Fire Pump Drive Engines

CFP59 Series

Operation and Maintenance Manual

Doc. A042J557
April 2017
English Version
 This manual contains proprietary information to equipment produced by
Cummins Inc. and is being supplied solely for the purpose of operating,
maintaining, and servicing the fire pump drive engine purchased from
Cummins Sales and Service.

Please visit us at www.cumminsfirepower.com to view this manual in color,

as well as experience a wealth of information about Cummins fire pump
drive engines.

This product has been manufactured under the controls established by a

Bureau Veritas Certification approved management system that conforms
with ISO 9001:2015.

© Copyright 2017, Cummins Inc.

Fire Pump
Drive Engine
Limited Warranty

Description
This limited warranty applies to all Cummins fire pump drive engines (hereinafter referred to as
“Cummins” branded fire pump drive engines and associated accessories (hereinafter referred to as
"Product")). This warranty covers any failures of the Product, under normal use and service, which
result from a defect in material or factory workmanship.

Warranty Period:
The warranty start date for stationary Product is the date of initial start-up, demonstration or eighteen
(18) months after factory ship date, whichever is sooner.
Base Engine Warranty Duration (whichever occurs first): 2 years/2000 hours.

Cummins Responsibilities:
In the event of a failure of the Product during the warranty period due to defects in material or
workmanship, Cummins will only be responsible for the following costs:
• All parts and labor required to repair the Product.
• Reasonable travel expenses to and from the Product site location.
• Maintenance items that are contaminated or damaged by a warrantable failure.

Owner Responsibilities:
The owner will be responsible for the following:
• Notifying a Cummins distributor or dealer within thirty (30) days of the discovery of failure.
• Installing, operating, commissioning and maintaining the Product in accordance with Cummins
published policies and guidelines.
• Providing evidence for date of commissioning.
• Providing sufficient access to and reasonable ability to remove the Product from the installation
in the event of a warrantable failure.
• In addition, the owner will be responsible for:
• Incremental costs and expenses associated with Product removal and reinstallation resulting
from difficult or non-standard installations.
• Costs associated with Fire Watch Protection during Product being repaired.
• Costs associated with labor overtime and premium shipping requested by the owner.
• All downtime expenses, fines, all applicable taxes, and other losses resulting from a warrantable
failure.

© 2017 | Cummins Sales and Service www.cumminsfirepower.com

Doc. A042G861 Rev. 1
Limitations:
This limited warranty does not cover Product failures resulting from:
• Inappropriate use relative to designated power rating or application guidelines.
• Normal wear and tear, negligence, accidents or misuse.
• Improper and/or unauthorized installation.
• Lack of maintenance or unauthorized repair.
• Noncompliance with any Cummins published guideline or policy.
• Use of improper or contaminated fuels, coolants or lubricants.
• Improper storage before and after commissioning.
• Owner’s delay in making Product available after notification of potential Product problem.
• Replacement parts and accessories not authorized by Cummins.
• Owner or operator abuse or neglect such as: operation without adequate coolant or lubricants; over-fueling;
over-speeding; lack of maintenance to lubricating, cooling or air intake systems; late servicing and maintenance;
improper storage, starting, warm-up, run-in or shutdown practices, or for progressive damage resulting from a
defective warning device.
• Damage to parts, fixtures, housings, attachments and accessory items that are not part of the fire pump package.

This limited warranty does not apply to:

• Costs of maintenance, adjustments, installation, commissioning or start-up.
• Starting batteries and enclosures.
• Components added to the Product after shipment from Cummins.
• Block heaters are warranted for one (1) year from date in service

Please contact your local Cummins Sales and Service for clarification concerning these limitations.

Extended Warranty
Cummins Inc. offers several levels of Extended Warranty Coverage (Base Engine Only). Please contact your local
Cummins Distributor for details.

Cummins Right to Failed Components:

Failed components claimed under warranty remain the property of Cummins. Cummins has the right to reclaim any
failed component that has been replaced under warranty.

THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS INC. IN REGARD
TO THE PRODUCT. CUMMINS INC. MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT IS CUMMINS INC. LIABLE
FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited warranty gives
the owner specific rights that may vary from state to state or from jurisdiction to jurisdiction.

See the Cummins Inc. warranty bulletins for additional base engine warranty details: US & Canada: 3381321
International: 3381322.

Cummins fire pump drive engines have been manufactured under the
controls established by a Bureau Veritas Certification approved man-
agement system that conforms with ISO 9001:2015.

Cummins Sales and Service

875 Lawrence Drive
DePere, Wisconsin 54115

www.cumminsfirepower.com
© 2017 | Cummins Sales and Service
Doc. A042G861 Rev. 1

2
 Table of Contents

Table of Contents
Section 1 - Safety
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Use of Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.1 Advisory Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.2 Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2 - Description
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Fire Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Fire Pump Digital Panel (FPDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.1 Engine STOP Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.2 Customer Access Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.4 Battery “A” and “B” Voltmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.5 SCREEN Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.6 RESET/STOP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.7 Crank Battery A and B Momentary Start Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.8 Automatic or Manual Mode of Operation Selector Switch and Indicator Lamps. . . . . . . . . . . . . . . 2-5
2.3.9 MENU Soft Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.10 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.11 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.12 Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.13 Overspeed Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5 Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Fuel Supply and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.8 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.9 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Section 3 - Installation
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.5 Fuel Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.6 Cooling Water Supply Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.7 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Signal and Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.8.1 FPDP Interface Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.8.2 Battery Charger Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.9 Coolant System Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.10 Charge Air Cooler (CAC) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.11 Lubricating Oil System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.12 Pre-Start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.13 Engine Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.14 Field Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Cummins Fire Pump Drive Engine CFP59 TOC-1

Doc. A042J557, Rev. 04/2017
Table of Contents

Section 4 - Operation
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Starting and Stopping Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.1 Local Starting/Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.2 Emergency Starting/Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Fire Pump Digital Panel (FPDP) Screens and Adjustments in Automatic Mode. . . . . . . . . . . . . . . . . . . 4-3
4.3.1 The MENU Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1.1 ENGINE SETUP Screen - SYSTEM OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.1.2 ENGINE SETUP Screen - TERMINAL BLOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1.3 Overspeed Test Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.1.4 Imperial/SI Values Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.1.5 Analog Values Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.1.6 DPEM Screen (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.2 The SCREEN Soft Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Section 5 - Maintenance
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Engine Operation Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Weekly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Air Cleaner Filter and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.4 Engine Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.6 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.7 Electrical Supply and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.8 Crankcase Ventilation Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.9 Cooling Water Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.10 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.11 Engine Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.12 Engine Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.12.1 Crank Termination Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.3.12.2 Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.2 Turbocharger Mounting Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.3 Engine Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.4 Fuel Pumps and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.5 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.4.6 Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.4.7 Coolant Pump/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.4.8 Raw Water Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.4.9 Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.4.10 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5 Every Two Years. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.6 Every Four Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6.1 Coolant Thermostat Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6.2 Coolant Pump/Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

TOC-2 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Table of Contents

Section 6 - Troubleshooting
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Engine Cranks But Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Engine Starts But Continues to Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5 Engine Will Not Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Low Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Section 7 - Component Parts and Assemblies

7.1 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Repairs and Technical Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 Recommended Spare Parts Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.4 Engine Data Sheet and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.5 Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

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Table of Contents

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TOC-4 Cummins Fire Pump Drive Engine CFP59

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 Section 1 - Safety
1.1 Introduction • Never attempt to manually clean a machine
Cummins engine manuals should be considered part while it is operating or in standby mode.
of the equipment. Keep the manuals with the equip-
ment. If the equipment is traded or sold, give the • Never open ports on tanks or piping while the
manuals to the new owner. engine is operating. Contact with pressurized
agents can cause severe personal injury.
All personnel responsible for operation and mainte-
nance of the equipment should read and thoroughly • Relieve all pressure in the air, oil, and the cool-
understand this manual. ing systems before any lines, fittings, or related
items are removed or disconnected.
1.2 General Safety Precautions • Engine fuel is flammable when in contact with
Read and understand all of the safety precautions electrical spark or flame sources. Remove all
and warnings before performing any repair. Special sources of spark or flame from the work area.
safety precautions are included in the procedures
when they apply. This list contains the general safety • Always use the same fastener part number (or
precautions that must be followed to provide per- equivalent) when replacing fasteners.
sonal safety:
• Some state and federal agencies in the United
• Perform a walk around inspection and alert all States have determined that used engine oil can
area personnel that the equipment will be start- be carcinogenic and can cause reproductive tox-
ing before manual operation. icity. Dispose of waste oil in accordance with
applicable requirements.
• Do not operate faulty or damaged equipment.
Ensure that all hoses, pipe connections, clamps 1.3 Use of Advisory and Cautionary
and guards are in place and securely fastened.
Statements
Electrical components should be kept in good
working condition and repaired immediately by 1.3.1 Advisory Statements
qualified personnel. Advisory statements are used throughout this
manual call attention to special information and
• After performing maintenance, remove all tools correct operating procedures. Throughout this
and foreign materials and reinstall and securely manual, these Advisory Statements are delineated by
fasten ALL guards, covers and protective the terms “NOTE” and “IMPORTANT” in uppercase
devices. letters:
• Exposed in-running belt nips can cause severe NOTE: A general advisory statement relating to
personal injury or dismemberment. Ensure that equipment operation and maintenance procedures
guards are in place and securely fastened
before operation. IMPORTANT: A specific advisory statement intended
to prevent damage to the equipment or associated
• Rotating drive shafts can lacerate, dismember or components.
cause strangulation. Keep hands, body parts,
long hair, or loose-fitting clothing clear at all
times.

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Safety

WARNING
1.3.2 Cautionary Statements Indicates the presence of a hazard which CAN
Cautionary Statements highlight particular safety cause severe personal injury.
precautions pertaining to personal injury and/or
damage to the equipment. Cautionary Statements are
always preceded by the following symbols: CAUTION
Indicates the presence of a hazard which CAN
cause personal injury, or cause equipment
damage.

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 Section 2 - Description
2.1 Introduction Laboratories (UL), Inc. and Underwriters Laboratories
of Canada (ULC). When replacement parts are
This manual contains information for the correct oper-
needed, we recommend using only genuine
ation and maintenance of a Cummins fire pump drive
Cummins parts.
engine. Read and follow all safety instructions in
Section 1 - Safety. Keep this manual with the equip-
ment. If the equipment is traded or sold, give the
manual to the new owner.
WARNING
Injury may result and warranty is voided if fuel
Cummins fire pump drive engines have been rate, revolutions per minute (RPM), or altitudes
designed and tested in accordance with National Fire exceed published maximum values for this model
Protection Association (NFPA) 20 guidelines. and application.

2.2 Fire Pump Controller

No deviations are permitted without prior written
The fire pump controller starts the engine automati-
approval. These engines are to be used only for fire
cally when the Fire Pump Digital Panel (FPDP) is in
protection applications. Figure 2-1 and Figure 2-2
automatic mode and a remote fire demand signal is
provide visual descriptions of the engine components
received. The fire pump controller automatically shuts
for this fire pump drive engine.
down the engine when the fire demand signal is dis-
continued. The fire pump controller is optionally sup-
Cummins Inc. reserves the right to make changes at plied by Cummins Sales and Service or Cummins
any time. If any differences are found between an Inc.
engine and the information in this manual, contact
your local Cummins Authorized Repair Location. NOTE: With the fire pump controller in manual mode,
starting and stopping the fire pump drive engine can
The latest technology and the highest quality compo-
be controlled by the FPDP, located on the fire pump
nents were used to produce this engine. Cummins
drive engine itself.
fire pump drive engines as packaged units (engine
and accessories) have been approved by Factory
Mutual (FM) Approvals and listed by Underwriters

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Description

20 1

3
19
4
18

17

16

7
15
9 8
10
14
11
12
13

1. Air Cleaner Assembly 11. Engine Oil Dipstick

2. Air Cleaner Service Indicator 12. Cooling Water Manifold
3. Engine Oil Fill Port 13. Fuel Pump
4. Terminal Box (inside the FPDP) 14. Engine Supports
5. Fire Pump Digital Panel (FPDP) 15. Heat Exchanger Cooling Water Discharge
6. Primary Fuel Filter 16. Coolant Heat Exchanger
7. Engine Aftercooler 17. Cooling Expansion Line
8. Cooling Water Inlet 18. Coolant Pressure/Fill Cap
9. Fuel Return Line (air mount) 19. Exhaust Flex Connection
10. Fuel Supply Line 20. Turbocharger
Figure 2-1 Engine Components - Fire Pump Digital Panel (FPDP) Side

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 Description

15
2
14
13
3

11 5
6
7
8
12
9
11 10

1. Manifold Heat Shield 9. Battery Starter Contactor A

2. Lower Coolant Hose/Tube 10. Battery Charger Interface
3. Alternator 11. Engine Supports
4. Engine Oil Filter 12. Flywheel Housing
5. Oil Pan and Drain 13. Engine Speed Setting Decals
6. Battery Starter Contactor B 14. Manual Start Instruction Decal
7. Engine Coolant Heater 15. Engine Serial Number Decal
8. Starter Motor
Figure 2-2 Engine Components - Turbocharger Side

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Description
2.3 Fire Pump Digital Panel (FPDP) engine performance, and controlling fire pump drive
engine operation.
The Fire Pump Digital Panel (FPDP) (shown in Figure
2-3) is mounted on the left hand side (or right hand
In manual mode, the FPDP remains active as long as
side - optional) of the flywheel end of the engine and
battery power is available. In automatic mode, start-
contains controls for starting the engine, monitoring
ing and stopping of the engine is controlled by the fire
pump controller.

4
15

14 5

13

12
6

11 10 9 8

1. Engine STOP Button 10. ECM A/ECM B Selector Switch (not operable
2. Customer Access Port on mechanical engines)
3. Tachometer 11. AUTO/MAN Mode Selector Switch and Indi-
4. Battery “A” Voltmeter cator Lamps
5. Battery “B” Voltmeter 12. MENU Soft Key
6. SCREEN Soft Key 13. Hour Meter
7. RESET/STOP Switch 14. Engine Oil Pressure Gauge
8. Crank Battery B Momentary Start Switch 15. Coolant Temperature Gauge
9. Crank Battery A Momentary Start Switch
Figure 2-3 Fire Pump Digital Panel (FPDP)

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 Description
2.3.1 Engine STOP Button 2.3.7 Crank Battery A and B Momentary Start
The Engine STOP Button (1) is located on the left Switches
side of the FPDP enclosure and is used to stop the The CRANK BATT A (12) and CRANK BATT B (11)
operation of the engine in either manual or automatic momentary start switches engage the starter when
mode. The button must be pressed and held until the the FPDP is in MANUAL mode.
engine has shut down.
CRANK BATT A energizes battery contactor A and
NOTE: Upon release of the Engine STOP Button, the CRANK BATT B energizes battery contactor B. Both
fire pump drive engine will attempt to restart, If there CRANK BATT A and CRANK BATT B buttons can be
is still a “pump on demand” signal present from the energized at the same time in the event both batter-
fire pump controller. The engine must also be ies are weak.
stopped at the fire pump controller.
2.3.8 Automatic or Manual Mode of Operation
2.3.2 Customer Access Port Selector Switch and Indicator Lamps
The customer access knock-out (2) is located on the The AUTO/MAN selector switch and indicator lamps
left side of the FPDP for ease of access. This is the (14) illuminate in yellow, indicating the operational
only 1 in. (25.4 cm) knock-out provided for the pump state of the FPDP.
controller interconnect.
The MAN selector switch (for manual operation) is
IMPORTANT: If additional holes are placed in the only to be selected for engine setup, testing, and
FPDP, all warranty on the fire pump drive engine will emergency and maintenance procedures. When the
be void. FPDP is in manual mode, the ECM keyswitch/FSO
and raw water solenoids are always activated, except
2.3.3 Tachometer under an overspeed condition.
The Tachometer (5) displays the engine speed in rev-
olutions per minute (RPM) whenever the engine is The AUTO selector switch (for automatic operation) is
operating. the normal state of the FPDP, in which the fire pump
controller starts and stops the engine. In automatic
2.3.4 Battery “A” and “B” Voltmeters mode, the fire pump drive engine shuts down or
The Battery “A” (6) and Battery “B” (7) Voltmeters enters engine cool down upon loss of a signal from
display the charge status - or Voltage Direct Current the fire pump controller.
(VDC) - of the relative battery connections.
2.3.9 MENU Soft Key
2.3.5 SCREEN Soft Key The MENU soft key (15) on the FPDP display allows
The SCREEN soft key (8) allows the user to switch to the user to open the menu options. A complete list of
a detailed pop up list of additional analog values - FPDP screens and their functionality is outlined in
exhaust temperature; cooling loop temperature; Section 4.3 - FPDP Screens and Adjustments.
cooling loop differential pressure; and J1939 values
including: oil temperature; intake manifold tempera- 2.3.10 Hour Meter
ture; and intake manifold pressure. The Hour Meter (16) maintains a running total of the
hours of engine operation (run time).
2.3.6 RESET/STOP Switch
The RESET/STOP Switch (9) serves multiple 2.3.11 Engine Oil Pressure Gauge
purposes: Based on user parameter selection, the Engine Oil
Pressure Gauge (17) displays the engine oil pressure
• To shut off the engine by removing the ECM key- in pounds per square inch (PSI) or kPa. The Engine
switch/Fuel Shutoff (FSO) valve until the engine Oil Pressure Gauge displays by default in three differ-
speed decelerates to 0 RPM. ent colors:

• To reset the fire pump drive engine after an over- • green - when the engine oil pressure is greater
speed fault has been activated, allowing subse- than 25 PSI (172 kPa);
quent restarts of the fire pump drive engine.

