cfp33 series - Cummins Power Generation

CFP33 SERIES
Operation & Maintenance Manual
Fire Pump Drive Engines
www.cumminsfirepower.com
Page ii
Foreword
This manual contains information for the correct operation and maintenance of a Cummins Fire Pump engine. 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 11. 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. 9774, Section 0, Rev. 02-07
Page iii
Index of Sections
Introduction ………………………………………………………………….……………….......................................... 1
Engine Identification …………………………………………………………………………… ................................... 2
Installation and Operation………………………………………………………….………….. ................................... 3
Maintenance Guidelines ……………………………………………………….…………... ........................................ 4
Maintenance Procedures …………………………………………………………….................................................. 5
System Diagrams …………………………………………………………………………... ......................................... 6
Adjustment, Repair and Replacement……………………………......................................................................... 7
Service Literature …………………………………………………………………………… ........................................ 8
Service Assistance ………..………………………………………………………………... ........................................ 9
Maintenance Specifications ……………………………………............................................................................ 10
Warranty Information…………………………………………………………………………………….. .................... 11
Troubleshooting …………………………………………………………………………….. ...................................... 12
Assembly Drawings............................................................................................................................................. 13
Drawing No. 9774, Section 0, Rev. 02-07
Page iv
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Drawing No. 9774, Section 0, Rev. 02-07
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Page 1-2
Section 1 – Introduction
CFP33 Series
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Drawing No. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 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
10.
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 Service Assistance in Section 9.
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 8.
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 10 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. 9774, Section 1, Rev. 02-07
Page 1-4
Section 1 – Introduction
CFP33 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.
Drawing No. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Page 1-6
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 Series
Page 1-7
General Safety Instructions (Cont.)
•
Naphtha 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. 9774, Section 1, Rev. 02-07
Page 1-8
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Page 1-10
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Page 1-12
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Page 1-14
Section 1 – Introduction
CFP33 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. 9774, Section 1, Rev. 02-07
Section 2 – Engine Identification
CFP33 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
Fire Pump Identification...................................................................................................................................2-10
Fuel Injection Pumps, Inline ............................................................................................................................2-11
Drawing No. 9774, Section 2, Rev. 02-07
Page 2-2
Section 2 – Engine Identification
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 2, Rev. 02-07
Section 2 - Engine Identification
CFP33 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. 9774, Section 2, Rev. 02-07
Page 2-4
Section 2 – Engine Identification
CFP33 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.
9.
10.
Instrument Panel
Terminal Box
Air Intake Cross-Over Tube
Turbocharger
Lubricating Oil Fill Location
Upper Water Hose/Tube
Fuel Filter
Fuel Pump
Lower Water Hose/Tube
Raw Water Outlet (1” NPT)
11.
12.
13.
14.
15.
16.
17.
18.
19.
Raw Water Inlet (¾” NPT)
Pulley/Belt Guard
Coolant Drain
Oil Pan Drain
Starter Motor
Engine Support
Fire Pump Dataplate
Electric Fuel Solenoid
Circuit Breaker
Drawing No. 9774, Section 2, Rev. 02-07
Section 2 - Engine Identification
CFP33 Series
Page 2-5
Turbocharger Side
1.
2.
3.
4.
5.
Air Cleaner Element
Manual Start Lever
Lubricating Oil Filter
Dipstick
Coolant Heater
Drawing No. 9774, Section 2, Rev. 02-07
6.
7.
8.
9.
10.
Alternator
Heat Exchanger
Top Tank Fill
Exhaust
Turbocharger and Exhaust Shield
Page 2-6
Section 2 – Engine Identification
CFP33 Series
Front View
Drawing No. 9774, Section 2, Rev. 02-07
Section 2 - Engine Identification
CFP33 Series
Top View
Drawing No. 9774, Section 2, Rev. 02-07
Page 2-7
Page 2-8
Section 2 – Engine Identification
CFP33 Series
Isometric Views
Drawing No. 9774, Section 2, Rev. 02-07
Section 2 - Engine Identification
CFP33 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. 9774, Section 2, Rev. 02-07
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 (Electronic Engines)
Page 2-10
Section 2 – Engine Identification
CFP33 Series
Fire Pump Identification
The fire pump dataplate shows specific information about your engine. The engine serial number (1) and Control
Parts List (CPL) (2) provide information for ordering parts and service needs.
NOTE: The fire pump dataplate must not be changed unless approved by Cummins Fire Power.
Factory Setting Tag
The Factory Setting Tag is located at the pump end
of the engine just above the redundant starter
solenoids. Refer to Drawing 8704 (CFP59-F10, F20,
F40, F50), (CFP59-F15, F25), (CFP59-F45) or
(CFP59-F55) in Section 13 for location details.
FACTORY SETTING
This tag identifies to rated operating speed at the
rated horsepower. It also provides the over speed
switch setpoint. Both values are set at the factory.
Refer to Installation Instructions in Section 3 for
procedures to verify or adjust either setpoint.
Drawing No. 9774, Section 2, Rev. 02-07
Section 2 - Engine Identification
CFP33 Series
Page 2-11
Fuel Injection Pumps, Inline
Bosch® In-Line Pump Identification Use Bosch® A
pump with RSV governor for an industrial application.
The A pump will use the RQV governor for
automotive engines. Some industrial engines will use
RQV governors.
Use Bosch® MW pump with RQV governor for an
automotive engine. The MW pump will use the RSV
governor for industrial applications. Some industrial
engines will use RQV governors.
Shown here is the Bosch® P7100 pumps with RQV-K
governor for an automotive B or C Series engine.
Shown here is the Nippon denso EP-9 pump with
RSV governor for marine and some industrial C
Series ratings.
Drawing No. 9774, Section 2, Rev. 02-07
Page 2-12
Section 2 – Engine Identification
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 2, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-1
Section 3 – Installation and Operation
Section Contents
Page
Section 3 – Installation and Operation 1
Section Contents................................................................................................................................................1
Installation Overview .........................................................................................................................................3
Physical Engine Installation .............................................................................................................................4
Fuel Supply Installation.....................................................................................................................................6
Fire Pump Installation........................................................................................................................................7
Raw Water Supply Installation..........................................................................................................................8
Battery and Electrical Installation ..................................................................................................................11
Signal and Control Installation .......................................................................................................................12
Coolant System Preparation...........................................................................................................................13
Lubricating Oil System Preparation...............................................................................................................15
Fuel System Preparation .................................................................................................................................16
Pre-Start Inspections .......................................................................................................................................18
Pre-Lubricate the Engine.................................................................................................................................19
Lubricate Zerk Fittings on Auxiliary Drive Shaft ..........................................................................................19
Check Engine to Pump Alignment .................................................................................................................20
Initial Start-Up...................................................................................................................................................21
Initial Start.........................................................................................................................................................27
Second Start .....................................................................................................................................................29
Rated Speed Setpoint Adjustment .................................................................................................................31
Overspeed Setpoint Adjustment and Testing ...............................................................................................33
Crank Terminate Adjustment and Testing.....................................................................................................37
Isolated Acceptance Testing ..........................................................................................................................40
Integrated Acceptance Testing.......................................................................................................................41
General Operating Information.......................................................................................................................42
Normal Remote Starting Procedure ...............................................................................................................43
Normal Local Starting Procedure...................................................................................................................44
Jumpering the Batteries ..................................................................................................................................48
Operating the Engine.......................................................................................................................................49
Emergency Manual Starting Procedures.......................................................................................................50
Emergency Manual Mode Non-Electrical Start (CFP33-F10, F20, F30 only) ..............................................51
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-2
Section 3 – Installation and Operation
CFP33 Series
Section Contents (Cont)
Emergency Starting in Automatic Mode with Failed Fuel Shut-Off Solenoid.............................................53
Starting Procedure - After Extended Shutdown or Oil Change...................................................................54
Emergency Manual Stopping Procedure .......................................................................................................55
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-3
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. 9774, Section 3, Rev. 02-07
Page 3-4
Section 3 – Installation and Operation
CFP33 Series
Physical Engine Installation
Location
Refer to Drawing CFP33_GEN in Section 13 for the general fire pump and engine layout.
Refer to the following drawings in Section 13 for the general fire pump engine power module assembly:
Model
Drawing
CFP33-F10, F20, F30
Drawing 8700
CFP33-F25, F35
Drawing 8701
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 10.
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Physical Engine Installation (Cont)
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 10.
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. 9774, Section 3, Rev. 02-07
Page 3-5
Page 3-6
Section 3 – Installation and Operation
CFP33 Series
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 10.
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 1/8” NPT (minimum) fuel return line.
Route this line to the bottom of the fuel tank in
order to minimize the return head.
Install a ¼” NPT (minimum) fuel supply line to
the fire pump engine.
Provide a pre-filter on the fuel line to the fire
pump engine.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-7
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. 9774, Section 3, Rev. 02-07
Page 3-8
Section 3 – Installation and Operation
CFP33 Series
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 6 for a simplified block diagram of the cooling weater
system. Refer to Cooling System Specifications in Section 10 for pipe size requirements.
Refer to Drawing 8682 in Section 13 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 6. 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 and Drain Piping 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 engine side of
the heat exchanger.
Provide an open waste cone raw water drain at
the outlet from of the heat exchanger.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Raw Water Supply Installation (Cont)
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 the raw water inlet piping
from the engine coolant heat exchanger. Refer
to Drawing 9636 in Section 13.
Temporarily remove the raw water supply
piping from the fire pump to the manifold.
Temporarily supply an alternate source of raw
water to the inlet to the raw water manifold.
The temporary water supply pressure should
exceed 414 kPa [60 psig].
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.
Apply water pressure to the raw water
manifold.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-9
Page 3-10
Section 3 – Installation and Operation
CFP33 Series
Raw Water Supply Installation (Cont)
NOTE: The heat exchanger is rated at 414 kPa
[60 psig].
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.
Provide a temporary 12 VDC (standard) or 24
VDC (optional) power source for the solenoid
valve at Pin 13 and Pin 17. Refer to Drawing
10423 Sheet 1 in Section 13.
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 engine.
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-11
Battery and Electrical Installation
Overview
Two redundant sets of batteries must be supplied for the selected operating voltage (standard 12 VDC or
optional 24 VDC).
Batteries must meet the requirement listed in Electrical System Specifications in Section 10.
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 (standard) or 24 VDC (optional) 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 9766 in Section 13.
If purchased, install the optional battery cable kit (Cummins FirePower Part No. 9609). Otherwise, install
equivalent customer supplied wiring.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-12
Section 3 – Installation and Operation
CFP33 Series
Signal and Control Installation
NOTE: Install signal and control wiring at Terminal Board TB. Refer to Drawing 10423 Sheet 1 in Section 13.
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 pump 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
VDC (standard) or 24 VDC (optional) 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 pump 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Coolant System Preparation
Check Cooling System Integrity
NOTE: Refer to Drawing 8700 (CFP33-F10,
F20, F30) or Drawing 8701 (CFP33-F15, F25)
in Section 13 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.
Add Coolant
Remove the pressure cap (Cummins Fire
Power Part No. 11407) from the heat
exchanger.
Refer to Cooling System Specifications and
Coolant Recommendations and Specifications
in Section 10.
NOTE: Use a mixture of at least 50 percent
antifreeze and 50 percent water.
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 (Cummins Fire Power
Part No. 11407) on the heat exchanger.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-13
Page 3-14
Section 3 – Installation and Operation
CFP33 Series
Coolant System Preparation (Cont)
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 (upper) 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 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
10. 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
7.
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: 10 N•m [7 ft-lb]
Install the air intake filter assembly. Refer to
Intake Air Filter Removal/Installation in Section
7.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-15
Page 3-16
Section 3 – Installation and Operation
CFP33 Series
Fuel System Preparation
Fill the Fuel Filter
Unscrew the combination fuel filter assembly
and remove it from the engine.
If open, close the air/water separator drain
cock.
Lubricate the o-ring seal with clean
lubricating oil.
NOTE: Refer to Fuel Recommendations and
Specifications in Section 10 for fuel
requirements.
Fill the fuel element with diesel 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Fuel System Preparation (Cont)
Fill the Fuel Tank
NOTE: Refer to Fuel Recommendations and
Specifications in Section 10 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.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-17
Page 3-18
Section 3 – Installation and Operation
CFP33 Series
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Pre-Lubricate the Engine
Disconnect the connector at the electric fuel
solenoid (Fuel Shutoff Valve).
Press the MANUAL position on the
AUTO/MANUAL rocker switch.
NOTE: Monitor engine oil pressure on the local
control panel. Some pressure indication is
expected. Also, the low oil pressure light should
go off.
Crank the engine about two revolutions using
either the CRANK BATT A or the CRANK BATT
B switch positions.
Repeat a second time if oil pressure did not
register on the gauge.
NOTE: Troubleshoot as per Lubricating Oil
Pressure Low in Section 12 if oil pressure did not
register on the gauge.
When pre-lubrication has been accomplished,
reconnect the connector at the fuel injection
pump solenoid (Fuel Shutoff Valve).
Lubricate Zerk Fittings on Auxiliary Drive Shaft
Some lubrication loss may occur during transport
and storage. It is recommended that all drive
shafts be re-lubricated upon installation.
Grease zerk fittings as shown.
See Lubricating Oil Recommendations and
Specifications in Section 10 for grease
specifications.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-19
Page 3-20
Section 3 – Installation and Operation
CFP33 Series
Check Engine to Pump Alignment
Ensure engine position is centered on
Frame side to side within +-1/32", by
measuring outside of frame side to engine
support leg mounting pad. (Compare two
front engine supports and Two back
engine supports).
Align engine centerline to pump centerline
within +-1/32".
The pump centerline to the engine crank
centerline (in vertical plane) is to be ½"
+0, -1/4" offset.
NOTE: The slip joint must rest in the
middle third of its travel when installed.
SIDE VIEW
Auxiliary Drive shaft mounting flanges
must be parallel within 1.5 degrees.
90°
90°
TOP VIEW
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-21
Initial Start-Up
NOTE: Contact personnel responsible for the fire protection system before starting and to obtain approval to
service or repair the system.
Check the Raw Water Valves
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.
Align raw water supply to the raw water supply
valves.
Align drainage from the heat exchanger raw
water outlet.
Open the raw water supply valves as shown.
Check the Engine Coolant Supply
Close all cooling system drains.
Verify that the vents are opened.
Remove the coolant tank cap.
Check coolant level.
Cold coolant level should be between the
bottom of the tube and above the top of the heat
exchange coils.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-22
Section 3 – Installation and Operation
CFP33 Series
Initial Start-Up (Cont)
Add coolant if necessary. Use a mixture of at
least 50 percent antifreeze and 50 percent
water.
Replace the coolant tank cap.
Make a visual check for coolant leaks.
Prime the Fuel System:
Fill the fuel filter (see Fuel Recommendations
and Specifications in Section 10).
Remove the fuel pump suction line and wet the
gear pump gears with clean lubricating oil.
Check and fill the fuel tanks.
Check the injectors to be sure they are properly
adjusted.
Check Initial Crankcase Oil Level:
CAUTION
Never operate the engine with the oil level
below the low (“L”) mark or above the high
(“H”) mark on the dipstick
Check the oil level.
NOTE: No change in oil viscosity or type is
needed for new or newly rebuilt engines.
If below the low mark, fill the crankcase to the
low “L” (low) mark on the dipstick.
See Lubricating Oil Recommendations and
Specifications in Section 10 for oil
specifications.
See the Lubricating Oil System Specifications
for quantity that may be required.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Initial Start-Up (Cont)
Pre-Lubricate 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 turbocharger oil inlet line.
Pre-lubricate the housing by adding 50 to 60 cc
(2 to 3 oz.) of clean engine lubricating oil.
Replace the line.
Pre-Lubricate the Engine
NOTE: Do not prime the engine lubricating
system from the by-pass filter.
On the top of the fuel pump, disconnect the
electric fuel solenoid. Make sure that the fuel
pump solenoid wire terminal does not touch the
engine.
Close the fuel shutoff valve from the fuel tank to
prevent the engine from starting.
Prime the engine lubricating system until a 30
psi [207 kPa] minimum pressure is obtained.
NOTE: Use the fire pump controller or manual
setting from the gauge panel to crank the engine
through two cranking cycles.
Crank the engine at least 15 seconds, while
maintaining the external oil pressure at a
minimum of 15 psi [103kPa].
CAUTION
Never operate the engine with the oil level
below the low (“L”) mark or above the high
(“H”) mark on the dipstick
Check the oil level again.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-23
Page 3-24
Section 3 – Installation and Operation
CFP33 Series
Initial Start-Up (Cont)
NOTE: No change in oil viscosity or type is
needed for new or newly rebuilt engines.
If below the high mark, fill the crankcase to the
high “H” (high) mark on the dipstick.
See Lubricating Oil Recommendations and
Specifications in Section 10 for oil
specifications.
See the Lubricating Oil System Specifications
for quantity that may be required.
Initial Test Run
Move the throttle lever to mid-speed position.
Start the engine.
Immediately move the throttle to the low idle
position.
Allow the engine to operate at low idle speed
(700 RPM).
Check the lubricating oil pressure within 15
seconds after the engine starts.
Operate the engine at set point for 8 to 10
minutes.
Check for leaks, unusual noises, or other
indications of incorrect operation. Shut off the
engine and correct any problems found during
the inspection before proceeding.
After 8 to 10 minutes, stop the engine.
Check the engine oil and expansion tank
coolant levels. Top off if necessary.
Clean the raw water strainer.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Initial Start-Up (Cont)
Supplemental Test Run
Start the engine.
Bring it to the fire pump required operating
speed.
Adjust the raw water pressure regulator to
obtain the required pressure.
Readjust the engine speed if necessary.
Overspeed Adjustment Procedure:
NOTE: Overspeed is already set at factory.
Resolve whether or not overspeed testing as
per NFPA 20 is required. Verify that the
overspeed is factory set for the specific speed
(1760, 2100, 2360, 2600) as per the Factory
Setting Tag.
Remove the calibrating screw cover from the
electronic overspeed switch.
Turn the small screw on the potentiometer
near the word “OVERSPEED” clockwise to
increase trip speed.
Move the throttle to the half throttle position.
Start the engine and move the throttle to the
minimum position.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-25
Page 3-26
Section 3 – Installation and Operation
CFP33 Series
Initial Start-Up (Cont)
NOTE: Test button triggers overspeed at 10%
below normal.
Depress the “TEST” button push-button on the
inside of the panel.
Turn the screw to increase speed.
Verify overspeed trip/indications.
Operate the RESET switch on the front of the
engine control panel.
Repeat if necessary to further adjust the
overspeed stop setting.
Start the engine.
Check operation at rated speed.
Shut off the engine.
Press the “AUTO” button so the fire pump will
be ready to start automatically.
Completion
Support fire pump testing as per NFPA or
applicable requirements.
Contact operating personnel responsible for
fire protection system that engine is ready for
service.
Obtain authorized signature of acceptance.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-27
Initial Start
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 12.
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 Factory
Setting Tag described in Section 2.
NOTE: If the engine fully loaded, it should
operate at rated speed. Unloaded, it may operate
about 10% faster. 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
about rated speed.
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 12.
Check that lubricating oil pressure is displayed
within 15 seconds after the engine starts.
Drawing No. 9774, Section 3, Rev. 02-07
FACTORY SETTING
ENGINE SPEED SETTING:
(@ HP SETTING)
OVERSPEED SWITCH SETTING:
Page 3-28
Section 3 – Installation and Operation
CFP33 Series
Initial Start (Cont)
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.
Stop 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-29
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.
NOTE: If oil pressure is not within the rated
range, troubleshoot as per Lubricating Oil
Pressure High or Lubricating Oil Pressure Low in
Section 12.
Check that the oil pressure is as specified in
Lubricating Oil System Specifications in Section
10.
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 12.
Check that engine operating temperature
stabilizes between about 82 and 95oC [180 and
203oF].
Stop the engine by pressing the AUTO position
on the AUTO/MANUAL rocker switch and by
momentarily pressing the RESET switch.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-30
Section 3 – Installation and Operation
CFP33 Series
Second Start (Cont)
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-31
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 Factory
Setting Tag described in Section 2.
FACTORY SETTING
ENGINE SPEED SETTING:
(@ HP SETTING)
OVERSPEED SWITCH SETTING:
Start the engine.
Observe that the engine starts and accelerates
the currently adjusted speed setpoint.
Adjust the speed setpoint to rated speed.
NOTE: Rated speed is adjusted by locating the
threaded bolts on each side of the throttle
bracket on the fuel pump side of the engine.
Rated speed adjustment
To increase the speed, turn the bolt clockwise
on the right side of the throttle bracket. The
adjustment of the bolt will pivot the throttle
bracket counter-clockwise and will allow more
fuel through the pump to speed up the engine.
The bolt on the left side of the bracket is for
maximum speed and may also need to be
adjusted if maximum speed cannot be reached.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-32
Section 3 – Installation and Operation
CFP33 Series
Rated Speed Setpoint Adjustment (Cont)
To increase the speed, turn the bolt clockwise on
the right side of the throttle bracket. The
adjustment of the bolt will pivot the throttle
bracket counter-clockwise and will allow more
fuel through the pump to speed up the engine.
The bolt on the left side of the bracket is for
maximum speed and may also need to be
adjusted if maximum speed can not be reached.
Loosen lock nut and turn bolt counter-clockwise
to increase the speed. When rated speed is
correct, tighten lock nut against stop.
To decrease the speed, turn the bolt counterclockwise on the right side of the throttle bracket.
The adjustment of the bolt will pivot the throttle
bracket clockwise and will allow less fuel to flow
through the pump to slow down the engine.
When rated speed is correct, tighten the locking
nuts against the stops.
Stop the engine.
Start the engine.
Observe that the engine starts and accelerates to
the rated speed setpoint.
Stop the engine. Repeat the above adjustment
until the desired speed is attained.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-33
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 Factory 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. 9774, Section 3, Rev. 02-07
FACTORY SETTING
ENGINE SPEED SETTING:
(@ HP SETTING)
OVERSPEED SWITCH SETTING:
Page 3-34
Section 3 – Installation and Operation
CFP33 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 following Test Procedure to check
the effect of the adjustment.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-35
Overspeed Setpoint Adjustment and Testing (Cont)
Test Procedure
NOTE: The overspeed trip setpoint is displayed
on the Factory Setting Tag described in Section
2.
FACTORY SETTING
ENGINE SPEED SETTING:
(@ HP SETTING)
OVERSPEED SWITCH SETTING:
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. 9774, Section 3, Rev. 02-07
Page 3-36
Section 3 – Installation and Operation
CFP33 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 in this section.
Stop the engine.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-37
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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-38
Section 3 – Installation and Operation
CFP33 Series
Crank Terminate Adjustment and Testing (Cont)
Adjust
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 13.
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Crank Terminate Adjustment and Testing (Cont)
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
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 10423 Sheet 1 in
section 13.
NOTE: The engine’s rated speed is displayed on
the Factory 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 (standard) or 24 VDC (optional) signal
output voltage.
When testing is done, stop the engine.
Remove the digital voltmeter.
Close the cover on the engine control panel.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-39
Page 3-40
Section 3 – Installation and Operation
CFP33 Series
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.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-41
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 web 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. 9774, Section 3, Rev. 02-07
Page 3-42
Section 3 – Installation and Operation
CFP33 Series
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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-43
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.
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.
Position the fuel shutoff, electrical switch, or mechanism control to the run position.
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.
Move the throttle position to idle as soon as the engine starts.
Engine oil pressure must be indicated on the gauge within 15 seconds after starting.
When starting a cold engine, increase the engine speed (rpm) slowly to make sure adequate lubrication is
available to the bearings.
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.
Engines used in fire pumps or standby service are expected to transition from crank to full load within a short
period of time.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-44
Section 3 – Installation and Operation
CFP33 Series
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.
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.
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.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-45
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 Factory
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).
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. 9774, Section 3, Rev. 02-07
Page 3-46
Section 3 – Installation and Operation
CFP33 Series
Normal Local Starting Procedure (Cont)
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 instructions 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Normal Local Starting Procedure (Cont)
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 instructions in this section.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-47
Page 3-48
Section 3 – Installation and Operation
CFP33 Series
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 7 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. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-49
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 10 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 (Cummins Fire Power Part
No. 11407) (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. 9774, Section 3, Rev. 02-07
Page 3-50
Section 3 – Installation and Operation
CFP33 Series
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.
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.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-51
Emergency Manual Starting Procedures (Cont)
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.
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 RESET switch.
Emergency Manual Mode Non-Electrical Start (CFP33-F10, F20, F30 only)
Starting the Engine
Open both manual valves in the raw water
bypass supply piping.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-52
Section 3 – Installation and Operation
CFP33 Series
Emergency Manual Mode Non-Electrical Start (CFP33-F10, F20, F30 only)
(Cont)
Throttle cable assembly is provided to allow the
operator to start the unit in manual mode.
The Throttle cable assembly is located on the
fuel pump side of the engine and has a pull
handle that is attached to the fuel pump lever
which activates the fuel solenoid shut-off
(FSO).
The throttle cable assembly is factory installed
and is securely fastened to the fuel pump lever
in position shown to allow engine to run in
closed/automatic mode.
Throttle Cable
In the event the automatic start is not
operational, pull on the throttle handle
assembly which will move the lever to the run
position to start the engine.
Turn handle assembly to lock throttle cable
assembly in position to allow the engine to run
in manual mode.
Press down on the crank solenoid lever to
engage the starter while in manual mode.
Depress until engine starts.
NOTE: If first crank solenoid lever does not
engage the starter, repeat on second crank
solenoid lever.
Stopping the Engine
Once engine is operational in automatic mode,
be sure to retract the throttle cable to the
closed or automatic position to allow the engine
to start in automatic mode.
NOTE: If throttle cable assembly does not
retract to correct closed position, manually
push the lever to the closed or automatic
position and adjust the throttle cable assembly
so that when activated, it opens and closes the
FSO lever accordingly.
Periodic inspection of the throttle cable
assembly is recommended.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Page 3-53
Emergency Starting in Automatic Mode with Failed Fuel Shut-Off
Solenoid (CFP33-F10, F20, F30 only)
Throttle cable assembly is provided to allow the
operator to start the unit in manual mode.
The Throttle cable assembly is located on the
fuel pump side of the engine and has a pull
handle that is attached to the fuel pump lever
which activates the fuel solenoid shut-off (FSO).
The throttle cable assembly is factory installed
and is securely fastened to the fuel pump lever
in position shown to allow engine to run in
closed/automatic mode.
Throttle Cable
In the event the Fuel Shut-off Solenoid has
failed, pull on the throttle handle assembly
which will move the lever to the run position to
start the engine.
Turn handle assembly to lock cable assembly in
position to allow the engine to run.
Stopping the Engine
Retract the throttle cable to the closed or
automatic position to allow the engine to stop.
Once engine is operational and fuel solenoid
has been replaced, the cable assembly to be
restored in the closed or automatic mode. The
engine is now ready to run in automatic mode.
NOTE: If throttle cable assembly does not
retract to correct closed position, manually push
the lever to the closed or automatic position and
adjust the throttle cable assembly so that when
activated, it opens and closes the FSO lever
accordingly.
Periodic inspection of the throttle cable
assembly is recommended.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-54
Section 3 – Installation and Operation
CFP33 Series
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 7.
Drawing No. 9774, Section 3, Rev. 02-07
Section 3 – Installation and Operation
CFP33 Series
Emergency Manual Stopping Procedure
Disconnect the connector at the electric fuel
solenoid (Fuel Shutoff Valve).
Reconnect the connector after the engine as
stopped.
Drawing No. 9774, Section 3, Rev. 02-07
Page 3-55
Page 3-56
Section 3 – Installation and Operation
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 3, Rev. 02-07
Section 4 – Maintenance Guidelines
CFP33 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.................................................................................................................................4-6
Drawing No. 9774, Section 4, Rev. 02-07
Page 4-2
Section 4 – Maintenance Guidelines
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 4, Rev. 02-07
Section 4 – Maintenance Guidelines
CFP33 Series
Page 4-3
Overview
Cummins Inc. recommends that the engine must 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.
