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Troubleshooting List
Troubleshooting List
Troubleshooting List
7.1 Troubleshooting
The following information is intended as a guide to
WARNING
troubleshooting some common nontechnical equip- Before equipment operation, ALL guards,
ment problems. Many problems can be resolved covers and protective devices MUST BE in
using corrective maintenance, adjustment or minor place and securely fastened. Serious personal
repair. Refer to the Vendor supplied literature, injury could result from contact with exposed or
electrical schematics and mechanical prints for moving components.
additional information.
CAUTION
For engine related issues, refer to Operation and AVOID SERVICING complex components such
Maintenance Manual, Industrial and Power Genera- as: printed circuit boards, and, ECM's, not
tion QSX15 Engines, Bulletin No. 3666423 or specifically authorized by Cummins Inc. Contact
contact the Cummins Customer Assistance Center a Cummins Fire Power Customer Service
at 1-800-DIESELS (1-800-343-7357). Department toll free at 1-800-343-7357 before
performing any extensive maintenance.
It is beyond the scope of this manual to cover all of
the various problems that may affect engine perfor-
mance.
CAUTION
Never climb or stand on the equipment frame,
WARNING guards, or enclosures. Contact with exposed or
The status checks should be performed ONLY moving components can cause personal injury
by a qualified technician. Contact with exposed or equipment damage.
electrical components could cause extreme
personal injury or death.
7.1 Alternator Overcharging Batteries have failed. Check the condition of the
with the Engine Running batteries. Replace any defective
batteries.
NOTE: If the batteries are
overcharged while the engine is Voltage regulator malfunction. Test the alternator electrically.
not running, troubleshoot the Contact an Authorized Cummins
customer supplied battery Repair Facility.
charging system.
Replace the alternator as neces-
sary.
7.2 Neither Battery is Charging Battery cables or connections are Check the battery cables and
with the Engine Running loose, broken, or corroded connections. Ensure that all
(excessive resistance). connections are free of corrosion
NOTE: If one or both batteries do and that no cables are broken.
not charge with the engine
stopped, troubleshoot the cus- Alternator rotor is not rotating. Test the alternator mechanically.
tomer supplied battery charging If the alternator shaft does not
system. spin freely because of a bad
bearing, replace the alternator.
NOTE: If only one battery is
maintaining charge, go to Only If the alternator does not turn
One Battery is Charging with the because of a bad drive belt,
Engine Running. replace the drive belt. Refer to
Section 6 - Maintenance.
Battery isolator input has faulted. Test continuity from the alternator
to the battery isolator input.
Repair any open circuit.
7-4
Section 7 - Troubleshooting
7.2 Neither Battery is Charging Alternator excitation is lost Locate and repair the open circuit
with the Engine Running. (Cont'd). or short to ground in the alterna-
(Cont'd) tor excitation wiring as neces-
sary.
7.3 Only One Battery is Charg- Battery has failed. Check battery charge.
ing with the Engine Running
Battery cables or connections are Check the battery cables and
NOTE: If one or both batteries do loose, broken, or corroded connections. Ensure connections
not charge with the engine (excessive resistance). clean and that no cables are
stopped, troubleshoot the cus- broken.
tomer supplied battery charging
system. Battery isolator has failed. Remove the battery isolator. Test
the internal diodes for open
NOTE: If neither battery is circuit or short to ground. Re-
maintaining charge, go to Neither place the battery isolator as
Battery is Charging with the necessary.
Engine Running.
7.4 Voltage Indications Differ Voltmeter is providing false See Voltage Indications Differ in
indication. this section.
NOTE: The two voltmeters may
differ slightly due to calibration One battery is discharged or Check battery condition. Replace
differences between the meters. failing. failing battery elements.
Normal differences in battery
condition may also cause differ- Check wiring for corrosion.
ences in indication. These are Ensure good electrical contact.
normal differences and require no
action. 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.
7-5
Section 7 - Troubleshooting
7.4 Voltage Indications Differ Breaker 1 or Breaker 2 is tripped. If the breaker trips again, locate
(Cont'd) and correct the overload or repair
the short circuit.