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Description
• yellow - when the engine oil pressure is between
17 (117 kPa) and 25 PSI (172 kPa); and

• red - when the engine oil pressure is below 16

PSI (110 kPa). NOTE: Engine oil pressure dis-
played in red will also be accompanied by a low
oil pressure fault. See Section 3 - Installation
and refer to TB-4.

2.3.12 Coolant Temperature Gauge

Based on user parameter selection, the Coolant Tem-
perature Gauge (18) displays the engine coolant tem-
perature in degrees Fahrenheit or degrees Celsius.
The Coolant Temperature Gauge displays in three
different colors: Figure 2-4 Overspeed Warning Indicator

• green - when the coolant temperature is 2.4 Air Intake System

between 100-199 °F (38-93 °C);
The air intake system supplies combustion air to the
• yellow - when the coolant temperature is fire pump drive engine cylinders. The air filter pre-
between 200-211 °F (93-100 °C) OR below 100 vents particulate matter from entering the air intake.
°F (38 °C). NOTE: when the coolant temperature Figure 2-5 shows how the combustion air is drawn
is below 100 °F (38 °C), the yellow gauge will into the system. Combustion air drawn into the
also be accompanied by a low coolant tempera- system by the turbocharger is directed through the
ture fault. See Section 3 - Installation and refer engine aftercooler before entering the cylinders.
to TB-312.; and

• red - when the coolant temperature is greater

than 212 °F (100 °C). NOTE: the red gauge will
also be accompanied by a high coolant tempera-
ture fault. See Section 3 - Installation and refer
to TB-5.

2.3.13 Overspeed Warning Indicator

As shown in Figure 2-4, “ENGINE OVERSPEED”
flashes in red at the top of the FPDP screen indicates
that the engine has exceeded its rated RPM and that
possible damage to the sprinkler system may occur.
This malfunction requires immediate and decisive
operator response. A three- or four-digit diagnostic
fault code will display on the FPDP which can then be
used to help diagnose the engine malfunction. Refer
to the Fault Code Chart in Section 6 - Troubleshoot-
ing. CFP_400

1. Filtered Air
2. Turbocharger Compressor
3. Air Crossover Tube
4. Engine Aftercooler
5. Intake Valve Port
Figure 2-5 Air Intake Flow Diagram (typical)

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 Description
2.5 Cooling Water System charge air cooler (CAC) and fuel heat exchanger are
not included in this engine model.
Figure 2-6 illustrates a typical cooling water manifold
and Figure 2-7 shows the path of water through the NOTE: The cooling water supply must be immedi-
engine cooling system. Water entering the cooling ately available when the engine is started.
system through the cooling water inlet first circulates Engine coolant is circulated through the integral after-
through the heat exchanger, cooling the compressed cooler on the engine.
air from the turbocharger outlet ducting. Note that the

9. Normal Water Pressure Regulator

1. Bypass Water Pressure Regulator 10. Normal Water Solenoid Valve (where
2. Bypass Water Strainer required)
3. Pre-Strainer Pressure Sensor 11. Outlet to Heat Exchanger
4. Cooling Water Inlet 12. Temperature Sensor
5. Normal Water Inlet Valve 13. Pressure Gauge Isolation Valve
6. Bypass Water Inlet Valve 14. Water Supply Pressure Gauge
7. Normal Water Strainer
8. Post Strainer Pressure Sensor
Figure 2-6 Cooling Water Manifold (typical)

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Description

2 3

20 4 5

18
16 15 14 13
14
19

17 16 15 12 11 8
14 10 9

CFP-401A

1. Coolant Heat Exchanger 11. Coolant Pump

2. Coolant Expansion Tank/Line 12. Coolant Filter
3. Coolant Pressure Cap 13. Bypass Piping
4. Exhaust Manifold 14. Manual Shut-off Valve
5. Exhaust Flex Connection 15. Cooling Water Strainer
6. Turbocharger 16. Cooling Water Pressure Regulator
7. Air Filter 17. Cooling Water Solenoid Valve
8. Engine Block 18. Cooling Water Pressure Gauge
9. Thermostat 19. Cooling Water Drain Line
10. Cooling Water Inlet Pipe 20. Intake Manifold
Figure 2-7 Engine Cooling System Flow Diagram (typical)

2-8 Cummins Fire Pump Drive Engine CFP59

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 Description
2.6 Fuel Supply and Drain ing rods, valves, cam shafts, shafts, and bearings).
The oil pump circulates oil from the oil pan, through
As shown in Figure 2-1, the fuel supply and return
the oil filter, and into engine areas where friction may
connections are centrally located on the FPDP side.
develop. Refer to the Cummins engine Operation and
Refer to the Engine Data Sheet in Section 8 - Compo-
Maintenance Manual for additional information.
nent Parts and Assemblies for the maximum allow-
able fuel tank supply locations above the fuel pump.
NOTE: Typically engine oil has been added during
manufacture and testing procedures; however,
2.7 Fuel System shipping restrictions can affect whether the oil is
The fire pump drive engine is equipped with a fuel maintained in the engine or drained for shipping.
system that provides fuel metering and timing based Check the oil level at the dipstick. Add oil as neces-
on engine speed and load. sary to bring the oil level to the H (high) mark on the
dipstick.
2.8 Engine Oil System
Figure 2-8 illustrates how the engine oil system lubri-
cates moving internal engine parts (pistons, connect-








CFP-010

     
1. Idler Gears 7. High Pressure Relief Valve
2. Viscosity Sensor 8. Oil Thermostat
3. Oil Pump 9. Combination Oil Filter
4. Pressure Regulator Valve 10. Filter Bypass Gears
5. Oil Return to Pan 11. Oil Cooler
6. Oil Return to Pan 12. Turbocharger
Figure 2-8 Engine Lubricating Oil System Flow Diagram (Typical)

Cummins Fire Pump Drive Engine CFP59 2-9

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Description
2.9 Exhaust System charges from the exhaust manifold, passes through
Figure 2-9 and Figure 2-10 show how the exhaust (drives) the turbocharger, and exits through the
system removes engine exhaust from the cylinders exhaust connection.
after the combustion process. The exhaust dis-

1
3

CFP-008

1. Exhaust Valve Ports 3. Combustion Air to Charge Air Cooler

2. Engine Exhaust Manifold 4. Turbocharger Turbine
Figure 2-9 Exhaust System Flow Diagram (typical)

2-10 Cummins Fire Pump Drive Engine CFP59

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 Description

CFP-158

1. Combustion Air to Low Temperature

Aftercooler (LTA)
2. Exhaust Flow to Flex Pipe
Figure 2-10 Turbocharger Exhaust Flow Diagram (typical)

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Description

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 Section 3 - Installation
3.1 Introduction Refer to National Fire Protection Association (NFPA)
20 for installation and applicable local code require-
This section provides instructions for the initial
ments and NFPA 25 for inspection, testing, and main-
installation, adjustment, and testing of the Cummins
tenance requirements.
fire pump drive engine. Appropriate portions of this
section should be used when returning the engine to
Follow these steps to install the drive shaft:
operation after overhaul or major maintenance.

3.2 Receiving and Handling

CAUTION
Cummins fire pump drive engines are pre-assembled Ensure that the lifting device is capable of safely
and tested before shipment. Parts not shipped lifting the weight of the engine or the combined
attached to the engine are sometimes shipped indi- weight of the assembled pump base, drive line,
vidually. The equipment was thoroughly inspected and pump. Do not use the engine lifting points for
and prepared for shipping before it was turned over to assembly!
the carrier. Upon receipt of the fire pump drive engine
from the shipper: 1. Ensure that the engine and pump are correctly
aligned.
1. Inspect the equipment for damage that may
have occurred in shipping; and a. Ensure that the engine position is centered
on the frame side to side within ± .76 mm (.03
2. Check each item carefully against the shipping in) by measuring outside of the frame side to
manifest or bill of lading. the engine support leg mounting pad. (Com-
pare the two front engine supports and two
3.3 Site Preparation back engine supports.)
The site should be clean and relatively level. Clear b. As shown in Figure 3-1, align the engine
the proposed equipment area of overhanging center line to the pump center line within ±
obstructions and obstacles protruding from the floor. .76 mm (.03 in).

c. Ensure that the pump center line to the

CAUTION engine crankshaft center line (in vertical
Avoid installation in a dusty or dirty environment. plane) is 2° +/- 1°.
Provide adequate physical protection from other
physical damage as may be present in the d. Ensure that the drive shaft mounting flanges
specific location. are parallel.

2. As illustrated in Figure 3-2, lubricate the grease

3.4 Drive Shaft Installation fittings on the drive shaft universal joint.
Drive shaft installation should be done by trained
technicians familiar with local, state, and federal 3. Check that the fire pump drive engine is properly
codes and regulations. installed per the pump manufacturer’s specifica-
tions.

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Installation
NOTE: Some lubrication loss may occur during trans-
1
port and storage. It is recommended that the drive
90 ° 90 ° shaft be re-lubricated upon installation.

3.5 Fuel Supply Installation

The following sections outline proper installation and
connection of the fuel supply.
2
NOTE: It is the responsibility of the customer to
provide and install a properly-rated fuel tank per
TOP NFPA 20 guidelines.

3 To properly install a fuel supply, follow these instruc-

tions:

1. Install an elevated no. 2 diesel fuel tank or other

fuel supply arrangement which is compatible
with American Society of Testing and Materials
(ASTM) no. 2 diesel fuel specifications.
SIDE 4
CFP-013 NOTE: The fuel supply line at the fuel tank must be
higher than the fuel intake port on the engine fuel
1. Planes must be parallel
filter. Ensure that the fuel system is installed in a safe
2. Align both mounting center lines to ± .76 mm
and effective manner.
(.03 in)
3. Distance to equal half of total travel 2. Size the fuel tank for the maximum expected full-
4. 2° +/- 1° load engine operation period with the initial fuel
Figure 3-1 Drive Shaft Alignment level at the minimum level for refueling.

3. Install a fuel return line and route this line to the

bottom of the fuel tank in order to minimize the
return head.

4. Install a fuel supply line to the fire pump drive

engine.

NOTE: For fuel line specifications, refer to the Engine

Data Sheet in Section 7 - Component Parts and
Assemblies.

NOTE: DO NOT use copper or galvanized pipe for

the fuel return or supply lines.

The fire pump drive engine fuel system has been

CFP-015
CFP-015 primed during manufacturing and test procedures.
The engine is equipped with an engine driven (gear)
Figure 3-2 Drive Shaft Universal Joint Grease Fit-
fuel pump.
tings
An optional fuel pre-filter and a fuel filter/water sep-
NOTE: Cummins recommends using a good quality
arator is integrated into the fuel delivery system of the
semi-synthetic, molybdenum-fortified National Lubri-
fire pump drive engine. To ensure that the filter/sep-
cating Grease Institute (NLGI) #2 lithium complex arator is free of water, open the fuel filter/water sep-
grease. arator drain at the bottom of the filter and drain the
fuel into a container until no water is present. Dispose

3-2 Cummins Fire Pump Drive Engine CFP59

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 Installation
of the contaminated fuel in accordance with local IMPORTANT: The manual water valves for the auto-
environmental regulations. matic loop should remain OPEN at ALL times. The
manual valves for the bypass loop should be
CLOSED during automatic (pump controller) opera-
CAUTION tion. When running, the engine should stabilize
Due to the precise tolerances of diesel injection between temperatures identified on the Engine Data
systems, it is extremely important that the fuel be Sheet. The flow rate may need to be adjusted to
kept clean and free of dirt or water. Dirt or water in maintain the desired engine temperature.
the system can cause severe damage to both the
fuel pump and the fuel injectors. NOTE: Excessively cold (4 °C to 23 °C [40 °F to 75
°F]) cooling water flow can cause condensation
inside the charge air cooler.
WARNING
Do not mix gasoline, alcohol, gasohol, ethanol, or IMPORTANT: Continuous operation with low coolant
methanol with diesel fuel. This mixture will cause temperature (below 70 °C [158 °F]) or high coolant
severe engine damage or explosion. temperature (above 107 °C [225 °F]) can damage the
engine.
CAUTION 3. Adjust the cooling water based on the water flow
Use ONLY no. 2 diesel (ASTM no. 2D) fuel. Any rather than the water pressure. The flow is
fuel other than no. 2 diesel fuel may affect emis- dependent on the cooling water temperature.
sion levels. Any adjustment to compensate for Refer to the Engine Data Sheet in Section 7 -
reduced performance with a fuel system using Component Parts and Assemblies for details.
alternate fuel is not warrantable.
4. To measure the water flow, use an appropriate-
3.6 Cooling Water Supply Installation sized container to measure the amount of water
and the elapsed time of the water to flow from
IMPORTANT: The cooling water supply must be
the discharge pipe and then formulate the calcu-
immediately available when the engine is started.
lations:
Ensure that the supply line valves are in the OPEN
position.
Flow rate = container size/ time to fill container.
NOTE: The flow rate of the cooling water should be
Example:
as great as possible without exceeding the maximum
allowable pressure shown in the Engine Data Sheet Time to fill a 20 gallon container = 15 seconds.
in Section 7 - Component Parts and Assemblies.
20 gallons divided by 15 seconds = 1.33 gallons per
second.
To install the cooling water supply:
Multiply by 60 seconds = 80 gallons per minute (gpm)
1. Provide a cooling water discharge line at the out- (FLOW RATE)
let of the engine coolant heat exchanger and
provide a cooling water supply line to the cooling
water inlet per the Engine Data Sheet in Section 5. Adjust both pressure regulators to a pressure
7 - Component Parts and Assemblies. that will provide a flow rate at or above the spec-
ifications listed in the Engine Data Sheet.
NOTE: The cooling water outlet piping from the heat
exchanger should be one pipe size larger than the
supply piping. CAUTION
When the cooling water piping is installed, adjust
2. Check the pressure regulator setting on the both of the pressure regulator set points before
cooling loop with water flowing through the heat operating the pump. Damage to the heat
exchanger. The cooling loop is supplied by Cum- exchanger may occur from improperly regulated
mins; both water pressure regulators have been cooling water supply pressure.
set at 207 kPa (30 psi) (or slightly less) water
pressure during manufacture and testing.