NOTE: If the engine is equipped with a component or an accessory not manufactured by Cummins, refer to the
component manufacturer's maintenance recommendations.
Drawing No. 9774, Section 4, Rev. 02-07
Page 4-4
Section 4 – Maintenance Guidelines
CFP33 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
3822524
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 (v-belts and ribbed with 4 or 5 ribs)
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. 9774, Section 4, Rev. 02-07
Section 4 – Maintenance Guidelines
CFP33 Series
Page 4-5
Maintenance Schedule
Activity
(as per engine specifications)
Check Air Intake Filter and Piping.
Check Coolant Level
Check Crankcase Breather Tube
Check Lubricating Oil Level
Drain Fuel-Water Separator
Check Coolant Heat Exchanger Piping
Check Coolant Heater Piping
Bleed Fuel Tanks
Clean Raw Water Strainers
Check Battery Condition
Test Run Engine
Check Hose Condition
Check Engine Coolant Heater
Inspect Heat Exchanger Zinc Plug
Inspect Electrical Components
Check Turbochargers Mounting Nuts
Check Engine Mounting Bolts
Check Cooling System Condition
Check Air Cleaner Service Indicator
Inspect Air Intake System Piping
Check Fuel Pump
Change Lubricating Oil and Filters
Change Fuel Filter (Spin-on Type)
Lubrication of Output Shafts
Drain and Flush Cooling System
Change Coolant Filter
Vent Fuel Supply Lines
Vent Injection Pump
Check Overspeed Switch Operation
Check Drive Belt, Tensioner Bearing
and Belt Tension
Adjust Valve Lash Clearance
Inspect Turbocharger
Inspect Vibration Damper
Inspect Water Pump
Engine Steam Cleaning
Inspect Overhead Set
Trimonthly
Daily
Weekly
1
2
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4
5
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Refer to Maintenance Procedures in Section 5 for instructions.
Drawing No. 9774, Section 4, Rev. 02-07
x
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Page 4-6
Section 4 – Maintenance Guidelines
CFP33 Series
Maintenance Record Form
Engine Serial No.
Owner's Name
Date
Hours or Time
Interval
Actual Hours
Engine Model
Equipment Name/Number
Check
Performed By
Performed
Comments
Drawing No. 9774, Section 4, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-1
Section 5 - Maintenance Procedures
Section Contents
Page
Daily .....................................................................................................................................................................5-3
Weekly..................................................................................................................................................................5-9
Every Three Months or 250 Hours ..................................................................................................................5-12
Every Six Months or 500 Hours.......................................................................................................................5-22
Every Year or 1000 Hours ................................................................................................................................5-31
Every Two Years or 2000 Hours......................................................................................................................5-41
Every Four Years or 5000 Hours .....................................................................................................................5-42
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-2
Section 5 – Maintenance Procedures
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-3
DAILY
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.
Engine Operation Report
The engine must be maintained in top mechanical condition if the operator is to get optimum satisfaction from its use. The
maintenance department needs daily running reports from the operator to make necessary adjustments in the time allocated.
The daily running report also helps to make provisions for more extensive maintenance work as the reports indicate the
necessity.
Comparison and intelligent interpretation of the daily report, along with a practical follow-up action, will eliminate most
failures and emergency repairs.
Report to the maintenance department any of the following conditions:
•
•
•
•
•
•
•
•
•
•
•
•
Low lubricating oil pressure
Low power
Power increases or engine surge
Erratic or no accelerator control or response
Any warning lights flashing or staying on
Abnormal water or oil temperature
Unusual engine noise
Excessive smoke
Excessive use of coolant, fuel, or lubricating oil
Any fuel, coolant, or lubricating oil leaks
Loose or damaged parts
Worn or damaged belts
Unusual Engine Noise
During daily maintenance checks, listen for any
unusual engine noise that can indicate that service
is required.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-4
Procedure 1
Section 5 – Maintenance Procedures
CFP33 Series
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 7 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 7 for
replacement procedures.
Torque loosened clamps.
Torque Value: 8 N•m [72 in-lb]
Procedure 2
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 (Cummins Fire Power Part No. 11407). 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
(Cummins Fire Power Part No. 11407).
NOTE: Coolant level should be at the bottom of the
fill neck. It must be above the raw water tubes.
Check coolant level.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
NOTE: Make up coolant added to the engine must
be mixed with the correct proportions of antifreeze,
supplemental coolant additive and water to avoid
engine damage.
Coolant specifications can be found in Coolant
Recommendations and Specifications in Section 7.
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 (Cummins Fire Power Part No. 11407).
Procedure 3
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.
Inspect the tube more frequently in icy conditions.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-5
Page 5-6
Procedure 4
Section 5 – Maintenance Procedures
CFP33 Series
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.
The engine must be level when checking the oil level
to make sure the measurement is correct.
Check the oil level on the dipstick.
NOTE: If the lube oil is excessively high, troubleshoot
as per Oil Level Rises in Section 7.
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
later in this section.
NOTE: If the lube oil is excessively low, troubleshoot
as per Lubricating Oil Consumption Excessive in
Section 12.
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 7.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Procedure 5
Page 5-7
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.
Spin-on Type
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 over-tighten
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
later in this section for removal and installation
instructions.
Canister Type
Shut off the engine.
Pull up on the drain valve lever until fluid drains out of
the drain tube. Drain the filter sump until clear fuel is
visible.
Push up on the drain valve until fluid drains out of the
drain tube.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-8
Procedure 6
Section 5 – Maintenance Procedures
CFP33 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 7 for replacement
procedures.
Procedure 7
Check Coolant Heater Piping
Visually inspect the engine coolant heater hoses 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 7 for
replacement procedures.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-9
WEEKLY
General Information
With the engine not running, perform the daily maintenance checks plus the following weekly checks:
Procedure 8
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.
Procedure 9
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.
Procedure 10
Check Battery Condition
Inspect the condition of the batteries.
Refer to Section 7 for inspection and maintenance
procedures.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-10
Procedure 11
Section 5 – Maintenance Procedures
CFP33 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 greater than 10 PSI.
Check coolant temperature between 140°F and
212°F.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Check that both battery voltmeters indicate 12 VDC
standard (24 VDC optional) depending upon the
application.
Check that the inlet air restriction indicator has not
popped-up. Red plunger would be popped as shown.
Check that the Fuel Injection Failure (F.I.F.) light is
not turned on.
End Test Run
Select the AUTO position on the AUTO/MANUAL
Switch.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-11
Page 5-12
Section 5 – Maintenance Procedures
CFP33 Series
Every Three Months or 250 Hours
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.
Procedure 12
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.
Procedure 13
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 of 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.
Procedure 14
Inspect Heat Exchanger Zinc Plug
Remove the zinc plug.
Inspect the plug. If it has eroded over 50 percent,
replace the plug (Cummins Fire Power Part No. 9750)
and brass fitting (Cummins Fire Power Part No.
9751).
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Procedure 15
Page 5-13
Inspect Electrical Components
Clean and tighten any loose electrical connections.
Follow the manufacturer’s recommended procedures
for servicing the electrical components and batteries.
Procedure 16
Check Turbocharger Mounting Nuts
Check the turbocharger mounting nuts. Tighten the
mounting nuts.
Torque Value: 65 N•m (50 ft-lb)
Procedure 17
Check Engine Mounting Bolts
CAUTION
Damaged engine mounts and brackets can cause
engine misalignment. Driveline component
damage can result in vibration complaints.
Inspect all rubber-cushioned mounts for cracks or
damage.
Inspect all mounting brackets for cracks or damaged
bolt holes.
Check the torque on the engine mounting nuts and
bolts. Tighten any that are loose.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-14
Section 5 – Maintenance Procedures
CFP33 Series
Procedure 18
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 (Cummins Fire Power Part No. 11407). Failure to do so can cause personal injury
from heated coolant spray.
Supplemental Coolant Additive(SCA)
Check the SCA concentration level:
~At least twice a year
~At every subsequent oil drain interval if the
concentration is above 3 units
~Whenever coolant is added to the cooling system
between filter changes.
Use Fleetguard® coolant test kit, Part No. CC2602, to
check the SCA concentration level. Instructions are
included with the test kit. Refer to Coolant
Recommendations and Specifications in Maintenance
Specifications (Section V) for the correct SCA and
antifreeze level.
Antifreeze
CAUTION
Over concentration of antifreeze or use of highsilicate antifreeze can damage the engine.
Check the antifreeze concentration.
Use a mixture of 50-percent water and 50-percent
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.
Procedure 19
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.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-15
NOTE: Follow the manufacturer's instructions when
cleaning or replacing the air cleaner element.
NOTE: Do not remove the felt washer from the
indicator. The felt washer absorbs moisture.
Check the air cleaner service indicator, if equipped.
A mechanical restriction indicator is available to
indicate excessive air restriction through a dry-type
air cleaner. This instrument can be mounted in the air
cleaner outlet or on the instrument panel.
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.
Procedure 20
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.
Procedure 21
Inspect the fuel injection pump mounting nuts,
including the support bracket, for loose or damaged
hardware.
Drawing No. 9774, Section 5, Rev. 02-07
Check Fuel Pump
Page 5-16
Procedure 22
Section 5 – Maintenance Procedures
CFP33 Series
Change Lubricating Oil and Filters
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.
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.
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.
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 3 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. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 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
[21.1 qt] of 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.
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. 9774, Section 5, Rev. 02-07
Page 5-17
Page 5-18
Section 5 – Maintenance Procedures
CFP33 Series
Remove
Clean the area around the lubricating oil filter head. Using an oil
filter wrench, remove the filter. Clean the gasket surface of the
filter head with a clean lint-free cloth.
NOTE: The o-ring can stick on the filter head. Make sure it is
removed before installing the new filter.
Install
CAUTION
The lubricating oil filter should be full of oil at
start-up to prevent engine damage.
Apply a light film of lubricating oil to the gasket
sealing surface before installing the filters.
Use clean 15W-40 oil to coat the gasket surface of
the filter.
Fill the filter with clean 15W-40 oil.
CAUTION
Mechanical over tightening can distort the
threads or damage the filter element seal.
Install the filter on the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
Install the filter as specified by the filter manufacturer.
Check and clean the oil drain plug threads and
sealing surface.
Install the oil drain plug.
Torque Value: 50 N•m [37 ft-lb]
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
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 5.
Fill the engine with clean oil to the proper level.
NOTE: Capacities assume standard pan. Total
system assumes standard pan plus filter.
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.
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.
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. 9774, Section 5, Rev. 02-07
Page 5-19
Page 5-20
Procedure 23
Section 5 – Maintenance Procedures
CFP33 Series
Change Fuel Filter (Spin-on Type)
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel
system.
CAUTION
Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not
spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters
must be discarded in accordance with local environmental regulations.
CAUTION
Mechanical overtightening can distort the threads as well as damage the filter element seal or filter canister.
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.
It will be necessary to fill the 10-micron water
stripping (suction side) fuel filter with fuel.
Do not fill the 10-micron (pressure side) 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.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-21
CAUTION
Mechanical over-tightening will distort the
threads, filter element seal or filter can.
Install the filter as specified by the filter manufacturer.
Finishing Steps
Once the engine is started, slowly increase the
engine speed while air is purged from the fuel
plumbing.
Procedure 24
Lubrication of Output Shafts
It is recommended that proper lubrication to drive
shafts and output shafts is to be completed on a
regular schedule.
Grease zerk fittings as shown.
See Lubricating Oil Recommendations and
Specifications in Section 10 for grease specifications.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-22
Section 5 – Maintenance Procedures
CFP33 Series
Every Six Months or 500 Hours
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.
Procedure 25
Drain and Flush Cooling System
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 (Cummins Fire Power Part No. 11407).
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. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Drain the cooling system by opening the drain valve
on the heat exchanger 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 heat exchanger 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. 9774, Section 5, Rev. 02-07
Page 5-23
Page 5-24
Section 5 – Maintenance Procedures
CFP33 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].
AUTO
Shut the engine off, and drain the cooling system.
MANUAL
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. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 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 50-percent
ethylene glycol antifreeze to fill the cooling system.
Coolant Capacity (Engine Only): 4.50 liters [1.19
US Gal]
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-25
Page 5-26
Section 5 – Maintenance Procedures
CFP33 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 (Cummins Fire Power Part
No 11407.).
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.
Procedure 26
Change Coolant Filter
Remove
WARNING
Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap
(Cummins Fire Power Part No. 11407). 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.
Remove the coolant system pressure cap (Cummins
Fire Power Part No. 11407).
Turn the shutoff valve to the OFF position by rotating
the knob from vertical to horizontal in the direction
shown.
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.
WARNING
Coolant is toxic. Keep away from children and pets.
If not reused, dispose of in accordance with local
environmental regulations.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
CAUTION
Use caution when draining coolant that coolant is not
spilled or drained into the bilge area. Do not pump
the coolant overboard. If the coolant is not reused, it
must be discarded in accordance with local
environmental regulations.
Remove and discard the coolant filter.
Clean
Clean the gasket surface.
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.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-27
Page 5-28
Section 5 – Maintenance Procedures
CFP33 Series
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 (Cummins
Fire Power Part No. 11407).
Operate the engine.
Check for coolant leaks.
After the air has been purged from the system,
check the coolant level again.
Procedure 27
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.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
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.
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.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-29
Page 5-30
Section 5 – Maintenance Procedures
CFP33 Series
Retighten Line Fittings
Tighten the line fittings and check for leaks.
Torque Value: 22 N•m [16 ft-lb]
Procedure 28
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. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-31
Every Year or 1000 Hours
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.
Procedure 29
Check Overspeed Switch Operation
Check the overspeed switch for operation.
Refer to Operating Instructions in Section 3 of the
Operational Manual for settings.
Procedure 30
Check Drive Belt, Tensioner Bearing and Belt Tension
Inspect
Remove heat exchanger, piping and hoses.
Remove the belt guard.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-32
Section 5 – Maintenance Procedures
CFP33 Series
Remove the drive belt.
Poly-Vee 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.
Belt damage can be caused by:
Incorrect tension
Incorrect size or length
Pulley misalignment
Incorrect installation
Severe operating environment
Oil or grease on the belts
Cogged Belt
Inspect the belts daily. Replace the belts if they are
cracked, frayed, or have chunks of material missing.
Small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface,
which indicates belt slippage. Correctly installed and
tensioned belts will show even pulley and belt wear.
Refer to Section A for belt adjustment and
replacement procedures.
Belt damage can be caused by:
Incorrect tension
Incorrect size or length
Pulley misalignment
Incorrect installation
Severe operating environment
Oil or grease on the belts
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Measure the belt tension in the center span of the
pulleys.
Refer to the Belt Tension Chart in Section V for the
correct gauge and tension value for the belt width
used.
An alternate method (deflection method) can be used
to check belt tension by applying 110 N [25 lbf] force
between the pulleys on v-belts. If the deflection is
more than one belt thickness per foot of pulley center
distance, the belt tension must be adjusted.
Refer to Section A for adjustment.
For cogged belts, make sure that the belt tension
gauge is positioned so that the center tensioning leg
is placed directly over the high point (hump) of a cog.
Other positioning will result in incorrect
measurement.
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.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-33
Page 5-34
Section 5 – Maintenance Procedures
CFP33 Series
Torque Value: Tension Limit: 360 to 490 N•m [266
to 361 ft-lb]
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.
3822524, 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].
Check the tensioner arm, pulley, and stops for
cracks. If any cracks are noticed, the tensioner must
be replaced.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 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: 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.
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.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-35
Page 5-36
Section 5 – Maintenance Procedures
CFP33 Series
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 wearout 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.
Tensioner cap
Tensioner arm
Spring case
Tensioner pulley
Clearance gap
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. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Procedure 31
Page 5-37
Adjust Valve Lash Clearance
Adjust
Remove the cylinder head cover.
WARNING
Do not use the fan to rotate the engine.
Rotate the crankshaft in the normal direction using
the crankshaft pulley mounting capscrews or the
alternator pulley mounting nut.
While watching the movement of the intake valve of
the No. 4 cylinder, bring the No.1 cylinder into
compression top dead center position.
Align the TOP engraved mark on the crankshaft
pulley (1) with pointer (2).
NOTE: The engraved mark on the crankshaft pulley
will read “1.4 TOP.” The No. 4 intake valve will start
to open when the No. 1 cylinder comes near
compression top dead center.
Loosen the locknut (3) on the adjustment screw (4).
Insert the feeler gauge (5) between the valve stem
(6) and the rocker arm (7).
Adjust the clearance with the adjustment screw until
slight drag is felt on the feeler gauge.
Valve Clearance (Engine Hot or Cold)
•
Intake Valve: 0.35 mm [0.014 in]
•
Exhaust Valve: 0.50 mm [0.020 in]
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-38
Section 5 – Maintenance Procedures
CFP33 Series
NOTE: Adjust intake and exhaust clearances in the
following firing order by rotating the crankshaft 180
degrees in the normal direction: 1-2-4-3.
Adjust the valve clearances for intake valves No. 1
and No. 3.
Adjust the valve clearances for exhaust valves No. 1
and No. 2.
Rotate the crankshaft in the normal direction one
revolution.
Adjust the valve clearances for intake valves No. 2
and No. 4.
Adjust the valve clearances for exhaust valves No. 3
and No. 4.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-39
Tighten the locknut to secure the adjustment screw.
Locknut Torque Value
•
Minimum 39 N•m [29 ft-lb]
•
Maximum 49 N•m [36 ft-lb]
Procedure 32
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.
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.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage is found. Contact
a Cummins Authorized Repair Location for
replacement.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-40
Section 5 – Maintenance Procedures
CFP33 Series
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 and
tighten the clamps.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Page 5-41
Every Two Years or 2000 Hours
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.
Procedure 33
Inspect Vibration 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.
Procedure 34
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.
Procedure 35
Engine Steam Cleaning
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.
Steam is the best method of cleaning a dirty engine
or a piece of equipment. If steam is not available, use
a solvent to wash the engine.
Protect all electrical components, openings, and
wiring from the full force of the cleaner spray nozzle.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-42
Section 5 – Maintenance Procedures
CFP33 Series
Every Four Years or 5000 Hours
General Information
All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in
addition to those listed under this maintenance interval.
Procedure 36
Inspect Overhead Set
Preparatory Steps
Remove the crankcase breather tube, rocker lever
cover mounted breather only.
Remove the variable geometry turbocharger actuator
air supply line, if equipped.
Remove the capscrews.
Remove the rocker lever cover and gasket.
NOTE: Rocker lever cover configurations will be
different based upon if the cover is center bolted or
perimeter bolted.
Remove the plastic fuel pump drive cover located on
the front of the engine.
Adjust
CAUTION
Engine coolant temperature should be less than
60°C [140°F].
Use the barring tool, Part Number 3824591, or
equivalent, and rotate the crankshaft to align the top
dead center marks on the gear cover and the fuel
pump gear.
Drawing No. 9774, Section 5, Rev. 02-07
Section 5 – Maintenance Procedures
CFP33 Series
Measure lash by inserting a feeler gauge between the
crosshead and the rocker lever ball insert and socket
while lifting up on the end of the rocker arm. If the
lash measurement is out of specification, loosen the
locknut and adjust the lash to the nominal
specification.
Lash Reset Specifications
mm
in
Intake
0.35
NOM
0.014
Exhaust
0.5
NOM
0.020
NOTE: Lash resets are only required at the interval
specified in the Maintenance Schedule, when lash is
measured and found out of specification, or when
engine repairs cause removal of the rocker arms
and/or loosening of the adjusting screws.
Tighten the locknut and measure again.
Torque Value: 24 N•m [18 ft-lb]
Finishing Steps
Center Bolted Rocket Lever Cover
Use the barring tool, Part Number 3824591, or
equivalent, and rotate the crankshaft 360 degrees
and measure lash for rocker arms 2E, 3l, 4E, 5l, 6l,
and 6E. Reset the lash, if out of specification.
Place the gasket on the cylinder head. Be sure the
gasket is properly aligned around the cylinder head
capscrews.
Install the rocker lever cover and capscrews.
Drawing No. 9774, Section 5, Rev. 02-07
Page 5-43
Page 5-44
Section 5 – Maintenance Procedures
CFP33 Series
Tighten the capscrews.
Torque Value: 12 N•m [106 in-lb]
Perimeter Bolted Rocker Lever Cover
NOTE: If the gasket has been removed from the
rocker lever cover, a new gasket must be used.
The following installation procedure must be used
when installing the press-in gasket.
Press the molded gasket into the corners of the
rocker lever cover.
Press the gasket around the capscrew mounting
holes.
Press the remaining gasket into the rocker lever
cover.
Install the rocker lever cover and capscrews.
Torque Value: 12 N•m [106 in-lb]
Install the crankcase breather tube, rocker lever
cover mounted breather only.
Install the variable geometry turbocharger actuator air
supply line, if equipped.
Drawing No. 9774, Section 5, Rev. 02-07
Section 6 – System Diagrams
CFP33 Series
Page 6-1
Section 6 – System Diagrams
Section Contents
Page
General Information............................................................................................................................................6-3
Flow Diagram, Fuel System ...............................................................................................................................6-4
Flow Diagram, Lubricating Oil System.............................................................................................................6-5
Flow Diagram, Cooling System .........................................................................................................................6-6
Flow Diagram, Air Intake System......................................................................................................................6-7
Flow Diagram, Exhaust System ........................................................................................................................6-8
Assembly Diagram, Raw Water Piping.............................................................................................................6-9
Drawing No. 9774, Section 6, Rev. 02-07
Page 6-2
Section 6 – System Diagrams
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 6, Rev. 02-07
Section 6 – System Diagrams
CFP33 Series
Page 6-3
General Information
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
•
Cooling System
•
Air Intake System
•
Exhaust System
•
Raw Water Piping
Knowledge of the engine systems can help in troubleshooting, service, and general maintenance of the engine.
Drawing No. 9774, Section 6, Rev. 02-07
Page 6-4
Section 6 – System Diagrams
CFP33 Series
Flow Diagram, Fuel System
1.
Fuel Injection Pump
5.
Fuel Tank
2.
Overflow Valve
6.
Water in Fuel Sensor (WIF)
3.
Fuel Shut-off Solenoid
7.
Fuel Filter
4.
Fuel Injection Nozzle
8.
Hand Priming Pump
Drawing No. 9774, Section 6, Rev. 02-07
Section 6 – System Diagrams
CFP33 Series
Page 6-5
Flow Diagram, Lubricating Oil System
1.
Oil Strainer
8.
Camshaft
2.
Oil Pump
9.
Piston
3.
Oil Cooler (Optional)
10.
Intake and Exhaust Valve
4.
Regulator Valve
11.
Rocker Arm
5.
Oil Filter
12.
Timing Gear
6.
Safety Valve
13.
Cooling Water
7.
Crankshaft
Drawing No. 9774, Section 6, Rev. 02-07
Page 6-6
Section 6 – System Diagrams
CFP33 Series
Flow Diagram, Cooling System
The engine is cooled by a heat exchanger system. Engine coolant is circulated around the outside of the heat
exchanger tube bundle and is cooled by raw water flowing through the bundle tubes.
Coolant flow returns from the aftercooler to the head between cylinders one and two. This provides the oil cooler
and aftercooler with the coolest possible coolant.
Drawing No. 9774, Section 6, Rev. 02-07
Section 6 – System Diagrams
CFP33 Series
Page 6-7
Flow Diagram, Air Intake System
1.
Filtered Air
4.
Intake Manifold
2.
Turbocharger Compressor
5.
Intake Valve Port
3.
Air Crossover Tube
Drawing No. 9774, Section 6, Rev. 02-07
Page 6-8
Section 6 – System Diagrams
CFP33 Series
Flow Diagram, Exhaust System
1.
Exhaust Valve Port
2.
Exhaust Manifold
3.
Turbocharger Turbine
Drawing No. 9774, Section 6, Rev. 02-07
Section 6 – System Diagrams
CFP33 Series
Page 6-9
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. 8682). 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 10 for process requirements. Refer to Raw Water Piping,
Lineup, and Configuration in Section 3.
1
4
2
3
6
9
5
12
11
10
7
8
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.
3/4” supply to the heat exchanger
Drawing No. 9774, Section 6, Rev. 02-07
Page 6-10
Section 6 – System Diagrams
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 6, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-1
Section 7 – Adjustment, Repair and Replacement
Section Contents
Page
Overview ..............................................................................................................................................................7-5
Belts
Belt Guard Removal/Installation .......................................................................................................................7-7
Belt Removal/Installation/Adjustment ..............................................................................................................7-9
Adjust Alternator Drive Belt Tension..............................................................................................................7-11
Coolant
Coolant Heat Exchanger Removal/Installation ..............................................................................................7-13
Coolant Heater Removal/Installation ..............................................................................................................7-21
Coolant Hose Removal/Installation ................................................................................................................7-27
Raw Water Pressure Regulator Removal/Installation...................................................................................7-36
Raw Water Solenoid Valve Removal/Installation...........................................................................................7-40
Water Temperature Gauge Removal/Installation ..........................................................................................7-43
Coolant Temperature Sender Removal/Installation ......................................................................................7-45
Coolant Temperature Switch Removal/Installation.......................................................................................7-47
Coolant Thermostat Removal/Installation......................................................................................................7-49
Coolant Thermostat Tests ...............................................................................................................................7-53
Coolant Water Pump Removal/Installation ....................................................................................................7-56
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-2
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Section Contents
Page
Electrical
Alternator Checks and Testing....................................................................................................................... 7-61
Alternator Removal/Installation...................................................................................................................... 7-64
Alternator Bracket Removal/Installation ....................................................................................................... 7-66
Battery Isolator Removal/Installation ............................................................................................................ 7-67
Engine Harness Removal/Installation............................................................................................................ 7-70
Voltmeter Removal/Installation ...................................................................................................................... 7-72
Battery Testing................................................................................................................................................. 7-74
Battery Removal/Installation........................................................................................................................... 7-79
Check Battery Cables and Connections........................................................................................................ 7-83
Starter Motor Assembly Removal/Installation .............................................................................................. 7-84
Crank Solenoid Assembly Removal/Installation .......................................................................................... 7-86
Control Panel Fuse Replacement................................................................................................................... 7-89
Exhaust
Exhaust Manifold Removal/Installation ......................................................................................................... 7-93
Exhaust Restriction Measurement................................................................................................................. 7-95
Exhaust Shield Removal/Installation ............................................................................................................. 7-96
Fuel
Air in Fuel.......................................................................................................................................................... 7-99
Fuel Filter Adapter Removal/Installation ..................................................................................................... 7-102
Checking and Adjusting Fuel Injection Timing........................................................................................... 7-103
Inline Fuel Injection Pump Removal/Installation ........................................................................................ 7-108
Fuel Injectors Removal/Installation ............................................................................................................. 7-111
Fuel Drain Manifold Removal/Installation ................................................................................................... 7-113
Low Pressure Fuel Supply Lines Removal/Installation ............................................................................. 7-114
High Pressure Injector Supply Lines Removal/Installation....................................................................... 7-116
Fuel Shutoff Valve (FSOV) Removal/Installation ........................................................................................ 7-118
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-3
Section Contents
Page
Intake Air
Air Leaks, Air Intake and Exhaust Systems.................................................................................................7-119
Intake Air Cleaner Element Removal/Installation ........................................................................................7-124
Air Intake Restriction Indicator Removal/Installation .................................................................................7-126
Air Crossover Pipe Removal/Installation .....................................................................................................7-127
Air Intake Manifold Removal/Installation .....................................................................................................7-128
Turbocharger Removal/Installation ..............................................................................................................7-130
Turbocharger Oil Drain Line Removal/Installation......................................................................................7-133
Turbocharger Oil Supply Line Removal/Installation...................................................................................7-134
Turbocharger Exhaust Piping Removal/Installation ...................................................................................7-135
Turbocharger Exhaust Connector Removal/Installation ............................................................................7-136
Oil
Lubricating Oil Cooler Removal/Installation................................................................................................7-137
Lubricating Oil Filter Removal/Installation ..................................................................................................7-138
Lubricating Oil Pan Removal/Installation.....................................................................................................7-140
Lubricating Oil Suction Tube Removal/Installation ....................................................................................7-142
Oil Pressure Sender Removal/Installation ...................................................................................................7-144
Oil Pressure Gauge Removal/Installation ....................................................................................................7-145
Oil Pressure Switch Removal/Installation....................................................................................................7-147
Lubricating Oil Pump Removal/Installation .................................................................................................7-148
Lubricating Oil Dip Stick/Guide Removal/Installation ................................................................................7-152
Lubricating Oil Filler Removal/Installation...................................................................................................7-153
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-4
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Section Contents
Page
Speed
Speed Sensor Removal/Installation............................................................................................................. 7-155
Tachometer Removal/Installation ................................................................................................................ 7-157
Overspeed Switch Removal/Installation...................................................................................................... 7-159
Tachometer Calibration................................................................................................................................. 7-161
Valves
Adjust Valve Lash Clearance........................................................................................................................ 7-163
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-5
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
manual.
