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Removal/Installation
Prepare
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
accordance with local environmental
regulations.
Drain the coolant, variable geometry
turbocharger only. Refer to Procedure 008-018.
Remove the oil supply line from the
turbocharger. Refer to Procedure 010-046.
Remove the oil drain line from the turbocharger.
Refer to Procedure 010-045.
Remove the turbocharger coolant lines, variable
geometry turbocharger only. Refer to Procedure
010-041.
Disconnect the turbocharger actuator air supply
line, variable geometry turbocharger only. Refer
to Procedure 010-118.
Disconnect the turbocharger speed sensor,
variable geometry turbocharger only. Refer to
Procedure 019-390 in the CM850 Electronic
Control System ISC and ISL Engines
Troubleshooting and Repair Manual, Bulletin
4021416.
Disconnect the turbocharger compressor air
inlet temperature sensor, if equipped. Refer to
Procedure 019-035 in the CM850 Electronic
Control System ISC and ISL Engines
Troubleshooting and Repair Manual, Bulletin
4021416.
Drawing No. 9771, Section 12, Rev. A
Page 12-257
Page 12-258
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Remove
Remove the exhaust piping.
Remove the turbocharger compressor air inlet
pipe.
Remove the turbocharger compressor outlet
elbow, v-band clamp, and o-ring from the
turbocharger compressor outlet.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and gasket.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Clean and Inspect for Reuse
Clean the turbocharger and exhaust manifold
gasket surfaces.
Inspect the turbocharger and exhaust manifold
gasket surfaces, and mounting studs for cracks
and damage.
Replace the turbocharger if any cracks are
found in the mounting flange surfaces. See the
Remove and Install steps in this procedure.
Replace the exhaust manifold if any cracks are
found in the mounting flange surfaces. Refer to
Procedure 011-007.
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Remove all carbon deposits and gasket material
from surfaces (1, 2, and 3).
Use solvent or steam to clean the exterior of the
turbocharger.
Dry with compressed air.
Drawing No. 9771, Section 12, Rev. A
Page 12-259
Page 12-260
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Inspect the turbine and compressor housings.
If cracks that go all the way through the outer
walls are found, the turbocharger must be
replaced.
NOTE: A charge air cooler failure can cause
progressive damage to the turbine housing. If
the turbine housing is damaged, check the
charge air cooler. Refer to Procedure 010-027.
NOTE: If the engine experiences a turbocharger
failure or any other occasion where oil or debris
is put into the charge air system, the charge air
system must be inspected and cleaned. Refer to
Procedure 010-027.
Install
Apply a film of high-temperature anti-seize
compound to the turbocharger mounting studs.
Use a new gasket and install the turbocharger.
Install and tighten the four mounting nuts.
NOTE: The torque values given have been
established using anti-seize compound as a
lubricant.
Torque Value: 45 N•m [33 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Install the turbocharger compressor outlet
elbow, v-band clamp, and new o-ring seal on
the turbocharger compressor discharge outlet.
Tighten the clamp.
Torque Value: 8 N•m [71 in-lb]
Install the intake pipe to the turbocharger
compressor inlet and tighten the clamp.
Torque Value: 8 N•m [71 in-lb]
Install the exhaust pipe to the turbocharger
turbine outlet and tighten the clamp.
Torque Value: 8 N•m [71 in-lb]
Prime
Install the turbocharger oil drain line. Refer to
Procedure 010-045.
Drawing No. 9771, Section 12, Rev. A
Page 12-261
Page 12-262
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Lubricate the bearings by pouring 59 to 89 ml [2
to 3 oz] of clean 15W40 engine oil into the
turbocharger oil supply line fitting. Rotate the
turbine wheel to allow oil to enter the bearing.
housing.
Install the turbocharger oil supply line. Refer to
Procedure 010-046.
Follow-Up
Install the turbocharger coolant lines, variable
geometry turbocharger only. Refer to Procedure
010-041.
Connect the turbocharger actuator air supply
line, variable geometry turbocharger only. Refer
to Procedure 010-118.
Connect the turbocharger speed sensor,
variable geometry turbocharger only. Refer to
Procedure 019-390 in the CM850 Electronic
Control System ISC and ISL Engines
Troubleshooting and Repair Manual, Bulletin
4021416.
Connect the turbocharger compressor air inlet
temperature sensor, if equipped. Refer to
Procedure 019-035 in the CM850 Electronic
Control System ISC and ISL Engines
Troubleshooting and Repair Manual, Bulletin
4021416.
Fill the cooling system, variable geometry
turbocharger only. Refer to Procedure 008-018.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Oil Drain Line Removal/Installation
Prepare
Remove
Remove the capscrews from the oil drain tube.
Pull the drain line out of the drain line boss.
Clean and Inspect for Reuse
Clean the gasket sealing surfaces.
Clean the o-ring seating bore and make sure it
is free of dirt and debris.
Inspect the line for cracks, wear, and damage.
Inspect the o-ring for fretting and cracking.
Replace if necessary.
Check the rubber section of the drain line for
deterioration.
Drawing No. 9771, Section 12, Rev. A
Page 12-263
Page 12-264
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Install
Apply a thin film of oil to the drain line o-rings.
Push the drain line into the drain line boss. Be
sure both o-rings are completely seated in the
bore.
Install a new gasket.
Install and tighten the turbocharger oil drain
line.
Torque Value: 27 N•m [20 ft-lb]
Follow-Up
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Oil Supply Line Removal/Installation
Prepare
Remove
Remove the oil supply line from the oil filter
head (1).
Remove the oil supply line from the
turbocharger bearing housing (2).
Inspect for Reuse
Inspect the line for cracks, wear, and damage.
Inspect o-rings for cracking and fretting.
Replace as necessary.
Install
Apply a thin film of oil to the o-ring seals.
Fill the turbocharger oil inlet with clean oil.
Install the oil supply line at both the filter head
and the turbo bearing housing.
Tighten the oil supply line to final torque.
Torque Value: 24 N•m [18 ft-lb ]
Drawing No. 9771, Section 12, Rev. A
Page 12-265
Page 12-266
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Wastegate Actuator Checks
Initial Check
CAUTION
All wastegates come pre-calibrated and can
not be adjusted in the field. Attempts to
adjust the wastegate can result in engine
damage.
The integral wastegate line takes boost from the
turbocharger compressor outlet to the
wastegate capsule.
Inspect the integral wastegate actuator hose for
cracks or holes. Replace the hose if damaged.
Inspect the wastegate mounting bracket,
actuator rod, and lever for damage. A bent
wastegate mounting bracket, actuator rod, or
lever can cause improper operation.
If the wastegate mounting bracket, actuator rod,
or lever is bent, it must be replaced.
Drawing No. 9771, Section 12, Rev. A
Page 12-267
Page 12-268
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Test
In some applications the turbocharger must be
removed to test the wastegate actuator. Refer
to Procedure 010-033.
Disconnect the integral boost line from the
wastegate capsule.
Attach a dial indicator (1) as shown, so that its
shaft is in line with the wastegate actuator rod.
Set the indicator to zero.
Connect clean, regulated air pressure and a
pressure gauge to the capsule. Apply 200 kPa
[29 psi] to make sure the wastegate is
functioning properly.
The rod must move approximately 5 mm [0.200
in] without any sticking or air leakage.
Air must not be heard, such as air leaking
through a functional wastegate capsule.
A small amount of travel when air pressure is
first applied is normal. The tolerance is being
removed from the system.
If no movement of the actuator rod is detected,
detach the actuator control rod from the
wastegate lever pin.
Actuate the lever by hand to be sure that the
shaft rotates freely and is not seized.
If the wastegate lever can not be moved by
hand, replace the turbocharger. Refer to
Procedure 010-033.
If the wastegate lever moves freely by hand,
replace the turbocharger wastegate actuator.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Wastegate Actuator Removal/Installation
Prepare
Remove
In some applications the turbocharger must be
removed in order to remove the wastegate
actuator. Refer to Procedure 010-033.
Prior to removal, note position length of the
control rod from the boost capsule housing and
orientation of the boost capsule hose connector
in relation to the mounting bracket.
Remove the retaining clip from the control lever.
Remove the integral boost line from the
wastegate capsule.
Drawing No. 9771, Section 12, Rev. A
Page 12-269
Page 12-270
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
CAUTION
Be careful not to bend the control lever.
Engine damage can result.
Air Regulator with Pressure Gauge
Remove the boost capsule actuator rod end
from the turbocharger wastegate lever. This can
be accomplished by slowly applying regulated
air pressure to the boost capsule until the
control rod is activated.
Remove the control rod from the turbocharger
wastegate lever pin.
If the boost capsule diaphragm material is
ruptured and will not hold air pressure, manually
pull the control rod outward in order to
overcome boost capsule spring tension for
removal of the control rod from the turbocharger
wastegate lever pin.
Loosen the boost capsule mounting capscrews,
disconnect the air supply hose, and remove the
assembly from the mounting bracket.
Clean and Inspect for Reuse
Inspect the wastegate actuator hose for cracks
or holes. Replace the hose if damaged.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Inspect the wastegate mounting bracket,
actuator rod, and lever for damage. A bent
wastegate mounting bracket, actuator rod, or
lever can cause improper operation.
If the wastegate mounting bracket, actuator rod,
or lever is bent, it must be replaced.
Install
Pre-calibrated Wastegate Actuator
In most applications, the turbocharger must be
removed in order to remove the wastegate
actuator. Refer to Procedure 010-033.
Fit the actuator mounting studs into the holes in
the bracket, and fit both actuator mounting
capscrews.
Refit the end-link onto the crank-pin. Install the
control rod retaining clip.
Torque Value: 8 N•m [71 in-lb ]
Cut the tie wrap and remove the tie wrap and
spacer piece.
Drawing No. 9771, Section 12, Rev. A
Page 12-271
Page 12-272
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Refit the air supply hose to the actuator using
the new hose clamp provided.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Turbocharger Wastegate Valve Body Inspection
Prepare
Check
Inspect the lever pin.
Replace the turbocharger if worn excessively,
Refer to Procedure 010-033.
Inspect the valve and valve seat for cracks or
erosion.
Replace the turbocharger if damage is found.
Refer to Procedure 010-033.
Actuate the lever by hand to verify that the shaft
rotates freely and is not seized.
Check for excessive movement between the
shaft and bushing.
Replace the turbine housing if the shaft and
bushing are damaged or seized.
Drawing No. 9771, Section 12, Rev. A
Page 12-273
Page 12-274
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Measure Intake Manifold Pressure
Prepare
Measure
Measure boost pressure at the intake manifold
by using INSITE™ for hookup and monitoring
procedures.
Operate the engine at rated rpm and full load.
Record the boost reading.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-275
Page 12-276
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Intake Connection Removal/Installation
Prepare
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the batteries and grid heater wiring.
Remove the air inlet crossover tube. Refer to
Procedure 010-019.
Remove the air inlet connection, if equipped.
Refer to Procedure 010-022.
Remove the injector supply lines, if required.
Refer to Procedure 006-051.
Remove
Remove the mounting capscrews.
Remove the air intake connection.
Tape off the intake manifold opening to prevent
debris from entering the intake system.
NOTE: Be sure not to tape over the entire
manifold edges so that the surface can be
cleaned.
NOTE: On engines with the grid heater
mounted on top of the intake manifold cover,
the grid heater will now be loose.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Clean and Inspect for Reuse
Clean the sealing surfaces.
NOTE: Keep gasket material and any other
material out of the air intake.
Inspect the air intake connection for cracks or
other damage.
Install
Install the air intake connection and a new
gasket.
Torque Value: 24 N•m [18 ft-lb]
NOTE: Some capscrews are shared with fuel
line braces on some engines.
NOTE: On some engines, the air intake
connection mounts on top of the grid heater and
shares capscrews.
Follow-Up
Install the injector supply lines, if removed.
Refer to Procedure 006-051.
Connect the air inlet connection, if equipped.
Refer to Procedure 010-022.
Install the air crossover tube. Refer to
Procedure 010-019.
Connect the cold starting aid and batteries.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-277
Page 12-278
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Air Intake Manifold Cover Removal/Installation
Prepare
Disconnect the cold starting aid.
Remove the air crossover tube. Refer to
Procedure 010-019.
Disconnect the air inlet connection, if equipped.
Refer to Procedure 010-022.
Remove the air intake connection. Refer to
Procedure 010-080.
Remove the injector supply lines, if required.
Refer to Procedure 006-051.
Remove the turbocharger control valve, if
equipped. Refer to Procedure 019-388 in
Troubleshooting and Repair Manual, CM870
Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
Remove
Some engines have a grid heater mounted on
top of the intake manifold cover. Remove the
grid heater, if equipped. Refer to Procedure
010-029.
Remove the mounting capscrews and the intake
cover.
Tape off the intake manifold opening to prevent
debris from entering the intake system.
NOTE: Be sure not to tape over the entire
manifold edges so that the surface can be
cleaned.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Clean and Inspect for Reuse
Clean the sealing surfaces.
NOTE: Keep the gasket material and any other
material out of the air intake.
Remove the tape.
Inspect the intake manifold for cracks or other
damage.
NOTE: When inspecting the intake manifold for
oil or debris from an air system failure, also
inspect the cylinder head for oil and debris.
Install
Install the cover with intake air heater (if
equipped) and a new gasket.
Torque Value: 24 N•m [18 ft-lb ]
NOTE: Some capscrews are shared with fuel
line braces on some engines.
Drawing No. 9771, Section 12, Rev. A
Page 12-279
Page 12-280
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Follow-Up
Install the grid heater, if equipped. Refer to
Procedure 010-029.
Install the injector supply lines, if removed.
Refer to Procedure 006-051.
Install the air intake connection. Refer to
Procedure 010-080.
Install the air inlet connection, if used. Refer to
Procedure 010-022.
Install the turbocharger control valve, if
equipped. Refer to Procedure 019-388 in
Troubleshooting and Repair Manual, CM870
Electronic Control System, ISC and ISL
Engines, Bulletin 4021416.
Install the air crossover tube. Refer to
Procedure 010-019.
Connect the cold starting aid.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Charge Air Cooler (CAC) Removal and Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-281
Page 12-282
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Clean the Charge Air Cooler
Clean
If the engine experiences a turbocharger failure
or any other occasion where oil or debris is put
into the charge air cooler, the charge air cooler
must be cleaned.
Remove the charge air cooler piping and charge
air cooler from the vehicle. Refer to the
equipment manufacturer's instructions.
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
CAUTION
Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air
cooler will result.
Flush the charge air cooler internally with
solvent in the opposite direction of normal
airflow. Shake the charge air cooler, and lightly
tap on the end tanks with a rubber mallet to
dislodge trapped debris. Continue flushing until
all debris or oil is removed (i.e., the water runs
clear).
NOTE: Make sure that the tubes are in the
vertical direction when flushing.
If the debris can not be totally removed from the
charge air cooler, the charge air cooler must be
replaced.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
CAUTION
The charge air cooler must be rinsed, dried,
and free of solvent, oil, and debris, or engine
damage will result.
After the charge air cooler has been thoroughly
cleaned of all oil and debris with solvent, wash
the charge air cooler internally with hot soapy
water to remove the remaining solvent. Rinse
thoroughly with clean water.