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Installation
IMPORTANT: Monitor the oil pressure and coolant IMPORTANT: Batteries must meet the requirement
temperature gauges frequently. Refer to Lubricating listed in the electrical system specifications. Batteries
Oil System Specifications or Cooling System Specifi- may be supplied by Cummins as an option, or may be
cations in the Engine Data Sheet in Section 7 - Com- supplied by the customer.
ponent Parts and Assemblies for recommended
operating pressures and temperatures. Shut off the To properly install the batteries:
engine if any pressure or temperature does not meet
the specifications. 1. As shown in Figure 3-3 or Figure 3-4, install the
NOTE: Maximum engine coolant temperature should Battery Cable Kit or equivalent customer-sup-
not exceed the temperature listed on the Engine Data plied wiring. Install battery sets in a well-venti-
Sheet found in Section 7 - Component Parts and lated or otherwise protected location.
Assemblies. The coolant expansion pressure/fill cap
must meet the minimum pressure of 10 kPa (15 psi).
WARNING
The engine coolant system contains a mixture of at Batteries can emit explosive gases during
least 50% antifreeze and 50% water. The coolant charging. Always ventilate the compartment
level should be maintained so it is visible in the before servicing the batteries. To avoid arcing,
coolant level sight gauge. remove the negative (-) battery cable first and
attach the negative (-) battery cable last.
3.7 Battery Installation
The minimum recommended Society of Automotive
Engineers (SAE) reserve capacity (RC) and SAE cold
cranking ampere (CCA) values for a particular engine
can be found on the Engine Data Sheet in Section 7 -
Component Parts and Assemblies. RC and CCA defi-
nitions can be found in SAE Standard J537. Refer to
NFPA 20 and FM 1333 standards for additional
battery installation information.

WARNING
Battery electrolyte (sulfuric acid) is highly caustic
and can burn clothing and skin. Wear impervious
neoprene gloves and safety goggles, or a full face Figure 3-3 Series Battery Connection 12 VDC
shield, when working with the batteries.

Figure 3-4 Series Battery Connection 24 VDC

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 Installation
2. Provide adequate room for servicing or replacing
the batteries. Provide protection from extremes
of temperature and weather.

3. Locate the batteries near the engine or increase

the size of the conductors as required by appli-
cable codes. Ensure that the batteries are con-
figured properly for 12 - or 24 - VDC standard
operations.

4. Check the battery cables and connections.

NOTE: Coat the terminals with petroleum jelly to

prevent corrosion. Install the cables and tighten the
battery connections.

3.8 Signal and Control Installation

The fire pump controller wires must be connected to
the terminal blocks (TBs) on the FPDP Interface Ter-
minal Strip and on the Battery Charger Interface. To
complete the signal and control installation:

1. Ensure that the fire pump controller is properly

installed and configured per the manufacturer’s
instructions.

2. Complete the fire pump controller wiring (cus-

tomer-supplied) per the manufacturer’s instruc-
tions.

3. Ensure electrical continuity and adequate insula-

tion resistance for the installed wiring. Refer to
Section 4.3.1.1 Engine Setup Screen to conduct
a Terminal Block Test from the FPDP.

3.8.1 FPDP Interface Terminal Strip

As shown in Figure 3-5, the TBs between the fire
pump controller and the fire pump driver are standard
UL and FM controller terminals and follow a direct
one-to-one correspondence (some TBs are optional):

a. TB-1 [Run Solenoid Circuit]: This B+ signal Thermocouple Input

is necessary for fire pump operations while in
the FPDP is in AUTO mode. The Electronic
Control Module (ECM) keyswitch/Fuel Shut-
off (FSO) and raw water solenoid are acti- Figure 3-5 FPDP Interface Terminal Strip
vated when voltage is present at TB-1. When
TB-1 is removed while the engine is running,
the FPDP will command electronic engines to
idle for up to three minutes.

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Installation
b. TB-2 [Crank Termination Switch]: This B+ k. TB-304 [ECM Failure]: Not applicable to
signal is provided by the FPDP to inform the mechanical engines.
pump controller that the engine is running.
Crank Termination indicates that the engine l. TB-305 [Custom Output 1]: A ground path is
has started and that the crank command from provided by the FPDP when the custom
the fire pump controller should stop immedi- alarm is configured and activated.
ately.
NOTE: If an Air Shutoff Valve is purchased, TB-305 is
c. TB-3 [Overspeed Switch]: This B+ signal is reserved for valve position feedback.
provided by the FPDP when the engine
speed has exceeded 115% of the rated m. TB-306 [Custom Output 2]: A ground path is
engine speed. When overspeed occurs, the provided by the FPDP when the custom
ECM keyswitch or FSO outputs and the raw alarm is configured and activated.
water cooling loop solenoid are immediately
deactivated in an attempt to stop the fire n. TB-307 [Custom Output 3]: A ground path is
pump drive engine. The FPDP will not allow provided by the FPDP when the custom
the engine to be restarted until after the over- alarm is configured and activated.
speed alarm has been reset.
o. TB-310 [Raw Water High Inlet Tempera-
d. TB-4 [Low Lubricant Pressure Switch]: A ture] - not applicable on radiator-cooled
ground path is provided by the FPDP when models: A ground path is provided by the
the oil pressure has dropped below the 16 psi FPDP when high raw water temperature is
(110 kPa) set point when the engine is run- sensed.
ning. A ground path is also provided to indi-
cate low oil pressure when the engine is NOT p. TB-311 [Clogged Raw Water Coolant Loop
running. Strainer] - not applicable on radiator-cooled
models: A ground path is provided by the
e. TB-5 [High Engine Temperature Signal]: A FPDP when the raw water supply restriction
ground path is present when the engine is is sensed.
running and the coolant temperature is at or
above 212 °F (100 °C). q. TB-312 [Low Engine Temperature Signal]:
A ground path is provided by the FPDP when
f. TB-9 [Main Battery Contactor One Coil or the engine coolant falls below 100 °F (37.8
Battery Relay One Coil]: This B+ signal is °C).
driven from the fire pump controller to contac-
tor A when desiring to crank the engine from r. Type K Thermocouple Input - optional: The
Battery A. Current in this circuit shall not screws to the Type K thermal couple input
exceed 10A continuous. may be loosened for installation of an
exhaust temperature.
g. TB-10 [Main Battery Contactor Two Coil or
Battery Relay Two Coil]: This B+ signal is 3.8.2 Battery Charger Interface
driven from the fire pump controller to contac- As shown in Figure 3-6, the Battery Charger Interface
tor B when desiring to crank the engine from provides power to the fire pump controller, as well as
Battery B. Current in this circuit shall not provides charging current to the fire pump drive
exceed 10A continuous. engine batteries. The Battery Charger Interface
includes:
h. TB-301 [ECM Switch]: Not applicable to
mechanical engines. a. TB-6 [Battery A Positive]: The fire pump
controller senses Battery A charge state and
i. TB-302 [Fuel Injection Malfunction (FIM)]: charges Battery A through TB-6.
Not applicable to mechanical engines.
b. TB-8 [Battery B Positive]: The fire pump
j. TB-303 [ECM Warning]: Not applicable to controller senses Battery B charge state and
mechanical engines. charges Battery B through TB-8.

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 Installation
c. TB-11 [Battery A and Battery B Negative]: 1. Inspect the engine coolant hoses and hose
The fire pump controller uses TB-11 as a clamps and ensure that all coolant hoses and
ground reference for incoming power, as well clamps are properly installed and water tight.
as to charge the fire pump drive engine bat-
teries. 2. Ensure that the engine coolant heater maintains
an engine coolant temperature of 49 °C (120 °F)
or above.

3. Ensure that coolant is present in the engine

coolant heater before plugging the heater
element into a dedicated circuit.

WARNING
Do not remove the pressure/fill cap from a hot
engine. Wait until the coolant temperature is
below 50 °C (122 °F) before removing the pres-
sure/fill cap. Heated coolant spray or steam can
cause personal injury.

3.10 Charge Air Cooler (CAC) Inspection

The charge air cooler (CAC) system reduces the tem-
perature of the compressed combustion air from the
Figure 3-6 Battery Charger Interface turbocharger before entering the air intake manifold.

NOTE: This is not intended to create a fully isolated Inspect the CAC piping and hoses for loose/missing
battery negative or ground system. Current in each hose clamps, hose punctures, leaking manifold seals,
terminal block shall not exceed 30A continuous. or corrosion. Torque the hose clamps to the recom-
mended torque value. Refer to the Engine Data
To complete the battery signal connections: Sheet in Section 7 - Component Parts and Assem-
blies.
1. Provide the initial charge on the redundant bat-
teries per the battery charger’s instructions. 3.11 Lubricating Oil System Preparation
The fire pump drive engine and turbocharger were
2. Check that both voltmeters on the FPDP indicate
initially lubricated during manufacture and testing. To
the approximate battery voltage.
prepare the lubricating oil system for operation:
NOTE: Both sets of batteries can be used for starting
1. Check the oil level using the dip stick before
the engine in the event that one set is low.
operating the fire pump drive engine.

3.9 Coolant System Preparation 2. Fill the oil fill port to the “H” mark on the dipstick
The fire pump drive engine cooling and lubrication with lubricating oil.
system was initially filled during manufacture and
testing. To properly prepare the coolant system: NOTE: 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 used during normal
CAUTION operation.
Ensure that all coolant systems have been filled
to the proper level before operation by checking
the coolant level sight gauge on the heat CAUTION
exchanger. Some regulatory and shipping restrictions may
require that all lubricants, fuels, and coolants be

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Installation
drained for transport. Ensure that all cooling and
lubrication systems have been filled to the proper WARNING
level before operation. Before operating the equipment, complete all
safety checks, remove all tools and foreign
NOTE: Using multi-viscosity lubricating oil can objects from the equipment, and ensure that all
improve oil consumption control and improve engine guards are in place and securely fastened. Alert
cranking in cold temperatures while maintaining lubri- area personnel that the equipment will be start-
cation at high operating temperatures. Cummins Inc. ing. Unintentional equipment start-up or contact
recommends Premium Blue® 15W-40 oil for most cli- with exposed or moving components can cause
mates. personal injury or equipment damage.

CAUTION CAUTION
Ensure that all cooling and lubrication systems If the oil pressure is not displayed on the gauge
have been filled to the proper level before opera- or if the low oil pressure message is displayed
tion. within fifteen seconds, STOP THE ENGINE IMME-
DIATELY! Continued operation without proper
IMPORTANT: Cummins recommends that provisions lubrication will cause engine damage.
be made within the VSPLC connection line to account
for any engine vibration and movement.
3.13 Engine Monitoring
3.12 Pre-Start Inspections When the engine starts, it is important to monitor the
displays:
Prior to starting the fire pump drive engine for the first
time, perform a visual inspection: 1. Immediately check that water flow is established
through the coolant heat exchanger. The water
1. Check that there is no apparent damage and flow should be established immediately, but
that all components are installed. some delay may occur before the flow exits the
heat exchanger drain connection.
2. Check that the drive belt is properly installed.
NOTE: Ensure that cooling water is flowing through
3. Check that all hoses and tubes are properly the heat exchanger and the water pressure shown on
installed. the local pressure gauge is no more than 414 kPa (60
psi). The minimum cooling water flow rate is identified
4. Check that all electrical connections are properly in the Engine Data Sheet in Section 7 - Component
installed. Parts and Assemblies.
5. Check that the fire pump drive engine is properly 2. Ensure that the engine operating temperature
installed per the pump manufacturer’s instruc- stabilizes between applicable ranges as identi-
tions, is correctly aligned, and is free to rotate. fied in the Engine Data Sheet in Section 7 -
Component Parts and Assemblies.
6. Lubricate the grease fittings on the axillary drive
shaft. 3. Operate the engine for eight to ten minutes.
NOTE: Use the same type of oil as used in normal 4. Inspect the engine for leaks, unusual noises, or
operation. Cummins Inc. recommends Premium other indications of incorrect operation.
Blue® 15W-40 oil for most climates.
5. Shut off the engine by pressing and holding the
After completing preliminary set-up procedures, overspeed RESET/STOP switch.
perform the engine start test as outlined in detail in
Section 4 - Operation. 6. Shortly after the engine stops, check that the
water flow stops automatically.

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 Installation
7. Correct any problems found during the inspec- 11. Perform engine speed control and safety system
tion before proceeding. tests per the instructions in Section 4 - Opera-
tion.
8. Check the engine lubricating oil level at the dip
stick. Add oil, if necessary. 3.14 Field Acceptance Testing
The required installation tests are outlined in the
9. Check the coolant expansion tank level. Add NFPA 20 Standards and shall be performed to vali-
coolant, if necessary. date automatic and manual operational requirements
for field acceptance testing.
10. Check the cooling water strainers. Clean the
strainers according to the maintenance schedule NOTE: The maximum engine speed should only be
in Section 5 - Maintenance. altered by a Cummins technician.

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 Section 4 - Operation
4.1 Introduction The engine may be stopped locally by pressing the
This section outlines general operating information RESET/STOP switch on the FPDP or by holding
for starting and stopping the fire pump drive engine, down the red Engine STOP button on the left side of
as well as instructions for navigating the menu the FPDP.
screens of the Fire Pump Digital Panel (FPDP). This
manual is provided for your equipment and should be NOTE: Upon release of the Engine STOP Button, the
considered a part of that equipment. All personnel fire pump drive engine will attempt to restart, If there
responsible for the operation and maintenance of the is still a “pump on demand” signal present from the
equipment should read and thoroughly understand FPDP. The engine must also be stopped at the fire
this manual. pump controller.

4.2.2 Emergency Starting/Stopping Procedure

WARNING The engine will start automatically in the event of a
fire emergency. However, if it fails to start automati-
Before preparing the equipment for normal ser-
cally, the engine can be started locally. The following
vice, complete all safety checks, remove all tools
procedure outlines an emergency manual mode
and foreign objects from the equipment, ensure
electrical start:
all guards are in place and securely fastened, and
alert area personnel that the equipment will be 1. As shown in Figure 4-1, open the water bypass
starting. valves in the cooling water supply piping or the
emergency cooling supply.
4.2 Starting and Stopping Procedures
By default, the fire pump drive engine will turn on
automatically when low system water pressure is
sensed by the pump controller. The engine will con-
tinue to operate as long as TB-1 is active. When the
TB-1 signal is terminated by the fire pump controller,
the engine will stop or enter a cool down procedure
by lowering the engine speed.

For testing purposes, the fire pump drive engine can

be turned on and off locally using the buttons on the
FPDP (see Figure 2-3), If the engine fails to start
automatically in the event of a fire emergency, follow
the Emergency Starting/Stopping Procedure outlined
Figure 4-1 Fire Pump Drive Engine Bypass Valve
in Section 4.2.2.
2. Press the AUTO/MAN mode switch on the FPDP
4.2.1 Local Starting/Stopping Procedure
to place the engine in MANUAL mode.
To start the engine locally from the FPDP:

1. Press the AUTO/MAN selector switch on the 3. As shown in Figure 4-2, open the FPDP panel
FPDP to place the engine in manual mode. door and slide the key switch override to the
“RIGHT” position. Verify that LED 49 - KEY FB
2. Press the CRANK BATT A and/or CRANK BATT (key feedback) switch is lit.
B button to crank the engine.

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Operation
.

Figure 4-2 FPDP Override Switch

CAUTION
To prevent damage to the starter, do not engage
the starting motor more than fifteen seconds.
Wait fifteen seconds between each attempt to
start, up to six attempts.
2
4. As shown in Figure 4-3, press downward on
either the Battery A or Battery B contactor lever
to start the engine. If crank contactor lever A
does not engage the starter, repeat using crank 1
contactor lever B. If the battery charge is low,
press downward on both battery contactor levers
at the same time. Release the contactor lever
immediately after the engine starts.