Base engine components are addressed in Cummins Manual No. 3666418, Troubleshooting and Repair
Manual, B3.3 Series Engines
Refer to Service Literature Section 8 for additional information about this manual.
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 in Section 9
for qualified service assistance.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-6
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
THIS PAGE INTENTIONALLY LET BLANK
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Belt Guard 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.
Remove
Remove the bolts and the belt guard.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-7
Page 7-8
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Belt Guard Removal/Installation (Cont)
Install
NOTE: Install only Cummins approved
replacement belt guard (Cummins Fire Power
Part No. 8805 for CFP33-F25, F35 or No. 9537
for CFP33-F10, F20, F30) or equivalent.
When other work is completed, install the belt
guard. Refer to Belt Guard Removal / Installation
in this section.
Torque as per Capscrew Markings and Torque
Values in Section 10.
Follow-Up
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Ensure that repairs are completed satisfactorily.
Stop the engine.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Belt Removal/Installation/Adjustment
Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard Removal / Installation
in this section.
Remove
Loosen the mounting capscrew of the adjustment
plate (1).
Loosen the alternator mounting capscrew and
nut.
Move the alternator toward the cylinder block and
remove the belt (2).
Install
NOTE: Install only Cummins approved
replacement v-ribbed belts (Cummins Part No.
C0412021745) or equivalent.
As required, position the fan belt (2) into the fan
pulley groove, and loosely tighten the adjustment
capscrew (1).
WARNING
Be careful not to injure your fingers or
damage the alternator when adjusting the belt
tension.
Insert a bar or pipe between the alternator and
the cylinder block. Raise the alternator to adjust
the fan tension.
NOTE: The belt must deflect 7 mm to 10 mm
[0.28 in to 0.39 in] when pushed with fingerpressure of 6 kg [13 lb] at a point midway
between the fan pulley and the crankshaft pulley.
Tighten the adjustment capscrew (1).
Torque Value:
•
Mounting Capscrew: 31 N•m [23 ft-lb]
•
Adjustment Capscrew: 31 N•m [23 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-9
Page 7-10
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Belt Removal/Installation/Adjustment (Cont)
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Adjust Alternator Drive Belt Tension
Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard Removal / Installation
in this section.
Adjust
WARNING
Be careful not to injure your fingers or
damage the alternator when adjusting the belt
tension.
Loosen the adjustment capscrew (1).
Insert a bar or pipe between the alternator and
the cylinder block. Raise the alternator to adjust
the fan tension.
NOTE: The belt must deflect 7 mm to 10 mm
[0.28 in to 0.39 in] when pushed with fingerpressure of 6 kg [13 lb] at a point midway
between the fan pulley and the crankshaft pulley.
When tension is correct, tighten the adjustment
capscrew (1).
Torque Value:
•
Mounting Capscrew: 31 N•m [23 ft-lb]
•
Adjustment Capscrew: 31 N•m [23 ft-lb]
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. 9774, Section 7, Rev. 02-07
Page 7-11
Page 7-12
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
THIS PAGE INTENTIONALLY LET BLANK
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-13
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 (Cummins Fire Power Part No. 11407) from a hot engine. Wait until the
coolant temperature is below 50°C [122°F] before removing the pressure cap (Cummins Fire Power Part
No. 11407). 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-14
Section 7 – Adjustment, Repair, and Replacement
CFP33 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
(Cummins Fire Power Part No. 11407).
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 5.
Remove the Upper Engine Coolant Hose from
the heat exchanger.
Remove the Lower Coolant Heater Hose and the
Lower Engine Coolant 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heat Exchanger Removal/Installation (Cont)
NOTE: If using piping supplied by Cummins Fire
Power, refer to Drawing 9636 in Section 13 for
raw water supply piping details.
Remove the ¾" NPT raw water inlet piping from
the valve manifold to the heat exchanger.
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" 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 3/4" 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. 9774, Section 7, Rev. 02-07
Page 7-15
Page 7-16
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
Torque Values: As per capscrew markings
and torque values in Section 10
If missing, install the pipe fittings removed from
the original heat exchanger. Refer to Drawing
8769 in Section 13 for component information.
Torque Values: As per capscrew markings
and torque values in Section 10
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 8769
in Section 13 for component information.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Install the Upper Engine Coolant Hose from the
heat exchanger.
Install the Lower Coolant Heater Hose and the
Lower Engine Coolant Hose at the heat
exchanger.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-17
Page 7-18
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heat Exchanger Removal/Installation (Cont)
NOTE: If using piping supplied by Cummins Fire
Power, refer to Drawing 9636 in Section 13 for
raw water supply piping details.
Install the ¾" NPT raw water inlet piping from the
valve manifold to the heat exchanger.
Also, Install any customer-supplied raw water
outlet fittings. Save these components for reuse.
Close the coolant drain valve.
Refill engine coolant. Refer to Drain and Flush
Coolant System in Section 5.
Install the coolant system pressure cap
(Cummins Fire Power Part No. 11407).
Reconnect the coolant heater power supply.
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heat Exchanger Removal/Installation (Cont)
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.
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.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-19
Page 7-20
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heat Exchanger Removal/Installation (Cont)
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 12.
Check that engine operating temperature
stabilizes between about 82 and 93oC [180 and
200oF].
Check that no coolant hoses are collapsed.
When temperature has stabilized, stop the
engine.
Ensure that repairs are completed satisfactorily.
WARNING
Do not remove the pressure cap (Cummins
Fire Power Part No. 11407) from a hot engine.
Wait until the coolant temperature is below
50°C [120°F] before removing the pressure
cap (Cummins Fire Power Part No. 11407).
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-21
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 (Cummins Fire Power Part No. 11407) from a hot engine. Wait until the
coolant temperature is below 50°C [122°F] before removing the pressure cap (Cummins Fire Power Part
No. 11407). 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-22
Section 7 – Adjustment, Repair, and Replacement
CFP33 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
(Cummins Fire Power Part No. 11407).
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 5.
Remove the Lower Coolant Heater Hose from
the coolant heater.
Remove the Upper Coolant Heater Hose from
the coolant heater.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heater Removal/Installation (Cont)
Remove
Remove the two capscrews, washers, bracket,
and coolant heater. Refer to Drawing 8813 in
Section 13 for component information.
If required, remove the nuts, bolts, washers and
mounting bracket from the coolant heater.
Install
If missing, install the nuts, bolts, washers and
mounting bracket on the coolant heater. Refer
to Drawing 8813 in Section 13 for 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 10.
Follow-Up
Install the Lower Coolant Heater Hose at the
coolant heater.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-23
Page 7-24
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heater Removal/Installation (Cont)
Install the Upper Coolant Heater Hose at the
coolant heater.
Close the coolant drain valve.
Refill engine coolant. Refer to Drain and Flush
Coolant System in Section 5.
Install the coolant system pressure cap
(Cummins Fire Power Part No. 11407).
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heater Removal/Installation (Cont)
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
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 (Cummins
Fire Power Part No. 11407) from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap (Cummins Fire Power Part No.
11407). 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.
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.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-25
Page 7-26
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Heater Removal/Installation (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-27
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.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-28
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
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 (Cummins Fire Power Part No. 11407) from a hot engine. Wait until the
coolant temperature is below 50°C [122°F] before removing the pressure cap (Cummins Fire Power Part
No. 11407). 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Ensure that the engine and engine coolant is cool
in order to avoid burns.
Remove the engine coolant pressure cap
(Cummins Fire Power Part No. 11407).
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 5.
Remove the Upper Engine Coolant Hose
NOTE: Refer to Assembly Drawing 8769 in
Section 13 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 Hose
NOTE: Refer to Assembly Drawing 8769 in
Section 13 for detailed construction.
Remove the Lower Coolant Heater Hose.
Loosen the hose clamp at the heat exchanger.
Loosen the hose clamp at the engine.
Pull the hoses from the heat exchanger and
engine.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-29
Page 7-30
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Hose Removal/Installation (Cont)
Remove the Upper Coolant Heater Hose
NOTE: Refer to Assembly Drawing 8813 in
Section 13 for detailed construction.
Loosen the hose clamp at the coolant heater.
Loosen the hose clamp at the engine.
Pull the hose and tubing assembly 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 8813 in
Section 13 for detailed construction.
Loosen the hose clamp at the Lower Engine
Coolant Hose.
Loosen the hose clamp at the water inlet and at
the coolant heater.
Pull the hose from the connections.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 8769 in
Section 13 for detailed construction.
Remove any debris or hose residue from the
fittings.
Position the hose clamps on the hose.
Push the hose onto the heat exchanger and
engine.
Tighten the hose clamp at the heat exchanger.
Tighten the hose clamp at the engine.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-31
Page 7-32
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Hose Removal/Installation (Cont)
Install the Lower Engine Coolant Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8769 in
Section 13 for detailed construction.
Remove any debris or hose residue from the
fittings.
Position the hose clamps on the hose.
Position the hose at the heat exchanger and
engine.
Tighten the lower engine coolant hose clamp at
the engine.
Position and tighten the lower engine coolant
hose clamp at the heat exchanger.
Install the Lower Coolant Heater Hose.
Torque Values: As per capscrew markings
and torque values in Section 10
Install the Upper Coolant Heater Hose
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
NOTE: Refer to Assembly Drawing 8813 in
Section 13 for detailed construction.
Remove any debris or hose residue from the
fittings.
As required, assemble the tube, hose
extensions, and clamps.
Insert the hose extension on the engine
connection.
Insert the hose extension on the heater
connection.
Position and tighten the hose clamps.
Torque Values: As per capscrew markings
and torque values in Section 10
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 8813 in
Section 13 for detailed construction.
Remove any debris or hose residue from the
fittings.
Position the hose clamps on the hose.
Position the hose and hose clamps on the tee
fitting on the Lower Engine Coolant Hose.
Position the hose and hose clamps on the fitting
at the coolant heater.
Position and tighten the hose clamps.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Close the coolant drain valve.
Refill engine coolant. Refer to Drain and Flush
Coolant System in Section 5.
Install the coolant system pressure cap
(Cummins Fire Power Part No. 11407).
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-33
Page 7-34
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Hose Removal/Installation (Cont)
Reconnect the coolant heater power supply.
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
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.
WARNING
Do not remove the pressure cap (Cummins
Fire Power Part No. 11407) from a hot engine.
Wait until the coolant temperature is below
50°C [120°F] before removing the pressure
cap (Cummins Fire Power Part No. 11407).
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Hose Removal/Installation (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-35
Page 7-36
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
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.
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Page 7-37
Page 7-38
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 instructions in 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. 9774, Section 7, Rev. 02-07
Page 7-39
Page 7-40
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Install
NOTE: Install only Cummins approved
replacement solenoid valves [Cummins Fire
Power Part No. 8210G003-12VDC (12 VDC) or
8210G3-24VDC (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. 9774, Section 7, Rev. 02-07
Page 7-41
Page 7-42
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Operate the engine. Refer to Operating
Instructions TBD in Section 3.
Check for leaks. Repair any leaks.
Check that raw water flow starts when the
engine starts.
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 12.
If raw water flow does not stop shortly after the
engine stops, refer to Troubleshooting Section
12.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Water Temperature Gauge 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 13 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 gauge from the panel.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-43
Page 7-44
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Water Temperature Gauge Removal/Installation (Cont)
Install
Orient the gauge 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
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 (Cummins
Fire Power Part No. 11407) from a hot
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap (Cummins Fire Power Part No. 11407).
Heated coolant spray or steam can cause
personal injury.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 5.
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. 9774, Section 7, Rev. 02-07
Page 7-45
Page 7-46
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Temperature Sender Removal/Installation (Cont)
Follow-Up
Fill coolant to proper level. Refer to Drain and
Flush Cooling System in Section 5.
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that engine operating temperature
stabilizes between 83 and 91oC [181 and
196oF]. If temperature does not stabilize, stop
the engine and refer to Troubleshooting Section
12.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 (Cummins
Fire Power Part No. 11407) from a hot
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap (Cummins Fire Power Part No. 11407).
Heated coolant spray or steam can cause
personal injury.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 5.
Remove
Disconnect the temperature switch wiring.
Remove the temperature switch.
Install
Apply liquid teflon sealant to the threads when
installing the temperature switch.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-47
Page 7-48
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Temperature Switch Removal/Installation (Cont)
Install the temperature switch.
Torque Value:
•
(Cast Iron) 50 N•m [37 ft-lb]
•
(Aluminum) 30 N•m [22 ft-lb]
Reconnect the wiring connector.
Follow-Up
Fill coolant to proper level. Refer to Drain and
Flush Cooling System in Section 5.
Install the coolant pressure cap (Cummins Fire
Power Part No. 11407).
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for leaks. Repair any leaks.
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 12.
Check that engine operating temperature
stabilizes between 82 and 94oC [180 and
201oF].
Stop the engine.
Check coolant level. Refer to instructions in
section 5.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-49
Coolant Thermostat Removal/Installation
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 (Cummins Fire Power Part No. 11407) from a hot engine. Wait until the
coolant temperature is below 50°C [120°F] before removing the pressure cap (Cummins Fire Power Part
No. 11407). 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.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
Disconnect the battery cables at the battery
source.
Drain the coolant. Refer to Drain and Flush
Cooling System in Section 5.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-50
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Thermostat Removal/Installation (Cont)
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 seal.
Use a clean rag to plug the water outlet until the
thermostat is installed.
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.
Replace any defective or excessively corroded
thermostat.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 water
pump.
Install the thermostat (Cummins Part No.
C6004216120) and new thermostat seal
(Cummins Part No. C6140116331) into the water
pump.
Install the water outlet connection and the two
mounting capscrews.
Torque Value: 19 N•m [14 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-51
Page 7-52
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Thermostat Removal/Installation (Cont)
Follow-Up
Connect the coolant hose. Refer to Install Upper
Engine Coolant Hose in this section.
Check that the lower coolant heater hose is
installed. Refer to Install Lower Coolant Heater
Hose in this section.
Fill the cooling system. Refer to Drain and Flush
Cooling System in Section 5.
Start the engine. Refer to Local Starting
Procedure for Test in Section 3.
NOTE: Monitor water temperature on the water
temperature gauge on the engine control panel.
Check for leaks. Repair any leaks.
Allow the engine to approach operating
temperature.
Check that engine operating temperature
stabilizes between about 82 and 95oC [180 and
203oF]. 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 12.
Stop the engine. Refer to Local Starting
Procedure for Test in Section 3.
Ensure that repairs are completed satisfactorily.
Place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Thermostat Tests
Coolant Thermostat Leak Test
CAUTION
The engine thermostat 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 (Cummins
Fire Power Part No. 11407) from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap (Cummins Fire Power Part No.
11407). Heated coolant spray or steam can
cause personal injury.
Allow the engine to cool well below 83oC
[181oF].
Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
NOTE: If coolant starts to leak at the hose
clamp, then drain the engine until the leakage
stops. Refer to Drain and Flush Cooling System
in Section 5.
Loosen the hose clamp on the Upper Engine
Coolant Hose.
Remove the hose from the water outlet
connection.
Install a hose of the same size on the water
outlet t long enough to reach a remote, dry
container used to collect coolant.
Install and tighten a hose clamp on the water
outlet.
Place the other end of the hose in a dry
container.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-53
Page 7-54
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Thermostat Tests (Cont)
Start the engine. Refer to Local Starting
Procedure for Test in Section 3.
Operate the engine at rated rpm for 1 minute.
Shut off the engine. Refer to Local Starting
Procedure for Test in Section 3.
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.
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. Refer to Local Starting
Procedure for Test in Section 3.
NOTE: Monitor water temperature on the water
temperature gauge on the engine control panel.
Allow the engine to approach operating
temperature.
Thermostat Initial Opening Temperature
•
MIN: 81oC [178oF]
•
MAX: 83oC [181oF]
When the coolant starts to flow or if temperature
exceeds the maximum, stop the engine. Refer
to Local Starting Procedure for Test in Section
3.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Thermostat Tests (Cont)
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.
Install the heat exchanger hose and tighten
hose clamp.
Refill any lost coolant. Refer to Check Coolant
Level in Section 5.
When work is completed, place the
AUTO/MANUAL Switch at the local panel in the
AUTO position.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-55
Page 7-56
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 (Cummins
Fire Power Part No. 11407) from a hot engine.
Wait until the coolant temperature is below
50oC [120oF] before removing the pressure
cap (Cummins Fire Power Part No. 11407).
Heated coolant spray or steam can cause
personal injury.
Press the MANUAL position on the
AUTO/MANUAL rocker switch on the fire pump
engine control panel.
Drain engine coolant as required for the intended
service. Refer to Drain and Flush Coolant System
in Section 5.
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.
If installed, remove the Upper Engine Coolant
Hose. Refer to Remove Upper Engine Coolant
Hose in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-57
Coolant Water Pump Removal/Installation (Cont)
Remove
Remove the four capscrews and the fan pulley
mounting.
Water Pump
Remove the mounting capscrews, water pump,
gasket, and o-ring.
Discard the gasket and o-ring.
Install
Replace any disassembled seals or gaskets with
new components.
Install the water pump.
Water Pump
Install the o-ring, gasket, water pump, and
mounting capscrews.
Tighten the capscrews.
Torque Value: 19 N•m [14 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Refer to Water Pump Service Parts
Page 7-58
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Water Pump Removal/Installation (Cont)
Install the four capscrews and the fan pulley
mounting.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Install the Upper Engine Coolant Hose. Refer to
Install Upper Engine Coolant Hose in this section.
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.
Ensure that the lower coolant heater hose is
reinstalled. Refer to Install Lower Coolant Heater
Hose in this section.
Refill engine coolant as required. Refer to Drain
and Flush Coolant System in Section 8.
If removed, install the heat exchanger pressure
cap (Cummins Fire Power Part No. 11407).
Start the engine. Refer to Local Starting
Procedure for Test in Section 3.
Check for leaks. Repair any leaks.
Check that the alternator is charging.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Coolant Water Pump Removal/Installation (Cont)
Check that engine operating temperature
stabilizes between 82 and 95oC [180 and 203oF].
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 12.
Stop the engine. Refer to Local Starting
Procedure for Test in Section 3.
Ensure that repairs are completed satisfactorily.
Place the AUTO/MANUAL Switch at the local
panel in the AUTO position.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-59
Page 7-60
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Alternator Checks and Testing
Alternator Wiring Integrity Check
NOTE: Refer to Drawing 10423 Sheet 1,
Drawing 10423 Sheet 2, and Drawing 9766 in
Section 13 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. 9774, Section 7, Rev. 02-07
Page 7-61
Page 7-62
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 10 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. 9774, Section 7, Rev. 02-07
Page 7-63
Page 7-64
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 8885 Sheet 1 in
Section 13 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 adjusting capscrew and washer.
Remove the capscrew, adjustment plate, and
spacer.
Remove the remaining capscrew and
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 capscrew.
Install the spacer, mounting capscrew, and
adjustment plate.
Loosely install the washer and adjustment
capscrew.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Alternator Removal/Installation (Cont)
WARNING
Be careful not to injure your fingers or
damage the alternator when adjusting the
belt tension.
NOTE: The belt must deflect 7 mm to 10 mm
[0.28 in to 0.39 in] when pushed with fingerpressure of 6 kg [13 lb] at a point midway
between the fan pulley and the crankshaft
pulley.
Insert a bar or pipe between the alternator and
the cylinder block.
Raise the alternator to adjust the fan tension.
Tighten the adjustment capscrew (1).
Torque Value: 31 N•m [23 ft-lb]
Tighten the mounting capscrew.
Torque Value: 31 N•m [23 ft-lb]
Follow-Up
NOTE: Refer to Drawing 8885 Sheet 1 in
Section 13 for wiring harness information.
Connect the engine wiring harness connectors
to the alternator.
Install the belt guard. Refer to Belt Guard
Removal/Installation in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-65
Page 7-66
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Alternator Bracket Removal/Installation
Prepare
Remove the alternator. Refer to Alternator
Removal/Installation in this section.
Remove
Remove the alternator mounting bracket and
capscrew.
Install
Install the capscrew and alternator mounting
bracket.
Torque as per Capscrew Markings and Torque
Values in Section 10.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Install the alternator. Refer to Alternator
Removal/Installation in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Page 7-67
Page 7-68
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
Torque Values: As per capscrew markings
and torque values in Section 10
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Battery Isolator Removal/Installation (Cont)
NOTE: Refer to Drawing 10423 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 3.
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. 9774, Section 7, Rev. 02-07
Page 7-69
Page 7-70
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Engine Harness 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: Refer to Drawing 8885 Sheet 1 in
Section 13 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 8885 Sheet 1 in
Section 13 for a depiction of the engine wiring
harness.
Connect the harness connection at each
terminal.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Page 7-71
Page 7-72
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 18 for electrical schematic details.
Open the local control panel.
NOTE: Ensure that the wires are clearly tagged
for reconnection.
10
12
8
14
16
18
VOLTS
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-73
Voltmeter Removal/Installation (Cont)
Install
Orient the voltmeter in the cutout in the
electrical panel.
Position the mounting bracket on the gauge.
10
12
8
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
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
VOLTS
14
16
18
Page 7-74
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Page 7-75
Page 7-76
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 26.7oC [80oF]
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 in Section 10. 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
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-77
Page 7-78
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Battery Testing (Cont)
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-79
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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Clear and ventilate the battery storage area.
Collect the necessary tools and safety
equipment.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-80
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
If new batteries are installed, charge the
batteries. Refer to Battery and Electrical
Installation in Section 3.
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-81
Page 7-82
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. 9774, Section 7, Rev. 02-07
Page 7-83
Page 7-84
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
Remove the three capscrews and starter motor.
Inspect the starter motor gears. If gear damage
is present, check also the ring gear.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Starter Motor Removal/Installation (Cont)
Install
NOTE: Use only the Delco 39MT replacement
starter Cummins Part No. ST9370 / 3971603
(12 VDC) or Cummins Part No. ST9258 /
3957598 (24 VDC).
Align and install the starter motor.
Install and tighten the three mounting
capscrews.
Torque Value: 43 N•m [32 ft-lb]
Follow-up
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
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.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-85
Page 7-86
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
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 10423 Sheet 1 in
Section 13 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 10423 Sheet 1 in
Section 13 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.
Torque Values: As per capscrew markings
and torque values in Section 10
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. 9774, Section 7, Rev. 02-07
Page 7-87
Page 7-88
Section 7 – Adjustment, Repair, and Replacement
CFP33 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. Refer to Normal Local Starting
Procedure in Section 3.
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. Refer to Normal Local
Starting Procedure in Section 3.
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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
Open the fire pump engine’s local control panel.
Loosen the cover screw and remove the fuse
block cover.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-89
Page 7-90
Section 7 – Adjustment, Repair, and Replacement
CFP33 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 10423 Sheet 1 in
Section 13 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. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Control Panel Fuse Replacement (Cont)
Follow-up
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
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. 9774, Section 7, Rev. 02-07
Page 7-91
Page 7-92
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Exhaust Manifold Removal/Installation
Prepare
Remove the air intake piping from the
turbocharger. Refer to instructions in this section.
Remove the heat shield. Refer to Exhaust Shield
Removal/Installation in this section.
Remove the exhaust outlet piping from the
turbocharger. Refer to Turbocharger Exhaust
Piping Removal/Installation in this section.
Remove the turbocharger. Refer to Turbocharger
in Engine Disassembly in Troubleshooting and
Repair Manual B3.3 Series Engines, Bulletin
Number 3666418-00.
Remove
Refer to Exhaust Manifold in Engine Disassembly
in Troubleshooting and Repair Manual B3.3
Series Engines, Bulletin Number 3666418-00.
Install
Refer to Exhaust Manifold in Engine Assembly in
Troubleshooting and Repair Manual B3.3 Series
Engines, Bulletin Number 3666418-00.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-93
Page 7-94
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Exhaust Manifold Removal/Installation (Cont)
Follow-Up
Install the turbocharger. Refer to Turbocharger in
Engine Assembly in Troubleshooting and Repair
Manual B3.3 Series Engines, Bulletin Number
3666418-00.
Install the exhaust outlet piping at the
turbocharger. Refer to instructions in this section.
Install the air outlet piping at the turbocharger.
Refer to instructions in this section.
Install the heat shield. Refer to Exhaust Shield
Removal/Installation in this section.
Install the air intake piping at the turbocharger.
Refer to instructions in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Exhaust Restriction Measurement
Measure
NOTE: The maximum acceptable exhaust
restriction is listed in Exhaust System
Specifications in Section 10.
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. 9774, Section 7, Rev. 02-07
Page 7-95
Page 7-96
Section 7 – Adjustment, Repair, and Replacement
CFP33 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove the air filter and air inlet pipe from the
turbocharger. Refer to instructions in this
section.
Remove
Remove the exhaust shield and fasteners. Refer
to Drawing 8795 in Section 13.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Exhaust Shield Removal/Installation (Cont)
Install
Install the exhaust shield and fasteners. Refer to
Drawing 8795 in Section 13.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Install the air filter and air inlet pipe at the
turbocharger. Refer to instruction in this section.
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
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.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-97
Page 7-98
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Exhaust Shield Removal/Installation (Cont)
If testing is completed, place the
AUTO/MANUAL rocker switch in the AUTO
position.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-99
Air in Fuel
General Information
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the
work area and areas sharing ventilation to reduce the possibility of severe personal injury or death
when working on the fuel system.
WARNING
Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold,
which can cause a fire.
The low-pressure fuel system for a Cummins engine consists of the fuel tank, lines between tank and engine,
transfer pump and lines, and fuel filter and lines. Air or bubbles at the injection pump can cause no or erratic
engine operation and/or subsequent malfunction of the fuel injection pump. Air can be introduced by leaks in the
fuel system prior to the transfer pump since fuel pressure is a vacuum. Bubbles can result from any number of
restrictions in the system:
Plugged fuel filter
Crimped fuel line
Stopped-up tank module
Inoperative transfer pump
If sufficient fuel reaches the injection pump from the low-pressure system, then solutions to engine operational
problems are elsewhere. The following steps will aid in evaluating low-pressure fuel system performance in
absence of fault codes.
NOTE: For cold-start/performance problems, perform the following steps:
Leave engine outside in cold environment for at least 12 hours.
Perform outlined test.
If the system fails to meet test criteria, replace the fuel lift pump.
Test
NOTE: A replacement of fuel supply lines, fuel
filters, fuel injection pump, high-pressure fuel
lines, and injectors will let air enter the fuel
system. Air in the system will make the engine
hard to start, run rough, misfire, produce low
power, and can cause excessive smoke and a
fuel knock.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-100
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air in Fuel (Cont)
NOTE: Since the fuel lift pump provides positive
pressure through the fuel filter and supply line to
the fuel injection pump, loose connections or
defective seals can show as a fuel leak, not as
an air leak.