Blow compressed air through the inside of the
charge air cooler in the opposite direction of
normal air flow until the charge air cooler is dry
internally.
Drawing No. 9771, Section 12, Rev. A
Page 12-283
Page 12-284
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Inspect Charge Air Cooler (CAC)
Inspect for Reuse
Inspect the charge air cooler for cracks, holes,
or damage.
Inspect the tubes, fins, and welds for tears,
breaks, or other damage. If any damage causes
the charge air cooler to fail the air leak check,
the charge air cooler must be replaced. Refer to
Procedure 010-024.
Install the charge air cooler and charge air
cooler piping on the vehicle. Refer to the vehicle
manufacturer's instructions.
NOTE: Always clean and inspect the charge air
cooler piping and hoses prior to installation.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Charge Air Cooler Pressure Test
Pressure Test
Mercury Manometer, Part Number ST-1111-3
Preferred Method
Measure the charge air cooler system pressure
drop with a mercury manometer.
Install one end of a mercury manometer, Part
Number ST-1111-3, in the 1/8-inch fitting in the
turbocharger compressor outlet elbow.
Install the other end of the mercury manometer
in the intake manifold.
Operate the engine at rated rpm and load.
Record the readings on the manometer.
If the differential pressure is greater than 152
mm Hg [6 in Hg], check the charge air cooler
and associated piping for plugging, restrictions,
or damage.
Clean or replace, if necessary.
Drawing No. 9771, Section 12, Rev. A
Page 12-285
Page 12-286
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Pressure Gauge, Part Number ST-1273
Optional Method
Obtain two pressure gauges, Part Number ST1273. Check both gauges on the same pressure
source at 206 kPa [30 psi] to maintain
consistency.
Install one pressure gauge in the 1/8-inch fitting
in the turbocharger compressor outlet elbow.
Install the other pressure gauge in the intake
manifold.
Operate the engine at rated rpm and load.
Record the readings on the two gauges.
If the differential pressure is greater than 152
mm Hg [6 in Hg], check the charge air cooler
and associated piping for plugging, restrictions,
or damage.
Clean or replace, if necessary.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Charge Air Cooler Leak Test
Leak Test
WARNING
To prevent possible injury if either plug
blows off during the test, secure safety
chains on the test plugs to any convenient
capscrew on the radiator assembly. This test
must be performed with securely fastened
safety chains.
To check the charge air cooler for cracked tubes
or header, remove the inlet and outlet hoses
from the cooler. The charge air cooler does not
have to be removed from the chassis.
Install a plug or cap over the outlet side of the
cooler. Install a pressure gauge and a regulated
shop air supply line with a shutoff valve to the
inlet side of the cooler.
Apply air pressure to the cooler until the
pressure gauge reads a steady 207 kPa [30 psi]
of air pressure.
Shutoff the air flow to the cooler, and start a
stopwatch at the same time. Record the leakage
at 15 seconds.
If the pressure drop is 48 kPa [7 psi] or less in
15 seconds, the cooler is operational.
If the pressure drop is greater than 48 kPa [7
psi] in 15 seconds, check all connections again.
Determine if the pressure drop is caused by a
leak in the charge air cooler or by a leaky
connection. Use a spray bottle filled with soapy
water applied to all hose connections, and
watch for bubbles to appear at the location of
the leak.
If the pressure drop is caused by a leaky
connection, repair the connection, and repeat
the test. If the leak is within the charge air
cooler, repeat the test to verify the accuracy of
the pressure drop measurement. Similar
pressure drop readings must be obtained at
least three consecutive tests before the reading
Drawing No. 9771, Section 12, Rev. A
Page 12-287
Page 12-288
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
can be considered accurate.
NOTE: If a charge air cooler leaks more than 48
kPa [7 psi] in 15 seconds, it will appear as a
major leak in a leak tank.
If the pressure drop is greater than 48 kPa [7
psi] in 15 seconds, the charge air cooler must
be replaced.
Refer to the equipment manufacturer's service
manual for replacement instructions.
NOTE: Charge air coolers are not designed to
be 100-percent leak-free. If the pressure drop is
less than 48 kPa [7 psi] in 15 seconds, then the
charge air cooler does not need to be replaced.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
Charge Air Cooler (CAC) Temperature Differential Test
Temperature Differential Test
Inspect the charge air cooler fins for
obstructions to air flow. Remove obstructions
such as a winterfront or debris. Manually lock
shutters in the OPEN position, if equipped.
Lock the fan drive in the ON mode to prevent
erratic test results. This can be done by
installing a jumper wire across the temperature
switch.
Install fluke digital thermometer, Part Number
3822666, into the intake manifold at the 1/8inch NPT tap near the air horn connection with
the intake manifold.
Another alternative is to use the monitor mode
on the INSITE™ electronic service tool.
Install another thermocouple at the air cleaner
inlet to measure ambient air temperature.
Perform a road test with the engine at peak
power and a vehicle speed of 48 kph [30 mph]
or greater.
Record the intake manifold temperature and the
ambient air temperature.
Calculate the differential temperature:
Intake Manifold Temperature minus Ambient Air
Temperature equals Differential Temperature
Maximum Differential Temperature equals
28°C [50°F].
Drawing No. 9771, Section 12, Rev. A
Page 12-289
Page 12-290
Section 12 – Adjustment, Repair, and Replacement
CFP08E Series
If the temperature differential is greater than the
specifications, check the charge air cooler for
dirt and debris on the fins and clean as
necessary. If the problem still exists, check the
charge air cooler for debris in the fins or
between the charge air cooler and radiator.
Confirm full fan engagement.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fill and Drain Lubricating Oil
Drain
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used
engine oil. If not reused, dispose of in
accordance with local environmental
regulations.
NOTE: Use a container that can hold at least
23.6 liters [25 qt] of lubricating oil.
NOTE: For composite oil pans, hold the external
locking nut in position with a separate wrench
while removing the drain plug. This will prevent
the bulkhead from loosening during drain plug
removal.
Operate the engine until the coolant
temperature reaches 60°C [140°F]. Shut off the
engine.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil
and suspended contaminants are removed from
the engine.
Drawing No. 9771, Section 12, Rev. A
Page 12-291
Page 12-292
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Fill
CAUTION
For composite oil pans, always use a new
sealing washer on the oil drain plug. Hold
the external locking nut in place while
tightening the oil drain plug.
Clean and check the lubricating oil drain plug
threads and sealing surface.
Install the lubricating oil pan drain plug.
Steel Oil Pan Torque Value 80 N•m [59 ft-lb]
Cast Aluminum Oil Pan Torque Value 60 N•m
[45 ft-lb]
Composite Oil Pan Torque Value 60 N•m [45
ft-lb]
NOTE: Use a high quality 15W-40 multiviscosity
oil, such as Cummins Premium Blue®, or
equivalent, in Cummins engines. Choose the
correct oil for your operating climate as outlined
in the Operation and Maintenance Manual.
Fill the engine with clean lubricating oil to the
proper level.
NOTE: When filling the oil pan, use the fill tube
on the side of the engine rather than on top of
the rocker lever cover.
Refer to Section V for lubricating oil pan
capacities.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
WARNING
If no oil pressure is noted within 15 seconds
after the engine is started, shut down the
engine to reduce the possibility of internal
damage.
Idle the engine to inspect for leaks at the drain
plug.
Shut off the engine. Wait approximately 10
minutes to let the oil drain from the upper parts
of the engine. Check the level again.
Add oil as necessary to bring the oil level to the
“H” (high) mark on the dipstick.
Drawing No. 9771, Section 12, Rev. A
Page 12-293
Page 12-294
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Cooler Removal/Installation
Prepare
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or steam
can cause personal injury.
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
WARNING
State and federal agencies have determined
that used engine oil can be carcinogenic and
cause reproductive toxicity. Avoid inhalation
of vapors, ingestion, and prolonged contact
with used engine oil. If not reused, dispose
of in accordance with local environmental
regulations.
Drain the coolant. Refer to Procedure 008-018.
Clean the area around the lubricating oil cooler
cover.
Remove the lubricating oil filter. Refer to
Procedure 007-013.
Remove the turbocharger oil supply line. Refer
to Procedure 010-046.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Remove
Remove the lubricating oil cooler cover, gaskets
and cooler element.
Clean
Clean the sealing surfaces of the cylinder block
and the oil cooler cover.
Leak Test
Pressure-test the lubricating oil cooler element
using leak test kit, Part Number 3823876.
Air Pressure Test
Minimum 449 kPa [65 psi]
Maximum 518 kPa [75 psi]
Install
NOTE: Be sure to remove the shipping plugs
from a new element.
Assemble the lubricating oil cooler gaskets,
element, and cooler cover.
Drawing No. 9771, Section 12, Rev. A
Page 12-295
Page 12-296
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Tighten the capscrews in the sequence shown
in the illustration.
Torque Value: 24 N•m [18 ft-lb]
Tighten the capscrews in the sequence shown
in the illustration, in two steps. The arrow (A)
points to the dimple.
Step one: Torque Value: 24 N•m [18 ft-lb]
Step two: Torque Value: 32 N•m [24 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
WARNING
State and federal agencies have determined
that used engine oil can be carcinogenic
and cause reproductive toxicity. Avoid
inhalation of vapors, ingestion, and
prolonged contact with used engine oil. If
not reused, dispose of in accordance with
local environmental regulations.
Install the turbocharger oil supply line. Refer to
Procedure 010-046.
Install the lubricating oil filter. Refer to
Procedure 007-013.
Fill the engine with coolant. Refer to Procedure
008-018.
Operate the engine and check for leaks.
Stop the engine and check the coolant and
lubricating oil levels.
Drawing No. 9771, Section 12, Rev. A
Page 12-297
Page 12-298
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Dipstick Tube Removal/Installation
Prepare
Clean the area around the dipstick tube before
removing to prevent debris from entering the oil
system.
Remove
Remove dipstick from the dipstick tube.
Remove dipstick tube from the cylinder block.
Service Tip: Use a dent puller and a M8 x 1.25
x 21-mm self-tapping capscrew. Thread the
capscrew into the dipstick tube and remove the
tube.
Install
Apply a thin bead of Loctite™ 609, part number
3823718 or equivalent, around the bottom of
the knurled end of the tube.
Place the knurled end of the tube into the
dipstick tube bore in the cylinder block.
Use a flat washer and hex head capscrew to
drive the tube into the cylinder block.
Lightly drive the dipstick tube until it seats
against the block casting.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install the dipstick into the dipstick tube.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-299
Page 12-300
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Dipstick Calibration
Prepare
Calibrate
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and can cause reproductive
toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used
engine oil. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
Drain the lubricating oil. Refer to Procedure
007-037.
Install the dipstick in the dipstick tube housing.
Use clean 15W-40 oil to fill the oil pan to the
specified LOW oil level. Refer to Lubricating Oil
System Specifications in Procedure 018-017 of
this manual for the correct engine oil capacity.
CAUTION
Use care when marking the dipstick. The
dipstick will break if the scribe mark is too
deep.
Remove the dipstick and scribe a mark across
the stick at the oil level. Label the mark with an
L to indicate the "LOW" oil level.
NOTE: If a new blank dipstick is being used, cut
the dipstick off approximately 38 mm [1.5 in]
below the LOW oil level mark.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Wipe off the dipstick and install it in the dipstick
tube housing.
Fill the oil pan to the specified HIGH oil level.
Refer to Lubricating Oil System Specifications
in Procedure 018-017 of this manual for the
correct engine oil capacity.
CAUTION
Use care when marking the dipstick. The
dipstick will break if the scribe mark is too
deep.
Remove the dipstick and scribe a mark across
the stick at the oil level. Label the mark with an
H to indicate the HIGH oil level.
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-301
Page 12-302
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Filter Removal/Installation
Prepare
Remove
Clean the area around the lubricating oil filter
head.
Remove the oil filter with oil filter wrench, Part
Number 3375049.
Clean the gasket surface of the filter head.
Install
Lubricate the oil filter gasket with clean engine
oil.
Fill the oil filter with clean engine oil.
Install the filter on the oil filter head. Tighten the
filter until the gasket contacts the filter head
surface.
Use oil filter wrench, Part Number 3375049, to
tighten the filter an additional ½ to ¾ of a turn,
or follow the instructions supplied with the oil
filter.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-303
Page 12-304
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Bypass Valve Removal/Installation
General Information
Whenever the pressure drop across the
lubricating oil filter exceeds a predetermined set
point, the oil filter bypass valve opens and
allows lubricating oil to bypass the lubricating oil
filter.
This condition can occur during cold ambient
(cold lubricating oil) engine start-ups.
The purpose of the bypass valve is to maintain
lubricating oil flow to the engine and prevent an
oil filter collapse.
Prepare
Remove the lubricating oil filter. Refer to
Procedure 007-013.
Remove the lubricating oil filter head. Refer to
Procedure 007-015.
Remove the 3/4-inch pipe plug from the end of
the oil filter head.
Remove
Using a screwdriver, gently push down on the
top of the bypass valve to remove it from the
bore.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Clean the bypass valve with solvent.
Dry with compressed air.
Inspect the bypass valve seat for damage.
Make sure the valve fully closes.
Drawing No. 9771, Section 12, Rev. A
Page 12-305
Page 12-306
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Insert the bypass valve into the bore. The
spring should be pointing upward into the bore.
Gently seat the bypass valve into the bore until
it seats.
Install the 3/4-inch pipe plug into the end of the
oil filter head.
Torque Value: 45 N•m [33 ft-lb]
Follow-Up
Install the lubricating oil filter head. Refer to
Procedure 007-015.
Install the lubricating oil filter. Refer to
Procedure 007-013.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Filter Head Removal/Installation
Prepare
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap. Heated coolant spray or
steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
accordance with local environmental
regulations.
Drain the coolant. Refer to Procedure 008-018.
Remove the lubricating oil cooler. Refer to
Procedure 007-003.
Remove
Remove the lubricating oil filter head
capscrews, filter head, and gasket.
Drawing No. 9771, Section 12, Rev. A
Page 12-307
Page 12-308
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
Use solvent to clean the adapter.
Inspect the adapter for cracks and other
damage.
Install
Install the oil filter head, gasket, and capscrews.
Torque Value: 24 N•m [18 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the lubricating oil cooler. Refer to
Procedure 007-003.
Fill the cooling system. Refer to Procedure 008018.
Operate engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-309
Page 12-310
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil High Pressure Relief Valve Removal/Installation
Prepare
Remove
Remove the oil cooler bypass valve.
Inspect for Reuse
Inspect for a damaged o-ring, broken spring or
other damage.
Install
Install the oil cooler bypass valve.
Torque Value: 50 N•m [37 ft-lb]
Follow-Up
Lubricating Oil Pan Removal/Installation
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Prepare
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used
engine oil. If not reused, dispose of in
accordance with local environmental
regulations.
Drain the lubricating oil. Refer to Procedure
007-037.
Remove
Remove the lubricating oil pan and gasket.
If suction tube must be removed, refer to
Procedure 007-035.
If the engine is equipped with a block stiffener
plate, refer to Procedure 001-089.
Drawing No. 9771, Section 12, Rev. A
Page 12-311
Page 12-312
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
WARNING
When using a steam cleaner, wear safety
glasses or a face shield, as well as
protective clothing. Hot steam can cause
serious personal injury.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Remove all gasket material from the cylinder
block and oil pan surface.