IMPORTANT: If the engine does not start after three

attempts, check the fuel supply system. Absence of
blue or white exhaust smoke during cranking indi-
cates that no fuel is being delivered.
Battery Contactor Levers

1. Battery A Starter Contactor

2. Battery B Starter Contactor
Figure 4-3 Manual Starter Contactors

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 Operation
5. Check that the engine starts and operates at the
rated speed.

NOTE: Engine oil pressure must be indicated on the

gauge within fifteen seconds after starting.

The engine may be stopped locally by pressing the

RESET/STOP button on the FPDP or by holding
down the red ENGINE STOP button on the left side of
the FPDP.

NOTE: Upon release of the Engine STOP Button, the

fire pump drive engine will attempt to restart, If there
is still a “pump on demand” signal present from the
FPDP. The engine must also be stopped at the fire
pump controller. If the fuel solenoid does not open,
then use the fuel solenoid override located above the
fuel pump. Turn the fuel solenoid handle counter-
clockwise to unlock and then pull the handle to run
the fire pump drive engine. Turn the handle clockwise Figure 4-4 FPDP User Interface Screen (Typical)
to lock the fuel solenoid. To stop the fire pump drive
engine, turn the fuel solenoid counter-clockwise and NOTE: Electronic engines display tachometer, engine
push the handle in. temperature and oil pressure values from J1939.
Mechanical engines display parameters via sensors
4.3 Fire Pump Digital Panel (FPDP) added by Cummins.
Screens and Adjustments in Automatic
NOTE: When the key switch is not on, the coolant
Mode temperature defaults to “0 °F” (or “0 °C”) and the oil
As shown in Figure 4-4, the FPDP consists of a pressure defaults to “0 PSI” (or “0 kPa”).
Liquid Crystal Display (LCD) touchpad that displays
the fire pump drive engine tachometer, coolant tem- The FPDP LCD will go into SLEEP MODE after
perature, oil pressure, Battery A voltage, Battery B fifteen minutes of inactivity by the user. The FPDP
voltage and hour meter, as well as includes two soft LCD will resume normal display features when the
keys: user presses a hard button or touches the LCD
screen.
• MENU Soft Key
4.3.1 The MENU Soft Key
• SCREEN Soft Key If the operator presses the MENU Soft Key from the
FPDP User Interface Screen, the Settings Menu
Screen appears as shown in Figure 4-5.

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Operation
Press SUBMIT to access the Engine Setup screen,
shown in Figure 4-7.

Figure 4-5 Settings Menu Screen (Typical)

The Settings Menu provides options for further opera-
tor input and monitoring of fire pump drive engine Figure 4-7 Engine Setup Screen (Typical)
parameters. Press the corresponding soft key to
access a sub-menu. As shown in Figure 4-8, the System Options sub
menu displays the custom configurations of the fire
4.3.1.1 ENGINE SETUP Screen - SYSTEM pump drive engine. When active, the soft buttons turn
OPTIONS green in color and display “ON.” Conversely, the soft
The fire pump drive engine was preconfigured with button will turn red in color and display “OFF”, if the
custom options (if applicable) at the factory prior to feature is disabled.
shipping to the customer. The System Options screen
provides a view of the custom configuration that has
been set up for your fire pump drive engine. The

Cummins Service Department must be notified if any

of these parameters are adjusted in the field.

As shown in Figure 4-6, press the soft number keys

to enter password 806 in the Engine Setup Login
screen.

Figure 4-8 System Options Screen (Sample)

The custom options of the System Options submenu

include:

DPEM – When active, the FPDP initiates communica-

tions with the Digital Panel Expansion Module
(DPEM).

Figure 4-6 Engine Setup Login Screen (Typical) Overspeed Shutdown – When active, the FPDP
shuts the engine fueling off when the engine speed

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 Operation
reaches or exceeds 115% of the configured rated
speed.

Cooling Loop – When active, the FPDP will monitor

and diagnose the cooling loop parameters.

IMPORTANT: The COOLING LOOP System Option

shall be enabled for FM-approved fire pump drive
engines.

Cooling Loop Sensor – The Gen II FPDP is config-

ured for two different sensors, a three-terminal 0-5V
sensor labeled “Cummins” and a single post-resistive
sensor labeled “Datcon”. When active, the applicable
soft key will display in green.
Figure 4-9 Terminal Block Test Screen (Sample)
IMPORTANT: The COOLING LOOP SENSOR
System Option must match the cooling loop sensor
installed on the engine for proper decoding and To perform a Terminal Block Test:
alarming of cooling loop parameters. Ensure that the 1. Starting at the User Interface Screen (Main
toggle switch on the FPDP Interface Terminal Strip Menu), press the MENU Soft Key;
also matches the cooling loop sensor System Option.
2. Press the ENGINE SETUP soft key from the
Loop Alarm Temp (F) – When active, the display Settings menu;
shows the alarm setpoint for the raw water tempera-
ture entering the cooling loop. When the cooling loop 3. Press the TERMINAL BLOCKS soft key from the
is disabled, the alarm will show “XXX”. Engine Setup menu;

Loop Alarm Pres (PSI) – When active, the display 4. Press the soft key corresponding to the terminal
shows the alarm setpoint for diagnosing a clogged block requiring verification;
raw water strainer in the cooling loop. When the
cooling loop is disabled, the alarm will show “XXX”. NOTE: If the selected terminal block soft key turns
green, but the pump controller alarm does not acti-
4.3.1.2 ENGINE SETUP Screen - TERMINAL vate, troubleshoot the terminal block connection for a
BLOCKS B+ or ground signal (see Section 3.8 - Signal and
The TERMINAL BLOCKS sub menu provides a con- Control Installation) or contact your local Cummins
venient means of checking the signal integrity Sales and Service representative.
between the fire pump controller and the terminal
block interface inside the FPDP. 5. To exit the Terminal Block Test menu, press the
RETURN soft key.
As shown in Figure 4-9, any of the signals on the ter-
minal block interface can be manually activated by NOTE: There is currently no diagnostic implemented
pressing the respective red soft key. When the button into the firmware to alert the user of a latched overrid-
turns green, the signal is active. den value via the Terminal Block Test screen.

4.3.1.3 Overspeed Test Screen

As shown in Figure 4-10, the Overspeed Test Screen
allows the operator to simulate an overspeed
shutdown for all engine models:
1. Starting at the User Interface Screen (Main
Menu), press the MENU Soft Key;

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Operation
2. Press the OVERSPEED TEST soft key from the To change the displayed units of measurement:
Settings Menu; and then
1. Starting at the User Interface Screen (Main
3. Press the SIMULATE soft button. Menu), press the MENU Soft Key;

4. “ENGINE OVERSPEED” written in red will flash 2. Press the IMPERIAL/SI VALUES soft key from
at the top of the FPDP screen. the Settings Menu;

3. Press the soft key for the desired unit of mea-

sure; and

4. Press the SUBMIT soft key.

5. To exit the Imperial/SI Values menu, press the

RETURN soft key.

4.3.1.5 Analog Values Screen

The Analog Values Screen shown in Figure 4-12 pro-
vides the information that is displayed on the Main
Screen - as well as additional information - in a digital
format. The Analog Values Screen can assist in trou-
bleshooting the cooling loop by identifying issues with
the pressure sensors. The additional information
Figure 4-10 Overspeed Test Screen (Sample)
includes:
5. Press the RESET/STOP Switch on the FPDP to
• Exhaust Temp - the exhaust temperature;
reset the fire pump drive engine.
IMPORTANT: A thermocouple must be purchased
4.3.1.4 Imperial/SI Values Screen
and installed from Cummins in order for exhaust tem-
The Imperial/SI Values Screen, shown in Figure 4-11, perature values to display.
allows the operator to select Imperial or Système
Internationale (SI) (also known as metric) units of NOTE: For exhaust temperature values less than
measurement. The default units of measure are 200 °F (93 °C) or not monitored, the value will be
Imperial units of degrees in Fahrenheit and pounds displayed as 0°.
per square inch (PSI).
• Diff Press Pre - the actual pressure value of the
cooling loop pressure transducer before the
strainer; and

• Diff Press Post – the actual pressure value of the

cooling loop pressure transducer after the
strainer.

Figure 4-11 Parameter Units Screen (Typical)

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Figure 4-12 Analog Values Screen (Sample)

Figure 4-13 DPEM Screen (Sample)
To view the information about the fire pump drive
engine in digital format: To exit the DPEM Screen, press the RETURN soft
key.
1. Starting at the User Interface Screen (Main
Menu), press the MENU Soft Key; and Additionally, there are two other ways to alert the
operator of a DPEM fault:
2. Press the ANALOG VALUES soft key from the
Settings Menu. From the FPDP - As shown in Figure 4-14, the
warning symbol will illuminate and the overlay will
3. To exit the Analog Values menu, press the activate in yellow with the text of the active fault
RETURN soft key.

NOTE: The display choice of Imperial or SI values is

made using the Imperial/SI Values Screen.

4.3.1.6 DPEM Screen (Optional)

As shown in Figure 4-13, the DPEM Screen displays
the function name, status, alarm setpoint, and relay
associated with the alarm (if applicable) of any
custom inputs that are configured on the fire pump
drive engine. When an analog input parameter
crosses the alarm setpoint or a switched input is
active, all information associated with that parameter
will turn red in color. To access the SDPEM Screen:

1. Starting at the User Interface Screen (Main

Menu), press the MENU Soft Key; and
Figure 4-14 DPEM Fault Screen (Sample)
2. Press the DPEM soft key from the Settings
Menu. From the DPEM/remote location - The terminal
block interface inside of the DPEM has been created
for connection to monitor alarms remotely. There is
an LED next to each terminal block that will also illu-
minate if the relay is commanded closed. Each set of
four relays has a common dry contact associated for
integration flexibility:

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Operation
• Terminal Blocks 13-16 (R1-R4) are dedicated to deactivate the Fault overlay, press the SCREEN Soft
switched inputs, with TB-17 being the common Key to make the overlay disappear from the LCD.
contact
Figure 4-16 shows the location of the Analog Values
• Terminal Blocks 18-21 (R5-R8) are dedicated to overlay when you press the SCREEN Soft Key. The
temperature inputs, with TB-22 being the com- Analog Values overlay background color displays in
mon contact gray.

• Terminal Blocks 23-26 (R9-R12) are dedicated

to pressure inputs, with TB-27 being the com-
mon contact

• Terminal Blocks 28-31 (R13-R16) are dedicated

to additional pressure inputs or J1939 setpoints,
with TB-32 being the common contact.

As shown in Figure 4-15, “DPEM Lost” will appear on

the FPDP HMI if communications between the FPDP
and DPEM are compromised.

Figure 4-16 SCREEN Soft Key Analog Values

Overlay (Sample)

To activate the overlay to display a list of analog

values for the fire pump drive engine, press the
SCREEN Soft Key. Additional values that may be dis-
played include:

• Exhaust temperature (when a pyrometer is

installed and landed to the Power Board).

Figure 4-15 DPEM Lost Fault Screen (Sample) • Cooling loop raw water temperature and strainer
status on FM-approved and UL-listed fire pump
4.3.2 The SCREEN Soft Key drivers.
The SCREEN Soft Key, on the bottom right of the
• J1939 parameters are not available on mechani-
LCD, deactivates and activates an overlay box which
cal engines. The oil temperature, intake manifold
lies atop the tachometer signal (the engine speed is
temperature, and intake manifold pressure val-
still digitally displayed). The overlay is used to:
ues display as “NWF.”
• Automatically - Warn the operator of ECM and/or
To deactivate the Analog Values overlay, press the
DPEM faults, when applicable (see Section
SCREEN Soft Key to make the overlay disappear
4.3.1.5 Analog Values Screen); and/or
from the LCD.l
• Operator-selected - Display additional analog
values not required by NFPA 20.

The overlay background color will display in gray,

unless there is an active fault present. Fault overlays
will display in the color of the most severe fault. To

4-8 Cummins Fire Pump Drive Engine CFP59

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 Section 5 - Maintenance
5.1 Introduction 5.2 Engine Operation Reports
Before performing maintenance procedures, read The engine must always be maintained in top
and understand Section 1 - Safety of this manual. mechanical condition. Proper maintenance of the fire
Improper performance or lack of critical information pump drive engine requires documenting regular
could result in personal injury or equipment damage. running reports to include the following:

Cummins encourages our customers to perform • Low engine oil pressure.

maintenance and repairs whenever necessary.
However, servicing complex components within the • Engine surge.
normal warranty period may void the Cummins war-
ranty and any specified warranty extended by the • Erratic operation or frequent shutdowns.
manufacturer of Original Equipment Manufacturer
(OEM) products. See the warranty information at the • Any warning lamps flashing or staying illumi-
beginning of this manual. nated.

Maintenance procedures should be performed by • Abnormal coolant or oil temperature.

skilled technicians who are familiar with the equip-
ment, local regulations, and service procedures for • Unusual engine noise or vibration.
fire pump drive engine and pump systems. Improper
maintenance can damage the engine or the fire pump • Excessive smoke.
drive engine, or cause severe personal injury.
• Excessive use of coolant, fuel, or engine oil.
The National Fire Protection Association (NFPA) 25
Standard outlines the maintenance tests to be per- • Any fluid leaks.
formed to validate automatic and manual operational
requirements for field acceptance testing. • Loose, worn, or damaged parts.

Cummins recommends that the engine be maintained The weekly running report also helps to make
according to the Cummins Operation and Mainte- provisions for more extensive maintenance, as the
nance Manual for that engine family. reports indicate the necessity.

NOTE: If your engine is equipped with a component The Fault Codes displayed on the Fire Pump Digital
or accessory not manufactured by Cummins Inc, refer Panel (FPDP) assist in recording operation irregulari-
to the component manufacturer’s vendor supplied ties. See Section 6 - Troubleshooting for a listing of
literature for specific maintenance recommendations. Fault Codes.

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Maintenance

Maintenance Chart
Task Period Page

Weekly Maintenance
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Air Cleaner Filter and Piping . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.4 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.6 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.7 Electrical Supply and Controls . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.8 Crankcase Ventilation Hose . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.9 Cooling Water Strainers . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.10 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.11 Engine Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.12 Engine Operation Checks . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.13 Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Annual Maintenance
6.4.1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.2 Turbocharger Mounting Nuts . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.3 Engine Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.4 Fuel Pumps and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . per Cummins Engine Operation and Maintenance Manual . . 6-10
6.4.5 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . per Cummins Engine Operation and Maintenance Manual . 6-11
6.4.6 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.7 Coolant Pump/Alternator Belt . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.8 Raw Water Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.9 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.10 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Every 2 Years or 2000 Hours

6.5.1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Every 4 Years or 5000 Hours

6.6.1 Coolant Thermostat Removal/Installation . . . . . . . . . . 4 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.6.2 Coolant Pump/Alternator Belt Replacement . . . . . . . . 4 Years. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.6.3 Charge Air Cooler (CAC) Heat Exchanger . . . . . . . . . 4 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

NOTE: All maintenance and inspections intervals are accumulative. When performing annual maintenance,
also perform maintenance listed under daily, weekly, monthly, and three month intervals.

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 Maintenance

Maintenance Record Form

Table 5-1.

Engine Serial Number: Engine Model:

Owner’s Name: Equipment Name/Number:

Hours or Time Check

Date Actual Hours Performed By Comments
Interval Performance

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Maintenance
5.3 Weekly Maintenance NOTE: Cummins recommends using an air cleaner
When the engine is running, be alert for mechanical filter element as listed on the Engine Data Sheet in
problems that could create unsafe or hazardous con- Section 7 - Component Parts and Assemblies.
ditions.