7.5 Coolant Contamination Coolant is rusty and has debris. Drain and flush the cooling
system per the instructions in
Section 6 - Maintenance.
Lubricating oil cooler is leaking oil Check the lubricating oil cooler
into the coolant. Coolant begins for coolant leaks and cracks.
to have the texture and color of
chocolate pudding. Replace the oil cooler gasket or
other parts as necessary.
7-6
Section 7 - Troubleshooting
7.5 Coolant Contamination Coolant Heat Exchanger is Drain and flush the cooling
(Cont'd) leaking raw water into the cool- system per the instructions in
ant. Coolant volume increases Section 6 - Maintenance.
and pressure is relieved when
the unit is operating. Antifreeze Perform a pressure test of the
concentration decreases. raw water side of the heat
exchanger. If the heat exchanger
leaks, it should be replaced.
7.6 Excessive Coolant Loss Adequate coolant was not added Check the coolant level. Add
following previous maintenance coolant as required and check
activities. engine operation. If coolant loss
persists, check for other prob-
lems.
7-7
Section 7 - Troubleshooting
7.6 Excessive Coolant Loss Pressure cap is malfunctioning or Check that the pressure cap does
(Cont'd) has low-pressure rating. not relieve coolant under normal
operating conditions. Replace a
leaking pressure cap, (Cummins
Fire Power Part No. 11407). Add
coolant as required and check
engine operation.
NOTE: The thermostat’s normal Raw water flow is improperly Check that the raw water mani-
operating temperature range is aligned. fold is aligned for normal flow
82-95° C (180-203° F) The High through the solenoid valve
Water Temperature lamp on the (preferred) or bypass flow around
local control panel. The lamp only the solenoid valve (alternative).
illuminates if the engine is Align flow if required.
running. If the lamp is illuminated
or if temperature is otherwise Raw water pressure regulator is Check the raw water pressure
excessive, the engine should be improperly adjusted. indication. If pressure is indicated
stopped as soon as practical and but is low, adjust the regulator. If
the problem corrected. NOTE: Pressure should be about pressure is not indicated or is
414 kPa [60 psig] or slightly less. excessively low, go to raw water
solenoid has failed.
7-8
Section 7 - Troubleshooting
7.7 Coolant Temperature Raw water solenoid has failed. If pressure is excessively low
Above Normal. (Cont'd) (Cont'd) when aligned for bypass flow,
open the normal valves.
Raw water piping or heat ex- Remove any blockage. Check for
changer is plugged. flow through the heat exchanger.
Replace the heat exchanger as
necessary.
7-9
Section 7 - Troubleshooting
7.7 Coolant Temperature Coolant mixture of antifreeze and Verify the concentration of
Above Normal (Cont'd) water is not correct. antifreeze in the coolant. Add
antifreeze or water to correct the
concentration.
Lubricating oil level is above or Check the oil level per the
below specification. instructions in Section 6.
7.8 Coolant Temperature Below The 120 VAC power supply to the Connect the power supply.
Normal (Engine Off) coolant heater is not connected. Correct any electrical faults in the
supply circuit.
Coolant is not free to circulate Ensure that the coolant hoses are
through the heater. clear. Repair or replace hoses as
necessary.
7-10
Section 7 - Troubleshooting
7.8 Coolant Temperature Below Coolant temperature sender is Replace the temperature sender.
Normal (Engine Running) malfunctioning.
(Cont'd)
Coolant temperature gauge is Replace the temperature gauge.
malfunctioning. Refer to Section 6 - Maintenance.
7.9 Raw Water Drain Steaming Raw water flow did not start when Check engine coolant tempera-
the engine started. ture. Go to, Coolant Temperature
NOTE: The raw water drain from Above Normal in this section.
the Coolant Heat Exchanger may
steam if raw water flow is inad- Engine coolant is leaking into the Remove the coolant heat ex-
equate when the engine is raw water piping in the coolant changer and perform the pres-
running. It may also steam shortly heat exchanger. sure test. Refer to Section 6 -
after the engine is stopped. If Maintenance. If pressure is not
coolant is leaking into the raw maintained, replace the heat
water drain piping, the steaming exchanger.
may last for some time while the
engine cools. Antifreeze may also
be observed in the raw water
drain.