If air continues to bubble out of the system for
several minutes, then an air leak is present.
NOTE: An often overlooked source from which
air can enter the fuel system is between the inlet
of the fuel transfer pump and the suction tube in
the tank. Fuel tanks that have the outlet fitting at
the top will have a suction tube that extends to
the bottom of the tank. Cracks or pin holes in
the weld that join the tube to the fitting can let air
enter the fuel system.
Also, check to make sure all the fittings from the
fuel supply line on the tank to the inlet of the fuel
transfer pump are tight.
Use a sight glass at the fuel lift pump inlet to
check for air in the fuel supply lines.
NOTE: Since the fuel pump provides a positive
pressure through the fuel filter and supply line to
the fuel injection pump, loose connections or
defective seals should show as a fuel leak, not
as an air leak.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air in Fuel (Cont)
NOTE: A stuck-open injector can also blow
combustion gas back into the pump and cause
air to be present in the overflow.
If the engine seems to be misfiring or running
rough, break all the injector supply lines loose at
the pump end.
Crank the engine, and observe the lines.
If combustion gas seems to be blowing back
through the line, the injector is stuck open.
Remove the injector.
Take the engine to an Authorized Cummins
Repair Facility/Dealer Location for testing.
Torque Value: 24 N•m [212 in-lb]
NOTE: Use two wrenches when loosening the
lines at the fuel pump: One to hold the delivery
valve and one to loosen the fuel line.
Disconnect the fuel line from the outlet of the
fuel filter.
If bubbles are present, check for air leaks in the
fuel supply circuit.
Measure the amount of fuel in the container. If
more than 1.33 liters [45 fl oz] are collected and
the fuel is bubble-free, then it is unlikely the lowpressure fuel system is the cause of engine
operational problems.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-101
Page 7-102
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Fuel Filter Adapter Removal/Installation
Prepare
Clean debris
Remove fuel filter.
Remove
Disconnect the fuel drain hose to the drain
manifold.
Tag the inlet and outlet fuel hoses for ease of
reconnection.
Disconnect the fuel inlet hose.
Disconnect the fuel outlet hose.
Remove the two mounting capscrews, the filter
head, and the mounting spacer.
Install
Install the two mounting capscrews, the filter
head, and the mounting spacer.
Tighten the capscrews. Refer to Capscrew
Markings and Torque Values in Section 10.
Connect the fuel drain hose.
Connect the fuel inlet hose.
Connect the fuel outlet hose.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-103
Checking and Adjusting Fuel Injection Timing
There are two methods for checking and
adjusting the fuel injection timing of an injection
pump.
The “MATCH MARK ALIGNMENT” method,
which is used when the injection pump is
installed on the original engine and the pump is
not being repaired.
The “MEASURING DEVICE” method, which is
used when a repaired or replaced injection
pump is installed on the engine.
Checking and Adjusting with the Match
Mark Alignment Method
NOTE: Set the No. 1 cylinder at compression
top dead center (TDC) by aligning the pointer
on the gear cover with the TDC line on the
crankshaft pulley. Confirm that the mark “C”
can be seen on the idler gear. If the mark “C”
can not be seen, rotate the crankshaft one
complete revolution and confirm that “C” can be
seen.
NOTE: Align the match mark “C” on the
injection pump gear with the match mark “C” on
the idler gear during installation for correct
alignment. Align the stamped line “a” on the
injection pump with the stamped line “b” on the
timing gear case during installation for correct
alignment.
Install the injection pump.
Drawing No. 9774, Section 7, Rev. 02-07
`
Page 7-104
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Checking and Adjusting Fuel Injection Timing (Cont)
If the stamp lines are out of alignment, loosen
nut (7). Align the stamp lines by rotating the
coupling.
Tighten the nut.
Torque Value: 31 N•m [23 ft-lb]
Checking and Adjusting with the Measuring
Device Method
NOTE: Set the No. 1 cylinder at compression
top dead center (TDC) by aligning the pointer
on the gear cover with the TDC line on the
crankshaft pulley.
Remove the distributor head bolt and copper
washer from the injection pump.
Discard the copper washer.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Checking and Adjusting Fuel Injection Timing (Cont)
Install the dial gauge, Part No. 3377259, into
the distributor head.
NOTE: Check that the stylus end of the dial
gauge contacts the plunger head.
Rotate the crankshaft opposite normal engine
rotation (counterclockwise) slightly, until the dial
gauge does not move any longer.
Set the dial gauge pointer to 0.
Rotate the crankshaft in the normal direction
until the dial gauge reads 1.0 ± 0.3 mm [0.04 ±
0.01 in].
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-105
Page 7-106
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Checking and Adjusting Fuel Injection Timing (Cont)
Look at the pointer on the crankshaft. It should
point to the timing mark in degrees as stamped
on the dataplate. The timing marks on the crank
pulley range from 6 to 14 degrees in two
degree increments.
NOTE: Check the values on the data plate.
Values may change as new ratings are
developed.
NOTE: The gauge reading ±0.03 mm [0.001 in]
is equivalent to ±0.5 degrees fuel injection
timing.
NOTE: The crankshaft must be rotated in the
normal direction (clockwise looking from the
front of the engine) without stopping.
If the dial readings are not within the standard
value, loosen nut. Adjust the fuel injection
timing to within standard value by rotating the
injection pump body.
Tighten the nut.
Torque Value: 31 N•m [23 ft-lb]
Remove the dial gauge.
Install the distributor head bolt and new copper
washer into the injection pump.
Tighten the bolt.
Torque Value: 17 N•m [13 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Checking and Adjusting Fuel Injection Timing (Cont)
Stamp a match mark on the injection pump and
the timing gear case.
Adjusting the Idle
Move the governor control lever to the desired
idling speed by using the idling adjustment
screw.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-107
Page 7-108
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Inline Fuel Injection Pump Removal/Installation
Prepare
Clean debris.
Remove injector supply lines.
Remove low pressure supply line.
Remove control linkage.
Remove fuel shutoff solenoid.
Remove oil line.
Remove high-pressure line, supply line, and
return line. Remove the AFC air line, oil line(s),
fuel shutoff solenoid, and control linkage.
Remove
CAUTION
Do not allow dirt or dust to enter the oil and
fuel inlet and outlet ports. Severe engine
damage will occur if contaminants are
allowed to enter the engine.
Remove the fuel supply tube from the fuel
injection pump.
Remove the mounting capscrew from the
bracket and fuel injection pump.
NOTE: The fuel injector pump, adapter plate,
and gear are removed as an assembly. The
gear can then be removed from the pump if
necessary.
Remove the mounting capscrews of the fuel
injector pump adapter plate.
Remove the fuel injector pump assembly,
adapter plate, and o-ring from the gear housing.
Discard the o-ring.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Inline Fuel Injection Pump Removal/Installation (Cont)
Remove the nut and washer from the fuel
injection pump.
Remove the fuel injection pump gear from the
fuel injection pump.
Remove the two mounting nuts, fuel injection
pump, and o-ring from the adapter plate.
Discard the o-ring.
Install
CAUTION
Do not allow dirt or dust to enter the oil and
fuel inlet and outlet ports. Severe engine
damage will occur if contaminants are
allowed to enter the engine.
Install new o-ring, fuel injection pump, and two
mounting nuts on the adapter plate.
Tighten the nuts.
Torque Value: 31 N•m [23 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-109
Page 7-110
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Inline Fuel Injection Pump Removal/Installation (Cont)
Install the fuel injection pump gear, washer, and
nut on the fuel injection pump.
Tighten the nut.
Torque Value: 70 N•m [52 ft-lb]
NOTE: Align the fuel injection pump gear match
mark “C” with the idler gear match mark “C”.
Install new o-ring, adapter plate, fuel injection
pump assembly, and mounting capscrews to
the gear housing.
Tighten the mounting capscrews.
Torque Value: 19 N•m [14 ft-lb]
Install the mounting capscrew on the fuel
injection pump support bracket.
Tighten the capscrew.
Torque Value: 19 N•m [14 ft-lb]
NOTE: The fuel supply tube has a 12-mm and
14-mm banjo fitting. The 12-mm banjo fitting
connects to the fuel injection pump. The 14-mm
banjo fitting connects to the fuel filter head,
which is installed later in the assembly process.
Install the fuel supply tube to the fuel injection
pump.
Torque Value: 20 N•m [15 ft-lb]
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Fuel Injectors Removal/Installation
Prepare
Clean around the injectors.
Disconnect the high-pressure fuel lines. Refer to
High Pressure Injector Supply Lines
Removal/Installation in this section.
Disconnect the fuel drain manifold. Refer to Fuel
Drain Manifold Removal/Installation in this
section.
Remove
CAUTION
Be careful not to damage the tip of the
injector when removing.
Remove the mounting capscrew, washer, and
injector.
NOTE: When removing the injector, clean
around the injector, and insert a blind plug to
prevent dust or dirt from entering the engine.
NOTE: Mark the injectors with tags showing the
cylinder number, and keep it in a safe place. If
there is no abnormality in the injector, install it in
the same position during assembly.
Install
NOTE: Install new injector gasket (Cummins
Part No. C6204113880) or replacement injector
kit (Cummins Option No. II3002.01).
Coat the injectors with anti-seize compound,
Part No. 3824879, before installation.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-111
Page 7-112
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Fuel Injectors Removal/Installation (Cont)
CAUTION
Be careful not to damage the tip of the
injector when installing.
NOTE: When installing the injector, clean
around the injector, and do not allow dust or dirt
to enter the engine.
NOTE: If there is no abnormality in the injector,
install it in the same position during assembly.
Install the injector, washer, and mounting
capscrew.
Tighten the capscrew.
Torque Value: 44 N•m [33 ft-lb]
Follow-Up
Reconnect the high-pressure fuel lines. Refer to
High Pressure Injector Supply Lines
Removal/Installation in this section.
Reconnect the fuel drain manifold. Refer to Fuel
Drain Manifold Removal/Installation in this
section.
Operate the engine.
Check for leaks.
Check function.
Stop the engine.
RTN
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Fuel Drain Manifold Removal/Installation
Prepare
Remove
Disconnect the hose connection at the fuel
pump.
Remove the braided drain hose from the end of
the drain rail shown to the engine mount fuel
drain connection.
Remove the three fuel drain tube sections and
clips from the injectors
Install
Install the three fuel drain tube sections and
clips to the injectors.
Install the braided drain hose from the end of
the drain rail shown to the engine mount fuel
drain connection.
Connect the hose connection at the fuel pump.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-113
Page 7-114
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Low Pressure Fuel Supply Lines Removal/Installation
Prepare
Low Pressure Fuel Line
Thoroughly clean all fittings and components
before removal. Make sure that the debris,
water, steam, or cleaning solution does not
reach the inside of the fuel system.
Remove
Diaphragm Style Lift Pump
Disconnect the fuel line from the lift pump and
filter head. Use two wrenches to disconnect the
line from the lift pump.
Piston Style Lift Pump
Disconnect the fuel line from the lift pump and
filter head. Use two wrenches to disconnect the
line from the lift pump.
Install
Diaphragm Style Lift Pump
Install the fuel line to the lift pump and filter
head. Use two wrenches to tighten the
connection to the lift pump.
Torque Value: 24 N•m [18 ft-lb]
NOTE: Do not overtighten the connection. Fuel
leaks can result from over-tightening.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Low Pressure Fuel Supply Lines Removal/Installation (Cont)
Piston Style Lift Pump
Install the fuel line to the lift pump and filter
head. Use two wrenches to tighten the
connection to the lift pump.
Torque Value: 24 N•m [18 ft-lb]
Injection Pump Supply Line Replacement
Remove the bleed screw banjo fitting.
Remove the supply line (Bosch® injection
pump).
NOTE: Replace the seals (1) in the fittings if the
line is disassembled.
Remove the supply line (Lucas CAV injection
pump). The Lucas CAV pump has two fittings
for the supply line.
Replace fitting sealing washers (1), and ferrules
(2) each time they are removed.
Torque Value: 32 N•m [24 ft-lb]
NOTE: Replace the seals in the fittings if the line
is disassembled.
Engines rated at 2500 rpm and above require
additional fuel line support. Install as illustrated.
Torque Value: 24 N•m [18 ft-lb]
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-115
Page 7-116
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
High Pressure Injector Supply Lines Removal/Installation
Prepare
Clean all debris from around the fittings.
Remove
Remove the two capscrews and clamp.
Loosen the tubing nuts at the fuel injection
pump.
Loosen the tubing connections at the fuel
injectors.
Remove the high pressure fuel injection tubes.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
High Pressure Injector Supply Lines Removal/Installation (Cont)
Install
NOTE: Before installing the fuel injection tubing,
blow compressed air through it to clean it.
CAUTION
To prevent damage to the fuel lines, they
must be connected to the injectors and fuel
injection pump in a free state without
forcing the connecting nuts. The fuel lines
are correctly sized for each application.
Bending the lines is not acceptable and can
cause fuel leaks.
Position the fuel injection tubing, and loosely
install the sleeve nuts on the fuel injection pump
and the injectors.
CAUTION
Install the support clamp in the original
position and, to prevent damage from highfrequency vibration, make sure the lines
have not been bent or do not contact each
other or another component.
Install the two capscrews and clamp.
Tighten the capscrews. Refer to Capscrew
Markings and Torque Values in Section 10.
Tighten the eight tube fittings.
Torque Value: 20 N•m [15 ft-lb]
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-117
Page 7-118
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Fuel Shutoff Valve (FSOV) Removal/Installation
Prepare
Remove
Remove the electrical wiring.
Remove the fuel drain line.
Install
Install the fuel drain line.
Torque Value: 14 N•m [124 in-lb]
Install the electrical wiring.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Leaks, Air Intake and Exhaust Systems
Prepare
Initial Check
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 intake air piping for cracked hoses,
damage, or loose clamps.
Replace damaged pipes, and tighten loose
clamps, as necessary, to make sure the air
intake system does not leak.
Torque Value: 8 N•m [71 in-lb]
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.
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. 9774, Section 7, Rev. 02-07
Page 7-119
Page 7-120
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Leaks, Air Intake and Exhaust Systems (Cont)
Operate the engine at full throttle and rated rpm
with maximum load.
Listen for a high-pitched whistling noise from
the turbocharger, nearby piping, and
connections.
The noise can be caused by an air leak from
the:
Turbocharger-to-discharge elbow connection.
Inspect for damage. Tighten loose clamps.
Torque Value: 8 N•m [71 in-lb]
Any charge air cooler tubing or connecting
hoses.
Inspect the hose and tubing for damage.
Tighten the hose clamps.
Refer to the manufacturer's specifications for
the correct torque value.
Turbocharger-to-exhaust-manifold mounting
gasket.
Replace the gasket. Refer to Procedure 010033.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Leaks, Air Intake and Exhaust Systems (Cont)
Operate the engine at full throttle and rated rpm
with maximum load.
Listen again for leaks.
Replace the turbocharger if the air piping is not
damaged and the noise can still be heard. Refer
to Procedure 010-033.
Loose connections or cracks in the suction side
of the intake pipe and after the air filter can
allow debris to be ingested by the engine,
causing rapid wear in the cylinders.
Leaks at the intake manifold, unsealed bolt
holes, or manifold cover gasket can also allow
dust and dirt to be ingested into naturally
aspirated engines.
Debris drawn into the air suction side can
damage the compressor blades, causing an
imbalance resulting in bearing failure.
To verify a bearing failure or damaged
compressor, remove the intake and exhaust
piping, and check for contact. The rotor
assembly must rotate freely and should not be
damaged. Measurement of axial and radial
clearance is described in this section.
Excessive smoke and low power from a
turbocharged engine can be caused by
pressurized air leaking from loose connections
or cracks in the crossover tube or intake
manifold. This can also cause a noise problem.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-121
Page 7-122
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Leaks, Air Intake and Exhaust Systems (Cont)
In addition to the inspection for cracks and
loose fittings, liquid soap can be applied to the
charge air cooler, connections, and the manifold
cover sealing surfaces to find the leaks. The
leaks will create bubbles that are easier to
detect. Measurement of manifold pressure is
described in this section.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-123
Page 7-124
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Intake Air Cleaner Element Removal/Installation
CAUTION
Never operate the engine without an air cleaner. Unfiltered foreign objects could cause engine damage.
Check Air Restriction Indicator. Replace the air
cleaner element when the restriction reaches
the maximum allowable limit, or clean according
to the manufacturer's recommendations. See
Air Cleaner Restriction Removal/Installation this
section.
Turbocharged engines must be operated at
rated RPM and full load to check maximum
intake air restriction.
Maximum intake air restriction is 762 mm H2O
[30.0 in H2O] for turbocharged engines.
Loosen air cleaner clamp.
Remove the air cleaner element.
Clean and Inspect for Reuse
Inspect the air cleaner for cuts, cracks, holes, or
excessive debris.
Clean or replace if necessary.
See Air Intake System Specifications in Section
10 for correct Cummins Fire Power replacement
part number.
Check for corrosion of the intake system piping
under the clamp. Corrosion can allow corrosive
products and dirt to enter the intake system.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Intake Air Cleaner Element Removal/Installation (Cont)
Re run engine at rated RPM at full load to
check maximum intake restriction.
Maximum intake air restriction is 762 mm H2O
[30.0 in H2O] for turbocharged engines.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-125
Page 7-126
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Intake Restriction Indicator Removal/Installation
A mechanical restriction indicator is available to
indicate excessive air restriction through a drytype air cleaner. This instrument is mounted on
the air cleaner outlet tube.
Refer to Air Filter Assembly Drawing in Section
13.
Change the filter element when the red indicator
flag (2) is at the raised position in the window
(1). See Air Cleaner Element
Removal/Installation this section.
NOTE: Do not remove the felt washer from the
indicator. The felt washer absorbs moisture.
After the air cleaner has been serviced, push
the button (3) to reset the service indicator. If
the indicator does not retract to the service
position with new air cleaner element installed,
the service indicator needs to be replaced.
Remove service indicator from Air Cleaner
Element piping. Apply Teflon sealant to the
threads on the indicator. Install new indicator on
Intake pipe.
Follow-Up
Run engine to determine if new indicator is
functioning.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Crossover Pipe Removal/Installation
Prepare
Remove
Loosen the hose clamp connection at the
turbocharger air outlet.
Remove the four capscrews at the intake
manifold connection.
Remove the crossover tube.
Install
NOTE: Install new air intake connection gasket.
NOTE: Install new hose and clamps.
Install one hose clamp and the molded hose on
the end of the tube. Do not tighten the hose
clamp at this time.
Align the crossover tube at the intake manifold
and start the four capscrews.
Position the other hose clamp and the molded
hose on the turbocharger air outlet.
Align the hose and clamps on the tube and
turbocharger. Then, tighten the hose clamps.
Tighten the four capscrews at the manifold.
Refer to Capscrew Markings and Torque
Values in Section 10.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-127
Page 7-128
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Intake Manifold Removal/Installation
Prepare
Remove the air crossover tube. Refer to Air
Crossover Pipe Removal/Installation in this
section.
Remove
Remove the six long capscrews, two short
capscrews, and the manifold.
Clean the air intake manifold and engine block
surfaces to remove the previous sealant.
Install
NOTE: Apply a 1-mm [0.039-in] bead of gasket
sealant, per Cummins specifications, to the
mounting surface of the intake manifold.
Apply sealant to the manifold.
Align the manifold and start the six long and two
short capscrews.
NOTE: Tighten the capscrews in two passes
alternating position to tighten the manifold
equally at all points.
Tighten the capscrews.
Torque Value: 40 N•m [30 ft-lb]
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Air Intake Manifold Removal/Installation (Cont)
Follow-Up
Install the air crossover tube. Refer to Air
Crossover Pipe Removal/Installation in this
section.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-129
Page 7-130
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Removal/Installation
Prepare
Remove the air intake piping from the
turbocharger. Refer to instructions in this
section.
Remove the exhaust heat shield. Refer to
instructions in this section.
Remove the customer installed exhaust piping.
Refer to instructions in this section.
Remove the turbocharger exhaust outlet tube.
Refer to instructions in this section.
Disconnect or remove the air crossover tube.
Refer to instructions in this section.
Remove the turbocharger lubricating oil supply
line. Refer to instructions in this section.
Disconnect the lubricating oil drain tube. Refer
to instructions in this section.
Remove
Remove the exhaust clamp, turbocharger
mounting nuts, turbocharger and gasket.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Removal/Installation (Cont)
Install
Install a new gasket.
Apply anti-seize compound, Part No. 3824759,
to the mounting studs.
NOTE: Use only lead free anti-seize compound
compatible with oxygen sensors.
Install the turbocharger and mounting nuts.
Tighten the nuts.
Torque Value: 31 N•m [23 ft-lb]
Connect the lubricating oil drain tube. Refer to
instructions in this section.
NOTE: New turbochargers must be prelubricated before start-up.
Pour 50 to 60 cc [2 to 3 ounces] of clean engine
oil into the oil supply fitting. Rotate the turbine
wheel to allow the oil to enter the bearing
housing.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-131
Page 7-132
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Removal/Installation (Cont)
Align the Housing
NOTE: New turbochargers may require
alignment.
If required, loosen the compressor housing vband clamp and position the housing to align
with the turbocharger air outlet tube.
If required, loosen the snap ring and align the
compressor housing with the turbocharger air
outlet connection.
Tighten the band clamp. Tap around the clamp
with a plastic hammer and tighten again.
Torque Value: 8.5 N•m [75 in-lb]
Follow-Up
Install the turbocharger lubricating oil supply
line. Refer to instructions in this section.Install
the turbocharger exhaust outlet tube. Refer to
instructions in this section.
Install the air crossover tube. Refer to
instructions in this section.
Install the customer installed exhaust piping.
Refer to instructions in this section.
Install the exhaust heat shield. Refer to
instructions in this section.
Install the air intake piping from the
turbocharger. Refer to instructions in this
section.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Oil Drain Line Removal/Installation
Prepare
Remove
Disconnect the lubricating oil drain tube from
the bottom of the turbocharger.
Install
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-133
Page 7-134
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Oil Supply Line Removal/Installation
Prepare
Remove
Remove the turbocharger lubricating oil supply
line and hose clamp from the turbocharger and
cylinder block.
Install
NOTE: If the turbocharger is new, add oil as per
Turbocharger Removal/Installation in this
section.
Position the oil drain line in the clamp and start
the capscrew.
Connect the oil supply line at the cylinder block.
Torque Value: 10 N•m [7 ft-lb]
Connect the oil supply line at the Turbocharger.
Torque Value: 10 N•m [7 ft-lb]
Tighten the capscrew at the clamp. Refer to
Capscrew Markings and Torque Values in
Section 10.
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Exhaust Piping Removal/Installation
Prepare
Remove the turbocharger exhaust shield.
Remove the customer-supplied exhaust piping.
Remove
Loosen the v-band clamp and remove the 90o
elbow.
Install
Ensure that the turbocharger exhaust connector
is uninstalled. Refer to Turbocharger Exhaust
Connector Removal/Installation in this section.
Align the 90o elbow on the turbocharger
exhaust connector and tighten the v-band
clamp (Cummins Part No. 3905216).
Torque Values: Refer to Capscrew Markings
and Torque Values in Section 10.
Install the customer-supplied exhaust piping.
Follow-Up
Install the customer-supplied exhaust piping.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-135
Page 7-136
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Turbocharger Exhaust Connector Removal/Installation
Prepare
Remove the Turbocharger Exhaust Piping.
Refer to Turbocharger Exhaust Piping
Removal/Installation in this section.
Remove
Remove the three nuts, the exhaust connector,
and the connector gasket.
If required, clean the gasket surfaces on the
turbocharger and on the exhaust connector.
Install
NOTE: If required, install three new exhaust
connector studs in the turbocharger.
NOTE: Install new connector gasket.
Install the three studs, gasket, connector, and
three nuts.
Tighten the nuts.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Install the Turbocharger Exhaust Piping. Refer
to Turbocharger Exhaust Piping
Removal/Installation in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Cooler Removal/Installation
Prepare
Drain the lubricating oil and remove the
lubricating oil filter. Refer to Change Lubricating
Oil and Filters in Section 5.
Drain the coolant. Refer to instruction in this
section.
Remove
Loosen the hose clamps and remove the
cooling water hoses from the oil cooler.
Remove the oil cooler from the engine.
If required, remove the oil filter hose nipple.
Install
Install the oil cooler on the engine.
If required, install the oil filter hose nipple.
Install the cooling water inlet and outlet hoses.
Tighten the hose clamps.
Torque Values: As per capscrew markings
and torque values in Section 10
Follow-Up
Refill the coolant. Refer to instructions in this
section.Install the oil filter and add lubricating
oil. Refer to Change Lubricating Oil and Filters
in Section 5.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-137
Page 7-138
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Filter Removal/Installation
Prepare
Drain lubricating oil. Refer to Change Lubricating
Oil and Filters in Section 5.
Remove
Unscrew and remove the lubricating oil filter.
NOTE: Dispose of old filters in accordance with
applicable environmental regulations.
Install
NOTE: Install replacement oil filters.
NOTE: Ensure that the lube oil cooler is installed.
Refer to Lube Oil Cooler Removal/Installation in
this section.
NOTE: Follow the manufacturer’s instructions.
Install the lubricating oil filter.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Filter Removal/Installation (Cont)
Follow-Up
Add lubricating oil. Refer to Change Lubricating
Oil and Filters in Section 5.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-139
Page 7-140
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pan Removal/Installation
Prepare
Remove
Remove the 24 capscrews, lubricating oil pan,
and gasket.
Discard the gasket.
Clean
If sludge is present in the oil pan, remove any
sludge.
NOTE: Troubleshoot sludge problems.
Refer to Troubleshooting in Section 12.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pan Removal/Installation (Cont)
Install
NOTE: Apply a 1-mm [0.039-in] bead of gasket
sealant, per Cummins specifications, to the
mounting surface of the lubricating oil pan.
Install a new gasket, lubricating oil pan, and 24
capscrews.
NOTE: Tighten the capscrews alternating from
side to side and from end to end.
Tighten the 24 capscrews.
Torque Value: 32 N•m [24 ft-lb]
If the oil drain plug was removed, install the
drain plug.
Torque Value: 51 N•m [38 ft-lb]
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-141
Page 7-142
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Suction Tube Removal/Installation
Prepare
Remove the lubricating oil pan. Refer to
Lubricating Oil Pan Removal/Installation in this
section.
Remove
Remove the two mounting capscrews,
lubricating oil suction tube, and o-ring.
Discard the o-ring.
Clean
If sludge is present in the oil pan, remove any
sludge from the oil suction tube.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Suction Tube Removal/Installation (Cont)
Install
Install a new o-ring, oil suction tube, and two
capscrews.
Tighten the capscrews.
Torque Value: 19 N•m [14 ft-lb]
Follow-Up
Install the lubricating oil pan. Refer to
Lubricating Oil Pan Removal/Installation in this
section.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-143
Page 7-144
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Oil Pressure Sender Removal/Installation
Prepare
Remove
Disconnect the oil pressure sensor wiring.
Remove the sender.
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.
Follow-Up
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Oil Pressure Gauge 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 13 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 gauge from the panel.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-145
Page 7-146
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Oil Pressure Gauge Removal/Installation (Cont)
Install
Orient the gauge 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
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Oil Pressure Switch Removal/Installation
Prepare
Remove
Disconnect the oil pressure switch wiring.
Remove the oil pressure switch.
Install
NOTE: Apply liquid teflon sealant to the threads
when installing the temperature switch.
Install the temperature sensor.
Torque Value:
•
(Cast Iron) 50 N•m [37 ft-lb]
•
(Aluminum) 30 N•m [22 ft-lb]
Reconnect the wiring.
Follow-Up
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-147
Page 7-148
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pump Removal/Installation
Prepare
Drain oil
Belt guard
Alternator belt
Remove
Crankshaft Pulley
Remove the capscrew and mounting plate.