5.3.1 General CAUTION

Each week, a general walk-around inspection should Never operate the engine without an air cleaner.
include the following areas: Intake air must be filtered to prevent dirt and
debris from entering the engine and causing pre-
1. Check fluid levels before starting the engine. mature wear. Dirt or foreign objects could cause
Check oil pressure and coolant temperatures engine damage.
frequently. Most engine problems give an early
a. If the red indicator flag is at the raised posi-
warning.
tion in the window, clean or replace the air fil-
ter per the manufacturer’s recommendation
2. Look and listen for changes in engine perfor-
as required. Do not remove the felt washer
mance, sound, or appearance that will indicate
from the indicator. The felt washer absorbs
that service or repair is needed. Be alert for mis-
moisture.
fires, vibration, excessive exhaust smoke, loss
of power, or increases in oil or fuel consumption.
b. After the air cleaner has been serviced, push
the flag in to reset the service indicator.
3. Check the engine appearance for excessive
heat, wiring short circuits, excessive end-play,
IMPORTANT: See the Engine Data Sheet in Section
vibrations, excessive wear, excessive abrasion,
7 - Component Parts and Assemblies for maximum
damaged electrical wiring, or loose electrical
intake air restriction.
wiring.
2. Check for corrosion under the clamps and hoses
4. Check the engine for odors of diesel fuel,
of the intake system piping. Corrosion can allow
burning rubber, electrical system failure, exhaust
corrosive products and dirt to enter the intake
fumes, or smoke.
system. Disassemble and clean as required.

3. Replace any damaged air filter or hoses and

WARNING tighten loose clamps, as necessary, to prevent
Engine fuel is highly flammable and represents the air system from leaking. Torque the hose
an extreme hazard for fire or explosion when clamps to the recommended torque value. Refer
exposed to electrical sparks or open flame. Clean to the Torque Tables in Section 7 - Component
up spilled fuel immediately. Keep sources of elec- Parts and Assemblies.
trical spark or open flame away from a fuel
source. 5.3.3 Cooling System
5.3.2 Air Cleaner Filter and Piping
On a weekly basis, perform the following inspections:
CAUTION
Do not remove a coolant pressure/fill cap from a
1. Visually inspect the air intake filter and piping hot engine. Shut down the engine and wait until
daily for blockage, damage to piping, loose the coolant temperature is below 50 °C (120 °F)
clamps, or punctures that can allow debris to before removing the pressure cap. Heated
enter the engine. If there is a blockage, the ser- coolant spray or steam can cause severe per-
vice indicator will be activated. Refer to Figure sonal injury.
2-2.
On a weekly basis, perform the following inspections
on the cooling system:
NOTE: Turbocharged engines must be operated at
rated revolutions per minute (RPM) and full load to
1. Inspect the cooling water piping, coolant heat
check maximum intake air restriction.
exchanger tanks, charge air cooling system,

5-4 Cummins Fire Pump Drive Engine CFP59

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 Maintenance
engine coolant hoses, and hose clamps for 5.3.4 Engine Oil System
loose fittings, leaks, damage, and corrosion.
WARNING
a. Tighten the hose clamps as necessary. Perform the specific checks in this section only
after the engine is fully stopped. Unless tests
b. Check for cracks, holes, or other damage. require engine operation, disconnect the battery
Repair or replace as necessary. leads from the batteries (negative terminal first).
Contact with exposed or moving components can
cause severe personal injury.
CAUTION
Never use a sealing additive to stop leaks in the Inspect the engine oil system on a weekly basis fol-
cooling system. This can result in cooling system lowing these steps:
plugging and inadequate coolant flow, causing
the engine to overheat. 1. For accurate dipstick readings, shut off the
engine and wait approximately ten minutes to
2. With the coolant expansion tank at ambient tem- allow the oil in the upper portions of the engine
perature, press down, unscrew, and remove the to drain back into the crankcase.
pressure cap as shown in Figure 2-1.
2. As shown in Figure 5-1, check the oil level at the
a. Ensure that the coolant level is visible by engine dipstick.
checking the coolant level sight gauge.

b. Add coolant, as required. DO NOT OVER-

FILL!

NOTE: Supplemental engine coolant should be a

mixture of 50% ethylene glycol antifreeze and 50%
water to avoid engine damage.

3. Check the antifreeze concentration at least six

times a year or whenever coolant is added to the
cooling system by using a refractometer.

4. Drain a small amount of coolant from the return

line petcock and inspect the coolant for exces-
sive rust or particulate matter. Change the
coolant more frequently if particles are present.
CFP-046

CAUTION 1. Oil Fill Port (on valve cover)

Do not mix coolant brands or chemical solutions, 2. Oil Level Dipstick
as this could damage the cooling system. Keep a 3. Engine Oil Filter
record of the coolant concentration and manufac-
Figure 5-1 Oil Level Dipstick
turer with the engine maintenance records.

5. Check for soft, overly-pliant hoses, oxidation, a. If the oil level is greater than the high mark
and loose hose clamps. Torque the hose clamps (H), drain the excess oil and recheck the
to the recommended torque value. Refer to the level.
Torque Tables in Section 7 - Component Parts
and Assemblies. Replace damaged hoses and b. If the oil level is consistently below normal
clamps as required. after a fill, check for leaks, loose or damaged
gaskets, or oil in the coolant system. If the oil
6. Check the heat exchanger for leaks, damage, level is below the low mark (L), add the
and dirt buildup. Clean and repair as required. equivalent type oil.

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Maintenance
NOTE: Cummins recommends using Premium Blue 5.3.8 Crankcase Ventilation Hose
S.A.E. 15W-40 Multi-viscosity Lubricating Oil or Inspect the crankcase ventilation hose for wear,
equivalent. damage, sludge, blockage, or dirt buildup (refer to
Figure 2-1). Clean the ventilation hose, if obstructed
5.3.5 Fuel System or blocked. Replace a worn or damaged hose.

WARNING 5.3.9 Cooling Water Strainers

Engine fuel is highly flammable and represents As shown in Figure 5-2, the (two) cooling water
an extreme hazard for fire or explosion when strainers should be cleaned weekly to remove sedi-
exposed to electrical sparks or open flame. Clean ment.
up spilled fuel immediately. Keep sources of elec-
trical spark or open flame away from a fuel To clean the normal line strainer, ensure that the
source. normal line valves are closed and the bypass line
valves are open.
To inspect the fuel system:
To clean the bypass line strainer, ensure that the
1. Shut off the engine. bypass line valves are closed and the normal line
valves are open.
2. Inspect the fuel supply line, return line, filter and
fittings for cracks or abrasions. For each cooling water strainer:

a. Ensure the lines are not rubbing against any- 1. Remove the plug.
thing that could damage the fuel system
hoses. Repair any leaks or alter line routing 2. Inspect and remove any debris.
to eliminate wear immediately.
3. Install the strainer plugs.
b. Relieve fuel line pressure by carefully
loosening the fuel inlet line. 4. When finished, open the normal line valves and
close the bypass line valves for normal opera-
NOTE: Refer to the Engine Data Sheet in Section 7 - tion.
Component Parts and Assemblies for Cummins rec-
ommended replacement components.

5.3.6 Engine Exhaust System

With the engine operating, inspect the entire exhaust
system: exhaust manifold, exhaust flex pipe, muffler,
and piping.

Check for leaks at all connections, welds, gaskets,

and joints. Make sure that the exhaust pipes are not
heating surrounding areas excessively. Repair any
leaks immediately. 1

5.3.7 Electrical Supply and Controls 2

Check the terminals on the starting batteries for clean
and tight connections. Loose or corroded connections
create resistance which can hinder starting. Inspect
the FPDP harness connections to be sure they are
secure.
1. Bypass Water Line Strainer
2. Normal Water Line Strainer
Figure 5-2 Cooling Water Strainer (typical)

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 Maintenance
5.3.10 Batteries
WARNING
CAUTION Battery electrolyte (sulfuric acid) is highly caustic
Batteries can emit explosive gases during and can burn clothing and skin, or cause blind-
charging. To reduce the possibility of personal ness. Wear protective clothing, impervious neo-
injury, always ventilate the battery compartment prene gloves, safety goggles, or full-face shield
before servicing the batteries. when working with the batteries.

4. Check the electrolyte level in the batteries

CAUTION monthly. If low, fill the battery cells to the bottom
To reduce the possibility of arcing, remove the of the filler neck with distilled water.
negative (-) battery cable first and attach the neg-
ative (-) battery cable last. 5. Check for continuity between terminals using a
digital multimeter or other test equipment. Also
For proper weekly maintenance of the batteries: check the insulation resistance to ground.
Correct any electrical faults.
1. Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive. 6. Reinstall the battery cables; attach the negative
(-) battery cable last.
2. Use a battery hydrometer to check the specific
gravity of the electrolyte in each battery cell. A 5.3.11 Engine Test Run
fully-charged battery will have a specific gravity Start the engine at least once a week for a minimum
of 1.260. Charge the battery if the specific of thirty minutes with as much load as possible.
gravity reading is below 1.215. Periods of no-load operation should be held to a min-
imum, because unburned fuel tends to accumulate in
3. Check the battery wiring and cable connections the exhaust system. Refer to the operating instruc-
for loose, corroded, worn, or damaged cables. tions in Section 4 - Operation.
Check both connectors at the alternator, battery
connections, and engine grounding lug (near the Check that the engine starts and operates at the rec-
starter motor). ommended fire pump drive engine speed specifica-
tion and inspect the following:
a. If the battery cables are corroded, remove
the battery cable clamps, starting with the 1. Check that the engine oil pressure is indicated
negative (-) battery cable. on the gauge within fifteen seconds after start-
ing.
b. Use a fine emery cloth or a wire brush to
clean the cable clamps and battery cables. 2. Check that the engine has attained a normal
The metal should be shiny. running temperature after running the engine for
a minimum of thirty minutes.
c. Wash the battery terminals with a solution of
baking soda and water (2 oz (1/4 cup) baking 3. Observe that the engine is operating at the
soda to 0.94 liter (1 qt) of water). proper operating speed. (If the engine is not
operating at the proper speed, see Section
d. Be careful to prevent the solution from enter- 5.3.12 Engine Operation Checks.)
ing the battery cells, and flush the batteries
with clean water when done. 4. Check for unusual engine noise. Listen for any
unusual engine noise which can indicate that
e. After cleaning the connections, coat the ter- service is required.
minals with a light application of petroleum
jelly. 5. Ensure that the oil pressure is greater than 69
kPa (10 psi).
f. Reinstall and tighten the cable clamps.
6. Check that the coolant temperature is between
70 °C (158 °F) and 107 °C (225 °F).

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Maintenance
7. Check that both battery voltmeters indicate NOTE: The bolt on the right side of the bracket is for
12 VDC for standard or 24 VDC for optional maximum speed and may also need to be adjusted if
operating systems. the maximum speed cannot be attained. Loosen the
lock nut and turn the bolt counter-clockwise to
8. Check that the air filter service indicator has not increase speed. When the rated speed is correct,
popped-up, indicating an air filter blockage. tighten the lock nut against the stops.
Replace the air filter as required.
b. To decrease the speed, turn the bolt on the
End the test run by pressing and holding the over- left side of the throttle bracket counter-clock-
speed RESET/STOP switch until the engine stops. wise. The adjustment of the bolt will pivot the
throttle bracket counter-clockwise and allow
5.3.12 Engine Operation Checks less fuel through the pump to slow down the
The following service inspections ensure that the engine.
engine starts and operates properly under normal
conditions. c. When the rated speed is correct, tighten the
locking nuts against the stops.

WARNING 4. Stop the engine.

Before equipment operation, ALL guards, covers,
and protective devices MUST BE in place and 5. Repeat Steps 1 through 4 until the desired
securely fastened. Serious personal injury could speed is attained.
result from contact with exposed or moving com-
ponents.

5.3.12.1 Crank Termination Set Point

The speed switch crank termination set point is
factory-set at 600 RPM and should not be changed
from this value.

Engine Speed CalibrationIf required, use this

section to adjust the normal operating speed to the
nameplate value on the fire pump drive engine.

CFP59-F10, F20, F40, and F50 Speed Adjustment

To adjust the speed on CFP59-F10, F20, F40, and

F50 fire pump drive engines, follow these steps:

1. Start the engine.

2. Observe that the engine starts and accelerates

to the currently adjusted speed setpoint.

3. Locate the threaded bolts on each side of the

throttle bracket on the fuel pump side of the
engine (see Figure 5-3). To adjust the speed set- Figure 5-3 Fire Pump Drive Engine Throttle
point to the rated speed, do the following: Bracket

a. To increase the speed, turn the bolt on the CFP59-F15, F25, and F65 Speed Adjustment
left side of the throttle bracket clockwise. The
adjustment of the bolt will pivot the throttle To adjust the speed on CFP59-F15, F25, and F65 fire
bracket clockwise and allow more fuel pump drive engines, follow these steps:
through the pump to speed up the engine.
1. Start the engine.

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 Maintenance
2. Observe that the engine starts and accelerates The engine coolant heater must maintain an engine
to the currently adjusted speed setpoint. coolant temperature of 49 °C (120 °F) or above. The
engine block must be warm to the touch (38 °C (100
3. Locate the threaded linkage rod on the fuel °F)) in the water jacket areas (see Figure 2-2).
pump side of the engine (see Figure 5-4).
Loosen the locking nuts against the stops on the If the heater does not appear to be working correctly,
outside of the threaded rod. To adjust the speed contact a Cummins Authorized Repair Location.
setpoint to the rated speed, do the following:
5.4 Annual Maintenance
a. To increase the speed, turn the rod upward All checks or inspections listed under previous main-
toward the engine. The adjustment of the rod tenance intervals must also be performed at the time
upward and toward the engine increases the of the annual maintenance, in addition to those listed
actual length of the rod to allow more fuel only under the annual maintenance interval.
through the pump to speed up the engine.
5.4.1 Electrical Components
a. To decrease the speed, turn the rod down-
ward toward the floor. The adjustment of the
rod toward the floor decreases the actual
CAUTION
length of the rod to allow less fuel through the AVOID SERVICING complex components such
pump to slow down the engine. as: printed circuit boards, programmable control-
lers, and ECMs not specifically authorized by
b. When the rated speed is correct, tighten the Cummins Inc. Contact a Cummins Authorized
locking nuts against the stops. Repair Location before performing any extensive
maintenance.
4. Stop the engine.
CAUTION
5. Repeat Steps 1 through 4 until the desired To reduce the possibility of arcing, remove the
speed is attained. negative (-) battery cable first and attach the neg-
ative (-) battery cable last.

The electrical components of the fire pump drive

engine must be thoroughly inspected on an annual
basis. Remove the battery terminal cables, starting
with the negative (-) cable first and check the follow-
ing:

1. Inspect the electrical wiring harness, electrical

terminal connections, and electrical plug-ins for
secure, clean electrical contacts, worn or dam-
aged insulation, burnt wires, broken wires, and
loose connections (see Figure 2-1).

a. Clean and tighten any loose electrical con-

nections.

b. Repair or replace worn, damaged, burnt, or

poorly insulated wiring immediately. Refer to
Figure 5-4 Fire Pump Drive Engine Linkage Rod Section 7 - Component Parts and Assem-
blies.
5.3.12.2 Engine Coolant Heater
NOTE: Perform this inspection procedure twenty-four IMPORTANT: Refer to the vendor-supplied literature
hours after shutting off the engine. for recommended maintenance procedures.

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Maintenance
2. Inspect the function of all gauges, voltmeters, support mounting capscrews. Torque the engine
switches, and warning lamps on the FPDP. mounting cap screws to the support bracket. Refer to
Replace the FPDP if any are not functioning the Torque Tables in Section 7 - Component Parts
properly. and Assemblies for recommended torque values.

3. Reinstall the battery cables; attach the negative 5.4.4 Fuel Pumps and Filters
(-) battery cable last. As shown in Figure 5-6, inspect the fuel injection
pump mounting nuts (including the support bracket)
5.4.2 Turbocharger Mounting Nuts for loose or damaged hardware. Inspect the fuel line
As shown in Figure 5-5, check the turbocharger hoses and fuel filters for wear, damage, loose fittings,
mounting nuts and torque the mounting nuts to the and leaks. Repair or replace damaged hoses and
recommended torque value. Refer to the Torque filters as required.
Tables in Section 7 - Component Parts and Assem-
blies.