Steam-clean the oil pan.
Dry with compressed air.
Inspect the oil pan, suction tube, and tube
braces for damage.
NOTE: If cracks are found, replace the
damaged part. Do not attempt to repair the oil
pan by welding.
If the suction tube must be replaced; refer to
Procedure 007-035.
Composite Oil Pan Only
Make sure the bulkhead fitting is tight. If it is
found to be loose, replace the o-ring and
tighten the bulkhead.
Torque Value: 24 N•m [20 ft-lb]
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Install
Use Three-Bond™ RTV sealant, or equivalent,
to fill the joints between the lubricating oil pan
rail, gear housing, and rear seal housing.
If the suction tube has been removed; refer to
Procedure 007-035 for installation instructions.
If the engine is equipped with a block stiffener
plate, refer to Procedure 001-089.
Install the gasket and lubricating oil pan.
Install the oil pan corner braces, if equipped.
NOTE: New noise isolators must be used with
oil pans using the isolated gasket system.
Assemble the washers and capscrews to
secure the lubricating oil pan as illustrated.
Tighten all capscrews in the sequence shown
in the accompanying chart.
Torque Value: 28 N•m [21 ft-lb]
Follow-Up
Fill the lubricating oil system. Refer to
Procedure 007-037.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-313
Page 12-314
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Pressure Regulator Removal/Installation
Prepare
Remove
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
Thoroughly clean the area around the pressure
regulator plug with clean solvent to prevent
debris from falling into the plunger bore when
the plug is removed.
Remove the threaded plug, spring, and plunger.
Service Tip: The plunger normally can be
removed by inserting one finger into the plunger
bore until snug and pulling down. If the plunger
can not be removed in this manner, the plunger
is probably stuck and will require removal of the
housing for cleaning the plunger.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
NOTE: If the plunger bore requires cleaning,
remove the housing to avoid flushing debris into
the engine.
Thoroughly clean all components with clean
solvent.
Dry with compressed air.
Inspect the plunger and plunger bore. Polished
areas on the plunger and bore are acceptable.
Drawing No. 9771, Section 12, Rev. A
Page 12-315
Page 12-316
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Verify that the plunger moves freely in the bore.
Install
Install a new sealing o-ring on the threaded plug
and lubricate with clean engine oil. Install the
pressure regulator assembly.
Torque Value: 80 N•m [59 ft-lb]
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Pump Removal/Installation
Prepare
Remove the fan drive belt. Refer to Procedure
008-002.
Remove the vibration damper. Refer to
Procedure 001-052.
Remove the front cover. Refer to Procedure
001-031.
Remove
Remove the four mounting capscrews.
Remove the pump from the bore in the cylinder
block.
Disassemble
If the lubricating oil pump is to be inspected for
reuse, follow these steps.
Inspect the lubricating oil pump gears for chips,
cracks, or excessive wear.
Remove the back plate.
NOTE: The ISC, QSC8.3, ISL, and QSL9
lubricating oil pump uses a large diameter 5/6
rotor set. The graphics in this manual illustrate a
4/5 rotor set.
Drawing No. 9771, Section 12, Rev. A
Page 12-317
Page 12-318
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Mark TOP on the gerotor planetary.
Remove the gerotor planetary.
Inspect for excessive wear or damage.
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions before
using.
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
Clean all parts in solvent.
Dry with compressed air.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect the lubricating oil pump housing and
gerotor drive for damage and excessive wear.
Assemble
CAUTION
Make sure that the gerotor planetary is
installed in the original position.
Install the gerotor planetary.
Measure the tip clearance.
Tip Clearance
Minimum 0.025 mm [0.001 in]
Maximum 0.1778 mm [0.007 in]
Measure the clearance of the gerotor
drive/gerotor planetary to port plate.
Gerotor Drive/Gerotor Planetary to Port
Plate Clearance
Minimum 0.025 mm [0.001 in]
Maximum 0.127 mm [0.005 in]
Drawing No. 9771, Section 12, Rev. A
Page 12-319
Page 12-320
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Measure the clearance of the gerotor planetary
to the body bore.
Gerotor Planetary to Body Bore Clearance
Minimum 0.1778 mm [0.007 in]
Maximum 0.381 mm [0.015 in]
Measure the backlash.
Lubricating Oil Pump Gears Backlash Limits
(Used Pump)
Minimum 0.076 mm [0.003 in]
Maximum 0.330 mm [0.013 in]
Install the back plate.
Install
CAUTION
Failure to fill the pump with oil during
installation can result in a failure of the
lubricating oil pump to prime at initial
engine start-up, resulting in severe engine
damage.
Lubricate the lubricating oil pump with clean
15W-40 engine oil.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAUTION
Make sure the idler gear pin is installed in
the locating bore in the cylinder block.
Install the lubricating oil pump.
Tighten capscrews in an X pattern, starting with
the upper right capscrew.
Torque Value: 24 N•m [18 ft-lb]
NOTE: Be sure the gear backlash is correct if
installing a new lubricating oil pump.
Measure the gear backlash.
Lubricating Oil Pump Gears Backlash Limits
(Installed)
A Minimum 0.076 mm [0.003 in]
A Maximum 0.330 mm [0.013 in]
B Minimum 0.076 mm [0.003 in]
B Maximum 0.330 mm [0.013 in]
NOTE: If the adjoining gear moves when you
measure the backlash, the reading will be
incorrect.
Lubricate the front gear train with clean 15W-40
engine oil.
Drawing No. 9771, Section 12, Rev. A
Page 12-321
Page 12-322
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
CAUTION
The seal lip and the sealing surface on the
crankshaft must be free from all oil residue
to prevent seal leaks.
Thoroughly clean the front seal area of the
crankshaft.
NOTE: Always replace the front seal when
removing and installing the front cover. Refer to
Procedure 001-031.
Follow-Up
Install the front cover. Refer to Procedure 001031.
Install the vibration damper. Refer to Procedure
001-052.
Install the fan drive belt. Refer to Procedure
008-002.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil Suction Tube Removal/Installation
Prepare
WARNING
To reduce the possibility of personal injury,
avoid direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used
engine oil. If not reused, dispose of in
accordance with local environmental
regulations.
Drain the lubricating oil. Refer to Procedure
007-037.
Remove the lubricating oil pan and gasket.
Refer to Procedure 007-025.
Remove
Remove the lubricating oil suction tube.
Clean and Inspect for Reuse
Clean the gasket surfaces.
Drawing No. 9771, Section 12, Rev. A
Page 12-323
Page 12-324
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Inspect the suction tube for cracks.
Install
Install the lubricating oil suction tube and new
gasket.
Install all capscrews finger tight and check for
correct alignment.
Torque the lubricating oil suction tube to the
block.
Torque Value: 10 N•m [89 in-lb]
Torque the lubricating oil suction tube brace to
the engine block.
Torque Value: 10 N•m [89 in-lb]
Torque the lubricating oil suction tube to the
brace.
Torque Value: 10 N•m [89 in-lb]
Use Three-Bond™ 1207-C, or equivalent, to fill
the joints between the lubricating oil pan rail,
gear housing, and rear seal housing.
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Follow-Up
Install the lubricating oil pan and gasket. Refer
to Procedure 007-025.
Operate the engine and check for leaks.
Drawing No. 9771, Section 12, Rev. A
Page 12-325
Page 12-326
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Lubricating Oil and Filter Analysis
Inspect
An analysis of used oil can help diagnose
internal engine damage and determine if it was
caused by one of the following:
•
Intake air filter malfunction
•
Coolant leaks
•
Oil diluted with fuel
•
Metal particles causing wear
For additional oil analysis information, Refer to
Cummins Engine Oil Recommendations,
Bulletin 3810340.
NOTE: Do not take apart an engine for repair
based solely on the results of an oil analysis.
Inspect the oil filters. If the oil filter shows
evidence of internal damage, find the source of
the problem, and repair the damage. Refer to
the appropriate procedure(s) based on the
following oil filter inspection.
WARNING
Restrain the full flow lubricating oil filter,
and carefully cut the filter (upper section of
combination filter) open. The filter element
spring is under compression and can cause
personal injury.
Use the tube cutter, Part No. 3376579, to open
the full-flow oil filter (upper section of the
bypass filter).
Inspect the filter element for evidence of
moisture or metal particles.
Metal
Copper
Possible Source
Bearings and
Bushings
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Chromium
Piston Rings
Iron
Cylinder Liners
Lead
Bearing Overlay
Material
Aluminum
Piston Wear or
Scuffing
Drawing No. 9771, Section 12, Rev. A
Page 12-327
Page 12-328
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Oil Pressure Switch Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Oil Pressure Sender Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-329
Page 12-330
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Oil Pressure Gauge Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Speed Sensor Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-331
Page 12-332
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Tachometer Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Overspeed Switch Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-333
Page 12-334
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Tachometer Calibration
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Primary ECM Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-335
Page 12-336
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
Secondary ECM Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Harness Removal/Installation
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-337
Page 12-338
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Engine Speed Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Engine Position Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-339
Page 12-340
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Oil Pressure Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Boost Pressure Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-341
Page 12-342
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Coolant Temperature Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Fuel Pressure Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-343
Page 12-344
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Fuel Temperature Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Ambient Air Pressure Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Page 12-345
Page 12-346
Section 12 – Adjustment, Repair, and Replacement
CFP8E Series
ECM Air Temperature Sensor
Prepare
Remove
Install
Follow-Up
Drawing No. 9771, Section 12, Rev. A
Section 13 – Service Literature
CFP8E Series
Page 13-1
Section 13 – Service Literature
Section Contents
Page
Additional Service Literature...........................................................................................................................13-3
Service Literature Ordering Location .............................................................................................................13-4
Drawing No. 9771, Section 13, Rev. 0
Page 13-2
Section 13 – Service Literature
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 13, Rev. 0
Section 13 – Service Literature
CFP8E Series
Page 13-3
Additional Service Literature
General Information
The following publications can be purchased at your selected Service Literature Ordering Location:
Bulletin
Title of Publication
3379001
Fuel for Cummins Engines Bulletin
3810340
Cummins Engine Oil Recommendations Bulletin
3666132
Coolant Requirements and Maintenance Bulletin
3379009
Operation - Cold Weather Bulletin
3379000
Air for Your Engine
3666194
Troubleshooting and Repair Manual, Electronic Control System, ISB and QSB5.9 Engines,
Volumes I and II
4021398
Troubleshooting and Repair Manual, Industrial QSB3.9-30, QSB4.5-30, and QSB5.9-30 Series
Engines
4021399
QSB3.9-30, QSB4.5-30, and QSB5.9-30 Wiring Diagram
Drawing No. 9771, Section 13, Rev. 0
Page 13-4
Section 13 – Service Literature
CFP8E Series
Service Literature Ordering Location
Contact Information
Region
United States and Canada
Ordering Location
Cummins Distributors
OR
Credit Cards at 1-800-646-5609
OR
Order online at www.powerstore.cummins.com
U.K., Europe, Mid-East, Africa, and Eastern European
Countries
Cummins Engine Co., Ltd.
Royal Oak Way South
Daventry
Northants, NN11 5NU, England
South and Central America (excluding Brazil and
Mexico)
Cummins Americas, Inc.
16085 N.W. 52nd Avenue
Hialeah, FL 33104
Brazil and Mexico
Cummins Inc.
International Parts Order Dept., MC 40931
Box 3005
Columbus, IN 47202-3005
Far East (excluding Australia and New Zealand)
Cummins Diesel Sales Corp.
Literature Center
8 Tanjong Penjuru
Jurong Industrial Estate
Singapore
Australia and New Zealand
Cummins Diesel Australia
Maroondah Highway,
P.O.B. 139 Ringwood 3134
Victoria, Australia
Drawing No. 9771, Section 13, Rev. 0
Section 14 – Service Assistance
CFP8E Series
Page 14-1
Section 14 – Service Assistance
Section Contents
Page
Routine Service and Parts ............................................................................................................................. 14-3
Problem Solving .............................................................................................................................................. 14-4
Drawing No. 9771, Section 14, Rev. 0
Page 14-2
Section 14 – Service Assistance
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 14, Rev. 0
Section 14 – Service Assistance
CFP8E Series
Page 14-3
Routine Service and Parts
Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your
engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been
trained to provide sound advice, expert service, and complete parts support. Check the telephone directory yellow
pages or refer to the directory in this section for the nearest Cummins Authorized Repair Location.
Emergency and Technical Service
The Cummins Customer Assistance Center provides a
24-hour, toll free telephone number to aid in technical
and emergency service when a Cummins Authorized
Repair Location can not be reached or is unable to
resolve an issue with a Cummins product.
If assistance is required, call Toll-Free:
1-800-DIESELS (1-800-343-7357)
Includes all 50 states, Bermuda, Puerto Rico, Virgin
Islands, and the Bahamas.
Outside of North America contact your Regional
Office. Telephone numbers and addresses are listed
in the International Directory.
See also www.cummins.com
Drawing No. 9771, Section 14, Rev. 0
Page 14-4
Section 14 – Service Assistance
CFP8E Series
Problem Solving
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cummins
Authorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest you. If
the problem has not been handled satisfactorily, follow the steps outlined below:
If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement.
If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, most
problems are solved below the Division or Regional office level. Telephone numbers and addresses are listed in
this section.
Before calling, write down the following information:
•
Engine model and serial number
•
Type and make of equipment
•
Total kilometers [miles] or hours of operation
•
Warranty start date
•
Nature of problem
•
Summary of the current problem arranged in the order of occurrence
•
Name and location of the Cummins Distributor or Dealer
If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office,
write to:
Cummins Customer Assistance Center - 41403,
Cummins Engine Company, Inc.,
Box 3005, Columbus, IN 47202-3005
Drawing No. 9771, Section 14, Rev. 0
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-1
Section 15 – Maintenance Specifications
Section Contents
Page
General Engine Data.........................................................................................................................................15-3
Fuel System Specifications .............................................................................................................................15-3
Lubricating Oil System Specifications ...........................................................................................................15-4
Cooling System Specifications .......................................................................................................................15-4
Air Intake System Specifications ....................................................................................................................15-4
Exhaust System Specifications ......................................................................................................................15-4
Electrical System Specifications ....................................................................................................................15-5
Cummins/Fleetguard® Filter Specifications..................................................................................................15-6
Fuel Recommendations and Specifications ..................................................................................................15-6
Lubricating Oil Recommendations and Specifications ................................................................................15-7
Coolant Recommendations and Specifications ............................................................................................15-8
Engine Component Torque Values.................................................................................................................15-9
Sealants ...........................................................................................................................................................15-10
Capscrew Markings and Torque Values.......................................................................................................15-11
Drawing No. 9771, Section 15, Rev. A
Page 15-2
Section 15 – Maintenance Specifications
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 15, Rev.A
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-3
General Engine Data
NOTE: The following engine and system specification data is extracted from the curves and data sheets that
were current when this document was prepared. Refer to Performance Curve Drawing 9722 and Data Sheet
Drawing 9723 for the most current information. Contact Cummins Fire Power at 920-337-9750 if current
information is required.
Refer to the base engine troubleshooting and repair manual for base engine coverage (see Service Literature in
Section 13).