Remove the crankshaft pulley using flange
puller, Part No. 3397890.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pump Removal/Installation (Cont)
Gear Housing Cover
Remove the 17 capscrews and the gear
housing cover.
NOTE: A noise damper is installed on some
engines. The noise damper must be removed
prior to removing the front oil seal.
Remove the front oil seal from the gear housing
cover.
Lubricating Oil Pump
Remove the five capscrews and the lubricating
oil pump.
Install
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-149
Page 7-150
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pump Removal/Installation (Cont)
Gear Housing Cover
NOTE: A noise damper is installed on some
engines. The noise damper must be installed
prior to installing the front oil seal.
Install the front oil seal using tool, Part No.
3824498.
Fill 40 to 60 percent of the space in the seal lip
with grease.
CAUTION
Do not apply excessive force to the seal lip
surface when aligning and installing the
gear housing cover. Damage to the engine
will occur if the seal is damaged.
NOTE: Apply gasket sealant, Part No. 3823494,
to the gear housing cover mounting surface.
Install the gear housing cover and 17
capscrews. Tighten the capscrews.
Torque Value: 19 N•m [14 ft-lb]
Measure the distance in height between the
cylinder block and the gear housing cover.
Maximum Height Difference: 0.15 mm [0.0059
in]
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Pump Removal/Installation (Cont)
Crankshaft Pulley
Align the crankshaft pulley with the crankshaft
key.
Install the crankshaft pulley, mounting plate,
and capscrew.
Tighten the capscrew.
Torque Value: 93 N•m [69 ft-lb]
Oil Pump
NOTE: Install the mounting spacer for the one
capscrew as shown.
Install the lubricating oil pump and five
capscrews.
Tighten the capscrews.
Torque Value: 19 N•m [14 ft-lb]
Measure the end play of the lubricating oil pump
drive gear.
Lubricating Oil Pump Drive Gear End Play
Minimum: 0.020 mm [0.0008 in]
Maximum: 0.070 mm [0.0028 in]
Follow-Up
Alternator belt
Belt guard
Add oil
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-151
Page 7-152
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Dip Stick/Tube Removal/Installation
Prepare
Remove
Remove the dipstick (1).
Remove the oil gauge tube (2).
Install
CAUTION
Excessive sealant can run back into the
engine and cause damage to other
components.
NOTE: Apply Loctite™ sealant, Cummins Part
No. 3375068, or equivalent, to the outside of
the dipstick tube.
Install the dipstick guide (2) (Cummins Part No.
C6204215410).
Install the dipstick (1) (Cummins Part No.
C6204215310).
Follow-Up
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Lubricating Oil Filler Removal/Installation
Prepare
Engine stopped.
Remove
Remove the filler cap (4) and gasket (5).
Remove the two mounting capscrews (3), the
filler tube (1), and cover plate gasket (2).
If necessary, clean the cover plate gasket
surface.
Install
Install new cover plate gasket (2) (Cummins
Part No. C6204216811), filler tube (1)
(Cummins Part No. C62052176110) and two
capscrews (3).
Tighten the capscrews. Torque as per
Capscrew Markings and Torque Values in
Section 10.
Torque Values: As per capscrew markings
and torque values in Section 10
Install the filler cap (4) (Cummins Part No.
C6136217120) and gasket (5) (Cummins Part
No. C6136217180).
Follow-Up
Run engine, check for leaks
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-153
Page 7-154
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Speed Sensor 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
The Mag Pick-Up (Speed Sensor) which is
mounted on the bell-housing and located over
the flywheel teeth. Both the Speed Switch and
the Tachometer (located in the Engine control
Panel) use the Mag Pick-Up as the engine
speed signal. The resistance on a good Mag
Pick-Up should be approximately 265 Ohms.
Remove the 2-wire cable that is connected to it.
(The cable wires are not polarity sensitive, so it
makes no difference how the wires are
connected to it). Remove the Mag Pick-Up by
turning it out counter-clockwise.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-155
Page 7-156
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Speed Sensor Removal/Installation (Cont)
Install
When installing a new Mag Pick-Up, first check
that the threads in the bell-housing are clean.
Any burrs may prevent proper installation.
Install the Mag Pick-Up by threading it into the
bell-housing until its tip is bottomed out against
the flywheel. Then back out the Mag Pick-Up ½
turn. Reconnect the 2-wire cable. Reconnect
the batteries.
Follow-up
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position on the fire pump panel.
Return the fire protection system controller back
to operating status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Tachometer 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their
terminals.
Remove
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 13 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 gauge from the panel.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-157
Page 7-158
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Tachometer Removal/Installation (Cont)
Install
Orient the gauge 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
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system to operating
status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Overspeed Switch 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.
REMOVE BATTERY POWER BEFORE
SERVICING ENGINE OR CONTROLS.
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls. Before
disconnecting the batteries, place the Firepump
Controller in its appropriate service position in
order to avoid a “Battery Failure” alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.
Remove
Begin removing the Speed Switch by first
documenting the wires that are connected to its
terminals. If necessary, place a piece of
masking tape on each wire, noting the terminal
number that it’s connected to.
Once all of the wires are removed, the Speed
Switch can be removed from the Engine Control
Panel by removing the four screws that are
securing it to the panel. Each screw is nutted to
the back of the Control Panel. In order to
access the four retaining nuts, the Control
Panel may have to be loosened from the engine
frame to allow clearance for a wrench.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-159
Page 7-160
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Overspeed Switch Removal/Installation (Cont)
Install
Once the Speed Switch is removed, install the
new one in reverse order. All Speed Switches
are factory calibrated for the specific Firepump
Engine model that it’s intended to be used with.
No adjustments will be necessary.
Follow-up
For safety reasons, both batteries must be reconnected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
Place the AUTO/MANUAL rocker switch in the
AUTO position.
Return the fire protection system controller back
to operating status.
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Page 7-161
Tachometer Calibration
After a new tachometer has been installed, it
will be necessary to calibrate it. In order to do
this, the engine must be started and verified
that it is operating at rated speed.
15
20
10
RPM x 100
25
5
0
With a small flat-blade screwdriver, turn the trim
pot, located on the back of the tachometer, until
its indicator agrees with the engine speed.
Drawing No. 9774, Section 7, Rev. 02-07
HOURS
30
Page 7-162
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Adjust Valve Lash Clearance
Prepare
Remove the belt guard. Refer to Belt Guard
Removal/Installation in this section.
Remove the cylinder head cover.
Remove and discard the old valve cover
gasket.
NOTE: Adjust intake and exhaust clearances
in the following firing order by rotating the
crankshaft 180 degrees in the normal
direction: 1-2-4-3.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-163
Page 7-164
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Adjust Valve Lash Clearance (Cont)
Align to Adjust
NOTE: Use either the crankshaft pulley
mounting capscrews or the alternator pulley
mounting nut to move the crankshaft while
watching the movement of the intake valve
of No. 4 cylinder, bring the No.1 cylinder into
compression top dead center position.
NOTE: The No. 4 intake valve will start to
open when the No. 1 cylinder comes near
compression top dead center.
NOTE: The engraved mark on the
crankshaft pulley will read “1.4 TOP.”
Rotate the crankshaft in the normal direction
(Clockwise from the front of the engine).
Align the TOP engraved mark on the
crankshaft pulley (1) with pointer (2).
NOTE: Adjust the valve clearances for the
following in this position:
Intake valves No. 1 and No. 3
Exhaust valves No. 1 and No. 2
Adjust
Loosen the lock nut (3) on the adjustment
screw (4).
Insert the feeler gauge (5) between the valve
stem (6) and the rocker arm (7).
Adjust the clearance with the adjustment
screw until slight drag is felt on the feeler
gauge.
Valve Clearance (Engine Hot or Cold)
•
Intake Valve 0.35 mm [0.014 in]
•
Exhaust Valve 0.50 mm [0.020 in]
Drawing No. 9774, Section 7, Rev. 02-07
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
Adjust Valve Lash Clearance (Cont)
Tighten the locknut to secure the adjustment
screw.
Locknut Torque Value
•
MIN 39.2 N•m 28.9 ft-lb
•
MAX 49 N•m 36.1 ft-lb
Repeat
Rotate the crankshaft in the normal direction
one revolution.
In this position, adjust the valve clearances
for the following as described above:
Intake valves No. 2 and No. 4
Exhaust valves No. 3 and No. 4
Follow-Up
Install new valve cover gasket (Cummins
Part No. C6204118810).
Install the cylinder head cover.
Torque Value: 24 N•m (18 ft-lb]
Install the belt guard. Refer to Belt Guard
Removal/Installation in this section.
Drawing No. 9774, Section 7, Rev. 02-07
Page 7-165
Page 7-166
Section 7 – Adjustment, Repair, and Replacement
CFP33 Series
This Page Intentionally Left Blank
Drawing No. 9774, Section 7, Rev. 02-07
Section 8 – Service Literature
CFP33 Series
Page 8-1
Section 8 – Service Literature
Section Contents
Page
Additional Service Literature.............................................................................................................................8-3
Service Literature Ordering Location ...............................................................................................................8-4
Drawing No. 9774, Section 8, Rev. 02-07
Page 8-2
Section 8 – Service Literature
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 8, Rev. 02-07
Section 8 – Service Literature
CFP33 Series
Page 8-3
Additional Service Literature
General Information
The following publications can be purchased at your selected Service Literature Ordering Location:
Bulletin
Title of Publication
3379000
Air for Your Engine
3379001
Fuel for Cummins Engines Bulletin
3379009
Operation - Cold Weather Bulletin
3666132
Coolant Requirements and Maintenance Bulletin
3666418
Troubleshooting and Repair Manual, B3.3 Series Engines
3810326
4B Series Standard Repair Times
3810340
Cummins Engine Oil Recommendations Bulletin
Drawing No. 9774, Section 8, Rev. 02-07
Page 8-4
Section 8 – Service Literature
CFP33 Series
Service Literature Ordering Location
Contact Information
Region
United States and Canada
Ordering Location
Cummins Distributors at 1-800-DIESELS
(1-800-343-7357)
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. 9774, Section 8, Rev. 02-07
Section 9 – Service Assistance
CFP33 Series
Page 9-1
Section 9 – Service Assistance
Section Contents
Page
Routine Service and Parts ................................................................................................................................9-3
Problem Solving .................................................................................................................................................9-4
Drawing No. 9774, Section 9, Rev. 02-07
Page 9-2
Section 9 – Service Assistance
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 9, Rev. 02-07
Section 9 – Service Assistance
CFP33 Series
Page 9-3
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. 9774, Section 9, Rev. 02-07
Page 9-4
Section 9 – Service Assistance
CFP33 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. 9774, Section 9, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-1
Section 10 – Maintenance Specifications
Section Contents
Page
General Engine Data.........................................................................................................................................10-3
Fuel System Specifications .............................................................................................................................10-4
Lubricating Oil System Specifications ...........................................................................................................10-4
Cooling System Specifications .......................................................................................................................10-4
Air Intake System Specifications ....................................................................................................................10-5
Exhaust System Specifications ......................................................................................................................10-5
Electrical System Specifications ....................................................................................................................10-5
Cummins/Fleetguard® Liquid Filter Specifications ......................................................................................10-6
Fuel Recommendations and Specifications ..................................................................................................10-6
Lubricating Oil Recommendations and Specifications ................................................................................10-7
Coolant Recommendations and Specifications ............................................................................................10-8
Engine Component Torque Values.................................................................................................................10-9
Sealants ...........................................................................................................................................................10-10
Capscrew Markings and Torque Values.......................................................................................................10-11
Drawing No. 9774, Section 10, Rev. 02-07
Page 10-2
Section 10 – Maintenance Specifications
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-3
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 the applicable performance curve drawing and the data sheet drawing 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 8).
Model
CFP33-F10
CFP33-F20
CFP33-F25
CFP33-F30
CFP33-F35
Model
CFP33-F10
CFP33-F20
CFP33-F25
CFP33-F30
CFP33-F35
Performance Curve Drawing
9728
9728
9730
9728
9730
9729
9729
9731
9729
9731
Data Sheet Drawing
Cummins Engine Co. Base
Engine
4BT3.3G2
4BT3.3G2
B3.3C85T
4BT3.3G2
B3.3C85T
Cummins Base Engine Fuel
Rating
FR30005
FR30005
FR30203
FR30005
FR30203
Type
Firing Order
Rotation, Viewed from the Front of the Engine
Compression Ratio:
Valves per cylinder: Inlet/Exhaust
Installation Drawing
Configuration Number
Fuel System
Aspiration
4 Cycle; In-Line; 4 Cylinder
1-2-4-3
Clockwise
17:1
1/1
8700 (see Section 13)
D782002GX03
Zexel A Direct Injection
Turbocharged
Bore
Stroke
Displacement
Intake Valve Clearance
Exhaust Valve Clearance
Dry Weight
Wet Weight
Metric
95 mm
115 mm
3.3 liter
0.35 mm
0.50 mm
272 kg
327 kg
Drawing No. 9774, Section 10, Rev. 02-07
US
3.74 in
4.53 in.
199 in.3
0.014 in
0.020 in
599 lb
722 lb
Page 10-4
Section 10 – Maintenance Specifications
CFP33 Series
Fuel System Specifications
Fuel
Recommended fuel filter
Recommended fuel filter
Type Number 2 Diesel Only
Komatsu ff30006
Komatsu/Denso FF30001 & FF30005
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
6.4 mm D.
3.2 mm D.
12.2 m
2030 mm
76 mm Hg
203 mm Hg
381 mm Hg
0.34 m3/hr
70 oC
US
0.25 in. D.
0.125 in. D.
40 ft.
80 in.
3 in. Hg
8 in. Hg
15 in. Hg
12 ft3/hr
158 oF
Lubricating Oil System Specifications
Recommended lube oil filter
Fleetguard OF30004
Oil pressure range at rated
Oil capacity of pan (high - low)
Total system capacity
Metric
276-414 kPa
7.0-5.5 liter
8 liter
US
40-60 PSI
1.9-1.45 U.S. Gal
2.1 U.S. Gal.
Cooling System Specifications
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)
Metric
414 kPa
19.1 mm D.
US
60 PSI
0.75 in. D.
25.4 mm D.
1.0 in. D.
4.5 liter
82-95oC
0.76 liter/s
1.2 U.S. Gal.
180-203 oF
12 U.S. GPM
Drawing No. 9774, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-5
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) K&N RU3570
(Optional) Donaldson B085001
Maximum temperature rise between ambient air and engine air
inlet
Maximum inlet restriction with dirty filter
8oC
Metric
762 mm H2O
18oF
US
30 in. H2O
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
76 mm D.
3 in. D.
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
10423 (see Section 13)
30H or 31
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
620 Amps
400 Minutes
0.002 Ohms
120 RPM
65 Amps
10.6 mm D.
00 AWG
(1) Cold soak at -18oC (0oF) or above
Drawing No. 9774, Section 10, Rev. 02-07
24V
310 Amps
800 Minutes
0.004 Ohms
120 RPM
35 Amps
10.6 mm D.
00 AWG
Page 10-6
Section 10 – Maintenance Specifications
CFP33 Series
Cummins/Fleetguard® Liquid 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 8, Service Literature, for ordering information.
Drawing No. 9774, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-7
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 8 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. 9774, Section 10, Rev. 02-07
Page 10-8
Section 10 – Maintenance Specifications
CFP33 Series
Coolant Recommendations and Specifications
Heavy-duty diesel engines require a balanced coolant mixture of water and antifreeze.
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 8 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. 9774, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-9
Engine Component Torque Values
Torque Table
Component
After cooler Mounting
After cooler 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
Rocker Lever Cover
Water-in-Fuel Sensor
Top-Load Filter Lid
Drawing No. 9774, Section 10, Rev. 02-07
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 or in-lb
24
18 ft-lb
5
44 in-lb
24
18 ft-lb
43
32 ft-lb
43
32 ft-lb
77
57 ft-lb
24
18 ft-lb
24
18 ft-lb
43
32 ft-lb
137
101 ft-lb
5
44 in-lb
8
71 in-lb
8
71 in-lb
Install as specified by filter manufacturer
32
24 ft-lb
3/4 Turn after Contact
24
18 ft-lb
80
59 ft-lb
55
41 ft-lb
80
59 ft-lb
80
59 ft-lb
43
32 ft-lb
24
18 ft-lb
43
32 ft-lb
24
18 ft-lb
24
18 ft-lb
Hand-Tighten
Hand-Tighten
Page 10-10
Section 10 – Maintenance Specifications
CFP33 Series
Sealants
General Information
Use either the sealants listed below or sealants containing equivalent properties.
Description
Pipe Plugs
Cup Plugs
O-Rings
Rear Camshaft Expansion Plug
Turbocharger Drain in Block
Oil Pan at T-Joint
Front Cover
Sealing Method
Precoated teflon or pipe sealer.
Loctite 277 or 11,264.
No sealant required.
Precoated or Loctite 59,241 liquid teflon.
Loctite 277 or 11,264.
Silicone Sealant (P/N 3823494)
Silicone Sealant (P/N 3823494)
Drawing No. 9774, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP33 Series
Page 10-11
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:
Meaning:
M8
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.
Commercial
Steel Class
8.8
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. 9774, Section 10, Rev. 02-07
Page 10-12
Section 10 – Maintenance Specifications
CFP33 Series
US Customary Capscrew Identification
Sample:
Value:
Meaning:
5/16 x 18 x 1-1/2
18
Number of threads per inch
5/16
Major thread diameter in
inches
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. 9774, Section 10, Rev. 02-07
Section 11 – Warranty Information
CFP33 Series
Page 11-1
Section 11 – Warranty Information
EXCLUSIVE EXPRESS LIMITED WARRANTY: Cummins NPower, LLC (“CNP”), expressly warrants to the
original end consumer only that, for a period not to exceed the earlier of two (2) years or 2000 hours of use from
the start-up date (or, if the original end consumer fails to register as purchaser with CNP, six (6) months from
CNP shipment date), the diesel fire pump drivers, manufactured and sold by CNP, shall be free from defects in
material and workmanship when used and serviced in accordance with the Operations and Maintenance manual
for the applicable Cummins Fire Pump engine model (the “Exclusive Warranty”). The Exclusive Warranty is
non-transferable and shall immediately terminate and be of no further force or effect upon the sale, lease,
assignment, transfer or other disposition by an original end consumer of a Cummins Fire Pump engine that
contains a diesel fire pump driver covered by this Exclusive Warranty. Nothing contained herein shall be
construed to extend the Exclusive Warranty, and the Exclusive Warranty shall not be extended, to:
•
•
•
•
•
Maintenance, adjustment, installation or start-up costs;
Diesel fire pump driver failure due to normal wear, accident, misuse, abuse, neglect, improper
installation or a defect attributable to a Cummins Fire Pump engine;
Alterations or modifications not authorized in writing by CNP;
Additional components added to a diesel fire pump driver package subsequent to shipment of the
engine; or
Starting batteries and heaters.
DISCLAIMER OF WARRANTIES: Except for the Exclusive Warranty provided above, which is in lieu of all other
express and implied warranties, CNP EXPRESSLY DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES,
INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
LIMITATION AND EXCLUSION OF REMEDIES: All claims under this Exclusive Warranty shall be deemed
waived by the original end consumer if not submitted to CNP or an authorized distributor within thirty (30) days
of initial discovery that a diesel fire pump driver is not conforming to the Express Warranty. The original end
consumer’s remedy under this Exclusive Warranty is limited, in CNP’s reasonable discretion, to repair,
replacement or other appropriate adjustment of a non-conforming diesel fire pump driver determined, upon
CNP’s inspection, to have been properly installed, maintained and operated in accordance with the Operations
and Maintenance manual furnished by CNP.
IN ANY EVENT, CNP SHALL NOT BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
The Cummins Industrial Warranty covers the base engine for a period of time not to exceed the earlier of two (2)
years or 2000 hours of operation from the date of delivery and start-up of the engine. Reference bulletin
numbers 3381321 US/Canada & 3381322 Outside US/Canada. Cummins Fire Power components are
warranted for a period of time not to exceed the earlier of two (2) years or 2000 hours of operation from the
start-up date of the fire pump system, and the coverage includes travel time and mileage for the first year of the
Limited Warranty, and repair or replacement of parts and reasonable cost of labor. The Cummins Fire Power
Limited Warranty does not cover failures or damage due to abuse or neglect and including, but not limited to:
shipping damage, improper storage, improper installation, unauthorized modification or lack of maintenance.
Cummins Fire Power is not responsible for incidental or consequential damages.
Drawing No. 9774, Section 11, Rev. 02-07
Page 11-2
Section 11 – Warranty Information
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 11, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-1
Section 12 – Troubleshooting
Section Contents
Page
Troubleshooting Procedures and Techniques ..............................................................................................12-3
Troubleshooting Symptoms Charts ...............................................................................................................12-3
Alternator Overcharging with the Engine Running.......................................................................................12-4
Neither Battery is Charging with the Engine Running..................................................................................12-5
Only One Battery is Charging with the Engine Running ..............................................................................12-7
Voltage Indications Differ ................................................................................................................................12-8
Coolant Contamination ....................................................................................................................................12-9
Excessive Coolant Loss.................................................................................................................................12-11
Coolant Temperature Above Normal ............................................................................................................12-13
Coolant Temperature Below Normal (Engine Off).......................................................................................12-17
Coolant Temperature Below Normal (Engine Running) .............................................................................12-18
Raw Water Drain Steaming ............................................................................................................................12-19
Raw Water Solenoid Valve Fails to Operate ................................................................................................12-20
Auto Start Failure - Does not Crank on A.....................................................................................................12-21
Auto Start Failure - Does not Crank on B.....................................................................................................12-22
Auto Start Failure - Does not Crank on A or B ............................................................................................12-23
Auto Start Failure – Cranks but does not Start ...........................................................................................12-24
Auto Start Failure – Engine Starts but Crank Terminate does not Occur ................................................12-26
Manual Start Failure from Solenoid Lever - Does not Crank on A ............................................................12-28
Manual Start Failure from Solenoid Lever - Does not Crank on B ............................................................12-29
Manual Start Failure from Solenoid Lever - Does not Crank on A or B ....................................................12-30
Manual Start Failure from Control Panel - Does not Crank on A...............................................................12-31
Manual Start Failure from Control Panel - Does not Crank on B...............................................................12-32
Manual Start Failure from Control Panel - Does not Crank on A or B ......................................................12-33
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) .............................................................12-34
Engine Cranks Slowly But Does Not Start ...................................................................................................12-38
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present .........................................................12-40
Engine Acceleration or Response Poor .......................................................................................................12-43
Engine Noise Excessive - Mechanical..........................................................................................................12-46
Engine Noise Excessive — Combustion Knocks........................................................................................12-48
Engine Runs Rough at Idle ............................................................................................................................12-49
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-2
Section 12 – Troubleshooting
CFP33 Series
Section Contents (Cont)
Page
Engine Runs Rough or Misfires Under Load .............................................................................................. 12-51
Engine Speed Surges at Idle......................................................................................................................... 12-53
Engine Speed Surges Under Load............................................................................................................... 12-55
Engine Vibration Excessive at Rated Speed............................................................................................... 12-57
Engine Stops During Operation ................................................................................................................... 12-58
Engine Will Not Reach Rated Speed (RPM) ................................................................................................ 12-60
Engine Will Not Shut Off Remotely .............................................................................................................. 12-63
Engine Will Not Shut Off Locally .................................................................................................................. 12-64
Excessive White Exhaust Smoke................................................................................................................. 12-65
Excessive Black Exhaust Smoke ................................................................................................................. 12-68
Fuel Consumption Is Excessive ................................................................................................................... 12-70
Fuel or Lubricating Oil Leaking From Exhaust Manifold........................................................................... 12-72
Lubricating Oil Contaminated....................................................................................................................... 12-73
Lubricating Oil Consumption Excessive..................................................................................................... 12-75
Lubricating Oil Pressure High ...................................................................................................................... 12-76
Lubricating Oil Pressure Low ....................................................................................................................... 12-77
Oil Level Rises ............................................................................................................................................... 12-78
Lubricating Oil Sludge in the Crankcase Excessive .................................................................................. 12-79
Turbocharger Leaks Engine Oil or Fuel ...................................................................................................... 12-80
Crankcase Gases (Blowby) - Excessive ...................................................................................................... 12-81
Engine Overspeed Trip.................................................................................................................................. 12-82
Tachometer Does Not Indicate Engine Speed ............................................................................................ 12-83
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-3
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 6, and the Assembly
Drawings in Section 13.
Do the easiest and most logical things first.
Find and correct the cause of the complaint.
Troubleshooting Symptoms Charts
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 section to aid in diagnosing specific engine symptoms.
Read each row of blocks from top to bottom.
Follow through the chart to identify the corrective action.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-4
Section 12 – Troubleshooting
CFP33 Series
Alternator Overcharging with the Engine Running
NOTE: If the batteries are overcharged while the engine is not running, troubleshoot the customer supplied
battery charging system.
Cause
Correction
Batteries have failed.
Check the condition of the batteries. Replace any
defective batteries.
The internal voltage regulator in the alternator is
malfunctioning.
Test the alternator electrically. Refer to Alternator
Checks and Testing in Section 7.
If required, replace the alternator. Refer to Alternator
Removal/Installation Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-5
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 7.
If the alternator shaft does not spin freely because of a
bad bearing, replace the alternator (refer to Alternator
Removal/Installation in Section 7).
If the alternator does not turn because of a bad drive
belt, replace the drive belt (refer to Belt
Removal/Installation in Section 7).
If the alternator does not charge because of poor drive
belt tension, adjust belt tension (refer to Adjust
Alternator Drive Belt Tension in Section 7).
If the alternator pulley spins freely on the shaft
because of a broken key, replace the alternator (refer
to Alternator Removal/Installation in Section 7).
Battery Isolator input has faulted.
Test continuity from the alternator to the battery
isolator input (refer to Drawing 10423 Sheet 2 in
Section 13). Repair any open circuit.
Test continuity through the battery isolator. If an
internal open circuit is detected, replace the battery
isolator (refer to Battery Isolator Removal/Installation in
Section 7).
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-6
Section 12 – Troubleshooting
CFP33 Series
Neither Battery is Charging with the Engine Running (Cont)
Cause
Alternator excitation is lost.
Correction
Test the alternator electrically. Refer to Alternator
Checks and Testing in Section 7.
If required, replace the replaceable diode. Refer to
Drawing 10423 Sheet 1 in Section 13.
If required, locate and repair the open circuit or short to
ground in the alternator excitation wiring.
Alternator internal voltage regulator is malfunctioning.
Test the alternator electrically. Refer to Alternator
Checks and Testing in Section 7.
If required, replace the alternator. Refer to Alternator
Removal/Installation Section 7.
Battery temperature is above specification.
Position the batteries away from heat sources.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-7
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. Refer to Battery Testing in
Section 7.
If the battery has failed, replace the failed battery
units. Refer to Battery Removal/Installation in Section
7.
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 7.
Test the internal diodes for open circuit or short to
ground. Refer to the Schematic, Electrical Wiring,
10423 Sheet 2 Section 13.
If required, obtain a replacement battery isolator
(Cummins Part No. 8838).
Install the battery isolator. Refer to Battery Isolator
Removal/Installation in Section 7.
Voltmeter is providing false indication.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Go to Voltage Indications Differ in this section.
Page 12-8
Section 12 – Troubleshooting
CFP33 Series
Voltage Indications Differ
NOTE: The two voltmeters may differ slightly due to calibration differences between the meters. Normal
differences in battery condition may also cause differences in indication. These are normal differences and
require no action. A voltage difference of more than three or four volts should be investigated.
Cause
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 10423
Sheet 1 in Section 13).
Check for apparent wire damage or shorts to grounds.
Replace the failed fuse. Refer to Fuse Replacement in
Section 7.
If the fuse operates again, locate and correct the
overload or repair the short circuit.
Open circuit or short to ground in indicator wiring.