1
2
3

Fuel filter or Filter/Separator

CFP-058-1

5 Figure 5-6 Fuel Pumps (typical)

1. Exhaust Flex Connection WARNING

2. Turbocharger Engine fuel is highly flammable and represents
3. Air Cleaner/Filter an extreme hazard for fire or explosion when
4. Service Indicator exposed to electrical sparks or open flame. Clean
5. Air Cleaner Piping up spilled fuel immediately. Keep sources of elec-
trical spark or open flame away from a fuel
Figure 5-5 Turbocharger (typical)
source.
5.4.3 Engine Supports
WARNING
CAUTION Do not open the fuel filter/water separator drain
Loose engine mount bolts or damaged brackets valve or dismantle the fuel lines on the high-pres-
can cause engine misalignment or excessive sure fuel system with the engine running. High
vibration. These conditions can cause engine or pressure fuel spray from an operating engine can
pump damage. cause serious personal injury or fire hazard.
Refer to Figure 2-1 for the location of the engine sup- To change the fuel filters:
ports and inspect all engine supports for cracks or
loose hardware. Check the torque on the engine 1. Shut off the engine.

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 Maintenance
2. Close any fuel valves (if equipped) to prevent NOTE: Engines used in fire pumps or standby service
fuel from draining or siphoning. are expected to immediately accelerate from crank to
full load.
3. Clean the area around the fuel filter or fuel/water
separator heads. 5.4.5 Engine Oil and Filter
Engine oil becomes contaminated and essential oil
NOTE: Refer to the Engine Data Sheet in Section 7 - additives are depleted with use. The amount of con-
Component Parts and Assemblies for filter replace- tamination is related to the total amount of fuel and oil
ment recommendations. consumed. Change the oil at least once annually.

4. Remove the spent filter canisters using a filter NOTE: For composite oil pans, always use a new
wrench. sealing washer on the oil drain plug. Hold the external
locking nut in place while tightening the oil drain plug.
5. Clean the filter mounting head surfaces of
sludge buildup and foreign particles. Ensure IMPORTANT: If the engine oil is drained from the oil
mating gasket surfaces are clean. pan to make an engine repair, new oil must be used.

6. Lubricate the gasket seals with clean SAE

15W-40 lubricating oil. WARNING
To reduce the possibility of personal injury, avoid
7. Center the filter ring on the threaded mounting direct contact of hot oil with your skin. Some
nipple. Screw the filter canister onto the mount- state and federal agencies have determined that
ing flange until the gasket is snug against the used engine oil can be carcinogenic. Prolonged,
mounting flange, then tighten an additional 1/4 repeated contact can cause skin disorders or
turn. other bodily injury. Wash thoroughly after con-
tact. Avoid inhalation of vapors and ingestion of
8. Open the fuel supply valves (if equipped). used engine oil. Dispose of the oil in accordance
with local environmental regulations.

CAUTION To change the oil and filter to remove the contami-

Mechanical over-tightening can distort the nants suspended in the oil:
threads or damage the filter element seal.
1. Operate the engine until the coolant temperature
9. Press either the CRANK BATT A or CRANK reaches 70 °C (158 °F). Shut the engine off.
BATT B button to start the engine to allow the
fuel to flow through the system. 2. Place an appropriate container under the oil pan
drain plug. Refer to the Engine Data Sheet in
10. Depress the contactor switch for up to fifteen Section 7 - Component Parts and Assemblies for
seconds or until the engine starts. Repeat up to oil pan capacity.
three times, if necessary.
3. Remove the oil drain plug and drain the oil
immediately to make sure all the oil and sus-
CAUTION pended contaminants are removed from the
To prevent damage to the starter, do not engage engine.
the starting motor more than fifteen seconds.
Wait fifteen seconds between each start attempt. 4. Remove the oil filter (see Figure 5-7) following
these steps:
IMPORTANT: If the engine does not start after three
attempts, check the fuel supply system. Absence of a. Clean the area around the engine oil filter
blue or white exhaust smoke during cranking indi- canister. Use a filter wrench to remove the fil-
cates no fuel is being delivered. ter.

b. Remove and discard the O-ring seal if it has

remained attached to the mounting flange.

Cummins Fire Pump Drive Engine CFP59 5-11

Doc. A042J557, Rev. 04/2017
Maintenance
Clean the filter mounting flange with a clean Torque the plug according to the Torque Tables
lint-free cloth. in Section 7 - Component Parts and Assemblies.

c. Apply a light film of 15W-40 lubricating oil to 8. Fill the engine to the proper level with clean, high
the replacement filter gasket before installing quality 15W-40 oil at the fill port.
the filter.

5. Fill the oil filter with a high-quality 15W-40 multi- CAUTION

viscosity lubricating oil, such as Premium Blue®, If no oil pressure is noted within fifteen seconds
or its equivalent. after the engine is started, shut down the engine
to reduce the possibility of internal damage.

9. Restart the engine and let it run for approxi-

mately one to two minutes.

10. Stop the engine.

11. Wait approximately fifteen minutes to let the oil

drain from the upper parts of the engine.

12. Check the oil level again. Add oil as necessary

to bring the oil level to the H (high) mark on the
dipstick.

5.4.6 Drive Shaft

It is recommended that proper lubrication to drive
shafts be completed on a regular schedule according
to these steps:

1. Remove the drive shaft guards.

2. Wipe the grease fittings and grease gun nozzle

1. Oil Fill Port (on valve cover)
with a clean cloth to avoid contamination.
2. Oil Level Dipstick
3. Engine Oil Filter
3. Add grease to the drive shaft universal joint
Figure 5-7 Oil Filter and Oil Level Dipstick (Typical) grease fittings (see Figure 3-2).

6. Center the filter ring on the threaded mounting 4. Wipe excess grease from the grease fittings.
nipple. Screw the filter canister onto the mount-
ing flange until the gasket is snug against the NOTE: Cummins Inc recommends using a good
mounting flange. Then tighten an additional 1/4 quality semi-synthetic, molybdenum-fortified NLGI #2
turn. lithium complex grease which protects from -47 to
204 °C (-54 to 400 °F).

CAUTION 5.4.7 Coolant Pump/Alternator Belt

Mechanical over-tightening can distort the On some engine models, the pump and alternator
threads or damage the filter element seal. belt drives both the pump and alternator.

NOTE: Cummins recommends using oil filter replace- To inspect the coolant pump and the alternator belt:
ment parts as outlined in the Engine Data Sheet in
Section 7 - Component Parts and Assemblies. 1. Press the AUTO/MAN button on the FPDP to
place the fire pump drive engine in MANUAL
7. Check and clean the oil pan drain plug threads operation.
and sealing surface. Install the oil pan drain plug.

5-12 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Maintenance
2. Disconnect both batteries at their terminals. 5. If the belt condition is acceptable, check the belt
Remove the negative (-) cable first. tension. There are two ways to check the belt
condition:
3. Remove the belt guard capscrews and the belt
guard. Set aside for re-installation (see Figure NOTE: Belts with glazed or shiny surfaces indicate
5-8). belt slippage. Correctly installed and tensioned belts
will show even pulley and belt wear.

   
CAUTION
Disconnect the batteries (negative cable first)
before performing service on the fire pump drive
engine or on any of its controls.

a. Use the Cummins belt tension gauge (Part

Number 3822524) to measure the drive belt
tension in the center span of the belt between
 the idler and alternator pulleys. Ensure that
the belt tension is set to the specifications

outlined in the Engine Operation Manual.

b. Use the deflection method and measure the
belt tension in the center span of the belt
between the alternator and idler pulleys. If
the belt deflection is more than one belt thick-
ness per foot of pulley center-to-center dis-
tance, adjust the belt tension.

1. Belt Guard 6. Reinstall the battery cables; attach the negative

2. Alternator Pulley (-) battery cable last.
3. Drive Belt
4. Idler Pulley 5.4.8 Raw Water Zinc Anode
5. Coolant Pump Pulley The zinc anode (see Figure 5-9) acts as a raw water
6. Balancer Pulley filter and must be checked for erosion and replaced,
7. Belt Tensioner when necessary. If the anode has eroded more than
fifty percent, it must be replaced.
Figure 5-8 Coolant Pump/Alternator Belt (typical)

4. Visually inspect the belt for frayed, worn, missing

pieces, or cracked belt surfaces. Check the belt
for intersecting cracks.
Zinc Anode

CAUTION
Belt damage can be caused by: incorrect tension,
incorrect size or length, pulley misalignment,
incorrect installation, severe operating environ-
ment, and/or oil or grease on the belt or pulley.

NOTE: Transverse cracks (across the belt width) are

acceptable. Longitudinal cracks (direction of belt
length) that intersect with transverse cracks are not Figure 5-9 Raw Water Zinc Anode (typical)
acceptable. Replace the belt if it is cracked, frayed, or
damaged.

Cummins Fire Pump Drive Engine CFP59 5-13

Doc. A042J557, Rev. 04/2017
Maintenance
5.4.9 Heat Exchanger debris from entering the engine and causing pre-
If internal leakage in the heat exchanger is sus- mature wear. Dirt or foreign objects could cause
pected, a heat exchanger pressure test may be per- engine damage.
formed prior to removal from the engine.
2. Remove the air intake and exhaust piping from
NOTE: Use Teflon™ tape or other pipe sealant when the turbocharger.
installing the test setup in order to prevent leaks.
3. Inspect the turbocharger turbine wheel for
NOTE: The size of fittings required on the water cracks in the housing or turbine blades, missing
outlets and inlets are listed on the Engine Data Sheet blades, mechanical binding, eccentric motion, or
in Section 7 - Component Parts and Assemblies. excessive end-play.

To test the heat exchanger pressure: 4. Replace the turbocharger if damage, excessive
end-play, binding, wear, or eccentric motion is
1. Install an adapter at the cooling water outlet of found. Contact a Cummins Authorized Repair
the heat exchanger. Location for replacement.

2. Install a pressure test setup with 689 kPa (100 IMPORTANT: The turbocharger must be removed for
psi) pressure gauge at the cooling water inlet to replacement or rebuild if the clearance is beyond the
the heat exchanger. limits, the housing is cracked, or the turbine wheel is
damaged.
3. Apply air pressure at 414 kPa (60 psi).
5. Reinstall the air intake filter and exhaust piping.
a. Isolate the pressure source and monitor the Tighten the clamps. Torque the loosened clamps
pressure gauge for five minutes. to the recommended torque value. Refer to the
Torque Tables in Section 7 - Component Parts
b. There should be no change in pressure for and Assemblies.
the duration of the test.
5.5 Every Two Years
4. After testing, release the pressure. Remove the
tubing adapters, plug, and test equipment. All checks or inspections listed under daily or previ-
ous maintenance intervals must also be performed at
5. If leakage is detected, the heat exchanger must this time, in addition to those listed under this mainte-
be replaced. nance interval.

5.4.10 Turbocharger 5.5.1 Coolant Pump

As shown in Figure 5-5, follow these steps to thor- Inspect the coolant pump for eccentric motion,
oughly inspect the turbocharger: mechanical binding, excessive end play, seal
damage, and excessive grease or coolant leakage
1. Visually inspect the air intake filter and piping around the pump shaft.
according to the steps outlined in Section 5.3.2.
Replace with a new or rebuilt pre-lubricated unit, as
NOTE: Turbocharged engines must be operated at necessary. Contact a Cummins Authorized Repair
rated revolutions per minute (RPM) and full load to Location for replacement.
check maximum intake air restriction.
5.5.2 Cooling System
NOTE: Cummins recommends using an air cleaner Figure 5-10 illustrates the cooling system. The
filter element as listed on the Engine Data Sheet in cooling system must be clean to work properly. If the
Section 7 - Component Parts and Assemblies. system shows excessive mineral buildup, particulate
matter, scale, oxidation, or oil contamination, drain
and flush the cooling system. If the coolant is exces-
CAUTION sively dirty or is mixed with oil, contact a Cummins
Authorized Repair Facility.
Never operate the engine without an air cleaner.
Intake air must be filtered to prevent dirt and

5-14 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Maintenance

WARNING
Do not remove the pressure/fill cap from a hot
engine. Shut down the engine and wait until the
coolant temperature is below 50 °C (120 °F)
before removing the pressure cap. Heated
coolant spray or steam can cause severe per-
sonal injury.

1. Disconnect both batteries at their terminals.

Remove the negative (-) cable first.

2. Press down, unscrew, and remove the coolant

expansion tank pressure/fill cap. The cap must 1
be removed to allow air to vent the cooling
system during the draining process. 2

3. Disconnect the engine coolant heater power

supply before draining the cooling system. 3
4
5
4. Place a container that will hold at least 57 liters
(15 gal) of liquid under the coolant drain valve. 1. Lower Coolant Tube
2. Coolant Drain Petcock
5. Ensure that the coolant filter shut-off valves are 3. Coolant Filter
OPEN. 4. Coolant Filter Shut-off Valve
5. Engine Coolant Heater
6. Open the drain petcock on the lower coolant
tube, allowing the coolant to drain into the waste Figure 5-10 Engine Coolant Drain
container.

7. When the system is empty, move the container CAUTION

under the engine coolant heater. Over-concentration of antifreeze or use of high-
silicate antifreeze can damage the engine. Do not
8. Disconnect either end of the engine heater use more than 50% antifreeze in the mixture
coolant hose and drain the engine heater. unless additional freeze protection is required.
Antifreeze at 68% concentration provides the
maximum freeze protection, and must never be
CAUTION exceeded under any condition. Antifreeze protec-
Coolant is toxic. Avoid prolonged and repeated tion decreases above 68%.
skin contact with used antifreeze - wash thor-
10. When the flushing water has fully drained, use a
oughly after contact. Prolonged, repeated contact
filter wrench to remove the water coolant filter
can cause skin disorders. Dispose of waste anti-
from the filter housing.
freeze in accordance with local environmental
regulations.
a. Clean the filter housing gasket mount of dirt
9. Flush with clean fresh water or heavy-duty heat buildup, oxidation, or particulate matter with a
exchanger cleaner. Follow the manufacturer’s clean cloth.
directions on the product container.
b. Coat the replacement filter gasket with a light
NOTE: Some cooling system cleaners or commercial coating of 15W-40 lubrication oil.
solvents require a soapy water rinse after use. Follow
the directions on the cleaning solution or solvent. 11. Center the filter ring on the threaded mounting
nipple. Screw the filter canister onto the mount-
ing flange until the gasket is snug against the

Cummins Fire Pump Drive Engine CFP59 5-15

Doc. A042J557, Rev. 04/2017
Maintenance
mounting flange, then tighten an additional 1/4 glycol or propylene-glycol and Supplemental Coolant
turn. If using a soapy water solution, flush again Additive (SCA) required for wet-sleeved engines in
with clear water. Allow time for the water to fully most climates. Contact your local Cummins Autho-
drain. rized Repair Location for additional information.

CAUTION Table 5-2.

Mechanical over-tightening can distort the
threads or damage the filter element seal. Ethylene-Glycol Propylene-Glycol

NOTE: Recommendations on filter replacements and 40% = -23 °C (-10 °F) 40% = -21 °C (-6 °F)
fill rates can be found on the Engine Data Sheet in
Section 7 - Component Parts and Assemblies. 50% = -37 °C (-34 °F) 50% = -33 °C (-27 °F)

60% = -54 °C (-65 °F) 60% = -54 °C (-65 °F)

12. Reconnect the engine heater coolant hose and
close the drain petcock on the lower coolant 68% = -71 °C (-96 °F) 68% = -63 °C (-82 °F)
tube.