Type
Firing Order
Rotation, Viewed from the Front of the Engine
Compression Ratio:
Valves per cylinder: Inlet/Exhaust
Cummins Base Engine Fuel Rating
Cummins Engine Co. Base Engine
4 Cycle; In-Line; 6 Cylinder
1-5-3-6-2-4
Clockwise
17.1:1
2/2
FR-91061
Installation Drawing
Configuration Number
Fuel System
Aspiration
8711 (see Section 18)
D413032CX03
C.A.P.S.
Turbocharged, Charge Air Cooled
Bore
Stroke
Displacement
Intake Valve Clearance
Exhaust Valve Clearance
Dry Weight
Wet Weight
Metric
114mm
135mm
8.3 liter
0.25 mm
0.51 mm
723kg
813kg
QSC8.3-C340
US
4.49 in
5.31 in.
506 in.3
0.010 in
0.020 in
1595 lb
1792 lb
NOTE: The engine features a no-adjust overhead. The valve train is designed such that adjustment of the valve
lash is not required for normal service during the first 5,000 hours. The valve train operates acceptably within
the limits of 0.152- to 0.381-mm [0.006- to 0.015-in] intake valve lash and 0.381- to 0.762-mm [0.015- to 0.030in] exhaust valve lash.
Fuel System Specifications
Fuel
Recommended primary fuel filter
Type Number 2 Diesel Only
Fleetguard 3843760
Minimum supply line size
Minimum drain line size
Maximum fuel line length between supply tank & fuel pump
Maximum fuel height above C/L crankshaft
Maximum restriction @ lift pump-inlet - with clean filter
Maximum restriction @ lift pump-inlet - with dirty filter
Maximum return line restriction - without check valves
Minimum fuel tank vent capability
Maximum fuel temperature @ lift pump inlet
Metric
12.7 mm D.
9.53 mm D.
12.2 m
2030 mm
102 mm Hg
203 mm Hg
254 mm Hg
0.707 m3/hr
71 oC
Drawing No. 9771, Section 15, Rev. A
US
0.5 in. D.
0.375 in. D.
40 ft.
80 in.
4 in. Hg
8 in. Hg
10 in. Hg
25 ft3/hr
160 oF
Page 15-4
Section 15 – Maintenance Specifications
CFP8E Series
Lubricating Oil System Specifications
Recommended lube oil filter
Fleetguard 3318853
Oil pressure range at rated
Oil capacity of pan (high - low)
Total system capacity
Metric
276-414 kPa
18.9-15.1 liter
23.8 liter
US
40-60 PSI
20-16 U.S. quarts
6.3 U.S. Gal.
Cooling System Specifications
Recommended Cooling Water Filter
Fleetguard WF2072
Metric
Maximum raw water working pressure range at heat exchanger
Recommended minimum water supply pipe size to heat
exchanger
Recommended minimum water discharge pipe size from heat
exchanger
Coolant water capacity (engine side)
Modulating thermostat range
Minimum raw water flow with water temperatures to 90 oF (32
o
C)
US
414 kPa
25.4 mm D.
60 PSI
1.0 in. D.
31.7 mm D.
1.25 in. D.
10.4 liter
82-93 oC
1.89 liter/s
2.8 U.S. Gal.
180-199 oF
30 U.S. GPM
Air Intake System Specifications
NOTE: Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping
is damaged or loose, unfiltered air will enter the engine and cause premature wear.
Recommended air cleaner element
(Standard) Donaldson B105006
(Optional) K&N RU5045
Maximum temperature rise between ambient air and engine air
inlet
Maximum inlet restriction with dirty filter
15 oC
30 oF
635 mm H2O
25 in. H2O
Metric
US
Exhaust System Specifications
Maximum exhaust back pressure imposed by complete exhaust
system
Exhaust pipe size normally acceptable
Metric
10.2 kPa
US
40.8 in. H2O
101.6 mm D.
4 in. D.
Drawing No. 9771, Section 15, Rev.A
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-5
Electrical System Specifications
Start Circuit
The start circuit consists of a single starter motor and redundant starter control relays as well as using
redundant power sources either 12 V or 24 V comprised of 12 V wet type storage batteries (optional at
shipment).
The battery, starter and starter solenoid positive terminals are booted with a non-conducting cover or otherwise
insulated from unintended grounding. Battery cable leads from the batteries to the designated connection points
in the starting circuit are minimum 6.53 mm D. (No. 2 AWG), neoprene or rubber insulated with a 1.5 mm (0.060
in.) minimum insulation thickness rated 80°C (176 oF) minimum. The starter and starter solenoid are all metal
enclosed.
Wiring for automatic starting (negative ground)
Reference wiring diagram
B.C.I. Group Size
Standard
8512 (see Section 18)
8D
Minimum recommended battery cold cranking amperes (CCA)(1)
Minimum recommended battery reserve capacity
Maximum resistance of starting circuit
Typical cranking speed
Alternator (standard), internally regulated
Battery Cable Size (Metric) (For less than 1.5 meters long)
Battery Cable Size (US) (For less than 5 feet long)
12V
1250 Amps
360 Minutes
0.002 Ohms
120 RPM
95 Amps
10.6 mm D.
00 AWG
(1) Cold soak at -18 oC (0 oF) or above
Drawing No. 9771, Section 15, Rev. A
24V
625 Amps
180 Minutes
0.004 Ohms
120 RPM
45 Amps
10.6 mm D.
00 AWG
Page 15-6
Section 15 – Maintenance Specifications
CFP8E Series
Cummins/Fleetguard® Filter Specifications
General Information
Fleetguard®/Nelson is a subsidiary of Cummins Inc. Fleetguard®/Nelson filters are developed through joint
testing at Cummins and Fleetguard®/Nelson. Fleetguard®/Nelson filters are standard on new Cummins
engines. Cummins Inc. recommends their use.
Fleetguard®/Nelson products meet all Cummins Source Approval Test standards to provide the quality filtration
necessary to achieve the engine's design life. If other brands are substituted, the purchaser should insist on
products that the supplier has tested to meet Cummins high-quality standards.
Cummins can not be responsible for problems caused by non-genuine filters that do not meet Cummins
performance or durability requirements.
Fuel Recommendations and Specifications
Fuel Recommendations
WARNING
Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept
clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the fuel
pump and the fuel injectors.
Use only number 2 diesel (ASTM no. 2D) fuel.
Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not
warrantable.
Additional information for fuel recommendations and specifications can be found in Fuel for Cummins Engines,
Bulletin No. 3379001. See Section 13, Service Literature for ordering information.
Drawing No. 9771, Section 15, Rev.A
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-7
Lubricating Oil Recommendations and Specifications
Oil Performance Recommendations
Using quality engine lubricating oils, along with appropriate oil drain and filter change intervals, is a critical factor
in maintaining engine performance and durability. Refer to Service Literature in Section 14 for reference to
related Cummins service bulletins.
Cummins Engine Company, Inc. recommends the use of a high-quality SAE 15W-40 heavy-duty engine oil
(such as Cummins Premium Blue®), which meets the American Petroleum Institute (API) performance
classification CH4/SG.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent.
New Engine Break-In Oils
Do not use special “break-in” lubricating oils for new or rebuilt Cummins engines. Use the same type of oil
during the “break-in” as that which is used in normal operation.
Recommended Oil Change Intervals
The oil change interval for turbocharged engines is every 6 months or 250 hours.
Oil Viscosity Recommendations
The use of multiviscosity lubricating oil has been found to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining lubrication at high operating temperatures.
While 15W-40 oil is recommended for most climates, refer to the accompanying table for oil viscosity
recommendations for extreme climates.
NOTE: Limited use of low-viscosity oils, such as 10W-30, can be used for easier starting and providing sufficient
oil flow at ambient temperatures below -35°C [23°F]. However, continuous use of low viscosity oils can decrease
engine life because of wear. Refer to the accompanying chart.
Drawing No. 9771, Section 15, Rev. A
Page 15-8
Section 15 – Maintenance Specifications
CFP8E Series
Coolant Recommendations and Specifications
General Information
Heavy-duty diesel engines require a balanced coolant mixture of water and antifreeze. Drain and replace the
mixture every 1 year or 1500 hours of operation (whichever occurs first) to eliminate buildup of harmful
chemicals.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant
freezing point and by raising its boiling point. Do not use more than 50-percent antifreeze in the mixture unless
additional freeze protection is required. Never use more than 68-percent antifreeze under any condition.
Use soft water in the coolant mixture. Contaminants in hard water neutralize the corrosion inhibitor components.
Water must not exceed 300-ppm hardness or contain more than 100 ppm of either chloride or sulfate.
Specifications
Use low-silicate antifreeze that meets ASTM4985 test (GM6038M spec.) criteria.
Refer to Service Literature in Section 14 for reference to related Cummins service bulletins.
Concentration
Antifreeze must be used in any climate for both freeze and boiling point protection. Cummins recommends a 50percent concentration level (40-percent to 60-percent range) of ethylene glycol or propylene glycol in most
climates. Antifreeze at 68-percent concentration provides the maximum freeze protection and must never be
exceeded under any condition. Antifreeze protection decreases above 68 percent.
Ethylene Glycol
Propylene Glycol
40% = -23°C [-10°F]
40% = -21°C [-6°F]
50% = -37°C [-34°F]
50% = -33°C [-27°F]
60% = -54°C [-65°F]
60% = -49°C [-56°F]
68% = -71°C [-90°F]
68% = -63°C [-82°F]
Concentration Testing
Antifreeze concentration must be checked using a refractometer (such as Fleetguard® Part No. CC2800).
“Floating ball” types of density testers or hydrometers are not accurate enough for use with heavy-duty diesel
cooling systems.
Drawing No. 9771, Section 15, Rev.A
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-9
Engine Component Torque Values
Torque Table
Component.
Aftercooler Mounting
Aftercooler Water Hose Clamp
Alternator Link (Delco 10-15 SI)
Alternator Link (Delco 20-27 SI)
Alternator Mtg. Bolt 10-15 Sl
Alternator Mtg. 27 Sl
Alternator Support (Upper)
Belt Tensioner Flat Bracket
Belt Tensioner Mounting
Crankshaft Damper and Pulley
Crossover Clamp
Tee Bolt Type Clamp
Exhaust Outlet Pipe, V Band Clamp
Fuel Filter
Fuel Filter Adapter Nut
Lubricating Oil Filter
Lubricating Oil Cooler Assembly
Lubricating Oil Pan Drain Plug (steel)
Lubricating Oil Pan Drain Plug (aluminum)
Lubricating Oil Pan Heater Plug
Lubricating Oil Pressure Regulator Plug
Starter Mounting
Thermostat Housing
Water Inlet Connection
Water Pump Mounting
Valve Cover
Water-in-Fuel Sensor
Top - Load Filter Lid
Drawing No. 9771, Section 15, Rev. A
Wrench Size.
10 mm
8 mm
13 mm
3/4 in
15 mm
18 mm
10 mm
Allen 5 mm
15 mm
15 mm
5/16 in
11 mm
7/16 in
75 to 85 mm
24 mm
75 to 85 mm
10 mm
17 mm
17 mm
27 mm
19 mm
10 mm
10 mm
15 mm
13 mm
15 mm
19 mm
10 mm
N•m
ft-lb
24
18
5
44
24
18
43
32
43
32
77
57
24
18
24
18
43
32
137
101
5
44
8
71
8
71
Install as specified by filter manufacturer
32
24
3/4 Turn after Contact
24
18
80
59
55
41
80
59
80
59
43
32
24
18
43
32
24
18
12
106
Hand-Tighten
Hand-Tighten
Page 15-10
Section 15 – Maintenance Specifications
CFP8E Series
Sealants
General Information
Use either the sealants listed below or sealants containing equivalent properties.
Item Description
Pipe plugs
Gaskets
Cups plugs
O-rings
Rear camshaft expansion plug
Fuel pump studs
Turbocharger drain (in block)
Dipstick tube (in block)
Wet flywheel housing to block
Rear seal (in rear cover)
Timing pin housing capscrews
Side oil fill
Oil pan at gear housing joint
Sealing Method
Pre-coated Teflon™ or pipe sealer
No sealant required
Loctite 277 or Cummins sealant, Part Number 3375068
Lubriplate™ 105
Loctite 277 or Cummins sealant, Part Number 3375068
Loctite 242
Loctite 277 or Cummins sealant, Part Number 3375068
Loctite 277 or Cummins sealant, Part Number 3375068
Three-Bond™ sealant, Part Number 3823494
No sealant required
No sealant required
Loctite 277 or Cummins sealant, Part Number 3375068
Three-Bond™ sealant, Part Number 3823494
Drawing No. 9771, Section 15, Rev.A
Section 15 – Maintenance Specifications
CFP8E Series
Page 15-11
Capscrew Markings and Torque Values
General Information
CAUTION
Always use a capscrew of the same measurement and strength as the capscrew being replaced. Using
the wrong capscrews can result in engine damage.
Always use the torque values listed in the following tables when specific torque values are not available.
Do not use the torque values in place of those specified in other sections of this manual.
The torque values in the table are based on the use of lubricated threads.
When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Metric Capscrew Identification
Sample:
Value:
M8
Meaning:
Major thread diameter in
millimeters
M8-1.25 x 25
1.25
Distance between threads in
millimeters
X 25
Length in millimeters
Metric Capscrew Head Markings
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the
surface of the nuts.
8.8
Commercial
Steel Class
10.9
12.9
Capscrew
Head Markings
Metric Capscrew Torque Values
Class:
Diameter
8.8
Cast Iron
10.9
Aluminum
Cast Iron
12.9
Aluminum
Cast Iron
Aluminum
mm
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
6
7
8
10
12
14
16
18
20
9
14
23
45
80
125
195
280
400
5
9
17
33
60
90
140
200
290
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
13
18
33
65
115
180
280
390
550
10
14
25
50
85
133
200
285
400
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
14
23
40
70
125
195
290
400
—
9
18
29
50
95
145
210
290
—
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
Drawing No. 9771, Section 15, Rev. A
Page 15-12
Section 15 – Maintenance Specifications
CFP8E Series
US Customary Capscrew Identification
Sample:
Value:
5/16
Meaning:
Major thread diameter in
inches
5/16 x 18 x 1-1/2
18
Number of threads per inch
1-1/2
Length in inches
U.S. Customary Capscrew Head Markings
U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
SAE Grade 5
SAE Grade 8
w/ three lines
U.S. Customary Capscrew Torque Values
Grade
Capscrew Body
Size
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-14
SAE Grade 5
Cast Iron
SAE Grade 8
Aluminum
Cast Iron
Aluminum
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
9
12
20
23
40
40
60
65
95
100
135
150
180
210
325
365
490
530
720
800
7
9
15
17
30
30
45
50
70
75
100
110
135
155
240
270
360
390
530
590
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650
6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480
15
18
30
33
55
60
90
95
130
150
190
210
255
290
460
515
745
825
1100
1200
11
13
22
24
40
45
65
70
95
110
140
155
190
215
340
380
550
610
820
890
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650
6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480
Drawing No. 9771, Section 15, Rev.A
Section 16 – Warranty Information
CFP8E Series
Page 16-1
Section 16 – Warranty Information
CUMMINS FIRE POWER
2 YEAR OR 2000 HR. Fire Pump Driver
LIMITED WARRANTY
Cummins Fire Power warrants diesel fire pump drivers to be free from defects in material and workmanship
under normal fire pump driver use and service. The warranty start date is the date of start up, or 18 months from
the date of factory shipment (whichever occurs first). This warranty is extended to the original using customer for
two (2) year or 2000 hours (whichever occurs first) from the warranty start date.