Locate and repair the electrical fault. (Refer to Drawing
10423 Sheet 1 in Section 13).
Voltmeter has failed.
Remove wiring at the voltmeter and apply test voltage.
If necessary, replace the faulted voltmeter. Refer to
Voltmeter Removal/Installation in Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-9
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 5.
If the drained coolant has excessive rust or debris,
change the coolant more frequently or contact a
Cummins Authorized Repair Facility.
Otherwise, refill with correct mixture of antifreeze and
water. Refer to Drain and Flush Cooling System in
Section 5.
Lubricating oil cooler is leaking oil into the coolant.
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 5.
Check the lubricating oil cooler for coolant leaks and
cracks. Refer to Lubricating Oil Cooler
Removal/Installation in Section 7. Replace the oil
cooler gasket or other parts.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section 5.
If the problem persists, the cylinder block may be
cracked or porous. Refer to a Cummins Authorized
Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-10
Section 12 – Troubleshooting
CFP33 Series
Coolant Contamination (Cont)
Cause
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.
Correction
Drain and flush the cooling system. Refer to Drain and
Flush Cooling System in Section 5.
Remove Coolant Heat Exchanger. Refer to Coolant
Heat Exchanger Removal/Installation in Section 7.
Perform a pressure test of the raw water side of the
heat exchanger. Refer to Coolant Heat Exchanger
Removal/Installation in Section 7. If the heat
exchanger leaks, it should be replaced.
Install a known good Coolant Heat Exchanger. Refer
to Coolant Heat Exchanger Removal/Installation in
Section 7.
Check and adjust raw water pressure regulator
setpoints. Refer to Raw Water Piping, Lineup, and
Configuration in Section 3.
Check and, if required, replace the Zinc Plug. Refer to
Inspect Heat Exchanger Zinc Plug in Section 5.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section 5.
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 5.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-11
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 5.
Replace and/or tighten loose hose clamps.
Replace any damaged hoses.
Refer to Coolant Hose Removal/Installation in Section 7.
Add coolant as required and check engine operation.
Pressure cap (Cummins Fire Power Part No. 11407)
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. 9774, Section 12, Rev. 02-07
Page 12-12
Section 12 – Troubleshooting
CFP33 Series
Excessive Coolant Loss (Cont)
Cause
Engine is overheating.
Correction
Refer to the Coolant Temperature Above Normal
symptom tree.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-13
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 (see Instrument Panel in Section 2) illuminates at 93 (92-94)oC
[200 (198-202)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
Drawing 8682 in Section 13).
Align flow if required.
Raw water pressure regulator is improperly adjusted.
NOTE: Pressure should be about 414 kPa [60 psig] or
slightly less.
Check the raw water pressure indication.
If pressure is indicated but is low, adjust the regulator
(Refer to Check Raw Water Pressure Regulator
Setpoints in Section 3.)
If pressure is not indicated or is 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 7.)
If pressure is excessively low when aligned for bypass
flow, open the normal valves.
Then, when practical, replace the pressure regulator.
(Refer to Raw Water Pressure Regulator
Removal/Installation in Section 7.)
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-14
Section 12 – Troubleshooting
CFP33 Series
Coolant Temperature Above Normal (Cont)
Cause
Raw water piping or heat exchanger is plugged.
Correction
Check the raw water strainer for blockage. Refer to
Drawing 8682 in Section 13. Clean the strainer if
necessary.
Check the Cummins supplied raw water piping for
blockage. Refer to Drawing 8682 and Drawing 9636 in
Section 13. Clean the piping if necessary.
Check the customer supplied raw water piping for
blockage. Remove any blockage.
Check for flow through the heat exchanger. If
necessary, replace the heat exchanger. Refer to
Coolant Heat Exchanger Removal/Installation in Section
7.
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 5. Replace any damaged hoses. Refer to
Coolant Hose Removal/Installation in Section 7.
Coolant thermostat is malfunctioning.
Remove and test the coolant thermostat. Refer to
Coolant Thermostat Removal/Installation in Section 7.
Replace the thermostat if it is defective.
Coolant water pump is malfunctioning.
Remove and inspect the water pump. Refer to Coolant
Water Pump Removal/Installation in Section 7. Replace
the thermostat if it is defective.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-15
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 5. Replace any damaged hoses. Refer to
Coolant Hose Removal/Installation in Section 7.
Coolant mixture of antifreeze and water is not correct.
Verify the concentration of antifreeze in the coolant.
Refer to Check Cooling System Condition in Section 5.
Add antifreeze or water to correct the concentration.
Refer to Coolant Recommendations and Specifications
in Section 10.
Lubricating oil level is above or below specification.
Check the oil level. Refer to Check Engine Oil Level in
Section 5. Add or drain oil, if necessary.
Coolant temperature sender is malfunctioning.
Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section 7.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section 7.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-16
Section 12 – Troubleshooting
CFP33 Series
Coolant Temperature Above Normal (Cont)
Cause
Coolant temperature switch is malfunctioning.
Correction
Remove the temperature switch. Refer to Coolant
Temperature Switch Removal/Installation in Section 7.
Test the temperature switch. Repair or replace the
switch, if necessary.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-17
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 temperature sender is malfunctioning.
Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section 7.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section 7.
Coolant is not free to circulate through the heater.
Ensure that the coolant hoses are clear. Refer to
Coolant Hose Removal/Installation in Section 7.
The coolant heater has failed electrically.
Replace the coolant heater. Refer to Coolant Heater
Removal/Installation in Section 7.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-18
Section 12 – Troubleshooting
CFP33 Series
Coolant Temperature Below Normal (Engine Running)
Cause
Coolant thermostat has failed open.
Correction
Test operation of the thermostat. Refer to Coolant
Thermostat Tests in Section 7.
If necessary, replace the thermostat. Refer to Coolant
Thermostat Removal/Installation in Section 7.
Coolant temperature sender is malfunctioning.
Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section 7.
Coolant temperature gauge is malfunctioning.
Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-19
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 7. If
pressure is not maintained, replace the heat
exchanger.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-20
Section 12 – Troubleshooting
CFP33 Series
Raw Water Solenoid Valve Fails to Operate
NOTE: The raw water solenoid failure may fail to open or to close. The normally closed valve may fail to open
when the engine starts. This fault will prevent raw water flow through the normal valves. Bypass flow should be
aligned in this event. The valve may also fail to close because of mechanical blockage. In this event, the raw
water flow from the heat exchanger does not stop when it should. Depending upon the fire protection system
piping, the open solenoid valve may drain all water from the fire protection system piping that is higher than the
engine’s piping.
Cause
Solenoid valve fails to close when the engine stops.
Correction
Replace the solenoid valve. Refer to Raw Water
Solenoid Valve Removal/Installation in Section 7.
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
7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-21
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 10423 Sheet 1 in Section 13.
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. 9774, Section 12, Rev. 02-07
Page 12-22
Section 12 – Troubleshooting
CFP33 Series
Auto Start Failure - Does not Crank on B
NOTE: The fire pump engine will not crank automatically when solenoid B is selected at the fire protection
system. However, it does start automatically when solenoid A is selected.
Cause
Correction
The electrical connection from the fire protection
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 10423 Sheet 1 in Section 13.
Relay K2 has failed.
Check de-energized continuity at Relay K2 pin 87 to
30. Replace K1 if the circuit is open.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-23
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.
Drawing No. 9774, Section 12, Rev. 02-07
Correction
Locate and correct the common mode fault in the Fire
Protection System.
Page 12-24
Section 12 – Troubleshooting
CFP33 Series
Auto Start Failure – Cranks but does not Start
NOTE: The fire pump engine will crank automatically when either solenoid A or solenoid B is selected at the fire
protection system. However, the engine does not start. The engine will start locally. If local starting problems are
identified, go to the applicable Manual Start Failure troubleshooting table.
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 10423 Sheet 1 in
Section 13.
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 10423 Sheet 1 in Section 13.
If required, replace the switch or repair other electrical
faults.
When done, close Circuit Breaker CB at the local
control panel and reset rocker switch to AUTO mode.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-25
Auto Start Failure – Cranks but does not Start (Cont)
The overspeed switch has failed.
Check power and grounding to the overspeed switch.
Refer to Drawing 10423 Sheet 1 in Section 13. Repair
any electrical faults.
If required, test and adjust the overspeed setting.
Refer to Overspeed Setpoint Adjustment and Testing
in Section 3.
Replace the overspeed switch. Refer to Overspeed
Switch Removal/Installation in Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-26
Section 12 – Troubleshooting
CFP33 Series
Auto Start Failure – Engine Starts but Crank Terminate does not Occur
Cause
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
10423 Sheet 1 in Section 13.
If signal is not present, go to The speed sensor has
failed. The tachometer also indicates zero speed in
this table.
Adjust the overspeed switch crank terminate setpoint.
Refer to Section 3.
If required, replace the overspeed switch. Refer to
Overspeed Switch Removal/Installation in Section 7.
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 10423 Sheet 1 in Section 13.
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 10423
Sheet 1 in Section 13.
If necessary, replace the speed sensor. Refer to
Speed Sensor Removal/Installation in Section 7.
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. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-27
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.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
When practical, test continuity and insulation from
ground between Fuse F3 and TB 2. Locate and repair
any electrical fault. Refer to Drawing 10423 Sheet 1 in
Section 13.
Page 12-28
Section 12 – Troubleshooting
CFP33 Series
Manual Start Failure from Solenoid Lever - Does not Crank on A
NOTE: The fire pump engine will not crank locally from the solenoid lever when solenoid A is actuated.
However, it does start when solenoid B is actuated.
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
10423 Sheet 1 in Section 13.
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 7.
If required, replace Solenoid A.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-29
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
10423 Sheet 1 in Section 13.
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 7.
If required, replace Solenoid B.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-30
Section 12 – Troubleshooting
CFP33 Series
Manual Start Failure from Solenoid Lever - Does not Crank on A or B
NOTE: The fire pump engine will not crank locally when either solenoid lever is actuated.
Cause
Correction
Starter motor has failed.
Replace the starter motor. Refer to Starter Motor
Removal/Installation in Section 7.
An electrical fault is present in the power or ground
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 10423 Sheet 1 in Section 13.
Engine is seized.
Bar the engine over to break the seizure.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-31
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 10423 Sheet
1 in Section 13. 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 10423 Sheet 1 in Section
13. 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 10423 Sheet 1 in Section 13.
Solenoid A fails to operate.
When practical, test the electrical operation of the
Solenoid A. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the solenoid if faulted.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-32
Section 12 – Troubleshooting
CFP33 Series
Manual Start Failure from Control Panel - Does not Crank on B
NOTE: The fire pump engine will not crank locally from the control panel when CRANK BATT B is selected.
However, it does start when CRANK BATT A is selected.
Cause
Correction
The CRANK BATT B switch fails to make contact.
When practical, test the electrical operation of the
CRANK BATT B switch. Refer to Drawing 10423 Sheet
1 in Section 13. Replace the switch if faulted.
Relay K2 fails in the local manual mode.
When practical, test the electrical operation of the
Relay K2. Refer to Drawing 10423 Sheet 1 in Section
13. 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 10423 Sheet 1 in Section 13.
Solenoid B fails to operate.
When practical, test the electrical operation of the
Solenoid B. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the solenoid if faulted.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-33
Manual Start Failure from Control Panel - Does not Crank on A or B
NOTE: The fire pump engine will not crank locally from the control panel when either CRANK BATT A or
CRANK BATT B is selected. However, it does start when a solenoid lever is actuated.
Cause
Correction
The MANUAL mode rocker switch contact fails to
close.
When practical, test the electrical operation of the
AUTO/MANUAL rocker switch. Refer to Drawing
10423 Sheet 1 in Section 13. Replace the solenoid if
faulted.
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 10423
Sheet 1 in Section 13.
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 10423 Sheet 1 in Section 13.
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 10423 Sheet 1 in Section 13.
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 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-34
Section 12 – Troubleshooting
CFP33 Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke)
Cause
Correction
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 7.
Manual fuel shutoff lever is binding.
Check to be sure manual shutoff lever is not binding
at the injection pump.
Fuel drain line is restricted.
Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as
necessary.
Fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 10.
Fuel injection pump is malfunctioning.
Perform the fuel injection pump test.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-35
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Correction
Fuel injection pump timing is not correct.
Check and adjust the fuel pump timing. Refer to Fuel
Adjust Fuel Pump in Section 7.
Fuel tank is empty.
Fill the fuel supply tank.
Fuel pre-filter is clogged.
Clean the customer-supplied fuel pre-filter.
Fuel pump overflow valve is malfunctioning.
Check the overflow valve. Replace if necessary.
Fuel Shutoff Valve (FSOV) fails to open.
If the fuel shutoff valve is not functioning, manually
override it. Refer to Emergency Starting With Failed
Fuel Shut-Off Solenoid in Section 3.
When practical, check the wiring for electrical faults.
Refer to Drawing 10423 Sheet 2 in Section 13.
If the wiring is OK, replace the Fuel Shutoff Valve. Refer
to Fuel Shutoff Valve (FSOV) Removal/ Installation in
Section 7.
Fuel suction line is restricted.
Check the fuel suction line for restriction.
Fuel connections on the suction side of the fuel lift
pump are loose.
Tighten all the fuel fittings and connections between the
fuel tanks and fuel lift pump.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-36
Section 12 – Troubleshooting
CFP33 Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Correction
Fuel suction standpipe in the fuel tank is broken.
Check and repair the standpipe, if necessary.
Fuel supply is not adequate.
Check the flow through the filter to locate the source
of the restriction.
Fuel tank air breather hole is clogged.
Clean the fuel tank breather.
Fuel lift pump is malfunctioning.
Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/
Installation in Section 7.
Injection pump driveshaft or driveshaft key is damaged.
Repair or replace the injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 7.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 7.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage. Refer to instructions in
Section 7.
Starting motor rotation is not correct.
Check the direction of crankshaft rotation. Refer to
instructions in Section 7.
Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 7.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-37
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause
Starting motor is not turning the engine.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Correction
Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 7.
Page 12-38
Section 12 – Troubleshooting
CFP33 Series
Engine Cranks Slowly But Does Not Start
NOTE: Typical engine cranking speed is 120 RPM. Engine cranking speed can be checked with a hand-held
tachometer, stroboscope, or electronic service tool.
Cause
Correction
The batteries are cold.
Ensure that the batteries are protected from extreme
temperatures.
The battery cables or connections are loose, broken, or
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 does 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
10.
If the wrong type or grade of oil is present, drain and
replace it. Refer to Change Lubricating Oil and Filters
in Section 7.
Engine temperature is too low.
Troubleshoot as per Coolant Temperature Below
Normal (Engine Off) in this section.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-39
Engine Cranks Slowly But Does Not Start (Cont)
Cause
Starting motor is malfunctioning.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Correction
Replace the starting motor. Refer to Starter Motor
Assembly Removal/Installation in Section 7.
Page 12-40
Section 12 – Troubleshooting
CFP33 Series
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present
NOTE: If the engine cranks slowly, refer to Engine Cranks Slowly But Does Not Start in this section.
Cause
Correction
Fuel tank level is low.
Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Fuel drain line is restricted.
Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as
necessary.
Fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 10.
Fuel injection pump is malfunctioning.
Perform the fuel injection pump test.
Fuel injection pump timing is not correct.
Check and adjust the fuel pump timing. Refer to Fuel
Adjust Fuel Pump in Section 7.
Fuel pre-filter is clogged.
Clean the customer-supplied fuel pre-filter.
Fuel pump overflow valve is malfunctioning.
Check the overflow valve. Replace if necessary.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-41
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Cont)
Cause
Correction
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 7.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 7.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage. Refer to instructions in
Section 7.
Intake air flow is restricted.
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 5.
Replace the air filter if required.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-42
Section 12 – Troubleshooting
CFP33 Series
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Cont)
Cause
Exhaust air flow is restricted.
Correction
Check the exhaust air piping for restriction. Remove any
restriction.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-43
Engine Acceleration or Response Poor
Cause
Correction
Fuel drain line is restricted.
Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as
necessary.
Fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of high-quality fuel.
Refer to Fuel Recommendations and Specifications in
Section 10.
Fuel injection pump is malfunctioning.
Perform the fuel injection pump test.
Fuel injection pump timing is not correct.
Check and adjust the fuel pump timing. Refer to Fuel
Adjust Fuel Pump in Section 7.
Fuel pre-filter is clogged.
Clean the customer-supplied fuel pre-filter.
Fuel pump overflow valve is malfunctioning.
Check the overflow valve. Replace if necessary.
Fuel suction line is restricted.
Check the fuel suction line for restriction.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-44
Section 12 – Troubleshooting
CFP33 Series
Engine Acceleration or Response Poor (Cont)
Cause
Correction
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 7.
Fuel injectors are plugged.
Replace the fuel injectors. Refer to Fuel Injectors
Removal/Installation in Section 7.
Throttle linkage misadjusted or damaged.
Adjust or repair the linkage. Refer to instructions in
Section 7.
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. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-45
Engine Acceleration or Response Poor (Cont)
Cause
Exhaust air is leaking.
Correction
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 7.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-46
Section 12 – Troubleshooting
CFP33 Series
Engine Noise Excessive - Mechanical
Cause
Correction
Lubricating oil is thin or diluted.
Check the oil level. Refer to Check Lubricating Oil
Level in Section 7. If the oil level is above the high
mark, go to Oil Level Rises in this section.
Lubricating oil pressure is below specification.
NOTE: Oil pressure should range between 69 and 345
kPa [10 to 50 PSI] with the engine running.
Check the oil pressure on the local control panel.
If the pressure is low, refer to the Lubricating Oil
Pressure Low symptom tree in this section.
Vibration damper is damaged.
Inspect the vibration damper. Refer to Inspect
Vibration Damper in Section 5. If the vibration damper
is damaged, refer to a Cummins Authorized Repair
Facility.
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.
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. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-47
Engine Noise Excessive – Mechanical (Cont)
Cause
Correction
Drive belt is squeaking due to insufficient tension or
high loading.
Check and adjust belt tension. Refer to Adjust Alternator
Drive Belt Tension in Section 7.
Intake air flow is restricted.
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 5.
Replace the air filter if required.
Exhaust air flow is restricted.
Check the exhaust air piping for restriction. Remove any
restriction.
Air leakage between the turbocharger and head.
Tighten the clamp between turbocharger and head.
Repair leaks between turbocharger and head.
Turbocharger does not rotate freely.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Replace the turbocharger. Refer to Turbocharger
Removal/Installation in Section 7.
Page 12-48
Section 12 – Troubleshooting
CFP33 Series
Engine Noise Excessive — Combustion Knocks
Cause
Correction
Engine is overloaded.
Check for added mechanical loading from damaged or
defective pump, changes in suction head, or changes
in discharge piping restriction.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine using the correct fuel. Refer to
Fuel Recommendations and Specifications in Section
10.
Air in present in the fuel supply to the engine.
Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and
fuel filters as necessary.
Vent air from the system. Refer to Air in Fuel in
Section 7.
The fuel injection pump’s timing is not correct.
Check and adjust the fuel injection pump timing. Refer
to Adjust Fuel Pump in Section 7.
The fuel injection pump is failing.
Replace the fuel injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 7.
Coolant temperature is below specification.
Refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree in this section.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-49
Engine Runs Rough at Idle
NOTE: Operation at idle speed is for maintenance only.
Cause
Engine is cold.
Correction
Allow the engine to warm to operating temperature.
If the engine will not reach operating temperature, refer
to the Coolant Temperature Below Normal (Engine
Running) symptom tree.
Idle speed is set too low.
Adjust the idle speed. Refer to instructions in Section
7.
Air is present in the fuel system.
Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and
fuel filters as necessary.
Vent air from the system. Refer to Air in Fuel in
Section 7.
Fuel filter is becoming plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Fuel supply to the engine is inadequate.
Locate and correct the restriction in fuel flow to the
engine.
The fuel lift pump is malfunctioning.
Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/
Installation in Section 7.
Engine mounts are worn or damaged.
Check the engine mounts. If damaged, refer to a
Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-50
Section 12 – Troubleshooting
CFP33 Series
Engine Runs Rough at Idle (Cont)
Cause
Correction
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 10.
Fuel pump overflow valve is malfunctioning.
Check the overflow valve. Replace if necessary.
Fuel injection pump timing is incorrect.
Check and adjust the injection pump timing. Refer to
Adjust Fuel Pump in Section 7.
Injector is malfunctioning.
Inspect the injectors.
Replace the injectors as necessary. Refer to Fuel
Injectors Removal/Installation in Section 7.
Fuel injection pump is malfunctioning.
Remove the fuel injection pump. Refer to Fuel Injection
Pump Removal/Installation in Section 7.
Check the calibration of the fuel injection pump.
Refer to instructions in Section 7.
Replace the pump if necessary.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-51
Engine Runs Rough or Misfires Under Load
Cause
Engine is cold.
Correction
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 7.
Fuel filter is becoming plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel supply to the engine is inadequate.
Locate and correct the restriction in fuel flow to the
engine.
The fuel lift pump is malfunctioning.
Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/
Installation in Section 7.
Engine mounts are worn or damaged.
Check the engine mounts. If damaged, refer to a
Cummins Authorized Repair Facility.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine on the required fuel. Refer to Fuel
Recommendations and Specifications in Section 10.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-52
Section 12 – Troubleshooting
CFP33 Series
Engine Runs Rough or Misfires Under Load (Cont)
Cause
Fuel pump overflow valve is malfunctioning.
Correction
Check the overflow valve. Replace if necessary.
Refer to instruction in Section 7.
Fuel injection pump timing is incorrect.
Check and adjust the injection pump timing. Refer to
Adjust Fuel Pump in Section 7.
Injector is malfunctioning.
Inspect the injectors.
Replace the injectors as necessary. Refer to Fuel
Injectors Removal/Installation in Section 7.
Fuel injection pump is malfunctioning.
Remove the fuel injection pump. Refer to Fuel Injection
Pump Removal/Installation in Section 7.
Check the calibration of the fuel injection pump.
Refer to instructions in Section 7.
Replace the pump if necessary.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-53
Engine Speed Surges at Idle
NOTE: Operation at idle speed is for maintenance only.
Cause
Correction
Fuel level is low in the tank.
Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Engine idle speed is set too low.
Adjust the idle speed. Refer to instructions in Section
7.
Air is in the fuel supply to the engine.
Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and
fuel filters as necessary.
Vent air from the system. Refer to Air in Fuel in
Section 7.
The fuel filter is plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Fuel flow to the engine is not adequate.
Locate and correct the restriction in the 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 7.
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
10.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-54
Section 12 – Troubleshooting
CFP33 Series
Engine Speed Surges at Idle (Cont)
Cause
The fuel injection pump is malfunctioning.
Correction
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 7.
Calibrate the fuel pump.
Refer to instructions in Section 7.
If required, replace the fuel injection pump.
A fuel supply line restriction exists between the fuel
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 7.
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. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-55
Engine Speed Surges Under Load
Cause
Correction
Pump suction head or pump discharge head changes.
Some variation in speed response to load changes is
normal. Excessive speed changes may occur upon
sudden failures in either suction or discharge piping
systems.
Fuel level is low in the tank.
Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Air is in the fuel supply to the engine.
Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and
fuel filters as necessary.
Vent air from the system. Refer to Air in Fuel in
Section 7.
The fuel filter is plugged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Fuel flow to the engine is not 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 7.
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
10.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-56
Section 12 – Troubleshooting
CFP33 Series
Engine Speed Surges Under Load (Cont)
Cause
The fuel injection pump is malfunctioning.
Correction
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 7.
Calibrate the fuel pump.
Refer to instructions in Section 7.
If required, replace the fuel injection pump.
A fuel supply line restriction exists between the fuel
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 7.
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. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-57
Engine Vibration Excessive at Rated Speed
Cause
Correction
Engine runs rough or is misfiring.
Refer to the Engine Runs Rough or Misfires Under
Load symptom tree in this section.
Fuel injection pump is adjusted incorrectly.
Adjust or replace the injection pump. Refer to Adjust
Fuel Pump and/or Fuel Injection Pump Removal/
Installation in Section 7.
Engine mounts are worn or damaged.
Inspect the engine mounts. Refer to Check Engine
Mounting Bolts in Section 5.
Replace the engine mounts as needed. Refer to a
Cummins Authorized Repair Facility.
Vibration damper is malfunctioning.
Inspect the vibration damper. Refer to Inspect
Vibration Damper in Section 5.
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 7.
Water pump bearing is worn or damaged.
Check if the water pump is vibrating excessively.
Replace the pump if necessary. Refer to Water Pump
Removal/Installation in Section 7.
Contact a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-58
Section 12 – Troubleshooting
CFP33 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 is required. This is a desirable outcome.
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 10423 Sheet 1 in Section 13.
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.
The fuel shutoff valve (FSOV) has failed.
Check the wiring continuity and insulation from ground
for the Fuel Shutoff Switch. Refer to Drawing 10423
Sheet 1 and Drawing 10423 Sheet 2 in Section 13.
Correct any electrical faults.
If required, replace the FSOV. Refer to Fuel Shutoff
Valve (FSOV) Removal/Installation in Section 7.
Fuel tank level is low.
Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-59
Engine Stops During Operation (Cont)
Cause
Correction
Clogged fuel tank air breather hole.
Clean the fuel tank breather.
Customer-supplied fuel pre-filter is clogged.
Clean the fuel pre-filter. Fill and bleed the fuel lines to
the engine.
Fuel piping to engine is clogged.
Clean and repair the fuel piping to the engine.
The fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Air is trapped in the low pressure fuel lines at the
engine.
Bleed the fuel lines. Refer to Air in Fuel in Section 7.
Fuel lift pump has failed.
Check the fuel lift pump for correct operation. Check the
pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/ Installation
in Section 7.
Fuel injection pump has failed.
Replace the fuel injection pump. Refer to Fuel Injection
Pump Removal/Installation in Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-60
Section 12 – Troubleshooting
CFP33 Series
Engine Will Not Reach Rated Speed (RPM)
Cause
Correction
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 instructions in Section
7.
Tachometer is not calibrated.
Compare the tachometer reading with a handheld
tachometer or an electronic service tool reading.
If out of calibration, calibrate the tachometer as
necessary at the CAL adjustment on the back of the
gauge. Refer to Tachometer Calibration in Section 7.
Tachometer is malfunctioning.
Replace the tachometer. Refer to Tachometer
Removal/Installation in Section 7.
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
10.
Fuel filter is clogged.
Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-61
Engine Will Not Reach Rated Speed (RPM) (Cont)
Cause
Correction
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.
Exhaust back pressure too high.
NOTE: The maximum allowable exhaust back pressure
is specified in Exhaust System Specifications in Section
10.
Measure the exhaust back pressure. Correct the
problem is it is above specification.
Fuel lift pump is malfunctioning.
Drawing No. 9774, Section 12, Rev. 02-07
Check the fuel lift pump for correct operation. Check the
pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/ Installation
in Section 7.
Page 12-62
Section 12 – Troubleshooting
CFP33 Series
Engine Will Not Reach Rated Speed (RPM) (Cont)
Fuel injection pump is malfunctioning.
Remove the fuel pump. Refer to Fuel Injection Pump
Removal/Installation in Section 7.
Calibrate the fuel pump.
If required, replace the fuel injection pump.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-63
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.
Fuel Shutoff Valve (FSOV) fails to close.
Press the RESET switch on the engine control panel.
Alternatively, operate the manual override.
NOTE: If the RESET switch did not close the valve, an
electrical fault to voltage may be present. Refer to
Drawing 10423 Sheet 1 and Drawing 10423 Sheet 2 in
Section 13.
If required, replace the fuel shutoff valve. Refer to Fuel
Shutoff Valve (FSOV) Removal/Installation in Section
7.
Engine running on fumes drawn into the air intake.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Identify and isolate the source of the combustible
fumes.
Page 12-64
Section 12 – Troubleshooting
CFP33 Series
Engine Will Not Shut Off Locally
Cause
Fuel Shutoff Valve (FSOV) fails to close.