NOTE: During filling, air must be vented from the

engine coolant passages. The air vents through the
CAUTION
coolant filler port. The fill rate can be found in the The system must be filled properly to prevent air
Engine Data Sheet in Section 7 - Component Parts locks. During filling, air must be vented from the
and Assemblies. engine coolant passages.

14. Check the condition of the pressure/fill cap.

13. Fill the coolant tanks with the proper antifreeze.
Use a mixture of 50% water and 50% ethylene-
a. If the pressure/fill cap seal is worn, damaged,
glycol base or propylene-glycol antifreeze (or
missing, or the pressure spring is damaged
pre-mixed solution) to protect the engine to -37
or shows signs of sticking, replace the filler
°C (-34 °F) year-around.
cap.

b. Re-install the expansion tank fill cap.

CAUTION
Use soft or distilled water in the coolant mixture. 15. Re-install the heater wiring.
Contaminants in hard water neutralize the corro-
sion inhibitor components. Water must not 16. Reinstall the battery cables; attach the negative
exceed 300-ppm hardness or contain more than (-) battery cable last.
100 ppm of either chloride or sulfate.
17. Operate the engine until it reaches a tempera-
ture of 82 °C (180 °F), and check for coolant
CAUTION leaks.
Never use a sealing additive to stop leaks in the
cooling system. This can result in cooling system 18. Ensure that the coolant level is just below the fill
blockage or restricted coolant flow, causing the neck and that the coolant heater is reconnected.
engine to overheat.
5.6 Every Four Years
NOTE: Cummins Inc. recommends using Fleet-
All maintenance checks and inspections listed in pre-
guard® ES COMPLEAT™ Ethylene-Glycol (EG) or vious maintenance intervals must also be performed
Fleetguard® Propylene-Glycol (PG) Plus™ Anti- at this time.
freeze/Coolants. Both products are available in con-
centrated or pre-mixed formulations. Use a 50% Cummins recommends performing maintenance on
concentration level (40% to 60% range) of ethylene- valve lash settings.

5-16 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Maintenance
6. Replace the thermostat flange and cap screws.
CAUTION
Disconnect both batteries (negative cable first)
before performing service on the fire pump drive
engine or on any of its controls. Wear safety
glasses when disconnecting batteries!

CAUTION
Valve lash maintenance should be performed by a
skilled technician. Improper maintenance can
damage the engine or cause severe personal
injury. Contact your local Cummins Authorized
Repair Location before performing any extensive
maintenance.

5.6.1 Coolant Thermostat Removal/Installation

The thermostat regulates the temperature of the
engine coolant circulating through the engine cooling
system. Refer to the Engine Manual for complete 3 2 1
instructions.

1. Hose Clamps
CAUTION 2. Upper Coolant Hose
3. Thermostat Housing
Always use the correct thermostat, and never
operate the engine without a thermostat installed. Figure 5-11 Thermostat Housing (typical)
The engine can overheat if operated without a
thermostat because the path of least resistance 5.6.2 Coolant Pump/Alternator Belt Replacement
for the coolant is through the bypass to the pump Referring to Figure 5-8, replace the coolant pump/
inlet. alternator belt if it is cracked, frayed, or has pieces of
material missing.
1. Remove the upper coolant hose clamps and
upper coolant hose at the thermostat housing. 1. Remove the belt guard.
2. Use a 3/8” drive ratchet or breaker bar to rotate
2. Remove the (2) thermostat housing flange cap the tensioner arm away from the belt and
screws and the thermostat flange (see Figure remove the belt.
5-11).
3. Check the belt tensioner cap screw torque. For
3. Remove the thermostat and gasket from the recommended torque values, refer to the Torque
housing. Tables in Section 7 - Component Parts and
Assemblies.
4. Clean the housing flange faces of dirt buildup,
oxidation, and sludge. 4. Check the tensioner arm, pulley, and stops for
cracks. If any cracks are noticed, the tensioner
5. If still in good condition, re-install the thermostat must be replaced.
in the housing.
5. Verify that the tensioner arm stop is not in
IMPORTANT: Inspect the seal on the thermostat contact with the spring casing stop. If either stop
housing flange surface and - if damaged or cracked - is touching, the tensioner must be replaced.
apply a new seal.
6. Inspect the tensioner for evidence of the ten-
NOTE: Recommendations on thermostat replace- sioner arm contacting the tensioner cap.
ment components can be found on the Engine Data If there is evidence of the two areas making con-
Sheet in Section 7 - Component Parts and Assem- tact, the pivot tube bushing has failed and the
blies. tensioner must be replaced.

Cummins Fire Pump Drive Engine CFP59 5-17

Doc. A042J557, Rev. 04/2017
Maintenance
7. Check the tensioner bearing. 9. After checking the torque, use a 3/8” drive
ratchet or breaker bar to rotate the tensioner
a. Rotate the belt tensioner pulley. The pulley
slowly away from the area of belt contact.
should spin freely with no mechanical bind-
ing, eccentric motion, or excessive end-play. 10. Install the replacement drive belt.
b. If the arm rotates with mechanical binding,
eccentric movement, or excessive end play, CAUTION
replace the tensioner. To prevent pulley or belt damage, do not roll a
8. Inspect the clearance between the tensioner belt over the pulley or pry it on with a tool. Move
spring case and the tensioner arm for uneven the tensioner arm away from the belt area before
bearing wear. installing the drive belt.

If the clearance exceeds 3 mm (0.12 in) at any 11. Check the location of the drive belt on the belt
point, the tensioner must be replaced as a com- tensioner pulley. The belt should be centered on,
plete assembly. Contact a Cummins Authorized or centered close to, the middle of the pulley.
Repair Location for replacement. 12. Reinstall the belt guard.
NOTE: Experience has shown that tensioners gener-
ally will show a larger clearance gap near the lower CAUTION
portion of the spring case, resulting in the upper Unaligned belts, either too far forward or back-
portion rubbing against the tensioner arm. Always ward, can cause belt wear, belt roll-off failures or
replace the belt when a tensioner is replaced. increase uneven tensioner bushing wear.

5-18 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Section 6 - Troubleshooting
6.1 Introduction
The following information is intended as a guide for CAUTION
some common non-technical equipment problems. AVOID SERVICING complex components such
The first part of this section includes troubleshooting as: printed circuit boards, programmable
charts that cross-reference the problem, the possible controllers, and ECMs not specifically authorized
cause, and the solution. The second section includes by Cummins Inc. Contact the Cummins Customer
complete Fault Code charts outlining a numerical Service Department toll free at 1-800-343-7357
listing of fault codes and their descriptions. before performing any extensive maintenance.

Many problems can be resolved using corrective

maintenance, adjustment, or minor repair. Refer to CAUTION
the vendor supplied literature, electrical schematics, Never climb or stand on the equipment frame,
and mechanical prints for additional information. guards, or enclosures. Contact with exposed or
moving components can cause personal injury or
For engine-related issues, refer to the engine Opera- equipment damage.
tion and Maintenance Manual or contact the
Cummins Customer Assistance Center at 1-800-
DIESELS (1-800-343-7357).

WARNING
The status checks should be performed ONLY by
a qualified technician. Contact with exposed elec-
trical components could cause extreme personal
injury or death.

Cummins Fire Pump Drive Engine CFP59 6-1

Doc. A042J557, Rev. 04/2017
Troubleshooting

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Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Troubleshooting

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6-3
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Troubleshooting

Engine Cranks But Will Not Start (cont.)

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6-4
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Troubleshooting

6.4 Engine Starts But Continues to Crank

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6-5
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Troubleshooting

6.5 Engine Will Not Stop

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6-6
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Troubleshooting

6.6 Low Battery Voltage

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6-7
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Troubleshooting

This page is intentionally left blank.

6-8 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 04/2017
 Section 7 - Component Parts and Assemblies
7.1 Ordering Parts If assistance is required, call Toll-Free: 1-800-
Replacement parts for the Cummins Inc. equipment DIESELS (1-800-343-7357). Includes all 50 states,
are manufactured to the same quality standards and Bermuda, Puerto Rico, Virgin Islands, and the Baha-
specifications as the original equipment. Unapproved mas.
substitution may result in poor performance, reduced
service life, lost production, or unsafe operation. Outside of North America contact your Regional
Office. Telephone numbers and addresses are listed
Cummins Inc. relies on the best and most cost effec- in the International Directory.
tive shipping methods, unless specific instructions or
requirements are requested by the customer. When Refer also to the Cummins Inc. web site at www.cum-
ordering parts, please be prepared to provide the fol- mins.com.
lowing information.
7.3 Recommended Spare Parts Inventory
• Model and serial number. To minimize downtime and increase productivity,
Cummins Inc. recommends maintaining a stock of
• Part description by name or number. spare parts critical to uninterrupted engine operation.
Shipping costs can be lower using ground transporta-
• Quantity required. tion rather than overnight or next day air freight. For
this reason, Cummins Inc. can provide a list of recom-
• Purchase order number. mended spare parts. Contact a Cummins Authorized
Repair Location for additional information.
NOTE: A purchase order number is desirable, even if
the part(s) are supplied on a Returned Goods Autho- 7.4 Engine Data Sheet and Torque Values
rization (RGA) issue number. A purchase order
The following pages outline applicable reference
number helps Cummins and its customer track the
material for the CFP59 fire pump drive engine. Table
parts and necessary credits.
7-1. CFP59 Engine Data Sheet represents the engine
data for the CFP59 and all its ratings at the time of
7.2 Repairs and Technical Service this printing. For a complete, up-to-date, Model Spec-
Personnel at Cummins Authorized Repair Locations ification Sheet, refer to www.cumminsfirepower.com.
can assist you with the correct operation and service Table 7-2. Cap Screw Markings and Torque Tables
of your engine. Cummins has a worldwide service outlines the recommended cap screw markings and
network of more than 5,000 Distributors and Dealers torque values for fire pump drive engines.
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.

The Cummins Customer Assistance Center provides

a 24-hour, toll free telephone number to aid in techni-
cal and emergency service when a Cummins Autho-
rized Repair Location cannot be reached or is unable
to resolve an issue with a Cummins product.

Cummins Fire Pump Drive Engine CFP59 7-1

Doc. A042J557, Rev. 04/2017
Component Parts and Assemblies

Table 7-1. CFP59 Engine Data Sheet

Air Induction System - CFP59 - F10/20/40/50

Maximum Temperature Rise Between Ambient Air and
30 °F (16.7 °C)
Engine Air Inlet
Maximum Inlet Restriction with Dirty Filter 25 in. H2O (635 mm H2O)
Recommended Air Cleaner Element - (Standard) Cummins FIltration AH1140
Recommended Air Cleaner Element - (Heavy Duty) Optional: primary element AF26124; secondary element AF26125

Lubrication System - CFP59 - F10/20/40/50

Oil Pressure Range at Rated 40-60 PSI (276-414 kPa)
Oil Capacity of Pan (High - Low) 15-13 qt. (14.2-12.3 L)
Total System Capacity 4.3 gal. (16.3 L)
Recommended Lube Oil Filter Cummins Filtration LF3959

Cooling System - CFP59 - F10/20/40/50*

Raw Water Working Pressure Range at Heat
60 PSI (413 kPa) MAX
Exchanger

Recommended Minimum Water Supply Pipe Size to

.75 in. (19.05 mm)
Heat Exchanger

Recommended Minimum Water Discharge Pipe Size

1.00 in. (25.40 mm)
From Heat Exchanger
Coolant Water Capacity (Engine Only) 4 gal. (15.1 L)
Standard Thermostat - Type Modulating
Standard Thermostat - Range 180-203 °F (82-95 °C)
Minimum Raw Water Flow:
- with Water Temperatures to 60 °F (16 °C) 28.7 GPM (1.81 L/sec)
- with Water Temperatures to 80 °F (27 °C) 30.2 GPM (1.91 L/sec)
- with Water Temperatures to 100 °F (38 °C) 32 GPM (2.02 L/sec)
* A jacket water heater is mandatory on this engine. The recommended heater wattage is 1500 down to 40 °F (4 °C)

Exhaust System - CFP59 - F10/20/40/50

Maximum Allowable Back Pressure by Complete Exhaust System 40.8 in. H2O (10.2 kPa)
Exhaust Pipe Size Normally Acceptable 4 in. (102 mm)

7-2
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Component Parts and Assemblies

Noise Emissions - CFP59 - F10/20/40/50

The noise emission values are estimated sound pressure levels at 3.3 ft. (1 m).

Top 99.0 dBa

Right Side 96.3 dBa
Left Side 98.9 dBa
Front 96.3 dBa
Exhaust 116.0 dBa

Fuel Supply/Drain System - CFP59 - F10/20/40/50

Operating Speed in RPM 1470 1760
CFP59 F-10 Fuel Rate - Gal/hr (L/hr) 4.8 (18.3) 5.6 (21.3)
CFP59 F-20 Fuel Rate - Gal/hr (L/hr) 6.3 (23.8) 7.3 (27.6)
CFP59 F-40 Fuel Rate - Gal/hr (L/hr) 7.2 (27.4) 8.4 (31.7)
CFP59 F-50 Fuel Rate - Gal/hr (L/hr) 7.9 (30) 9.2 (34.9)

Fuel Type No. 2 diesel only

Minimum Supply Line Size 0.25 in. (6.35 mm)
Minimum Drain Line Size 0.125 in. (3.18 mm)
Maximum Fuel Height above C/L Fuel Pump 71 in. (1.8 m)
Recommended Fuel Filter - Primary Cummins Filtration FS1251
Recommended Fuel Filter - Secondary None
Maximum Restriction @ Lift Pump-Inlet - With Clean Filter 4.0 in. Hg (102 mm Hg)
Maximum Restriction @ Lift Pump-Inlet - With Dirty Filter 8.0 in. Hg (203 mm Hg)
Maximum Return Line Restriction - Without Check Valves 20 in. Hg (508 mm Hg)
Minimum Fuel Tank Vent Capability 12 ft3/hr (0.36 m3/hr)
Maximum Fuel Temperature @ Lift Pump Inlet 160 °F (71 °C)

Starting and Electrical System - CFP59 - F10/20/40/50

Min. Recommended Battery Capacity - Cold Soak at 0 °F (-18 °C) or
12V 24V
Above
Engine Only - Cold Cranking Amperes 900 CCA* 900 CCA*
Engine Only - Reserve Capacity 430 minutes* 430 minutes*
*Based on FM requirement for a minimum of 900 CCA and 430 Reserve Capacity Minutes

Battery Cable Size - Minimum of 2/0 AWG and Maximum Cable

12V 24V
Length Not to Exceed 6 ft. (1.5 m)
Maximum Resistance of Starting Circuit 0.002 Ohms 0.002 Ohms
Typical Cranking Speed 120 RPM 120 RPM
Alternator (Standard), Internally Regulated 95 amps 45 amps

7-3
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Component Parts and Assemblies

Operating Conditions - CFP59 - F10/20/40/50

Operating Speed in RPM 1470 1760

CFP59 F-10
Output - BHP (kW) 100 (75) 115 (86)
Ventilation Air Required - CFM (litre/sec) 189 (89) 260 (123)
Exhaust Gas Flow - CFM (litre/sec) 489 (231) 626 (295)
Exhaust Gas Temperature - °F (°C) 924 (496) 846 (452)
Heat Rejection to Coolant - BTU/min. (kW) 2673 (47) 3078 (54)
Heat Rejection to Ambient - BTU/min. (kW) 1240 (22) 1276 (22)

CFP59 F-20
Output - BHP (kW) 130 (97) 149 (111)
Ventilation Air Required - CFM (litre/sec) 226 (107) 309 (146)
Exhaust Gas Flow - CFM (litre/sec) 617 (291) 773 (365)
Exhaust Gas Temperature - °F (°C) 1016 (547) 918 (492)
Heat Rejection to Coolant - BTU/min. (kW) 3334 (59) 3771 (66)
Heat Rejection to Ambient - BTU/min. (kW) 1291 (23) 1329 (23)