Repair, replacement or adjustment, at Cummins Fire Power’s discretion, will be furnished if the part, upon
Cummins Fire Power’s inspection, is found to be properly installed, maintained and operated in accordance with
instruction manuals furnished by Cummins Fire Power.
This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, repair or service
by unauthorized persons, or normal wear and tear.
Any implied or statutory warranties, including any warranty of merchantability or fitness of purpose, is expressly
limited to the duration of this warranty. In no event is Cummins Fire Power, liable for incidental or consequential
damages.
This Warranty Shall Not Apply to:
* Cost of maintenance, adjustments, installation or start-up.
* Failures due to normal wear, accident, misuse, abuse, neglect or improper installation.
* Alterations or modifications not authorized in writing by Cummins Fire Power.
* Failures caused by defects in the system in which the set is installed.
* Rental equipment/expense while repairs are being made.
* Starting batteries.
* Components added to the engine after shipment from Cummins Fire Power.
No person is authorized to give any other warranties or to assume any other liabilities on Cummins Fire Power’s
behalf.
All claims must be brought to the attention of Cummins Fire Power, or an authorized distributor within thirty (30)
days of discovery of the part or parts failing to meet this warranty.
See Cummins Inc. warranty bulleting number 3381321 for additional details.
THERE ARE NO OTHER EXPRESS OR IMPLIED WARRANTIES BEYOND THE DESCRIPTION OF THE
FACE HEREOF.
© 2004 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.
Drawing No. 9771, Section 16, Rev. A
Page 16-2
Section 16 – Warranty Information
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 16, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-1
Section 17 – Troubleshooting
Section Contents
Page
Troubleshooting Procedures and Techniques ..............................................................................................17-3
Troubleshooting Symptoms Charts ...............................................................................................................17-3
Alternator Overcharging with the Engine Running.......................................................................................17-4
Neither Battery is Charging with the Engine Running..................................................................................17-5
Only One Battery is Charging with the Engine Running ..............................................................................17-7
Voltage Indications Differ ................................................................................................................................17-8
Coolant Contamination ....................................................................................................................................17-9
Excessive Coolant Loss.................................................................................................................................17-11
Coolant Temperature Above Normal ............................................................................................................17-13
Coolant Temperature Below Normal (Engine Off).......................................................................................17-17
Coolant Temperature Below Normal (Engine Off).......................................................................................17-18
Coolant Temperature Below Normal (Engine Running) .............................................................................17-19
Raw Water Drain Steaming ............................................................................................................................17-20
Raw Water Solenoid Valve Fails to Operate ................................................................................................17-21
Auto Start Failure - Does not Crank on A.....................................................................................................17-22
Auto Start Failure - Does not Crank on B.....................................................................................................17-23
Auto Start Failure - Does not Crank on A or B ............................................................................................17-24
Auto Start Failure – Cranks but does not Start ...........................................................................................17-25
Auto Start Failure – Engine Starts but Crank Terminate does not Occur ................................................17-27
Manual Start Failure from Solenoid Lever - Does not Crank on A ............................................................17-29
Manual Start Failure from Solenoid Lever - Does not Crank on B ............................................................17-30
Manual Start Failure from Solenoid Lever - Does not Crank on A or B ....................................................17-31
Manual Start Failure from Control Panel - Does not Crank on A...............................................................17-32
Manual Start Failure from Control Panel - Does not Crank on B...............................................................17-33
Manual Start Failure from Control Panel - Does not Crank on A or B ......................................................17-34
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) .............................................................17-35
Engine Cranks Slowly But Does Not Start ...................................................................................................17-39
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present .........................................................17-40
Engine Acceleration or Response Poor .......................................................................................................17-43
Engine Noise Excessive - Mechanical..........................................................................................................17-46
Engine Noise Excessive — Combustion Knocks........................................................................................17-48
Drawing No. 9771, Section 17, Rev. A
Page 17-2
Section 17 – Troubleshooting
CFP8E Series
Section Contents (Cont)
Page
Engine Runs Rough at Idle ........................................................................................................................... 17-50
Engine Runs Rough or Misfires Under Load .............................................................................................. 17-52
Engine Speed Surges at Idle......................................................................................................................... 17-54
Engine Speed Surges Under Load............................................................................................................... 17-56
Engine Vibration Excessive at Rated Speed............................................................................................... 17-59
Engine Stops During Operation ................................................................................................................... 17-61
Engine Will Not Reach Rated Speed (RPM) ................................................................................................ 17-64
Engine Will Not Shut Off Remotely .............................................................................................................. 17-67
Engine Will Not Shut Off Locally .................................................................................................................. 17-68
Exhaust Smoke Excessive At Idle, White.................................................................................................... 17-69
Exhaust Smoke Excessive At Idle, Black .................................................................................................... 17-72
Exhaust Smoke Excessive Under Load....................................................................................................... 17-73
Fuel Consumption Is Excessive ................................................................................................................... 17-75
Fuel or Lubricating Oil Leaking From Exhaust Manifold........................................................................... 17-77
Lubricating Oil Contaminated....................................................................................................................... 17-78
Fuel in the Lubricating Oil............................................................................................................................. 17-79
Coolant in the Lubricating Oil....................................................................................................................... 17-81
Lubricating Oil Consumption Excessive..................................................................................................... 17-82
Lubricating Oil Pressure High ...................................................................................................................... 17-84
Lubricating Oil Pressure Low ....................................................................................................................... 17-85
Oil Level Rises ............................................................................................................................................... 17-87
Lubricating Oil Sludge in the Crankcase Excessive .................................................................................. 17-88
Turbocharger Leaks Engine Oil or Fuel ...................................................................................................... 17-89
Crankcase Gases (Blowby) - Excessive ...................................................................................................... 17-90
Engine Overspeed Trip.................................................................................................................................. 17-91
Tachometer Does Not Indicate Engine Speed ............................................................................................ 17-92
Engine Decelerates Slowly ........................................................................................................................... 17-93
Neither ECM Active........................................................................................................................................ 17-94
Either ECM Not Active ................................................................................................................................... 17-95
STOP Light On, Engine Stops ...................................................................................................................... 17-96
WARN Light On, Engine Running ................................................................................................................ 17-97
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-3
Troubleshooting Procedures and Techniques
General information
This guide describes some typical engine operating problems, their causes, and some acceptable corrections to
those problems.
WARNING
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 11, and the Assembly
Drawings in Section 18.
Do the easiest and most logical things first.
Find and correct the cause of the complaint.
Troubleshooting Symptoms Charts
WARNING
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 pages of this in 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. 9771, Section 17, Rev. A
Page 17-4
Section 17 – Troubleshooting
CFP8E 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
malfunctioning.
Test the alternator electrically. Refer to Alternator
Checks and Testing in Section 12.
If required, replace the alternator. Refer to Alternator
Removal/Installation Section 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-5
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
corroded (excessive resistance).
Check the battery cables and connections. Ensure that
all connections are free of corrosion and that no cables
are broken.
Alternator rotor is not turning.
Test the alternator mechanically. Refer to Alternator
Checks and Testing in Section 12.
If the alternator shaft does not spin freely because of a
bad bearing, replace the alternator (refer to Alternator
Removal/Installation in Section 12).
If the alternator does not turn because of a bad drive
belt, replace the drive belt (refer to Belt
Removal/Installation in Section 12).
If the alternator does not charge because of poor drive
belt tension, replace the automatic tensioner (refer to
Automatic Belt Tensioner Removal/Installation in
Section 12).
If the alternator pulley spins freely on the shaft
because of a broken key, replace the alternator (refer
to Alternator Removal/Installation in Section 12).
Battery Isolator input has faulted.
Test continuity from the alternator to the battery
isolator input (refer to Drawing 8512 Sheet 2 in Section
18). 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 12).
Drawing No. 9771, Section 17, Rev. A
Page 17-6
Section 17 – Troubleshooting
CFP8E Series
Neither Battery is Charging with the Engine Running (Cont)
Cause
Alternator excitation is lost.
Correction
Test the alternator electrically. Refer to Alternator
Checks and Testing in Section 12.
If required, replace the replaceable diode. Refer to
Drawing 8512 Sheet 1 in Section 18.
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 12.
If required, replace the alternator. Refer to Alternator
Removal/Installation Section 12.
Battery temperature is above specification.
Position the batteries away from heat sources.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-7
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
Battery has failed.
Correction
Test battery condition.
If the battery has failed, replace the failed battery
units.
Battery cables or connections are loose, broken, or
corroded (excessive resistance).
Check the battery cables and connections. Ensure
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 12.
Test the internal diodes for open circuit or short to
ground. Refer to the Schematic, Electrical Wiring,
8512 Sheet 2 Section 18.
If required, obtain a replacement battery isolator.
Install the battery isolator. Refer to Battery Isolator
Removal/Installation in Section 12.
Voltmeter is providing false indication.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Go to Voltage Indications Differ in this section.
Page 17-8
Section 17 – Troubleshooting
CFP8E 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
One battery is discharged or failing.
Correction
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 8512
Sheet 1 in Section 18.)
Check for apparent wire damage or shorts to grounds.
Replace the failed fuse.
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
8512 Sheet 1 in Section 18.)
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 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-9
Coolant Contamination
Cause
Coolant is rusty and has debris.
Correction
Drain and flush the cooling system. Refer to Drain and
Flush Cooling System in Section 8.
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 8.
Lubricating oil cooler is leaking oil into the coolant.
Coolant begins to have the texture and color of
chocolate pudding.
Drain and flush the cooling system. Refer to Drain and
Flush Cooling System in Section 8.
Check the lubricating oil cooler for coolant leaks and
cracks. Refer to Lubricating Oil Cooler
Removal/Installation in Section 12. Replace the oil
cooler gasket or other parts.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section 8.
If the problem persists, the cylinder block may be
cracked or porous. Refer to a Cummins Authorized
Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-10
Section 17 – Troubleshooting
CFP8E Series
Coolant Contamination (Cont)
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.
Drain and flush the cooling system. Refer to Drain and
Flush Cooling System in Section 8.
Remove Coolant Heat Exchanger. Refer to Coolant
Heat Exchanger Removal/Installation in Section 12.
Perform a pressure test of the raw water side of the
heat exchanger. Refer to Coolant Heat Exchanger
Removal/Installation in Section 12. 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 12.
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 7.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section 8.
Coolant is inadvertently contaminated with unknown
liquids.
Drain and flush the cooling system. Refill with correct
mixture of antifreeze and water. Refer to Drain and
Flush Cooling System in Section 8.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-11
Excessive Coolant Loss
Cause
Adequate coolant was not added following previous
maintenance activities.
Correction
Check the coolant level. Refer to Check Coolant Level
in Section 5.
Add coolant as required and check engine operation.
If coolant loss persists, check for other problems.
Inadvertent coolant leak is present.
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 7.
Replace and/or tighten loose hose clamps.
Replace any damaged hoses.
Refer to Coolant Hose Removal/Installation in Section
12. Add coolant as required and check engine
operation.
Pressure cap is malfunctioning or has low-pressure
rating.
Check that the pressure cap does not relieve coolant
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 components.
Add coolant as required and check engine operation.
Drawing No. 9771, Section 17, Rev. A
Page 17-12
Section 17 – Troubleshooting
CFP8E Series
Excessive Coolant Loss (Cont)
Engine is overheating.
Refer to the Coolant Temperature Above Normal
symptom tree.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-13
Coolant Temperature Above Normal
NOTE: The thermostat’s normal operating temperature range is 82-95 oC [180-203 oF]. The High Water
Temperature lamp on the local control panel illuminates at oC [ oF]. 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
Raw water flow is improperly aligned.
Correction
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 Section 18).
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 excessively 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 12.)
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 12.)
Drawing No. 9771, Section 17, Rev. A
Page 17-14
Section 17 – Troubleshooting
CFP8E Series
Coolant Temperature Above Normal (Cont)
Cause
Raw water piping or heat exchanger is plugged.
Correction
Check the raw water strainer for blockage. Refer to
Drawing Section 18. Clean the strainer if necessary.
Check the Cummins supplied raw water piping for
blockage. Refer to Drawings LATER in Section 18.
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 12.
Coolant level is below specification.
Check the coolant level. Refer to Check Coolant Level
in Section 5. Add coolant as required.
If coolant level was excessively low, go to Excessive
Coolant Loss in this section.
Cooling system hose is collapsed or restricted.
Inspect the hoses. Refer to Check Hose Condition in
Section 7. Replace any damaged hoses. Refer to
Coolant Hose Removal/Installation in Section 12.
Coolant thermostat is malfunctioning.
Remove and test the coolant thermostat. Refer to
Coolant Thermostat Removal/Installation in Section
12. Replace the thermostat is it is defective.
Coolant water pump is malfunctioning.
Remove and inspect the water pump. Refer to
Coolant Water Pump Removal/Installation in Section
12. Replace the thermostat is it is defective.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-15
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 leaking.
Inspect the hoses. Refer to Check Hose Condition in
Section 7. Replace any damaged hoses. Refer to
Coolant Hose Removal/Installation in Section 12.
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 15.
Lubricating oil level is above or below specification.
Check the 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
12.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section
12.
Drawing No. 9771, Section 17, Rev. A
Page 17-16
Section 17 – Troubleshooting
CFP8E Series
Coolant Temperature Above Normal (Cont)
Cause
Coolant temperature switch is malfunctioning.
Correction
Remove the temperature switch. Refer to Coolant
Temperature Switch Removal/Installation in Section
12.
Test the temperature switch. Repair or replace the
switch, if necessary.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-17
Coolant Temperature Below Normal (Engine Off)
Cause
Correction
The 120 VAC power supply to the coolant heater is not
connected.
Connect the power supply. Correct any electrical
faults in the supply circuit.
The heater’s overload thermostat has operated.
Ensure that there is coolant in the heater. Allow time
for the automatic overload reset to occur.
Coolant is not free to circulate through the heater.
Ensure that the coolant hoses are clear. Refer to
Coolant Hose Removal/Installation in Section 12.
The coolant heater has failed electrically.
Replace the coolant heater. Refer to Coolant Heater
Removal/Installation in Section 12.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-18
Section 17 – Troubleshooting
CFP8E Series
Coolant Temperature Below Normal (Engine Off)
Cause
Correction
The 120 VAC power supply to the coolant heater is not
connected.
Connect the power supply. Correct any electrical
faults in the supply circuit.
The heater’s overload thermostat has operated.
Ensure that there is coolant in the heater. Allow time
for the automatic overload reset to occur.
Coolant temperature sender is malfunctioning.
Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section
12.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section
12.
Coolant is not free to circulate through the heater.
Ensure that the coolant hoses are clear. Refer to
Coolant Hose Removal/Installation in Section 12.
The coolant heater has failed electrically.
Replace the coolant heater. Refer to Coolant Heater
Removal/Installation in Section 12.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-19
Coolant Temperature Below Normal (Engine Running)
Cause
Electronic fault codes are active
Correction
For instructions on how to read active fault codes,
refer to Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
Coolant thermostat has failed open.