7.10 Raw Water Solenoid Valve Solenoid valve fails to close Replace the solenoid valve.
Fails to Operate when the engine stops. Clean the raw water strainer
more frequently. Increase the
NOTE: The raw water solenoid frequency of operational testing.
failure may fail to open or to
close. The normally closed valve Solenoid valve fails to energize. Check electrical continuity and
may fail to open when the engine insulation from ground to the
starts. This fault will prevent raw solenoid. Repair any open or
water flow through the normal short circuits in the wiring.
valves. Bypass flow should be
aligned in this event. The valve Solenoid fails to open mechani- Apply temporary voltage to the
may also fail to close because of cally. NOTE: Apply 24 VDC. solenoid. If the solenoid fails to
mechanical blockage. In this operate, replace it. Contact an
event, the raw water flow from Authorized Cummins Repair
the heat exchanger does not stop Facility.
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.
7-11
Section 7 - Troubleshooting
7.11 Auto Start Failure - Does The electrical connection from Test continuity and insulation
not Crank on BATT A or B the fire protection system to from ground between the fire
terminal board has failed. 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 Fire Protection System fails Locate and correct the common
to produce either redundant start mode fault in the Fire Protection
signal to the fire pump. System.
7.12 Auto Start Failure - Cranks The overspeed switch as actu- Press the RESET switch on the
but does not Start ated. The overspeed lamp is local control panel.
illuminated on the local control
NOTE: The fire pump engine will panel.
crank automatically when either
solenoid A or solenoid B is Control power from the Fire Locate and correct the fault in the
selected at the fire protection Protection System is not avail- Fire Protection System or the
system. However, the engine able at local control panel TB-1. field wiring to the local control
does not start. The engine will panel as necessary.
start locally. If local starting
problems are identified, go to the Circuit Breaker CB is open in the Check whether Circuit Breaker
applicable Manual Start Failure local control panel. CB at the local control panel is
troubleshooting table. open.
7-12
Section 7 - Troubleshooting
7.12 Auto Start Failure - Cranks The overspeed switch has failed. Check power and grounding to
but does not start (Cont'd) the overspeed switch. Repair any
electrical faults.
7.13 Auto Start Failure – The overspeed switch not With the engine running, verify
Engine Starts but Crank correctly adjusted or has failed. speed sensor input to the
Terminate Does Not Occur overspeed switch.
Breaker has tripped. The raw Open the raw water bypass
water solenoid valve fails to valves. RESET breaker switch.
open. Locate and repair any local
electrical fault.
The speed sensor has failed. The Locate and repair any electrical
tachometer indicates zero RPM. fault in the speed sensor circuitry.
Replace the speed sensor as
necessary.
7-13
Section 7 - Troubleshooting
7.14 Manual Start Failure from Crank Batter A and B switches Test electrical operation of Crank
Solenoid Lever - Does not failed to make contact. Batt A and B Switches. Replace
Crank on A or B the faulty switches as necessary.
NOTE: The fire pump engine will Relay fails in the local manual Test the electrical operation of
not crank locally when either mode. the relay. Replace the relay if
solenoid lever is actuated. faulted.
7.15 Manual Start Failure from The MANUAL Mode Rocker Test the electrical operation of
Control Panel - Does not Switch contact fails to close. the AUTO/MANUAL Rocker
Crank on A or B Switch. Replace the faulty switch
as necessary.
NOTE: The fire pump engine will
not crank locally from the control An electrical fault exists in the Test continuity and insulation
panel when either CRANK BATT signal power circuit or the ground from ground between the AUTO/
A or CRANK BATT B is selected, to the Relays. MANUAL Rocker Switch and the
however, it does start when a Relays. Check the relay connec-
solenoid lever is actuated. tion to ground. Locate and repair
any electrical fault.
Breaker Switch has tripped. The Open the raw water bypass
raw water solenoid valve also valves. Locate and repair any
fails to open. local electrical fault. RESET the
Breaker Switch.