Correction
Press the RESET switch on the engine control panel.
Alternatively, operate the manual override.
NOTE: If the RESET switch did not close the valve, an
electrical fault to voltage may be present. Refer to
Drawing 10423 Sheet 1 and Drawing 10423 Sheet 2
in Section 13.
If required, replace the fuel shutoff valve. Refer to
Fuel Shutoff Valve (FSOV) Removal/Installation in
Section 7.
Engine is running on fumes drawn into the air intake.
Identify and isolate the source of the combustible
fumes.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-65
Excessive White Exhaust Smoke
Cause
Correction
Engine is operating at low ambient temperature.
Refer to Cold Weather Operation, Bulletin Number
3387266, and the Operation and Maintenance
manual, Bulletin Number 3666417 for cold weather
operating aids and guidelines.
Air in the fuel system.
Check for air in the fuel system by installing a clear
hose on the suction side of the fuel pump. Verify fuel
drain is below the fuel level in the tank as air will enter
the suction and drain lines if fuel drain is not below
fuel level. Injectors can also be a source of
combustion gases leaking back into the fuel system.
Fuel grade is not correct for the application or the fuel
quality is poor.
Operate the engine from a tank of good fuel (40
Cetane min. above 32°F, 45 Cetane min. below 32°F).
Refer to Fuel recommendations and Specifications in
the Operation and Maintenance manual, Bulletin
Number 3666417.
Fuel filter is plugged.
Measure the fuel inlet restriction to the filter head (3
in. Hg max.). Measure the fuel pressure drop across
the fuel filter (1.5 in. Hg. max). Max. restriction to fuel
pump is 4.5 in. Hg.
Air intake system restriction is above specification.
Check the air intake system for restriction. Clean or
replace the air filter and inlet piping as necessary.
Air intake or exhaust leaks.
Visually inspect the air intake and exhaust systems for
air leaks by looking for cracks, listening for high pitch
whining or sucking noises, or use a soapy solution in
the suspect areas.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-66
Section 12 – Troubleshooting
CFP33 Series
Excessive White Exhaust Smoke (Cont)
Cause
Correction
Fuel drain line restriction is above specification.
Check the fuel drain lines for restriction (7.5 in. Hg
max). Clear or replace the fuel lines or tank vents as
necessary.
Fuel pump static injection timing is not correct.
Verify the static injection timing with the value listed
on the engine data tag. Refer to the Troubleshooting
and Repair manual, Bulletin Number 3666418 for
procedure. Turbocharged engines = 8°BTDC +/- 1°
Overhead adjustments are not correct.
Adjust the overhead settings. Refer to the
Troubleshooting and Repair manual, Bulletin Number
3666418.
Injectors are not correct.
Remove the injectors and compare the identification
number on the injector with the injector crossreference table 1.
Injector is malfunctioning.
Test the injector opening pressures (min 167 bar for
used injectors). Replace injectors as necessary. Refer
to the Troubleshooting and Repair manual, Bulletin
Number 3666418.
Fuel injection pump is malfunctioning.
Replace the fuel pump. Refer to the Troubleshooting
and Repair manual, Bulletin Number 3666418.
Raw fuel in the intake manifold (external source).
Check the intake manifold for fuel. Locate the fuel
sources and repair as necessary.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-67
Excessive White Exhaust Smoke (Cont)
Cause
Correction
Coolant is leaking into the combustion chamber.
Check for head gasket leaks, cylinder head or block
cracks.
Front gear train is not aligned properly.
Align the match marks of the idler gear, crankshaft
gear, camshaft gear and fuel pump gears. Refer to the
Troubleshooting and Repair Manual, Bulletin Number
3666418.
Internal engine damage.
Analyze the oil and inspect the filter to locate the area
of probable damage.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-68
Section 12 – Troubleshooting
CFP33 Series
Excessive Black Exhaust Smoke
Cause
Correction
Engine is being lugged down.
Increase pump suction head or decrease pump
discharge head.
Clogged air cleaner element.
Clean or replace the air cleaner element.
Muffler is crushed or clogged.
Replace the muffler.
Refer to the OEM's service manual.
Air leakage between the turbocharger and head.
Tighten the clamp between turbocharger and head.
Repair leaks between turbocharger and head.
Exhaust leak between turbocharger and exhaust
manifold.
Inspect and change gaskets.
Turbocharger does not rotate freely.
Replace the turbocharger.
Defective or clogged injection nozzle.
Replace the defective or clogged injection nozzle.
Injection pump is adjusted incorrectly causing
excessive injection.
Adjust or replace the injection pump.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-69
Excessive Black Exhaust Smoke (Cont)
Cause
Correction
Incorrect injection timing.
Adjust injection timing.
Overhead adjustments are not correct.
Measure and adjust the overhead settings.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-70
Section 12 – Troubleshooting
CFP33 Series
Fuel Consumption Is Excessive
Cause
Correction
Fuel is leaking.
Check the fuel lines, fuel connections, and fuel filters
for leaks. Check the fuel lines to the supply tanks.
Repair any leaks.
Poor-quality fuel is being used.
Assure good-quality No. 2 diesel fuel is being used.
Refer to Fuel Recommendations and Specifications in
Section 10.
Intake or exhaust restriction.
Refer to troubleshooting logic for Exhaust Smoke
Excessive Under Load in this section.
Defective or clogged injection nozzle.
Replace the defective or clogged injection nozzle.
Refer to instructions in Section 7.
Incorrect injection timing.
Adjust injection timing. Refer to instructions in Section
7.
Injection pump is adjusted incorrectly causing
excessive injection.
Adjust or replace the injection pump. Refer to
instructions in Section 7.
Hour meter is not calibrated.
Check the hour meter. Calibrate or replace the hour
meter if necessary.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-71
Fuel Consumption Is Excessive (Cont)
Cause
Correction
Air intake or exhaust leaks.
Check for loose or damaged piping connections and
missing pipe plugs. Check the turbocharger and exhaust
manifold mounting. Repair any leaks. Refer to
instructions in Section 7.
Air intake system restriction is above specification.
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 5.
Replace the air filter as necessary.
Lubricating oil level above specification.
Check the oil level. Refer to Check Engine Oil Level in
Section 5. Drain excess oil and correct the deficiency in
maintenance processes.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-72
Section 12 – Troubleshooting
CFP33 Series
Fuel or Lubricating Oil Leaking From Exhaust Manifold
Cause
Intake air restriction is high.
Correction
Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 5.
Replace the air filter if required.
Turbocharger drain line is restricted.
Remove the turbocharger drain line and check for
restriction. Refer to instructions in Section 7.
If required, clean or replace the drain line.
Turbocharger oil seal is leaking.
Check the turbocharger for oil seals and for leaks.
Refer to the Turbocharger Leaks Engine Oil or Fuel
symptom tree in this section.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-73
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 10.
Drain the oil and replace with non-contaminated oil.
Also, replace the oil filter. Refer to Change Lubricating
Oil and Filters in Section 7.
Fuel is present in the lubricating oil.
Refer to the Fuel in Lubricating Oil symptom tree.
Coolant is present in the lubricating oil.
Refer to the Coolant in Lubricating Oil symptom tree in
this section.
Metal is present in the lubricating oil.
Contact an Authorized Cummins Repair Facility.
Identify unknown lubricating oil contamination.
Analyze the oil and inspect the filters to identify the
contamination.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-74
Section 12 – Troubleshooting
CFP33 Series
Lubricating Oil Consumption Excessive
Cause
Correction
Lubricating oil leak (external).
Inspect the engine for external oil leaks. Tighten the
capscrews, pipe plugs, and fittings. Replace the
gaskets if necessary.
Intake system is contaminated with dust.
Remove and clean intake manifold.
Dipstick is not calibrated correctly.
Verify the dipstick is correctly marked.
Breather or breather hose is clogged.
Clean the breather and breather hose.
Turbocharger compressor or turbine oil seal is leaking.
Replace the compressor or turbine seal.
Rear crankshaft seal or seal surface is damaged.
Repair or replace seal and surface.
Valve stem, guide, or seal is damaged.
Repair or replace the damaged component.
Worn or broken piston ring or cylinder.
Replace the worn or broken piston ring or cylinder.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-75
Lubricating Oil Pressure High
Cause
Correction
Engine is cold.
Allow the engine to warm to operating temperature. If
the engine will not reach operating temperature, refer
to the Coolant Temperature Below Normal (Engine
Running) symptom tree in this section.
Lubricating oil viscosity not correct.
Drain the oil and replace the oil filter. Refer to Change
Lubricating Oil and Filters in Section 7.
Use the correct oil. Refer to Lubricating Oil
Recommendations and Specifications in Section 10.
Lubricating oil filter is not correct.
Replace the oil filter. Refer to Change Lubricating Oil
and Filters in Section 7.
Use the correct oil filter. Refer to Lubricating Oil
Recommendations and Specifications in Section 10.
The pressure gauge is malfunctioning.
Install a temporary pressure gauge at main oil rifle.
Compare the indications with the engine running.
If required, replace the pressure sender. Refer to
Lubricating Oil Pressure Sensor, OEM (007-052) in
Troubleshooting and Repair Manual B3.9, B4.5, and
B5.9 Series Engines, Bulletin Number 3666087-02.
If required, replace the pressure gauge. Refer to Oil
Pressure Gauge Removal/ Installation in Section 7.
Pressure regulator valve has malfunctioned.
Drawing No. 9774, Section 12, Rev. 02-07
Check and replace valve. Refer to Lubricating Oil
Pressure Regulator (Main Rifle) (007-029) in
Troubleshooting and Repair Manual B3.9, B4.5, and
B5.9 Series Engines, Bulletin Number 3666087-02.
Page 12-76
Section 12 – Troubleshooting
CFP33 Series
Lubricating Oil Pressure High (Cont)
Lubricating oil pump installation not correct.
Verify that the correct lubricating oil pump and o-rings
are installed. Refer to Lubricating Oil Pump (007-031)
in Troubleshooting and Repair Manual B3.9, B4.5,
and B5.9 Series Engines, Bulletin Number 366608702.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-77
Lubricating Oil Pressure Low
Cause
Lubricating oil level is below specification.
Correction
Check the oil level.
Verify the dipstick calibration and the oil pan capacity.
Fill the system to the specified level.
Oil level or oil pressure sensor is damaged.
Replace the oil level or oil pressure sensor.
Lubricating oil filter is clogged.
Replace the filter.
Fuel or coolant is in the lubricating oil.
Refer to Oil Level Rises symptom tree.
Regulator or relief valve is not adjusted correctly.
Adjust the regulator or relief valve.
Lubricating oil pan strainer is clogged.
Clean the strainer.
Lubricating oil suction tube is damaged.
Repair or replace the suction tube.
Lubricating oil pump is damaged.
Replace the oil pump.
Main or rod bearing is worn or damaged.
Replace the bearing.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-78
Section 12 – Troubleshooting
CFP33 Series
Oil Level Rises
NOTE: Oil level may increase due to thermal expansion as the engine warms up and then decrease as the
engine cools down. Slight variations due to temperature changes are normal.
Cause
Correction
Excessive oil has been added to the engine.
Drain the excess oil. Refer to Change Lubricating Oil
and Filters in Section 7.
Fuel is leaking into the oil system.
Troubleshoot as per Lubricating Oil Contaminated in
this section.
Coolant is leaking into the oil system.
Troubleshoot as per Lubricating Oil Contaminated in
this section.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-79
Lubricating Oil Sludge in the Crankcase Excessive
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 10.
Drain the oil and replace with non-contaminated oil.
Also, replace the oil filter. Refer to Change Lubricating
Oil and Filters in Section 7.
Coolant temperature is below specification.
Refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree in this section.
Crankcase ventilation system is plugged.
Check and clean the crankcase breather and vent
tube. Refer to Crankcase Breather Tube (003-018) in
Troubleshooting and Repair Manual B3.9, B4.5, and
B5.9 Series Engines, Bulletin Number 3666087-02.
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 10.
Lubricating oil does not meet specifications for
operating conditions.
Check the grade and type of oil. Refer to Lubricating
Oil Recommendations and Specifications in Section
10.
If the wrong type or grade of oil is present, drain and
replace it. Refer to Change Lubricating Oil and Filters
in Section 7.
Lubricating oil drain interval is excessive.
Drawing No. 9774, Section 12, Rev. 02-07
Verify the correct lubricating oil drain interval. Refer to
Change Lubricating Oil and Filters in Section 7.
Page 12-80
Section 12 – Troubleshooting
CFP33 Series
Lubricating Oil Sludge in the Crankcase Excessive (Cont)
Lubricating oil is contaminated with coolant or fuel.
Go to the Lubricating Oil Contaminated symptom tree
in this section.
Crankcase pressure is excessive.
Check for excessive blowby. Refer to the Crankcase
Gases (Blowby) Excessive symptom tree in this
section.
Closed crankcase ventilation hoses are leaking or
damaged.
Inspect the closed crankcase ventilation system hoses
and connections for leaks, obstruction, or damage.
Refer to Closed Crankcase Ventilation Hoses (003024) in Troubleshooting and Repair Manual B3.9,
B4.5, and B5.9 Series Engines, Bulletin Number
3666087-02.
Close crankcase ventilation valve is leaking or
malfunctioning.
Inspect the closed crankcase ventilation valve for
obstruction or damage. Refer to Closed Crankcase
Ventilation Valve (003-023) in Troubleshooting and
Repair Manual B3.9, B4.5, and B5.9 Series Engines,
Bulletin Number 3666087-02.
Refer to a Cummins Authorized Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-81
Turbocharger Leaks Engine Oil or Fuel
Cause
Correction
Engine is operating for extended periods under light or
no-load conditions (slobbering).
Operate the engine at idle speed for maintenance
activities only.
Lubricating oil or fuel is entering the turbocharger.
Check the turbocharger for oil or fuel in the piping.
Refer to Turbocharger (010-033) in Troubleshooting
and Repair Manual B3.9, B4.5, and B5.9 Series
Engines, Bulletin Number 3666087-02.
Turbocharger drain line is restricted.
Remove the turbocharger drain line and check for
restriction. Clean or replace the drain line. Refer to
Turbocharger Oil Drain Line (010-045) in
Troubleshooting and Repair Manual B3.9, B4.5, and
B5.9 Series Engines, Bulletin Number 3666087-02.
Turbocharger oil supply line is loose or leaking.
Check and tighten oil supply line fitting(s), if
necessary. Refer to Turbocharger Oil Supply Line
(010-046) in Troubleshooting and Repair Manual B3.9,
B4.5, and B5.9 Series Engines, Bulletin Number
3666087-02.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-82
Section 12 – Troubleshooting
CFP33 Series
Crankcase Gases (Blowby) - Excessive
NOTE: Crankcase gases or blowby may be measured. Refer to Crankcase Blowby, Measure (014-010) in
Troubleshooting and Repair Manual B3.9, B4.5, and B5.9 Series Engines, Bulletin Number 3666087-02.
Cause
Correction
Cylinder head valve guides are excessively worn.
Check the valve guides for wear. Replace the cylinder
head if necessary. Refer to Cylinder Head (002-004)
in Troubleshooting and Repair Manual B3.9, B4.5,
and B5.9 Series Engines, Bulletin Number 366608702.
Pistons or piston rings are worn, damaged, or not
correct.
Check the pistons for correct part numbers. Refer to
Control Parts List (CPL), Bulletin 3379133 or
4021327. Check the pistons and rings for wear and
damage. Refer to Piston (001-043) and Piston Rings
(001-047) in Troubleshooting and Repair Manual
B3.9, B4.5, and B5.9 Series Engines, Bulletin Number
3666087-02.
Turbocharger oil seal is leaking.
Check the turbocharger compressor and turbine
seals. Refer to Turbocharger (010-033) in
Troubleshooting and Repair Manual B3.9, B4.5, and
B5.9 Series Engines, Bulletin Number 3666087-02.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 12 – Troubleshooting
CFP33 Series
Page 12-83
Engine Overspeed Trip
NOTE: An engine overspeed trip occurs when the engine’s speed exceeds the value specified on the Factory
setting Tag described in Section 2. The trip isolates the fuel supply to the engine and it stops immediately. The
trip is indicated on the local control panel and inside the local control panel on the speed switch. Additionally, a
trip output is supplied to the fire protection system for remote display.
Cause
Correction
Engine actually operated at too great a speed due to
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 Factory
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
Factory 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 10423 Sheet 1 in Section 13.
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 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Page 12-84
Section 12 – Troubleshooting
CFP33 Series
Tachometer Does Not Indicate Engine Speed
Cause
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 10423 Sheet 1 in
Section 13.
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 10423 Sheet 1 in Section 13.
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 10423 Sheet 1
in Section 13. 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 7.
The tachometer has failed.
Check the operation of the tachometer with a pulse
generator. Replace the tachometer is it has failed.
Refer to Tachometer Removal/Installation in Section 7.
Contact an Authorized Cummins Repair Facility.
Drawing No. 9774, Section 12, Rev. 02-07
Section 13 – Assembly Drawings
CFP33 Series
Page 13-1
Section 13 – Assembly Drawings (1)
Description
Drawing, Installation, FirePump, CFP33-F10/20/30 (B3.3-G2)
Drawing, Installation, FirePump, CFP33-F25/35 (B3.3-C85T)
Assembly, Raw Water Cooling, ¾” Generic
Options, Engine, FirePump, G-Drive, CFP33-F10/20/30 (B3.3-G2)
Options, Engine, FirePump, Industrial, CFP33-F25/35 (B3.3-C85T)
Assembly, Air Cleaner, CFP33-F10/20/30
Assembly, Air Cleaner, CFP33-F25/35
Assembly, Air Filter Cover Implementation Date of April, 2009
Assembly, Heat Exchanger, CFP33
Assembly, Support, Engine, CFP33
Leg, Engine Support, Front, CFP33
Leg, Engine Support, Rear, CFP33
Assembly, Coolant Heater, CFP33
Assembly, Sensor Package, CFP33-F10/20/30
Assembly, Sensor Package, CFP33-F25/35
Assembly, Fuel Supply and Return Lines, CFP33-F10/20/30
Assembly, Fuel Supply and Return Lines, CFP33-F25/35
Misc. Piping, Cooling Loop, Raw Water, CFP33
Hose, Water, CFP33
Assembly, Fuel Solenoid Override, CFP33-F10/20/30
Fuel Line, Flex Extension, ¼” NPT,
Fuel Line, Flex Extension, 1/8” NPT,
Assembly, Operators Station, CFP33 Effective Date to 01-09
Assembly, Operators Station, CFP33 New Effective Date 01-09
Assembly, Panel, Instrument, 12VDC Effective Date to 08-08
Assembly, Panel, Instrument, 12VDC New Effective Date 09-08
Assembly, Panel, Instrument, 24VDC Effective Date to 08-08
Assembly, Panel, Instrument, 24VDC New Effective Date 09-08
Heat Shield, CFP33 New Effective Date 01-09
Exhaust, 3” Bellows w/ Elbow
Guard, Pulley, CFP33-F10/20/30
Guard, Pulley, CFP33-F25/35
Assembly, Drive Shaft & Guard
Assembly, Stub Shaft & Guard
Kit, Loose Wires; 3.3 liter Fire Pumps
General Layout, FirePump, CFP33
Schematic, Control Panel, Alternate Beginning 9/06
Wiring Harness, B3.3
Drawing No.
8700
8701
8682
8720
8721
8766
11142
13439
8769
8798
8799
8801
8813
9570-01
9570
9571
9571-01
9636
11148
10111
10235
10242
8765
11138
10452
13236
10453
13237
11143
8550
9537
8805
10163
9676
9766
CFP33_GEN
10423
8885
Sheet No
Revision
F
F
D
B
A
D
B
C
D
C
F
D
B
A
B
A
A
A
F
B
E
E
1-6
1-2
C
D
C
A
A
D
G
E
F
(1): Also see Engine Identification in Section 2 the System Diagrams in Section 6. The most current revisions to
these drawings and related documents are accessible at http://www.cumminsfirepower.com/products.html.
Drawing No. 9774, Section 13, Rev. 10-08
Page 13-2
Section 13 – Assembly Drawings
CFP33 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9774, Section 13, Rev. 10-08
63.28
[1607,4]
BILL OF MATERIAL
SETTINGS
DECALS
#9526-02
& 9526-03
MANUAL START
INSTRUCTION
DECAL
#9526-08
ITEM
ENGINE DATA
PLATE #9534
AIR FILTER COVER
PN: 13439
15.32
[389,2]
MANUAL
START
10.82
[274,9]
15.89
[403,5]
QTY
DESCRIPTION
PART NUMBER
1
1
ASSEMBLY, RAW WATER COOLING, 3/4" NPT, FIREPUMP
8682
2
1
ENGINE, B3.3
8720
3
1
ASSEMBLY, AIR CLEANER, CFP33-F10/20/30, FIREPUMP, 8700
8766
4
1
ASSEMBLY, HEAT EXCHANGER, FIREPUMP, B3.3
8769
5
1
ASSEMBLY, SUPPORT, ENGINE, FIREPUMP, B3.3
8798
6
1
ASSEMBLY, COOLANT HEATING, B3.3
8813
7
1
HARNESS, ENGINE, B3.3, NOT SHOWN, FIREPUMP
8885
8
1
ASSEMBLY, SENSOR PACKAGE, B3.3, FIREPUMP
9570
9
1
ASSEMBLY, FUEL PLUMBING, B3.3, FIREPUMP
9571
10
1
MISC PIPING, RAW WATER, CFP33, FIREPUMP
9636
11
1
ASSEMBLY, THROTTLE SOLENOID OVERIDE, FIREPUMP
10111
12
1
FUEL LINE, #6, 1/4" NPT x 12" LG
10235
13
1
FUEL LINE, #4, 1/8" NPT x 12" LG
10242
14
1
ASSEMBLY, OPERATORS STATION, CFP33, FIREPUMP
11138
15
1
SHIELD, TURBO, CFP33, FIREPUMP
11143
16
1
ASSY TELESCOPING GUARD 24" DS, SAE # 4 CFP 3.3 L
11812
17
1
ASSEMBLY, AIR FILTER COVER, -
13439
18
1
FLEX, EXHAUST, 3" FLANGE, FIREPUMP
19
1
FLANGE, COMPANION, -
20
1
GUARD, PULLEY, B3_3, G2, FIREPUMP
9537
21
1
ADAPTER, U-JOINT, HAYES #127727-01
9673
22
1
CLAMP, U-BOLT, GUILLOTINE, 3.00"
8550
8606_OLD
89545K
3" NPT EXHAUST
HIGH CURRENT DECAL #9526-05
GROUND DECAL
#9526-07
SCALE 0.100
SCALE 0.100
22.16
[562,9]
COOLANT FILL
FILL INSTRUCTION
DECAL #9526-09
RAW WATER INLET
3/4" NPT
53.69
[1363,6]
RAW WATER
OUTLET
1" NPT
42.78
[1086,6]
5.63
[142,9]
18.40
[467,4]
7.50
[190,5]
FLEX
FUEL
LINE
EXTENSION
13.13
[333,4]
1/4" NPT FUEL SUPPLY
2.74
[69,5]
18.15
[461,1]
14.81
[376,2]
CENTER OF 0.69
DIA MTG HOLES
19.54
[496,2]
35.03
20.14
1/8" NPT FUEL RETURN
21.64
COOLANT DRAIN
[511,6]
OPTIONAL COOLING LOOP
3/4" NPT CONNECTION
[549,7]
[889,8]
REF. SCALES
This document contains confidential and trade secret information, is the
property of Cummins NPower, LLC and is given to the receiver in confidence.
The receiver, by receiving and retaining of the document accepts the
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
confidential or trade secret information therein, (2) not copy the document,
(3) not disclose to others either the document or the confidential or trade
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE
ADDED PN:13439 & 89545K ENF PN:2008-275
E
REV PER OP STATION & SHIELD
D1 GRAPHICS UPDATE
REV
DESCRIPTION OF REVISION
F
MAC
10-14-2008
DAVE N
28NOV06
DAVE N
12JUL05
REV BY
DATE
ANGULAR DIMENSIONS 1± IMPERIAL UNITS
MACHINE TOLERANCES
THIRD ANGLE PROJECTION .XX
=±
0.010
.XXX = ±
0.005
METRIC UNITS
MACHINE TOLERANCES
.X = ±
0.4
.XX = ± 0.2
FORM TOLERANCES
.XX = ±
0.030
.XXX = ± 0.015
FORM TOLERANCES
.X = ±
0.8
.XX = ± 0.4
FAB TOLERANCES
.XX = ±
0.060
.XXX = ± 0.030
FAB TOLERANCES
.X = ±
1.5
.XX = ± 0.8
CUMMINS NPOWER, LLC
CORPORATE OFFICE
1600 BUERKLE ROAD
WHITE BEAR LAKE, MN
WWW.NPOWER.CUMMINS.COM
NPOWER SYSTEMS
DESIGN CENTER
875 LAWRENCE DRIVE
DEPERE, WISCONSIN
TITLE 1: ASSEMBLY, POWER MODULE, CFP33-F10/20/30
TITLE 2: FIREPUMP, B3.3-G2
DWG UNITS:
IN/LB/S
DRAWN BY: DAVE N
DATE: 25-FEB-2004
APPD BY:
DATE:
EST WEIGHT:
889.000
SCALE: DO NOT
0.150
SCALE
SHEET
1OF1
DRAWING NO: REV:
8700
F
BILL OF MATERIAL
SETTINGS DECALS
#9526-02 & 9526-03
ITEM
MANUAL
START
7.68
[195,0]
14.11
[358,3]
PART NUMBER
1
ASSEMBLY, RAW WATER COOLING, 3/4" NPT, FIREPUMP
8682
2
1
ENGINE, B3.3
8721
3
1
ASSEMBLY, HEAT EXCHANGER, FIREPUMP, B3.3
8769
4
1
ASSEMBLY, SUPPORT, ENGINE, FIREPUMP, B3.3
8798
5
1
ASSEMBLY, COOLANT HEATING, B3.3
8813
6
1
HARNESS, ENGINE, B3.3, NOT SHOWN, FIREPUMP
8885
7
1
ASSEMBLY, SENSOR PACKAGE, B3.3, FIREPUMP
9570
8
1
ASSEMBLY, FUEL PLUMBING, CFP33-F25/35, FIREPUMP
9
1
MISC PIPING, RAW WATER, CFP33, FIREPUMP
10
1
FUEL LINE, #6, 1/4" NPT x 12" LG
10235
11
1
FUEL LINE, #4, 1/8" NPT x 12" LG
10242
12
1
ASSEMBLY, OPERATORS STATION, CFP33, FIREPUMP
11138
13
1
ASSEMBLY, AIR CLEANER, CFP33-F15/25, FIREPUMP, 8701
11142
14
1
SHIELD, TURBO, CFP33, FIREPUMP
11143
15
1
ASSY TELESCOPING GUARD 24" DS, SAE # 4 CFP 3.3 L
11812
16
1
ASSEMBLY, AIR FILTER COVER, -
13439
17
1
FLEX, EXHAUST, 3" FLANGE, FIREPUMP
18
1
FLANGE, COMPANION, -
19
1
GUARD, PULLEY, B3_3, CONSTRUCTION ENGINE, FIREPUMP
8805
20
1
ADAPTER, U-JOINT, HAYES #127727-01
9673
21
1
CLAMP, U-BOLT, GUILLOTINE, 3.00"
AIR FILTER COVER
PN:13439
15.32
[389,2]
DESCRIPTION
1
ENGINE DATA
PLATE #9534
MANUAL START INSTRUCTION
DECAL #9526-08
QTY
9571-01
9636
8550
8606_OLD
89545K
HIGH CURRENT DECAL #9526-05
GROUND DECAL #9526-07
SCALE 0.100
SCALE 0.100
50.39
[1279,8]
21.00
[533,5]
COOLANT FILL
FILL INSTRUCTION
DECAL #9526-09
42.78
[1086,6]
55.56
[1411,2]
RAW WATER INLET
3/4" NPT
RAW WATER
OUTLET
1" NPT
5.63
[142,9]
18.92
[480,5]
13.13
[333,4]
7.50
[190,5]
COOLANT DRAIN
1.61 [40,8]
18.15 [461,1]
FLEX FUEL LINE
EXTENSIONS
CENTER OF
0.69 DIA.
MTG HOLES
19.01 [482,9]
20.51 [521,0]
1/4" NPT FUEL SUPPLY
1/8" NPT FUEL RETURN
14.81
[376,2]
33.90 [861,1]
OPTIONAL COOLING LOOP
3/4" NPT CONNECTION
REF. SCALES
This document contains confidential and trade secret information, is the
property of Cummins NPower, LLC and is given to the receiver in confidence.