Test operation of the thermostat. Refer to Coolant
Thermostat Tests in Section 12.
If necessary, replace the thermostat. Refer to Coolant
Thermostat Removal/Installation in Section 12.
Coolant temperature sender is malfunctioning.
Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section
12.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section
12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-20
Section 17 – Troubleshooting
CFP8E 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 the raw water drain.
Cause
Correction
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
the coolant heat exchanger.
When practical, remove the coolant heat exchanger
and perform the pressure test. Refer to Coolant Heat
Exchanger Removal/Installation in Section 12. If
pressure is not maintained, replace the heat
exchanger.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-21
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
Solenoid valve fails to close when the engine stops.
Correction
Replace the solenoid valve. Refer to Raw Water
Solenoid Valve Removal/Installation in Section 12.
Clean the raw water strainer more frequently.
Increase the frequency of operational testing.
Solenoid valve fails to energize,
Check electrical continuity and insulation from ground
to the solenoid. Repair any open or short circuits in the
wiring.
Solenoid fails to open mechanically.
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
12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-22
Section 17 – Troubleshooting
CFP8E 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
system to Terminal Board TB 9 has failed.
Test continuity and insulation from ground between the
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
Relay K1 has failed.
Test continuity and insulation from ground between the
TB 9 and Relay K1. Locate and repair any electrical
fault. Refer to Drawing 8512 Sheet 1 in Section 18.
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.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-23
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
system to Terminal Board TB 10 has failed.
Test continuity and insulation from ground between the
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
to Relay K2 has failed.
Test continuity and insulation from ground between the
TB 10 and Relay K2. Locate and repair any electrical
fault. Refer to Drawing 8512 Sheet 1 in Section 18.
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.
Drawing No. 9771, Section 17, Rev. A
Page 17-24
Section 17 – Troubleshooting
CFP8E Series
Auto Start Failure - Does not Crank on A or B
NOTE: The fire pump engine 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
The Fire Protection System fails to produce either
redundant start signal to the fire pump.
Correction
Locate and correct the common mode fault in the Fire
Protection System.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-25
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.
Cause
Correction
The overspeed switch as actuated. The overspeed
lamp is illuminated on the local control panel.
Press the RESET switch on the local control panel.
Control power from the Fire Protection System is not
available at local control panel TB1.
When practical, locate and correct the fault in the Fire
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 8512 Sheet 1 in
Section 18.
If open, reset the circuit 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
AUTO mode.
When practical, open Circuit Breaker CB at the local
control panel and test switch operation electrically.
Refer to Drawing 8512 Sheet 1 in Section 18.
If required, replace the switch or repair other electrical
faults.
When done, close Circuit Breaker CB at the local
control panel and
Drawing No. 9771, Section 17, Rev. A
Page 17-26
Section 17 – Troubleshooting
CFP8E Series
Auto Start Failure – Cranks but does not Start
The overspeed switch has failed.
Check power and grounding to the overspeed switch.
Refer to Drawing 8512 Sheet 1 in Section 18. 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 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-27
Auto Start Failure – Engine Starts but Crank Terminate does not Occur
Cause
The overspeed switch not correctly adjusted or has
failed.
Correction
When practical, with the engine running, verify speed
sensor input to the overspeed switch. Refer to Drawing
8512 Sheet 1 in Section 18.
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 12.
Fuse 3 has opened. The raw water solenoid valve also
fails to open.
Open the raw water bypass valves.
When practical, replace Fuse F3.
Locate and repair any local electrical fault. Refer to
Drawing 8512 Sheet 1 in Section 18.
The speed sensor has failed. The tachometer also
indicates zero speed.
When practical, locate and repair any electrical fault in
the speed sensor circuitry. Refer to Drawing 8512
Sheet 1 in Section 18.
If necessary, replace the speed sensor. Refer to
Speed Sensor Removal/Installation in Section 12.
An electrical fault is present in the Fire Protection
System.
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.
An electrical fault is present between Control Panel TB
2 and the Fire Protection System.
When practical, test continuity and insulation from
ground between the fire protection system and the
engine control panel. Locate and repair any electrical
fault in the field wiring.
Drawing No. 9771, Section 17, Rev. A
Page 17-28
Section 17 – Troubleshooting
CFP8E Series
Auto Start Failure – Engine Starts but Crank Terminate does not Occur
(Cont)
An electrical fault is present in the control panel
between Fuse F3 and TB 2.
When practical, test continuity and insulation from
ground between Fuse F3 and TB 2. Locate and repair
any electrical fault. Refer to Drawing 8512 Sheet 1 in
Section 18.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-29
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.
Cause
Correction
Battery A is discharged or has failed.
Recharge or replace the battery.
An electrical fault is present between Battery A and the
starter motor.
When practical, test continuity and insulation from
ground between Battery A and the starter motor.
Locate and repair any electrical fault. Refer to Drawing
8512 Sheet 1 in Section 18.
Solenoid A’s switch contact does not close.
Remove and test Solenoid A lever and switch
operation. Refer to Crank Solenoid Assembly
Removal/Installation in Section 12.
If required, replace Solenoid A.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-30
Section 17 – Troubleshooting
CFP8E 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.
Cause
Correction
Battery B is discharged or has failed.
Recharge or replace the battery.
An electrical fault is present between Battery B and the
starter motor.
When practical, test continuity and insulation from
ground between Battery B and the starter motor.
Locate and repair any electrical fault. Refer to Drawing
8512 Sheet 1 in Section 18.
Solenoid B’s switch contact does not close.
Remove and test Solenoid B lever and switch
operation. Refer to Crank Solenoid Assembly
Removal/Installation in Section 12.
If required, replace Solenoid B.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-31
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.
Cause
Correction
Starter motor has failed.
Replace the starter motor. Refer to Starter Motor
Removal/Installation in Section 12.
An electrical fault is present in the power or ground
circuit for the starter motor.
Test continuity and insulation from ground between the
battery splice, the ground connection, and the starter
motor. Locate and repair any electrical fault. Refer to
Drawing 8512 Sheet 1 in Section 18.
Engine is seized.
Bar the engine over to break the seizure.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-32
Section 17 – Troubleshooting
CFP8E Series
Manual Start Failure from Control Panel - Does not Crank on A
NOTE: The fire pump engine will not crank locally from the control panel 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 8512 Sheet
1 in Section 18. Replace the switch if faulted.
Relay K1 fails in the local manual mode.
When practical, test the electrical operation of the
Relay K1. Refer to Drawing 8512 Sheet 1 in Section
18. Replace the relay if faulted.
Solenoid A fails to energize due to electrical fault in the
power or ground circuit.
Test continuity and insulation from ground between the
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 8512 Sheet 1 in Section 18.
Solenoid A fails to operate.
When practical, test the electrical operation of the
Solenoid A. Refer to Drawing 8512 Sheet 1 in Section
18. Replace the solenoid if faulted.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-33
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 8512 Sheet
1 in Section 18. Replace the switch if faulted.
Relay K2 fails in the local manual mode.
When practical, test the electrical operation of the
Relay K2. Refer to Drawing 8512 Sheet 1 in Section
18. Replace the relay if faulted.
Solenoid B fails to energize due to electrical fault in the
power or ground circuit.
Test continuity and insulation from ground between the
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 8512 Sheet 1 in Section 18.
Solenoid B fails to operate.
When practical, test the electrical operation of the
Solenoid B. Refer to Drawing 8512 Sheet 1 in Section
18. Replace the solenoid if faulted.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-34
Section 17 – Troubleshooting
CFP8E Series
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.
When practical, test the electrical operation of the
AUTO/MANUAL rocker switch. Refer to Drawing 8512
Sheet 1 in Section 18. Replace the solenoid if faulted.
An electrical fault exists in the signal power circuit or
the ground to the Relays K1 and K2.
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 8512 Sheet
1 in Section 18.
Fuse F3 has opened. The raw water solenoid valve
also fails to open.
Open the raw water bypass valves.
When practical, replace Fuse F3.
Locate and repair any local electrical fault. Refer to
Drawing 8512 Sheet 1 in Section 18.
An electrical fault exists in the signal power circuit or
the ground to the overspeed switch’s crank circuit.
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 8512 Sheet 1 in Section 18.
Overspeed switch crank circuit fails to reset with
engine shutdown.
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 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-35
Engine Cranks Normally But Will Not Start (No Exhaust Smoke)
Cause
Electronic fault codes are active.
Correction
NOTE: For instructions on how to read active fault
codes, refer to .
If fault codes are active, contact a Cummins
Authorized Repair Facility.
Electronic control module (ECM) is locked up.
Disconnect the battery cables for 30 seconds. Then,
reconnect the battery cables, and start the engine.
Battery voltage supply to the electronic control module
(ECM) is low, interrupted, or open.
Check the battery connections, the fuses, and the
battery supply circuit.
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 filters as necessary
Vent air from the system. Refer to Air in Fuel in
Section 12.
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 8.
Drawing No. 9771, Section 17, Rev. A
Page 17-36
Section 17 – Troubleshooting
CFP8E Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Correction
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 15.
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 12.
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 suction line is restricted.
Check the fuel suction line for restriction.
Fuel connections on the suction side of the fuel lift
pump are loose.
Tighten all the fuel fittings and connections between
the fuel tanks and fuel lift pump.
Fuel suction standpipe in the fuel tank is broken.
Check and repair the standpipe, if necessary.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-37
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Correction
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 12.
Injection pump driveshaft or driveshaft key is damaged.
Repair or replace the injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 12.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 12.
Moisture in the wiring harness connectors.
Dry the connectors with Cummins electronic cleaner,
Part Number 3824510.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage.
Starting motor rotation is not correct.
Check the direction of crankshaft rotation.
Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 12.
Drawing No. 9771, Section 17, Rev. A
Page 17-38
Section 17 – Troubleshooting
CFP8E Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Starting motor is not turning the engine.
Correction
Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-39
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 corroded creating excessive resistance.
Check the battery cables and connections. Ensure that
connections are clean and tight
The battery is not properly charged or has failed.
Recharge the battery. If the battery doers not take the
charge, replace it.
Lubricating oil level is too high.
Check the oil level. Refer to Check Engine Oil Level in
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
15.
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.
Starting motor is malfunctioning
Replace the starting motor. Refer to Starter Motor
Assembly Removal/Installation in Section 12.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-40
Section 17 – Troubleshooting
CFP8E 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.
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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 8.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 15.
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 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-41
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Cont)
Cause
Correction
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 suction line is restricted.
Check the fuel suction line for restriction.
Fuel connections on the suction side of the fuel lift
pump are loose.
Tighten all the fuel fittings and connections between
the 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 12.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 12.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage.R.
Drawing No. 9771, Section 17, Rev. A
Page 17-42
Section 17 – Troubleshooting
CFP8E Series
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Cont)
Cause
Correction
Intake air flow is restricted.
Check the air intake system 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.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-43
Engine Acceleration or Response Poor
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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 8.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 15.
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 12.
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. 9771, Section 17, Rev. A
Page 17-44
Section 17 – Troubleshooting
CFP8E Series
Engine Acceleration or Response Poor (Cont)
Fuel suction line is restricted.
Check the fuel suction line for restriction.
Fuel connections on the suction side of the fuel lift
pump are loose.
Tighten all the fuel fittings and connections between
the 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 12.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 12.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage.R.
Intake air flow is restricted.
Check the air intake system 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. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-45
Engine Acceleration or Response Poor (Cont)
Exhaust air is leaking.
Check the exhaust piping 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 12.
The charge air cooler is restricted or leaking
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Inspect the charge air cooler for air restrictions or
leaks. If required, replace the charge air cooler. Refer
to Charge Air Cooler Removal/Installation in Section
12.
Page 17-46
Section 17 – Troubleshooting
CFP8E Series
Engine Noise Excessive - Mechanical
Cause
Lubricating oil is thin or diluted
Correction
Check the oil level. Refer to Check Lubricating Oil
Level in Section 5. If the oil level is above the high
mark, go to Oil Level Rises in this section.
Otherwise, ensure that the correct type and grade of
lubricating oil is being g used. Refer to the Lubricating
Oil Recommendations and Specifications in Section
15.
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.
Vibration damper is damaged.
Inspect the vibration damper. Refer to Inspect
Vibration Damper in Section 10. If the vibration
damper is damaged, refer to a Cummins Authorized
Repair Facility.
Engine mounts are worn or damaged.
Inspect the engine mounts. If the engine mounts are
worn or damaged, refer to a Cummins Authorized
Repair Facility.
Reference?
Coolant temperature is above specification
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. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-47
Engine Noise Excessive – Mechanical (Cont)
Drive belt is squeaking due to insufficient tension or
high loading.
Check the automatic belt tensioner. If required,
replace the tensioner. Refer to Automatic Belt
Tensioner Removal/Installation in Section 12.
Intake air flow is restricted.
Check the air intake system 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.
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
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Replace the turbocharger. Refer to Turbocharger
Removal/Installation in Section 12.
Page 17-48
Section 17 – Troubleshooting
CFP8E Series
Engine Noise Excessive — Combustion Knocks
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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
quality is poor.
Operate the engine using the correct fuel. Refer to
Fuel Recommendations and Specifications in Section
15.
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 from the system. Refer to Air in Fuel in
Section 12.
The fuel injection pump’s timing is not correct.
Check and adjust the fuel injection pump timing. Refer
to Adjust Fuel Pump in Section 12.
The fuel injection pump is failing.
Replace the fuel injection pump. Refer to Fuel Injection
Pump Removal/Installation in Section 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-49
Engine Noise Excessive — Combustion Knocks (Cont)
Coolant temperature is below specification.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree in this section.
Page 17-50
Section 17 – Troubleshooting
CFP8E Series
Engine Runs Rough at Idle
NOTE: Operation at idle speed is for maintenance only.
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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.
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 12.
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 correct5 the restriction in fuel flow to the
engine.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-51
Engine Runs Rough at Idle (Cont)
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 12.
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
quality is poor
Operate the engine on the required fuel. Refer to Fuel
Recommendations and Specifications in Section 15.
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 12.
Injector is malfunctioning
Inspect the injectors.
Replace the injectors as necessary. Refer to Fuel
Injectors Removal/Installation in Section 12.
Fuel injection pump is malfunctioning
Remove the fuel injection pump. Refer to Fuel Injection
Pump Removal/Installation in Section 12.
Check the calibration of the fuel injection pump.
Replace the pump if necessary.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-52
Section 17 – Troubleshooting
CFP8E Series
Engine Runs Rough or Misfires Under Load
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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.
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 12.
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 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-53
Engine Runs Rough or Misfires Under Load (Cont)
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
quality is poor.
Operate the engine on the required fuel. Refer to Fuel
Recommendations and Specifications in Section 15.
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 12.
Injector is malfunctioning.
Inspect the injectors.
Replace the injectors as necessary. Refer to Fuel
Injectors Removal/Installation in Section 12.
Fuel injection pump is malfunctioning.
Remove the fuel injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 12.
Check the calibration of the fuel injection pump.
Replace the pump if necessary.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-54
Section 17 – Troubleshooting
CFP8E Series
Engine Speed Surges at Idle
NOTE: Operation at idle speed is for maintenance only.