7-14
Section 7 - Troubleshooting
7.15 Manual Start Failure from An electrical fault exists in the Test continuity and insulation
Control Panel - Does not signal power circuit or the ground from ground between breaker
Crank on A or B (Cont'd) to the overspeed switch’s crank and the overspeed switch’s crank
circuit. circuit. Check the crank circuit
output to the CRANK BATT
Switches. Locate and repair any
electrical fault.
Overspeed switch crank circuit Test and adjust the crank setting
fails to reset with engine shut- as necessary. Refer to
down. Overspeed Set Point Adjustment
and Testing in Section 6. Replace
the overspeed switch as neces-
sary.
7.16 Engine Cranks Normally Electronic fault codes are active. Refer to the Vendor supplied
But Will Not Start (No literature or contact an Autho-
Exhaust Smoke). rized Cummins Repair Facility for
Fault Codes.
Air is in the fuel system. Check for air in the fuel system.
Tighten or replace the fuel
connections, fuel lines, fuel tank
stand pipe and fuel filters as
necessary. Vent air from the
system.
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.
7-15
Section 7 - Troubleshooting
7.16 Engine Cranks Normally Fuel grade is not correct for the Operate the engine from a tank of
But Will Not Start (No application or the fuel quality is high-quality no. 2 diesel fuel.
Exhaust Smoke) (Cont'd) poor.
Fuel suction line is restricted. Check the fuel suction line for
restriction.
Fuel connections on the suction Tighten all the fuel fittings and
side of the fuel lift pump are connections between the fuel
loose. tanks and fuel lift pump.
Fuel suction stand pipe in the fuel Check and repair the stand pipe,
tank is broken. if necessary.
Fuel tank air breather is blocked. 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.
7-16
Section 7 - Troubleshooting
7.17 Engine Cranks Slowly But The battery cable connections Check the battery cables and
Does Not Start are loose, broken, or corroded connections. Ensure that connec-
creating excessive resistance. tions are clean and tight.
NOTE: Typical engine cranking
speed is 120 RPM. Engine The battery is not properly Recharge the battery. If the
cranking speed can be checked charged or has failed. battery doers not take the
with a hand-held tachometer, charge, replace it.
stroboscope, or electronic service
tool. Lubricating oil level is too high. Check the oil level per instruc-
tions in Section 6. Drain any
excess oil.
Lubricating oil is the wrong grade Check the grade and type of oil.
or type. Refer to Lubricating Oil Recom-
mendations and Specifications in
Section 6.
7.18 Engine Stops During Normal automatic mode shut- No action required. This is a
Operation down occurs when the fire desirable outcome.
protection systems removes the
signal power feed to the local
control panel.
7-17
Section 7 - Troubleshooting
7.18 Engine Stops During In the automatic mode, the signal Locate and correct the electrical
Operation (Cont'd) power feed is lost from the fire fault in the fire protection system
protection system to the control or the field wiring to the engine
panel. control panel.
Fuel tank level is low. Fill the fuel tank. Fill and bleed
the fuel lines to the engine.
Clogged fuel tank air breather Clean the fuel tank breather.
hole.
Air is trapped in the low pressure Bleed the fuel lines. Refer to Air
fuel lines at the engine. in Fuel in Section 6.
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.
Contact an Authorized Cummins
Repair Facility.
Fuel injection pump has failed. Replace the fuel injection pump.
Contact an Authorized Cummins
Repair Facility.
7-18
Section 7 - Troubleshooting
7.18 Engine stops during Electronic fault codes are active. Refer to the Vendor supplied
Operation (Cont'd) literature or contact an Autho-
rized Cummins Repair Facility.
Fuel grade not correct for the Operate the engine with a good
application, or fuel quality is poor. quality no. 2 diesel fuel.
Fuel suction line is restricted. Check the fuel suction line for
restriction.
Air-fuel tube leaking, waste gate Tighten the fittings, repair plumb-
diaphragm ruptured, or waste ing, replace waste gate dia-
gate plumbing damaged. phragm.
Charge air cooler restricted. Inspect the air cooler for internal
and external restrictions. Replace
the restricted cooler if necessary.
Stop circuit malfunction in the fire In the AUTO mode, the fire pump
pump controller of field wiring. engine stops upon loss of signal
power from the fire pump control-
ler. Check stop circuit in Fire
Pump Controller.