The receiver, by receiving and retaining of the document accepts the
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
confidential or trade secret information therein, (2) not copy the document,
(3) not disclose to others either the document or the confidential or trade
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
19.54
[496,2]
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE
ANGULAR DIMENSIONS 1± IMPERIAL UNITS
F
E
REV
ADDED PN: 13439 & 89545K ENF PN:2008-275
REV PER OP STATION & SHIELD
DESCRIPTION OF REVISION
MAC
DAVE N
REV BY
10-14-2008
26SEP06
DATE
MACHINE TOLERANCES
THIRD ANGLE PROJECTION .XX
=±
0.010
.XXX = ±
0.005
METRIC UNITS
MACHINE TOLERANCES
.X = ±
0.4
.XX = ± 0.2
FORM TOLERANCES
.XX = ±
0.030
.XXX = ± 0.015
FORM TOLERANCES
.X = ±
0.8
.XX = ± 0.4
FAB TOLERANCES
.XX = ±
0.060
.XXX = ± 0.030
FAB TOLERANCES
.X = ±
1.5
.XX = ± 0.8
CUMMINS NPOWER, LLC
CORPORATE OFFICE
1600 BUERKLE ROAD
WHITE BEAR LAKE, MN
WWW.NPOWER.CUMMINS.COM
NPOWER SYSTEMS
DESIGN CENTER
875 LAWRENCE DRIVE
DEPERE, WISCONSIN
TITLE 1: ASSEMBLY, POWER MODULE, CFP33-F15/25/35
TITLE 2: FIREPUMP, B3.3-C85
DWG UNITS:
IN/LB/S
DRAWN BY: S.DANFORTH
DATE: 25-FEB-2004
APPD BY:
DATE:
EST WEIGHT:
889.000
SCALE: DO NOT
0.160
SCALE
SHEET
1OF1
DRAWING NO: REV:
8701
F
PN
SO
Model
Config
Option
CONS 436
AF30203
AP30201
BC30261
DF30001
EE30008
FA30005
FF30001
FH30001
FR30203
FV30003
FW30001
LC30001
LG30004
LT30001
OB30000
OF30001
OP30002
SD30001
SS30001
ST30201
TB30004
TU30005
WO30001
XS30001
8721
94475
B3.3-C
D782001CX03
Desc
B3.3-C
ADAPTER,FRONT DR
APPROVAL,AGENCY
ENGINE,BASE
DRIVE,FRO GER TR
ALTERNATOR
DRIVE,FAN
FILTER,FUEL
HOUSING,FLYWHEEL
RATING,FUEL
VALVE,FUEL SHUTO
FLYWHEEL
COOLER,ENGINE OI
GAUGE,OIL LEVEL
LITERATURE
ARRANGEMENT,OIL
FILTER,LUBRICATI
PAN,OIL
PLUMBING,SENSOR
PAINT
STARTER
TURBOCHARGER
TURBOCHARGER
CONNECTION,WATER
CONNECTION,EXHAU
BILL OF MATERIAL
ITEM
QTY
DESCRIPTION
PART NUMBER
1
1
CLAMP, 2.5" NOMINAL, AC250
8754
2
2
CLAMP, 3" NOMINAL, AC300
8816
3
1
AIR FILTER, 3" DIA. INLET, CFP33, 39 FIREPUMP
9604
4
1
TUBE, AIR CLEANER EXTENSION, 3" DIA, FIREPUMP
5
1
COUPLING, RUBBER, 2-1/2" TO 3", DONALDSON #P10280
P102820
6
1
RESTRICTION INDICATOR, 30" H20, 1/8" NPT
X002354
11141
6
3
5
2
4
1
REF. SCALES
This document contains confidential and trade secret information, is the
property of Cummins NPower, LLC and is given to the receiver in confidence.
The receiver, by receiving and retaining of the document accepts the
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
confidential or trade secret information therein, (2) not copy the document,
(3) not disclose to others either the document or the confidential or trade
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE
D
OMIT PN:8756
C
B
REV
ENF PN:2008-275
MAC
10-14-2008
REV PER TUBE, IND, AIR CLEANER
DAVE N
01SEP06
REV PER BRACKETS
DAVE N
20AUG04
DESCRIPTION OF REVISION
REV BY
DATE
ANGULAR DIMENSIONS 1± IMPERIAL UNITS
MACHINE TOLERANCES
THIRD ANGLE PROJECTION .XX
=±
0.010
.XXX = ± 0.005
FORM TOLERANCES
.XX = ±
0.030
.XXX = ± 0.015
FAB TOLERANCES
.XX = ±
0.060
.XXX = ± 0.030
METRIC UNITS
MACHINE TOLERANCES
.X = ±
0.4
.XX = ± 0.2
FORM TOLERANCES
.X = ±
0.8
.XX = ± 0.4
FAB TOLERANCES
.X = ±
1.5
.XX = ± 0.8
CUMMINS NPOWER, LLC
CORPORATE OFFICE
1600 BUERKLE ROAD
WHITE BEAR LAKE, MN
WWW.NPOWER.CUMMINS.COM
NPOWER SYSTEMS
DESIGN CENTER
875 LAWRENCE DRIVE
DEPERE, WISCONSIN
TITLE 1: ASSEMBLY, AIR CLEANER, CFP33-F10/20/30
TITLE 2: FIREPUMP, 8700
DWG UNITS:
IN/LB/S
DRAWN BY: DAVE N
DATE: 26MAY2004
APPD BY:
DATE:
EST WEIGHT:
14.621
SCALE: DO NOT
0.500
SCALE
SHEET
1OF1
DRAWING NO: REV:
8766
D
BILL OF MATERIAL
ITEM
6
QTY
DESCRIPTION
PART NUMBER
1
1
CLAMP, 2.5" NOMINAL, AC250
8754
2
1
CLAMP, 3" NOMINAL, AC300
8816
3
1
AIR FILTER, 3" DIA. INLET, CFP33, 39 FIREPUMP
9604
4
1
TUBE, AIR CLEANER EXTENSION, 3" DIA, FIREPUMP
11141
5
1
COUPLING, RUBBER, 2.36" TO 3"
3H236
6
1
RESTRICTION INDICATOR, 30" H20, 1/8" NPT
X002354
3
4
5
2
1
REF. SCALES
This document contains confidential and trade secret information, is the
property of Cummins NPower, LLC and is given to the receiver in confidence.
The receiver, by receiving and retaining of the document accepts the
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
confidential or trade secret information therein, (2) not copy the document,
(3) not disclose to others either the document or the confidential or trade
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE
ANGULAR DIMENSIONS 1± IMPERIAL UNITS
B
A
REV
OMIT PN: 8756 ENF PN: 2008-275
REV PER RESTRICTION INDICATOR
DESCRIPTION OF REVISION
MAC
DAVE N
REV BY
10-14-2008
05SEP06
DATE
MACHINE TOLERANCES
THIRD ANGLE PROJECTION .XX
=±
0.010
.XXX = ± 0.005
FORM TOLERANCES
.XX = ±
0.030
.XXX = ± 0.015
FAB TOLERANCES
.XX = ±
0.060
.XXX = ± 0.030
METRIC UNITS
MACHINE TOLERANCES
.X = ±
0.4
.XX = ± 0.2
FORM TOLERANCES
.X = ±
0.8
.XX = ± 0.4
FAB TOLERANCES
.X = ±
1.5
.XX = ± 0.8
CUMMINS NPOWER, LLC
CORPORATE OFFICE
1600 BUERKLE ROAD
WHITE BEAR LAKE, MN
WWW.NPOWER.CUMMINS.COM
NPOWER SYSTEMS
DESIGN CENTER
875 LAWRENCE DRIVE
DEPERE, WISCONSIN
TITLE 1: ASSEMBLY, AIR CLEANER, CFP33-F15/25
TITLE 2: FIREPUMP, 8701
DWG UNITS:
IN/LB/S
DRAWN BY: DAVE N
DATE: 01SEP2006
APPD BY:
DATE:
EST WEIGHT:
14.542
SCALE: DO NOT
0.500
SCALE
SHEET
1OF1
DRAWING NO: REV:
11142
B
Fire Pump
Applications
Installation & Maintenance Manual
Universal Joint Driveshafts
www.cumminsfirepower.com
Table of Contents
Section 1 – General
1.1 Introduction
1.2 Safety Precautions
1.3 Warranty Statement
1.4 Basic Guidelines
Section 2 – Installation
2.1 Drive Shaft
2.2 Companion Flanges
2.3 Shaft Alignment
2.4 Vertical Offset
2.5 Horizontal Offset
Section 3 – Lubrication
3.1 Lubrication Procedure
Section 4 - General Inspection
Section 5 - Application Calculations
Section 6 - Application Charts
Section 7 - Dimensional Attributes
Section 8 - Troubleshooting
This Manual contains proprietary information to equipment
produced by Cummins Fire Power or Cummins Inc. and is
being supplied solely for the purpose of operating, maintaining
and servicing the fire pump engine driveshaft application
purchased from Cummins Fire Power.
Copyright 2009, Cummins Fire Power
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
toc-i
Section 1 - General
1.1 Introduction
This manual provides information for the
installation and maintenance of universal
joint driveshafts intended for use with
diesel engine drivers. Following proper
installation and maintenance procedures
produces the optimum results in shaft
performance and safety.
Cummins Fire Power Manuals should be
considered part of the equipment. It is
recommended to keep the manuals with
the equipment. If the equipment is sold or
traded, please transfer manuals to the
new owner.
All personnel responsible for operation
and maintenance of the equipment should
read and thoroughly understand this
manual.
Driveshafts shall be installed in
accordance with the Standard for
Installation of Stationary Pumps for Fire
Protection, NFPA 20.
It is recommended that a torsional
analysis be conducted on the actual drive
system arrangement.
Warning: Rotating shafts can be
dangerous. Follow all safety and lockout
precautions during installation,
maintenance and operation.
Warning: Perform a walk
around inspection and alert all area
personnel that the equipment will be
starting before operation.
Caution: Consult applicable local
and national safety codes for proper
guarding of rotating members. Observe
all safety rules when installing or servicing
couplings and driveshafts.
Warning: After performing
maintenance, remove all tools and foreign
materials, reinstall and securely fasten
ALL guards, covers and protective
devices.
1.2 Safety Precautions
Warning: Read and understand
all of the safety precautions and
warnings before performing any repair.
This manual contains the general safety
precautions that must be followed to
provide personal safety.
Warning: Rotating shafts can
be dangerous. Keep hands,
body parts, long hair, or loose
fitting clothing clear at all times.
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
1.3 Warranty
Limited Warranty does not cover failures
or damage due to abuse or neglect and
including, but not limited to: shipping
damage, improper storage, improper
installation, unauthorized modifications or
lack of maintenance. Cummins Fire
Power is not responsible for incidental or
consequential damages.
Rev 01-2010
Page 1
1.4 Basic Guidelines to Universal
Joint Driveshafts
Even though driveshafts have the
unique capability of accepting both
axial and offset movements, the
following precautions must be taken:
1.4.1 They must work in pairs. A
universal joint, working at an angle, will
vibrate if it is not cancelled by another
joint. The second joint (opposite side of
the shaft) must be working at the same
angle and in the same plane. (See
Figures 1 & 2)
Figure 2
1.4.6 The universal joint operating angle
shall be within 1-3 degrees.
1.4.7 To determine the correct amount of
working angle; a) Measure the length in
inches from centerline of yoke bore(s) to
centerline of opposing yoke bore(s). b)
Measure parallel offset between centerline
of drive and driven shafts.
Figure 1
1.4.2 Joint angles must be equal within ½
degree. Joints, working in pairs will
vibrate if they are not working at the same
angle within ½ degree. (See Figure 2).
1.4.3 Yokes must be in phase (Figures 1
& 2). Joints, working in pairs, will vibrate
if their yoke ears are not in the same
plane.
1.4.4 Standard installation (Figure 1) requires
that the input and output shafts be parallel.
Figure 3
The actual offset shall measure 0.42 +/0.20 inches per 12 inches of shaft length.
Following this offset relationship will yield
an operating angle of 1-3 degrees.
1.4.5 In the alternate installation (Figure 2)
the centerlines of the output and input shafts
must intersect at the center of the driveshaft.
Consult factory for installation using this
method.
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
Page 2
Section 2 - Installation
2.1 Driveshaft Installation
2.1.6 Verify offset and shaft operating angles.
2.1.1 Clean flange faces removing all
paints or contaminants from the surface.
Examine mating surfaces for any damage
or nicks in the machine finish. Failure to
properly clean the mating surfaces can
result in premature driveshaft connection
failure.
2.1.7 Install proper shaft guarding prior to
start up.
2.1.2 Inspect companion flanges for
proper installation (see Section 2.2).
2.1.3 Compress driveshaft and place into
position between mating flanges (see
Figure 4). Large universal joint shaft
assemblies are very heavy, use proper
lifting equipment during installation.
Carefully align pilot bore boss into/onto
companion flange mating diameter. Align
bolt holes on driveshaft flange with holes
on companion flange. Secure flange to
driveshaft with proper hardware. Extend
shaft at slip section until pilot bore boss
aligns with companion flange pilot bore
boss. Align holes and secure flange.
Figure 4
2.2 Companion Flange installation
There are two types of mating flanges
available for connecting the drive and driven
unit shaft ends to the driveshaft. Type (1) SF
standard flange accepts through bolting.
Type (2) SLF large bore flange are drilled and
threaded to accept fasteners or stud kit (see
Figure 5). Stock bore companion flanges SF
or SLF are bored with a plus 0.001” minus
0.000” tolerance and shall be a slip fit over
mating shaft.
Figure 5
2.2.1 Align flange keyway with shaft key
and gently tap flange onto shaft with soft
face mallet. Take extreme care not to
damage flange face or flange. If flange
does not install easily, remove and retry.
Note: The drive/driven shaft shall not
extend out beyond the flange face or pilot
bore/boss.
2.1.4 Torque fasteners to proper
specification (see Table B).
2.2.2 Tighten setscrew(s) to
recommended torque (see Table C).
2.1.5 Lubricate all joints, splines (where
applicable) before startup. Lubricate until
lubricant appears at all four bearing cap
seals.
2.2.3 Check concentricity of companion
flange face and pilot. Maximum allowable
TIR is 0.003” on face and pilot (see Figure
6).
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
Page 3
2.4 Vertical Offset
2.4.1 Position (rotate) shaft so that the
inboard shaft yokes are vertical as shown
(Figure 8a & 8c).
2.4.2 Measure distance from point A to
B as shown (Figure 8a or 8c).
Figure 6
2.2.4 Thoroughly clean and inspect
flange mounting face removing any oils,
dirt, or contaminants.
2.3 Shaft Alignment
The procedure below is based on a fire
pump installation where the engine
crankshaft centerline is on the same
centerline as the pump when examined
from the top view and parallel in the side
view (see Figure 7). If installation
requires another configuration, please
consult factory customer service for
assistance. For all measurements vernier
caliper or dial indicator will be needed.
2.4.3 Measure distance from point C to
D as shown in (Figure 8a or 8c).
2.4.4 On Table A locate row of shaft
Part Number being aligned.
2.4.5 Raise or lower drive or driven unit
until measurements AB & CD are within
the Vertical Offset Tolerance range as
note in Table A.
2.4.6 When finished, measurements AB
and CD must also have equal values
within tolerance ranges identified in Table
A.
2.5 Horizontal Offset
Because the centerlines of the crankshaft
and pump unit are designed to be on the
same centerline, the horizontal offset
alignment check is to confirm near zero
misalignment.
2.5.1 Position (rotate) the shaft so that
the inboard yokes are horizontal (Figure
8b or 8d).
2.5.2 Measure distance from point J to K
as shown (Figure 8b or 8d).
2.5.3 Measure distance from point L to M
as shown (Figure 8b or 8d).
Figure 7
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
2.5.4 See Table A and identify the proper
row with applicable values of the shaft
that is being installed.
Rev 01-2010
Page 4
2.5.5 Measured values at the four
positions referenced (JK, LM, NP, RS)
may not vary more than the published
tolerance in the column listed as
Horizontal Offset Tolerance as noted in
Table A.
Table A
Weight in
lbs per
PN
series
Shaft
Series
Listed
Shaft PN
Vertical
Offset
Measurement
AB & CD
(inches)
Vertical
Offset
Tolerance
(+ or -)
(inches)
Horizontal Offset
Tolerance
(+ or -)
JK, LM, NP & RS
(inches)
1410
13417
2.36
0.04
0.012
13.5
1480
13418
2.27
0.04
0.012
19.5
1550
13419
2.78
0.05
0.017
29.5
1610
13420
3
0.05
0.018
44
1710
13421
3.17
0.05
0.022
54
1810
13422
3.77
0.06
0.027
78
1880
13423
4.08
0.07
0.032
142
U3101
13424
2.45
0.03
0.009
11
U3127
13427
3.64
0.04
0.013
27
U3126
13426
3.67
0.04
0.013
40
U3144
13428
4.46
0.04
0.016
45
U3158
13429
4.66
0.05
0.02
57
U3172
13430
4.87
0.05
0.023
74
**Measurement taken from yoke side of flange face to far side of universal bearing plate as
shown in the referenced Figures 8a-8d which are to be used for measuring instruction.
For parts and service inquiries, please
contact:
Visit us on the web at:
www.cumminsfirepower.com
Cummins Fire Power, LLC
875 Lawrence Drive
De Pere, WI 54115
Phone: 1-800-236-9750 in the US.
Fax: 1-920-337-9746
Please provide Engine serial number or
the Driveshaft serial no. and tag
information.
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
Page 5
Series 1410 – 1550 (13418 – 13419)
Series U3101 – U3172 (13424 – 13430)
Vertical Offset Sectional View
Figure 8a
Horizontal Offset Sectional View
Figure 8b
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
Page 6
Series 1610 – Series 1880 (13420-13423) Only
Vertical Offset Sectional View
Figure 8c
Horizontal Offset Sectional View
Figure 8d
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Rev 01-2010
Page 7
Section 3 - Lubrication
3.0 Lubrication
The majority of premature universal joint
and slip spline failures are due to
improper lubrication. Proper lubrication
practice flushes contaminants from the
bearings promoting maximum functional
life. A high quality NLGI Grade 2 EP
lithium grease is recommended for both
universal joint and slip splines. Note: Do
not use lubricants with molybdenum
disulfide additives in universal joint
bearings.
Lubrication intervals vary depending on
the application, installation environment,
and operating conditions. Continuously
operating assemblies should be lubricated
every 200 operating hours. Limited usage
joints should be lubricated every 6 months
in protected environmental conditions,
every 60 days in harsh environments.
3.1 Lubrication Procedure
3.1.1 Using the proper NLGI Grade 2
lubricant, purge all four bearing seals of
the universal joint. Pressure fill universal
joint through fitting “A” in Figure 9. This
flushes contaminants from each bearing
assembly and assures all four are filled
completely.
Figure 9
Note: If any seal fails to purge, move the
driveshaft from side to side and then reapply pressure to the fitting.
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
3.1.2 Lubricate slip splines through fitting
“B” on the shaft assembly. Only shafts
stamped Series 1410-1880 (13418 –
13423) require spline lubrication using the
following procedure. Cover the vent hole
and pressure fill the spline shaft until
grease purges the shaft seal.
Note: On applications where spline shafts
traverse in cold conditions, care must be
taken to purge excess grease from the
cavity immediately after lubricating.
Failure to do so can cause excess axial
pressure on components resulting in
damage to the driveshaft or mating parts.
Note: Shafts stamped Series U3101U3172 (13424-13430) are Rilsan coated
and are maintenance free for the spline
section only.
Table B
Flange Fastener Torque Values
Grade
Dry Torque
Shaft Series Thread Size (Class)
Value
1410
7/16 – 20
75 lb x ft
1480
1/2 – 20
110 lb x ft
1550
1/2 – 20
110 lb x ft
8
1610
3/8 – 24
45 lb x ft
1710
3/8 – 24
45 lb x ft
1810
7/16 – 20
75 lb x ft
1880
5/8 – 18
230 lb x ft
U3101
U3126
U3127
U3144
U3158
U3172
M8 - 1.25
25 lb x ft
M12 - 1.75
90 lb x ft
M12 - 1.75
90 lb x ft
10.9
M14 - 2.0
140 lb x ft
M14 - 2.0
140 lb x ft
M16 - 2.0
215 lb x ft
Table C
Setscrew Tightening Torques
Key Width
Thread Size
Torque Value
Below .313
1/4 - 28
6 lb x ft
.313 to .500
3/8 - 16
20 lb x ft
.501 to .750
1/2 - 13
50 lb x ft
Over .751
3/4 10
170 lb x ft
Rev 01-2010
Page 8
Section 4 – General Inspection
4.0. Inspection Guidelines
NOTE: Shaft assemblies must be
inspected annually to maintain peak
performance and safety.
4.1 Check companion flanges for
attachment to mating shaft. Verify that
setscrews remain secure.
4.2 Check fastener connection between
companion flange and driveshaft. Torque
to the specified values as detailed in
Table B.
4.3 Check universal joints for excessive
endplay. The allowable amount is 0.006
inches. See Figure 10 for inspection
diagram. Use dial indicator if any
looseness is perceived.
4.4 Check slip spline for radial movement.
Side to side movement in spline section
shall not be more than 0.007 inches in
any direction.
shaft seal, universal joint seals, spline end
plug, universal joint retaining rings or spun
bearing caps.
4.7 If any of the defects in Sections 4.3 to
4.5 are found, the shaft shall be
removed from service, replaced, and
returned to the factory for repair.
Warning: Rotating shafts can be
dangerous. Follow all safety and lockout
precautions during installation,
maintenance, and operation. Proper
guarding required. Consult local safety
regulations for compliance.
Section 5 – Application
Calculations
Rated Torque = Max Torque
5252
Rated HP = Rated Torque x RPM
Service Factor (SF)
For Centrifugal Fire Pump Application
5.1 A service factor is applied to the
calculated end-use application torque.
The calculated end-use application
torques, as adjusted by the service factor,
shall not exceed the torque rating of the
flexible coupling or connecting shaft at the
applicable speed.
Figure 10
4.5 Inspect overall length of shaft as
referenced in Section 7 to determine that
it is within the required tolerance.
4.6 Visually inspect for any damage to
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
Service Factor (SF) = 1.5 (6 Cylinders or
More-diesel engine)
Service Factor (SF) = 2.0 (5 Cylinders or
Less-diesel engine)
5.2 Selection of Flexible connecting
driveshaft shall be based on rating of the
driver and not the pump.
Rev 01-2010
Page 9
Section 6 - Application Charts
Shaft Series
Shaft PN
Rated Speed RPM
1470 1760 1800 1900 2100 2250 2300 2350 2600 2800 3000
1410
13417
Rated Torque
ft/lb
N-m
379
43
359
41
-
-
341
39
-
-
330
37
320
36
-
-
1480
13418
Rated Torque
ft/lb
N-m
499
56
473
53
-
462
52
448
51
-
-
434
49
420
47
-
-
1550
13419
Rated Torque
ft/lb
N-m
625
71
592
67
-
579
65
562
63
-
-
543
61
526
59
515
58
505
57
1610
13420
Rated Torque
ft/lb
N-m
950
107
950
107
-
950
107
946
107
-
-
915
103
887
100
868
98
850
96
1710
13421
Rated Torque
ft/lb
N-m
1200
136
1200
136
-
1200
136
1200
136
1200
136
1200
136
-
-
-
-
1810
13422
Rated Torque
ft/lb
N-m
1525
172
1525
172
-
1525
172
1525
172
-
-
-
-
-
-
1880
13423
Rated Torque
ft/lb
N-m
2158
244
2046
231
2034
230
-
-
-
-
-
-
-
-
U3101
13424
Rated Torque
ft/lb
N-m
433
49
410
46
-
-
389
44
-
-
376
42
365
41
-
-
U3126
13426
Rated Torque
ft/lb
N-m
950
107
950
107
-
950
107
950
107
-
-
950
107
950
107
950
107
944
107
U3127
13427
Rated Torque
ft/lb
N-m
549
62
549
62
-
549
62
549
62
-
-
549
62
549
62
-
-
U3144
13428
Rated Torque
ft/lb
N-m
1200
136
1200
136
-
1200
136
1200
136
-
1187
134
-
-
-
-
U3158
13429
Rated Torque
ft/lb
N-m
1525
172
1493
169
-
1459
165
1416
160
-
-
-
-
-
-
U3172
13430
Rated Torque
ft/lb
N-m
2200
249
2177
246
2163
244
-
-
-
-
-
-
-
-
Note: All rated torque values have been tested with a Diesel Engine Driver. Torque Ratings within the stated speed ranges are
determined by use of linear interpolation between torques and have been developed at minimum and maximum speeds. Driveshafts
are designed for minimum B-10 Life of 5000 Hours.
Section 7- Dimensional Attributes
Section 8 – Troubleshooting
Cause:
8.1
Flange Loose on Shaft
1. Set screw over keyway not tightened
2. Weight limitations exceeded for bored
flanges or shaft diameter undersized.
8.2
Solution:
1. Remove and inspect set screw. Replace if
damaged. Reassemble with new or original
and torque set screw.
2. Add additional set screw or replace flange
with interference fit bore.
Vibration
1. Companion flange or fastener loose.
2. Driveshaft mounting fasteners loose.
3. Flange faces not seated.
4. Flange face or pilot run-out exceeding
.005” TIR.
5. Excessive radial movement at the slip
yoke or binding movement.
6. Dry or brinelled (needle bearing
indentations).
7. Driveshaft yokes out of phase.
8. Exceeding maximum joint
acceleration.
9. Driven shaft or driver run-out.
10. Driver or driven shafts/companion
flange not parallel within 1 degree.
11. Driver or driven components out of
balance.
12. Operating at or near driver or driven
equipment natural frequency.
13. Operation near critical or half cycle
speed resonance.
14. Operation speed within a torsional
vibration mode.
15. System resonance or vibration.
16. Pump noise.
Cummins Fire Power, LLC
Drive Shaft Application Doc. 14390
1. Remove and inspect set screw. Replace if
damaged. Reassemble with new or
original and torque set screw.
2. Remove and inspect fasteners, drive shaft
and flange face for burs, paint and debris.
Clean or de-bur face. Replace damaged
fasteners. Reassemble and torque to
specifications.
3. Remove driveshaft fasters. Inspect
components for burs, paint and debris.
Clean or de-bur face. Reassemble and
torque to specification.
4. Inspect for run-out. Consult factory if out
of specification.
5. Lack of adequate lubrication or overload
condition. Consult factory.
6. Replace defective joints. Review and
recheck the working angle of shaft.
7. Disassemble and realign yoke.
8. Reduce angle and/or reduce speed.
Secure fastener and inspect for vibrations.
9. Consult with equipment manufacturer.
10. Align and adjust. Shimming structure may
be necessary.
11. Consult with equipment manufacturer.
12. Consult with equipment manufacturer.
13. Consult with equipment manufacturer.
Resizing of driveshaft may be required.
14. Perform torsional vibration analysis.
Consult manufacturer for assistance if
needed.
15. Perform torsional vibration analysis.
Consult manufacturer for assistance if
needed.
16. Consult with pump manufacturer.
Rev 01-2010
Page 12