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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.
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 12.
The fuel filter is plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel flow to the engine is not adequate.
Locate and correct the restriction in the customersupplied fuel lines 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 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-55
Engine Speed Surges at Idle (Cont)
Cause
Correction
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine with the required fuel. Refer to
Fuel Recommendations and Specifications in Section
15.
The fuel injection pump is malfunctioning.
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 12.
Calibrate the fuel pump.
If required, replace the fuel injection pump.
A fuel supply line restriction exists between the fuel
injection pump and the injectors.
Check the fuel supply line or passage for sharp bends
or restriction. Remove any restrictions
A fuel injector is malfunctioning.
Replace the malfunctioning injector. Refer to Fuel
Injectors Removal/Installation in Section 12.
Moisture is present in the wiring harness connectors.
Dry the connectors with Cummins electronic cleaner,
Part Number 3824510.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-56
Section 17 – Troubleshooting
CFP8E Series
Engine Speed Surges Under Load
Cause
Electronic fault codes are active.
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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 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 12.
The fuel filter is plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel flow to the engine is not adequate.
Locate and correct the restriction in the customersupplied fuel lines 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 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-57
Engine Speed Surges Under Load (Cont)
Cause
Correction
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine with the required fuel. Refer to
Fuel Recommendations and Specifications in Section
15.
The fuel injection pump is malfunctioning.
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 12.
Calibrate the fuel pump.
If required, replace the fuel injection pump.
A fuel supply line restriction exists between the fuel
injection pump and the injectors.
Check the fuel supply line or passage for sharp bends
or restriction. Remove any restrictions
A fuel injector is malfunctioning.
Replace the malfunctioning injector. Refer to Fuel
Injectors Removal/Installation in Section 12.
Moisture is present in the wiring harness connectors.
Dry the connectors with Cummins electronic cleaner,
Part Number 3824510.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-58
Section 17 – Troubleshooting
CFP8E Series
Engine Vibration Excessive at Rated Speed
Cause
Electronic fault codes are active.
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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 12.
Engine mounts are worn or damaged.
Inspect the engine mounts. Refer to Check Engine
Mounting Bolts in Section 7.
Replace the engine mounts as needed. Refer to a
Cummins Authorized Repair Facility
Vibration damper is malfunctioning.
Inspect the vibration damper. Refer to Inspect
Vibration Damper in Section 10.
Replace, if necessary. Refer to a Cummins Authorized
Repair Facility
Alternator bearing is worn or damaged.
Check if the alternator is vibrating excessively.
Replace the alternator if necessary. Refer to Alternator
Removal/Installation in Section 12.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-59
Engine Vibration Excessive at Rated Speed (Cont)
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 12.
Automatic belt tensioner bearing is worn or damaged.
Check if the belt tensioner is vibrating excessively.
Replace the tensioner if necessary. Refer to Automatic
Belt Tensioner Removal/Installation in Section 12.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-60
Section 17 – Troubleshooting
CFP8E Series
Engine Stops During Operation
Cause
Correction
Normal automatic mode shutdown occurs when the
fire protection systems removes the signal power feed
to the local control panel.
No action required This is a desirable outcome.
The selected engine control module (ECM) has
detected a serious fault condition. The ECM’s STOP
light is displayed.
For instructions on how to read active fault codes,
refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
In the automatic mode, the signal power feed is lost
from the fire protection system to the control panel.
Locate and correct the electrical fault in the fire
protection system or the field wiring to the engine
control panel.
Signal power is lost by the operation of the circuit
breaker the engine control panel.
Press the circuit breaker reset button on the engine
control panel .
Locate and correct the electrical fault in engine control
panel. Refer to Drawing 8512 Sheet 1 in Section 18.
An overspeed trip has occurred. The overspeed trip
light is illuminated on the local control panel. Remote
indications may also be present.
Go to Engine Overspeed Trip in this section.
Alternatively, a related overspeed switch failure has
occurred. The trip indications may not be present.
Power supply or grounding fault exists at the Electronic
Control Module.
Locate and correct the electrical fault in the power
supply or grounding for the Electronic Control Module.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-61
Engine Stops During Operation (Cont)
Cause
The selected ECM has failed.
Correction
Select the alternate ECM.
When practical, replace the failed ECM. Refer to the
Electronic Control Module (ECM) (Primary)
Removal/Installation or Electronic Control Module
(ECM) (Secondary) Removal/Installation in Section
12.
Fuel tank level is low.
Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
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 7.
Air is trapped in the low pressure fuel lines at the
engine.
Bleed the fuel lines. Refer to Air in Fuel in Section 12.
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 12.
Drawing No. 9771, Section 17, Rev. A
Page 17-62
Fuel injection pump has failed.
Section 17 – Troubleshooting
CFP8E Series
Replace the fuel injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-63
Engine Will Not Reach Rated Speed (RPM)
Cause
Electronic fault codes are active
Correction
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
Programmable parameters or selected features are not
correct.
Check the programmable parameters and the selected
features with an electronic service tool.
Set the parameters and features again if necessary.
Refer to a Cummins Authorized Repair Facility.
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.
Refer to Section 3.
Replace if necessary. Refer to Section 12.
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 12.
Tachometer is malfunctioning.
Drawing No. 9771, Section 17, Rev. A
Replace the tachometer. Refer to Tachometer
Removal/Installation in Section 12.
Page 17-64
Section 17 – Troubleshooting
CFP8E Series
Engine Will Not Reach Rated Speed (RPM) (Cont)
Cause
Correction
Engine power output is low.
Refer to the Engine Acceleration or Response Poor
symptom tree in this section.
Fuel grade is not correct for the application, or the fuel
quality is poor.
Operate the engine with the required fuel. Refer to
Fuel Recommendations and Specifications in Section
15.
Fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 8.
Fuel suction line is restricted.
Check the fuel suction line for restriction.
Air-fuel tube leaking, wastegate diaphragm ruptured,
or wastegate plumbing damaged.
Tighten the fittings, repair plumbing, replace
wastegate 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 customersupplied fuel lines to the engine.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-65
Engine Will Not Reach Rated Speed (RPM) (Cont)
Cause
Exhaust back pressure too high.
Correction
NOTE: The maximum allowable exhaust back
pressure is specified in Exhaust System Specifications
in Section 15.
Measure the exhaust back pressure. Correct the
problem is it is above specification.
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 12.
Fuel injection pump is malfunctioning.
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 12.
Calibrate the fuel pump.
.If required, replace the fuel injection pump.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-66
Section 17 – Troubleshooting
CFP8E Series
Engine Will Not Shut Off Remotely
Cause
Stop circuit malfunction in the fire pump controller of
field wiring.
Correction
NOTE: In the AUTO mode, the fire pump engine stops
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/MANUAL switch at the engine control panel.
Replace the switch if the switch contacts fail to
operate properly.
Electronic fault codes are active.
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-67
Engine Will Not Shut Off Locally
Cause
The AUTOMANUAL Rocker Switch has failed.
Correction
NOTE: In the MANUAL mode, the fire pump engine
stops when the AUTO/MANUIAL switch is returned to
the AUTO mode.
Check operation of the switch contacts of the
AUTO/MANUAL switch at the engine control panel.
Replace the switch if the switch contacts fail to
operate properly.
Inadvertent power source is present from the fire pump
controller.
NOTE: In the MANUAL mode, the fire pump engine
stops when the AUTO/MANUIAL switch is returned to
the AUTO mode.
Check for inadvertent voltage on the wiring to TB 1 at
the engine control panel. Correct any wiring errors.
Electronic fault codes are active.
NOTE: For instructions on how to read active fault
codes, refer to Diagnostic Fault Codes in Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
Engine running on fumes drawn into the air intake.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Identify and isolate the source of the combustible
fumes.
Page 17-68
Section 17 – Troubleshooting
CFP8E Series
Exhaust Smoke Excessive At Idle, White
Cause
Starting procedure is not correct
Correction
Verify the correct starting procedure.
Refer to Section 3.
Coolant temperature is below specification
Refer to the OEM service manual.
Intake manifold air temperature is below specification
Refer to the OEM service manual.
Fuel rate is low, fuel pressure is low, intake manifold
pressure is low
Check the fuel pump output pressure, pulsation
damper, and pressure regulator.
Replace the fuel pump if necessary.
Injection timing incorrect
Check injection timing.
Refer to the OEM service manual.
Fuel pump return overflow valve is malfunctioning
Inspect the return overflow valve.
Replace if necessary.
Refer to the OEM service manual.
Injector sealing washer not correct
Check to see if an extra sealing washer is installed
under injector.
Remove any additional sealing washer.
Only one is required.
Refer to the OEM service manual.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-69
Exhaust Smoke Excessive At Idle, White (Cont)
Cause
Injector sealing washer not correct
Correction
Remove injector and install the proper sealing washer.
Refer to the OEM service manual.
Injector is malfunctioning
Inspect the injectors.
Replace the injectors as necessary.
Refer to the OEM service manual.
Coolant flow through the radiator is not correct
Refer to the OEM service manual.
Fuel injection pump is malfunctioning
Remove the fuel pump.
Refer to the OEM service manual.
Calibrate the fuel pump.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-70
Section 17 – Troubleshooting
CFP8E Series
Exhaust Smoke Excessive At Idle, Black
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-71
Exhaust Smoke Excessive Under Load
Cause
Correction
Engine is being lugged down
Use lower gear.
Air in the fuel system
Check for air in the fuel system.
Completely bleed air from the fuel system.
Refer to the OEM service manual.
Air filter is restricted
Check the air filter for restrictions.
Refer to Section 4.
Fuel injection pump timing is not correct
Put the engine at top dead center.
Check and adjust the fuel timing.
Refer to the OEM service manual.
Intake or exhaust leak
Check intake and exhaust systems for loose or
damaged piping connections and/or missing pipe
plugs.
Check turbocharger and exhaust manifold mounting.
Refer to the OEM service manual.
Injector sealing washer not correct
Check to see if an extra sealing washer is installed
under injector.
Remove any additional sealing washer.
Only one is required.
Refer to the OEM service manual.
Drawing No. 9771, Section 17, Rev. A
Page 17-72
Section 17 – Troubleshooting
CFP8E Series
Exhaust Smoke Excessive Under Load (Cont)
Cause
Injector is malfunctioning
Correction
Inspect the injectors.
Replace the injectors as necessary.
Refer to the OEM service manual.
Turbocharger is malfunctioning
Monitor the turbocharger boost pressure with an
electronic service tool.
Refer to the OEM service manual.
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.
Fuel injection pump is malfunctioning
Remove the fuel pump.
Refer to the OEM service manual.
Calibrate the fuel pump.
Air-fuel (AFC) control is leaking or obstructed
Check the AFC for leaks.
Repair any leaks found, if necessary.
Check and clean AFC tubing and fittings for
obstructions.
Refer to the OEM service manual.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-73
Fuel Consumption Is Excessive
Cause
Electronic fault codes are active.
Correction
NOTE: For instructions on how to read active fault
codes, refer to Section 3.
If fault codes are active, contact a Cummins
Authorized Repair Facility.
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 15.
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.
Incorrect injection timing
Adjust injection timing.
Injection pump is adjusted incorrectly causing
excessive injection
Adjust or replace the injection pump.
Drawing No. 9771, Section 17, Rev. A
Page 17-74
Section 17 – Troubleshooting
CFP8E Series
Fuel Consumption Is Excessive (Cont)
Cause
Correction
Hour meter is not calibrated
Check the hour meter. Calibrate or replace the hour
meter if necessary.
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.
Air intake system restriction is above specification
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 7.
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.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-75
Fuel or Lubricating Oil Leaking From Exhaust Manifold
Cause
Intake air restriction is high
Correction
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 7.
Replace the air filter if required.
Turbocharger drain line is restricted
Remove the turbocharger drain line and check for
restriction.
If required, clean or replace the drain line.
Injector needle valve sticking.
Inspect the injectors.
Replace if necessary.
Turbocharger oil seal is leaking
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Check the turbocharger for oil seals and for leaks.
Refer to the Turbocharger Leaks Engine Oil or Fuel
symptom tree in this section.
Page 17-76
Section 17 – Troubleshooting
CFP8E Series
Lubricating Oil Contaminated
NOTE: If excessive sludge is present in the oilpan, refer to Lubricating Oil Sludge in the Crankcase Excessive in
this section.
Cause
Bulk oil supply is contaminated
Correction
Check the bulk oil supply. Replace it is necessary.
Refer to Lubricating Oil Recommendations and
Specifications in Section 15.
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.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-77
Fuel in the Lubricating Oil
Cause
Correction
Engine idle time is excessive
Low oil and coolant temperatures can be caused by
long idle time (greater than 10 minutes). Shut off the
engine rather than idle for long periods. If idle time is
necessary, raise the idle speed.
Injector o-rings are damaged or missing
Remove and check the injectors. Replace the injector
o-rings. Refer to Injector (006-026) in the
Troubleshooting and Repair Manual, ISC, QSC8.3,
ISL, and QSL9 Series Engines, Engines, Bulletin
4021418.
Injector is malfunctioning
Perform the automated cylinder performance test.
Replace injectors as necessary. Refer to Injector
(006-026) in the Troubleshooting and Repair Manual,
ISC, QSC8.3, ISL, and QSL9 Series Engines,
Engines, Bulletin 4021418.
Fuel injection pump is malfunctioning
Inspect the cam housing for cracks and damage.
Refer to Fuel Pump Cam Housing Module (005-088)
in the Troubleshooting and Repair Manual, ISC,
QSC8.3, ISL, and QSL9 Series Engines, Engines,
Bulletin 4021418.
Fuel injection pump is malfunctioning
Replace the accumulator module. Refer to Fuel Pump
Accumulator Module (005-085) in the Troubleshooting
and Repair Manual, ISC, QSC8.3, ISL, and QSL9
Series Engines, Engines, Bulletin 4021418.
Fuel injection pump is malfunctioning
Inspect the injection pump gear pump module oil seal.
Replace gear pump module if there are signs or
leakage. Refer to Fuel Pump Gear Pump (005-025) in
the Troubleshooting and Repair Manual, ISC,
QSC8.3, ISL, and QSL9 Series Engines, Engines,
Bulletin 4021418.
Drawing No. 9771, Section 17, Rev. A
Page 17-78
Section 17 – Troubleshooting
CFP8E Series
Cylinder head is cracked or porous
Remove intake and exhaust manifolds. Check for
evidence of coolant leak. If necessary, operate engine
at low idle. Pressure-test the cylinder head. Refer to
Cylinder Head (002-004) in the Troubleshooting and
Repair Manual, ISC, QSC8.3, ISL, and QSL9 Series
Engines, Engines, Bulletin 4021418.
Internal engine damage
Analyze the oil and inspect the filters to locate an area
of probable damage. Refer to an Authorized Cummins
Repair Facility.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-79
Coolant in the Lubricating Oil
Cause
Correction
Lubricating oil cooler is malfunctioning
Check the oil cooler. Refer to Lubricating Oil Cooler
(007-003) in the Troubleshooting and Repair Manual,
ISC, QSC8.3, ISL, and QSL9 Series Engines,
Engines, Bulletin 4021418.