7-19
Section 7 - Troubleshooting
7.20 Engine Will Not Shut Off Stop circuit malfunction in the fire Correct any faults. Check for
Remotely pump controller of field wiring. short to voltage on the signal
wiring from the fire pump control-
ler to the engine control panel.
Correct any faults. Check opera-
tion 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.
7.21 Engine Will Not Shut Off Inadvertent power source is In the MANUAL Mode, the fire
Locally present from the fire pump pump engine stops when the
controller. AUTO/MANUAL Switch is
returned to the AUTO Mode.
7.22 Fuel Consumption Is Fuel is leaking. Check the fuel lines, fuel connec-
Excessive tions, and fuel filters for leaks.
Check the fuel lines to the supply
tanks. Repair any leaks.
7-20
Section 7 - Troubleshooting
7.22 Fuel Consumption Is Injection pump is adjusted Adjust or replace the injection
Excessive (Cont'd) incorrectly causing excessive pump.
injection.
Air intake system restriction is Check the air intake system for
above specification. restriction. Refer to Check Air
Cleaner Service Indicator in
Section 6. Replace the air filter
as necessary.
7.23 Fuel or Lubricating Oil Intake air restriction is high. Check the air intake system for
Leaking From Exhaust restriction. Refer to Check Air
Manifold Cleaner Service Indicator in
Section 6. Replace the air filter if
required.
7.24 Lubricating Oil is Con- Bulk oil supply is contaminated. Check the oil supply. Replace it
taminated is necessary. Drain the oil and
replace with non-contaminated
oil. Also, replace the oil filter.
Refer to Change Lubricating Oil
and Filters in Section 6.
7-21
Section 7 - Troubleshooting
7.25 Lubricating Oil Consump- Verify the oil consumption rate. Check the amount of oil added
tion Excessive versus the operating hours.
Lubricating oil does not meet Change the oil and filters per the
specifications for operating instructions in Section 6.
conditions.
Piston, cylinder liner, or piston Check for air intake system leaks.
rings are worn or damaged. Contact an Authorized Cummins
Repair Facility.
7-22
Section 7 - Troubleshooting
7.26 Lubricating Oil in the Bulk coolant supply is contami- Check the coolant expansion
Coolant nated. tank per the instructions in
Section 6. Drain the coolant and
replace with non-contaminated
coolant. Refer to Drain and Flush
Cooling System in Section 6.
Replace the coolant filter. Refer
to Change Coolant Filter in
Section 6.
7.27 Engine Overspeed Trip Engine operated at too great a Correct the cause of the load
speed due to catastrophic load failure. Contact a Cummins
NOTE: An engine overspeed trip failure such as pipe break, pump Authorized Repair Facility.
occurs when the engine’s speed mechanical failure, or loss of
exceeds the value specified on suction.
the Factory Setting Tag de-
scribed in Section 2. The trip Engine actually operated at too Check rated speed setting as
isolates the fuel supply to the great a speed due to configura- specified on the Factory Setting
engine and it stops immediately. tion error. Tag. Refer to Rated Speed Set
The trip is indicated on the local Point Adjustment and Testing in
control panel and inside the local Section 6.
control panel on the speed
switch. Additionally, a trip output Overspeed switch is set at too Check overspeed speed setting
is supplied to the fire protection low a set point. as specified on the Factory
system for remote display. Setting Tag. Refer to Overspeed
Set Point Adjustment and Testing
in Section 6.
7-23
Section 7 - Troubleshooting
7.27 Engine Overspeed Trip Speed switch wiring failure has Check continuity and insulation
(Cont'd) occurred. from ground for the signal power
wiring and ground wiring to the
speed switch. Replace defective
components and repair electrical
faults.
7.28 Tachometer Does Not An electrical fault exists in the Check continuity and insulation
Indicate Engine Speed tachometer power and grounding from ground for the power wiring
circuits. and ground wiring to the tachom-
eter. Contact an Authorized
Cummins Repair Facility. Re-
place 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. Contact an
Authorized Cummins Repair
Facility.
7-24