Cylinder head core and expansion plugs leaking or
misassembled
Check cylinder head. Refer to Cylinder Head (002004) in the Troubleshooting and Repair Manual, ISC,
QSC8.3, ISL, and QSL9 Series Engines, Engines,
Bulletin 4021418.
Cylinder head gasket is leaking
Check the cylinder head gasket. Refer to Cylinder
Head Gasket (002-021) in the Troubleshooting and
Repair Manual, ISC, QSC8.3, ISL, and QSL9 Series
Engines, Engines, Bulletin 4021418.
Cylinder head is cracked or porous
Pressure-test the cylinder head. Refer to Cylinder
Head (002-004) in the Troubleshooting and Repair
Manual, ISC, QSC8.3, ISL, and QSL9 Series Engines,
Engines, Bulletin 4021418.
Cylinder block is cracked or porous
Remove the oil pan. Pressure-test the cooling system
to check for leaks. Refer to Cooling System
Diagnostics (008-020) in the Troubleshooting and
Repair Manual, ISC, QSC8.3, ISL, and QSL9 Series
Engines, Engines, Bulletin 4021418.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-80
Section 17 – Troubleshooting
CFP8E Series
Lubricating Oil Consumption Excessive
Cause
Correction
Verify the oil consumption rate.
Check the amount of oil added versus the operating
hours.
An external lubricating oil leak is present.
Inspect the engine for external oil leaks. Tighten the
capscrews, pipe plugs, and fittings. Replace gaskets, if
necessary.
Crankcase ventilation system is plugged
Check and clean the crankcase breather and vent tube.
Refer to Crankcase Breather Tube (003-018) and
Crankcase Breather (Internal) (003-002) in
Troubleshooting and Repair Manual ISC, ISCe,
QSC8.3, ISL and QSL9 Engines, Bulletin Number
4021418-00.
Lubricating oil does not meet specifications for
operating conditions
Change the oil and filters. Refer to Change Lubricating
Oil and Filters in Section 7.
Use the oil type recommended in Lubricating Oil
Recommendations and Specifications in Section 15.
Lubricating oil drain interval is excessive
Verify the correct lubricating oil drain interval. Refer to
Change Lubricating Oil and Filters in Section 7.
Lubricating oil cooler is leaking
Check the lubricating oil cooler for coolant leaks. Refer
to Lubricating Oil Cooler (007-003) in Troubleshooting
and Repair Manual ISC, ISCe, QSC8.3, ISL and QSL9
Engines, Bulletin Number 4021418-00.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-81
Lubricating Oil Consumption Excessive (Cont)
Cause
Correction
Turbocharger oil seal is leaking
Check the turbocharger compressor and turbine seals.
Refer to Turbocharger (010-033) in Troubleshooting
and Repair Manual ISC, ISCe, QSC8.3, ISL and QSL9
Engines, Bulletin Number 4021418-00.
Piston rings are not seated correctly (after an
engine rebuild or piston installation)
Check blowby. Refer to Engine Testing (Chassis
Dynamometer) (014-002) in Troubleshooting and
Repair Manual ISC, ISCe, QSC8.3, ISL and QSL9
Engines, Bulletin Number 4021418-00.
If blowby is excessive, check the piston rings for correct
seating. Refer to Piston (001-043) and Piston Rings
(001-047) in Troubleshooting and Repair Manual ISC,
ISCe, QSC8.3, ISL and QSL9 Engines, Bulletin Number
4021418-00.
Piston or piston rings are worn or damaged
Check the pistons and piston rings for wear or damage.
Refer to Air Leaks, Air Intake and Exhaust Systems
(010-024) in Troubleshooting and Repair Manual ISC,
ISCe, QSC8.3, ISL and QSL9 Engines, Bulletin Number
4021418-00.
Internal engine damage
Analyze the oil and inspect the filters to locate an area
of probable damage. Refer to Lubricating Oil and Filter
Analysis (007-083) in Troubleshooting and Repair
Manual ISC, ISCe, QSC8.3, ISL and QSL9 Engines,
Bulletin Number 4021418-00.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Page 17-82
Section 17 – Troubleshooting
CFP8E Series
Lubricating Oil Pressure High
Cause
Lubricating oil pressure sensor or gauge is
malfunctioning or is not in the correct location
Correction
Check the oil pressure switch or gauge for correct
operation and location.
Refer to the OEM service manual.
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.
Lubricating oil does not meet specifications for
operating conditions
Change the oil and filters.
Lubricating oil pressure is above specification
Check the oil pressure.
Use the oil type recommended in Section 15 of the
engine operation and maintenance manual.
Refer to the OEM service manual.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-83
Lubricating Oil Pressure Low
Cause
Correction
Lubricating oil level is low
Check and replenish lubricating oil.
Lubricating oil pressure sensor or gauge is
malfunctioning or is not in the correct location
Check the oil pressure switch or gauge for correct
operation and location.
Refer to the OEM service manual.
Lubricating oil is diluted with fuel
Change the oil.
If the oil becomes diluted again, contact an Authorized
Cummins Repair Facility.
Lubricating oil is diluted with water
Check for a missing dipstick, rain caps, or oil fill caps.
Change the oil.
Refer to the OEM service manual.
Lubricating oil does not meet specifications for
operating conditions
Change the oil and filters.
Lubricating oil leak (external)
Inspect the engine for external oil leaks.
Use the oil type recommended in Section 15 of the
engine operation and maintenance manual the OEM
service manual.
Tighten the capscrews, pipe plugs, and fittings.
Replace gaskets, if necessary.
Refer to the OEM service manual.
Drawing No. 9771, Section 17, Rev. A
Page 17-84
Section 17 – Troubleshooting
CFP8E Series
Lubricating Oil Pressure Low (Cont)
Cause
Lubricating oil viscosity not correct
Correction
Make sure the correct lubricating oil is being used.
Refer to Section 5.
Lubricating oil high-pressure relief valve is
malfunctioning or lubricating pump pressure regulator
Remove and inspect the high-pressure relief valve.
Lubricating oil filter is plugged
Change the oil and filter.
Refer to the OEM service manual.
Refer to Section 4.
Contact a Cummins Authorized Repair Facility
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-85
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.
Drawing No. 9771, Section 17, Rev. A
Page 17-86
Section 17 – Troubleshooting
CFP8E Series
Lubricating Oil Sludge in the Crankcase Excessive
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Turbocharger Leaks Engine Oil or Fuel
Drawing No. 9771, Section 17, Rev. A
Page 17-87
Page 17-88
Section 17 – Troubleshooting
CFP8E Series
Crankcase Gases (Blowby) - Excessive
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-89
Engine Overspeed Trip
NOTE: An engine overspeed trip occurs when the engine’s speed exceeds the value specified on the Field
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
catastrophic load failure such as pipe break, pump
mechanical failure, or loss of suction.
Correct the cause of the load failure.
Engine actually operated at too great a speed due to
configuration error.
Check rated speed setting as specified on the Field
Setting Tag described in Section 2. Refer to Rated
Speed Setpoint Adjustment and Testing in Section 3.
Overspeed switch is set at too low a setpoint.
Check overspeed speed setting as specified on the
Field Setting Tag described in Section 2. Refer to
Overspeed Setpoint Adjustment and Testing in Section
3.
Speed switch wiring failure has occurred.
Check continuity and insulation from ground for the
signal power wiring and ground wiring to the speed
switch. Refer to Drawing 8512 Sheet 1 in Section 18.
Replace defective components and repair electrical
faults.
Speed switch failure has occurred.
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 12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Page 17-90
Section 17 – Troubleshooting
CFP8E Series
Tachometer Does Not Indicate Engine Speed
Cause
Fuse F4 has opened.
Correction
If required, replace Fuse F4.
Locate and correct the electrical fault that caused the
fuse to operate. Refer to Drawing 8512 Sheet 1 in
Section 18.
An electrical fault exists in the tachometer power and
grounding circuits.
Check continuity and insulation from ground for the
power wiring and ground wiring to the tachometer.
Refer to Drawing 8512 Sheet 1 in Section 18. Replace
defective components and repair electrical faults.
An electrical fault exists in the speed sensor input
circuit. This fault may also cause a failure in the crank
terminate signal to the fire protection system.
Check continuity and insulation from ground for the
speed sensor circuit. Refer to Drawing 8512 Sheet 1 in
Section 18. Replace defective components and repair
electrical faults.
The speed sensor has failed.
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
Speed Sensor Removal/Installation in Section 12.
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
12.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-91
Engine Decelerates Slowly
Drawing No. 9771, Section 17, Rev. A
Page 17-92
Section 17 – Troubleshooting
CFP8E Series
Neither ECM Active
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
Page 17-93
Either ECM Not Active
Drawing No. 9771, Section 17, Rev. A
Page 17-94
Section 17 – Troubleshooting
CFP8E Series
STOP Light On, Engine Stops
Drawing No. 9771, Section 17, Rev. A
Section 17 – Troubleshooting
CFP8E Series
WARN Light On, Engine Running
Drawing No. 9771, Section 17, Rev. A
Page 17-95
Page 17-96
Section 17 – Troubleshooting
CFP8E Series
This Page Intentionally Left Blank
Drawing No. 9771, Section 17, Rev. A
Section 18 – Assembly Drawings
CFP8E Series
Page 18-1
Section 18 – Assembly Drawings (1)
Description
Assembly, Panel, Instrument, 12VDC
Schematic, Electrical Wiring, 12 Volt
Schematic, Electrical Wiring, 12 Volt
Schematic, Electrical Wiring, 12 Volt (ECM Components)
Harness, Engine, Non-Electronic, Non-3.3L
Harness, Engine, Non-Electronic, Non-3.3L
Assembly, Panel, Instrument, 24 VDC (Non ECM)
Assembly, Panel, Instrument, Electronic, 12VDC
Assembly, Drive Shaft Guard
SAE #3 Shaft Guard QSB, QSC, 4B, 6B, 6C
Assembly, Stub-Shaft, SAE #3, 2.25” QSB, QSC, 4B, 6B, 6C
Assembly, Raw Water Cooling, 1” Generic
Drawing, Installation, Firepump, CFP8E (QSC8.3-C340)
Options, Engine, Firepump, Industrial, QSC8.3
Exhaust, 4” Bellows w/ Elbow
Enclosure Assembly, Instrument Panel, Pivot Face
Instrument Sensor Locations (Non-ECM)
Wiring Harness Testing Extension
ECM Wiring Harness, QSB, QSC
Assembly, Engine Mounting, C8.3, QSC
Assembly, Heat Shield, QSC8.3
Assembly, Coolant Heater, QSC8.3
Assembly, Heat Exchanger, QSC8.3
Assembly, Charge Air Cooling, CFP08E, CFP83-F40
Assembly, Operator Station, QSC8.3
Assembly, Air Cleaner, QSC8.3
ECM Junction Board Wiring, QSC
Assembly, Sensor Package, C8.3, QSC (Non-ECM)
Assembly, Fuel System Plumbing, QSC8.3
Assembly, Plumbing, CAC Heat Exchanger, QSC8.3
Junction Box Assembly, Secondary ECM, QSC
Assembly, Plumbing, CAC Heat Exchanger, QSC, QSM
Assembly, Pulley Guard, QSC
Kit, Loose Wires, 4B, 6B, 6C, QSB, QSC
Assembly, Secondary ECM & BRKT, QSC
General Layout, Firepump, CFP8E
Drawing No.
8508
8512
8512
8512
8513
8513
8532
8583
8600
8602
8619
8683
8711
8737
8780
8825
8875
8878
8878
8907
8937
8941
8944
8967
9502
9531
9548
9574
9590
9591
9593
9595
9627
9767
9784
CFP8E_GEN
Sheet No
1
2
3
1
2
Revision
C
J
D
E
J
J
D
C
C
B
D
D2
A
C
C
4
5
B
A
C
C
A
B
B
B
A
C
A
B
A
A
(1): Also see Engine Identification in Section 2 the System Diagrams in Section 11. The most current revisions
to these drawings and related documents are accessible at http://www.cumminsfirepower.com/products.html.
Drawing No. 9771, Section 18, Rev. B
Page 18-2
Section 18 – Assembly Drawings
CFP8E Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9771, Section 18, Rev. B
PN
SO
Model
Config
Option
FIRE 25
AP 9348
BB 9107
BB 9108
BR 9068
CH 9033
CP 9184
DA 9073
DF 9059
DO 9348
EC 9015
EH 9311
EE9242
FA 9201
FA 9717
FF 9151
FF 9526
FF 9810
FH 9207
FP97940
FP98655
FP99221
FR91061
FS 9226
FT97074
FW 9349
FW 9335
GG 9706
GG 9752
HC 9010
IC 9142
IT 9006
LA 9028
LC 9060
LC 9702
LF 9049
LF 9130
LG 9343
LO 9004
LP 9011
LP 9713
OB 9101
OP 9153
PH 9840
PP 8151
PP97176
PP97421
PP97774
RL 9705
RP 9013
SB 9054
SC97416
SK 9003
SM 9080
SP 9057
SR 9003
SS 9238
ST 9237
TB 9439
TK 9006
TP97014
VC 9062
VC 9728
WF 9028
WF 9101
WI 9064
WO 9028
WP 9016
8737
35329
QSC8.3
D413032CX03
Desc
QSC8.3
APPROVAL,AGENCY
BLOCK,CYLINDER
HOUSING,FRONT GE
BREATHER,CRANKCA
AID,COO HEATER S
COMPRESSOR,AIR
DAMPER,VIBRATION
DRIVE,FRO GER TR
SOFTWARE,CUS INT
THERMOSTAT
MOUNTING,ALTERNA
Alternator, 12V, 95A, Delco 11SI
DRIVE,FAN
MOUNTING,FAN DRI
LOCATION,FUEL FI
FILTER,FUEL
PLUMBING,FUEL FI
HOUSING,FLYWHEEL
COUPLING,FUEL PU
PUMP,FUEL INJECT
CALIBRATION,FUEL
RATING,FUEL
PUMP,FUEL TRANSF
PLUMBING,FUEL
FLYWHEEL
Flywheel, 8/10
COVER,FRONT GEAR
MOUNTING,GEAR CO
PLUMBING,CABIN H
CONNECTION,AIR I
CONNECTION,AIR T
ARRANGEMENT,LIFT
HEAD,OIL FILTER
COOLER,ENGINE OI
FILTER,FULL FLOW
FILTER,LUBRICATI
GAUGE,OIL LEVEL
OIL,LUBRICATING
PUMP,LUBRICATING
PUMP,LUBRICATING
ARRANGEMENT,OIL
PAN,OIL
MODULE,ENGINE CO
PARTS,PERFORMANC
HEAD,CYLINDER
INJECTOR
TURBOCHARGER
LEVER,ROCKER
VENT,ENGINE COOL
BATTERY
SOFTWARE,CALIBRA
ARRANGEMENT,SHIP
MOUNTING,STARTIN
SPACER,FAN PILOT
SHIELD,DEBRIS
PAINT
MOTOR,STARTING
ARRANGEMENT,TURB
COOLER,TOR CONVE
PLUMBING,TURBOCH
COVER,VALVE
MOUNTING,VALVE C
LOCATION,CRN RES
RESISTOR,CORROSI
CONNECTION,WATER
CONNECTION,WATER
PUMP,WATER
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