CFP59 F-40
Output - BHP (kW) 150 (112) 171 (128)
Ventilation Air Required - CFM (litre/sec) 252 (119) 347 (164)
Exhaust Gas Flow - CFM (litre/sec) 706 (333) 882 (416)
Exhaust Gas Temperature - °F (°C) 1054 (568) 951 (511)
Heat Rejection to Coolant - BTU/min. (kW) 3809 (67) 4209 (74)
Heat Rejection to Ambient - BTU/min. (kW) 1345 (24) 1384 (24)

CFP59 F-50
Output - BHP (kW) 164 (122) 188 (140)
Ventilation Air Required - CFM (litre/sec) 284 (134) 391 (185)
Exhaust Gas Flow - CFM (litre/sec) 757 (357) 972 (459)
Exhaust Gas Temperature - °F (°C) 1041 (561) 947 (508)
Heat Rejection to Coolant - BTU/min. (kW) 3587 (63) 4205 (74)
Heat Rejection to Ambient - BTU/min. (kW) 1401 (25) 1442 (25)

7-4
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Component Parts and Assemblies

Air Induction System - CFP59 - F15-F25

Maximum Temperature Rise Between Ambient Air and
30 °F (16.7 °C)
Engine Air Inlet
Maximum Inlet Restriction with Dirty Filter 25 in. H2O (635 mm H2O)
Recommended Air Cleaner Element - (Standard) Cummins FIltration AH1140
Recommended Air Cleaner Element - (Heavy Duty) Optional: primary element AF26124; secondary element AF26125

Lubrication System - CFP59 - F15-F25

Oil Pressure Range at Rated 10-50 PSI (69-345 kPa)
Oil Capacity of Pan (High - Low) 15-13 qt. (14.2-12.3 L)
Total System Capacity 4.3 gal. (16.3 L)
Recommended Lube Oil Filter Cummins Filtration LF3959

Cooling System - CFP59 - F15-F25*

Raw Water Working Pressure Range at Heat
60 PSI (413 kPa) MAX
Exchanger

Recommended Minimum Water Supply Pipe Size to

.75 in. (19.05 mm)
Heat Exchanger

Recommended Minimum Water Discharge Pipe Size

1.00 in. (25.40 mm)
From Heat Exchanger
Coolant Water Capacity (Engine Only) 4 gal. (15.1 L)
Standard Thermostat - Type Modulating
Standard Thermostat - Range 180-200 °F (82-93 °C)
Minimum Raw Water Flow:
- with Water Temperatures to 60 °F (16 °C) 28.7 GPM (1.81 L/sec)
- with Water Temperatures to 80 °F (27 °C) 30.2 GPM (1.91 L/sec)
- with Water Temperatures to 100 °F (38 °C) 32 GPM (2.02 L/sec)
* A jacket water heater is mandatory on this engine. The recommended heater wattage is 1500 down to 40 °F (4 °C)

Exhaust System - CFP59 - F15-F25

Maximum Allowable Back Pressure by Complete Exhaust System 40.8 in. H2O (10.2 kPa)
Exhaust Pipe Size Normally Acceptable 4 in. (102 mm)

7-5
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Component Parts and Assemblies

Noise Emissions - CFP59 - F15-F25

The noise emission values are estimated sound pressure levels at 3.3 ft. (1 m).

Top 96.3 dBa

Right Side 96.3 dBa
Left Side 99.0 dBa
Front 98.9 dBa
Exhaust 114.0 dBa

Fuel Supply/Drain System - CFP59 - F15-F25

Operating Speed in RPM 2100 2350 2600
CFP59 F-15 Fuel Rate - Gal/hr (L/hr) 6.5 (24.8) 7.1 (26.8) 7.4 (27.9)
CFP59 F-25 Fuel Rate - Gal/hr (L/hr) 7.5 (28.4) 7.9 (29.8) 8.2 (31.0)

Fuel Type No. 2 diesel only

Minimum Supply Line Size 0.25 in. (6.35 mm)
Minimum Drain Line Size 0.125 in. (3.18 mm)
Maximum Fuel Height above C/L Fuel Pump 50.5 in. (1.3 m)
Recommended Fuel Filter - Primary Cummins Filtration FS5052
Recommended Fuel Filter - Secondary None
Maximum Restriction @ Lift Pump-Inlet - With Clean Filter 4.0 in. Hg (102 mm Hg)
Maximum Restriction @ Lift Pump-Inlet - With Dirty Filter 8.0 in. Hg (203 mm Hg)
Maximum Return Line Restriction - Without Check Valves 20 in. Hg (508 mm Hg)
Minimum Fuel Tank Vent Capability 12 ft3/hr (0.36 m3/hr)
Maximum Fuel Temperature @ Lift Pump Inlet 160 °F (71 °C)

Starting and Electrical System - CFP59 - F15-F25

Min. Recommended Battery Capacity - Cold Soak at 0 °F (-18 °C) or
12V 24V
Above
Engine Only - Cold Cranking Amperes 900 CCA* 900 CCA*
Engine Only - Reserve Capacity 430 minutes* 430 minutes*
*Based on FM requirement for a minimum of 900 CCA and 430 Reserve Capacity Minutes

Battery Cable Size - Minimum of 2/0 AWG and Maximum Cable

12V 24V
Length Not to Exceed 6 ft. (1.5 m)
Maximum Resistance of Starting Circuit 0.002 Ohms 0.002 Ohms
Typical Cranking Speed 120 RPM 120 RPM
Alternator (Standard), Internally Regulated 95 amps 45 amps

7-6
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Component Parts and Assemblies

Operating Conditions - CFP59 - F15-F25

Operating Speed in RPM 2100 2350 2600

CFP59 F-15
Output - BHP (kW) 122 (91) 126 (94) 126 (94)
Ventilation Air Required - CFM (litre/sec) 329 (155) 383 (181) 415 (196)
Exhaust Gas Flow - CFM (litre/sec) 762 (360) 865 (408) 975 (460)
Exhaust Gas Temperature - °F (°C) 785 (418) 776 (413) 780 (416)
Heat Rejection to Coolant - BTU/min. (kW) 2636 (46) 3262 (57) 3520 (62)
Heat Rejection to Ambient - BTU/min. (kW) 683 (12) 739 (13) 810 (14)

CFP59 F-25
Output - BHP (kW) 140 (104) 140 (104) 140 (104)
Ventilation Air Required - CFM (litre/sec) 346 (163) 398 (188) 430 (203)
Exhaust Gas Flow - CFM (litre/sec) 868 (410) 968 (457) 1035 (489)
Exhaust Gas Temperature - °F (°C) 893 (478) 878 (470) 880 (471)
Heat Rejection to Coolant - BTU/min. (kW) 3021 (53) 3656 (64) 3810 (67)
Heat Rejection to Ambient - BTU/min. (kW) 811 (14) 864 (15) 910 (16)

7-7
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Component Parts and Assemblies

Table 7-2. Cap Screw Markings and Torque Tables

Cap Screw Markings and Torque Values

CAUTION
Always use a cap screw of the same measurement and strength as the cap screw being
replaced. Using the wrong cap screws can result in engine damage.
Always use the torque values listed in the following tables when specific torque values are not
available.
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 Cap Screw Identification

Sample: M8-1.25 x 25
Value: M8 1.25 X 25
Major thread diameter in Distance between threads
Meaning: Length in millimeters
millimeters in millimeters

Metric Cap Screw Head Markings

Metric cap screws and nuts are identified by the grade number stamped on the head of the cap
screw or on the surface of the nuts.
Commercial
8.8 10.9 12.9
Steel Class

Caps Screw
8.8 10.9 12.9
Head Markings

US Customary Cap Screw Identification

Sample: 5/16 x 18 x 1-1/2
Value: 5/16 18 1-1/2
Major thread diameter in
Meaning: Number of threads per inch Length in inches
inches

U.S. Customary Cap Screw Head Markings

U.S. Customary cap screws are identified by radial lines stamped on the head of the cap screw.
SAE Grade 5
SAE Grade 8
w/ three lines

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Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 Component Parts and Assemblies

Metric Cap Screw Torque Values (lubricated threads)

Class: 8.8 10.9 12.9
Diameter Cast Iron Aluminum Cast Iron 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 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 — — 550 400 — — — — — —

U.S. Customary Cap Screw Torque Values (lubricated threads)

Grade: SAE Grade 5 SAE Grade 8
Cap Screw
Cast Iron Aluminum Cast Iron Aluminum
Body Size
N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4-20 9 7 8 6 15 11 8 6
1/4-28 12 9 9 7 18 13 9 7
5/16-18 20 15 16 12 30 22 16 12
5/16-24 23 17 19 14 33 24 19 14
3/8-16 40 30 25 20 55 40 25 20
3/8-24 40 30 35 25 60 45 35 25
7/16-14 60 45 45 35 90 65 45 35
7/16-20 65 50 55 40 95 70 55 40
1/2-13 95 70 75 55 130 95 75 55
1/2-20 100 75 80 60 150 110 80 60
9/16-12 135 100 110 80 190 140 110 80
9/16-18 150 110 115 85 210 155 115 85
5/8-11 180 135 150 110 255 190 150 110
5/8-18 210 155 160 120 290 215 160 120
3/4-10 325 240 255 190 460 340 255 190
3/4-16 365 270 285 210 515 380 285 210
7/8-9 490 360 380 280 745 550 380 280
7/8-14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1-14 800 590 650 480 1200 890 650 480

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Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
Component Parts and Assemblies

7.5 Assembly Drawings

The most current revisions to these drawings and related documents are accessible at: http://www.cummins-
firepower.com/products.html.

Drawing
Description
No.
General Arrangement, Installation, Fire Pump, CFP59-F15-25, F10/20/40/50 A042J655
Assembly, Fire Pump, CFP59-F10/20/40/50 (6BTA5.9-G3) A042H677
Assembly, Fire Pump, CFP59-F15-25 (6BT5.9-C165) A042H678
Options, Engine, CFP59-F10/20/40/50 (BTA5.9-G3) 8724
Options, Engine, CFP59-F15-25 (6BT5.9-C165) 8725
Assembly, Heat Exchanger Cooling Assembly CFP59 F15-25, F10/20/40/50 8650
Assembly, Coolant Heater CFP59 F15-25, F10/20/40/50 A042J846
Assembly, Sensors and Harnessing CFP59 F15-25, F10/20/40/50 A042J820
Assembly, Air Filter CFP59-F15/F25 A042J156
Assembly, Air Filter CFP59-F10/20/40/50 A042J147
Assembly, Accessory Mounting CFP59-F10/20/40/50, F15/F25 A042J146
Assembly, Throttle Positioning, CFP59-F15-25 8585
Assembly, Solenoid Override, CFP59-F15-25 9839
Assembly, Solenoid Override, CFP59-F10/20/40/50 9699
Assembly, Control Panel Mounting 21249
Assembly, All Components Top-level:
Assembly, Panel, Digital Mechanical A042G184
Battery Contactors 12V 8824-12
Kit, Fuel Lines CFP59-F10/20/40/50 15204
Kit, Fuel Lines CFP59-F15-25 A042B473
Misc. Piping, Raw Water Cooling Loop 25983
Assembly, Raw Water Cooling Loop, 3/4" Vertical A042H724
Assembly, Raw Water Cooling Loop, 3/4" Horizontal 12V A042H725
Assembly, Raw Water Cooling Loop, 3/4" Horizontal 24V A042H726
Misc. Piping, Cooling Loop, Sea Water A042E017
Assembly, Sea Water Cooling Loop, 3/4" Vertical A042H727
Assembly, Sea Water Cooling Loop, 3/4" Horizontal 12V A042H728
Assembly, Sea Water Cooling Loop, 3/4" Horizontal 24V A042H729
Assembly, Stub-Shaft & Guard SAE#3, 1.50" QSB, QSC, 4B, 6B, 6C 8618
Assembly, Stub-Shaft & Guard SAE#3, 2.25" QSB, QSC, 4B, 6B, 6C 8619
Schematic, CFP59 A042J119

7-10
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 04/2017
 P/N A042C868 P/N A042H306

TO PUMP TB-6
CONTROLLER TB-8
TB-11

*NOTE* SEE SHEET 6 FOR BETTER VIEW OF POWER CIRCUITS

FPDP GEN II P/N A042G196

TB-301

TB-311
TB-302

TB-312
TB-303
TB-304
TB-310

TB-305

TB-306
TB-307
TB-10
TB-1

TB-2
TB-3
TB-4
TB-5

TB-9
CS P/N A042G184 POWER BOARD
SS P/N A042G186

POS NEG

LED 7
U7(PIN21)
+10V +10V +10V +10V

LED 60
BAT A

LED 47

LED 58

LED 59

K23
K15

K21

K22
POWER
U14(P1) U18(P0) U18(P1) U18(P2)
LED 19

HEARTBEAT

U9(P0)
LED 20
+10V +10V +10V +10V

LED 18
LED 15

LED 16

LED 17
D72

K14
K11

K12

K13
+10V

LED 14
TO OVERLAY

K10
U14(P4) U14(P5) U14(P6) U14(P7) POS NEG
ECM SELECTOR BUTTON
AUTO/MANUAL BUTTON

RESET / STOP BUTTON

U14(P3) P/N A042G197 J1 C1 BAT B

JP1
MANUAL MODE LED

TO LCD BATTERY A
AUTO MODE LED

+10V VBATT 6 1
CRANK BATT A

CRANK BATT B

D1
TOUCHSCREEN USB BATTERY B S
+10V +10V 4 2
ECM A LED

ECM B LED

Y BOTTOM

D2

LED 53

LED 13

LED 3
GROUND

GROUND

GROUND

GROUND
X RIGHT

K17

K9

K3
5 3
X LEFT

Y TOP

VBUS
+3.3V

TO LCD 3
GROUND
4
D+
D-

U17(P1) U14(P2) U3(P3) CRANK A

2 12
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 40 PIN FLEX CABLE +10V VBATT

LED 4
K4
+3.3V
U2(PIN93)

U2(PIN76)

U2(PIN94)

U2(PIN98)

U2(PIN77)

U2(PIN78)

U2(PIN81)

U2(PIN82)

U2(PIN99)

U4(PIN25)

U4(PIN26)

U4(PIN23)

U4(PIN24)

U2(PIN54)

U4(PIN56)

U4(PIN57)

U3(P4) CRANK B
1 13
+10V VBATT
P/N A042G198

LED 5
JP1 JP7 BATTERY ISOLATOR

K5
GROUND
1 1 JP6 ALT C4
GROUND U3(P5) OR U7(PIN12) ALTERNATOR EXCITE
2 2 9 14 B+ C
D6 D7
GROUND
15 15 LED 50 EXCITE
GROUND
16 16
+10V +10V CONFIGURABLE INPUT 1
+10V
3 3 U9(P1)
D30 4 10
+10V
+10V +10V LED 8

LED 11

LED 52
4 4 CONFIGURABLE INPUT 2

K16
K7
+10V U9(P2)
D31 15 11
13 13 LED 9
+10V CONFIGURABLE INPUT 3
14 14 U14(P0) OR U7(PIN11) U17(P0)
U9(P3) 18 19 C9
RS485 SHIELD D32
19 19 LED 10 8 BATTERY A

RS485 + 9 BATTERY B
U19(A) 17 17
POWER RS485 - 10 GROUND
U19(B) 18 18 +10V +10V
U20G

LED 21
LED 1 MAG PICK-UP
12 12 7 CONFIGURABLE SWITCH INPUT 1

LED 6
U2(PIN74) +10V

K27
IN OUT

K6

LED 54
SCL COM 1 DPEM

K18
U2(PIN66) 7 7 SCL CONFIGURABLE SWITCH INPUT 2
HEARTBEAT +10V
SDA U3(P6)
LED 2 U2(PIN67) 8 8 SDA U3(P2) 2 CONFIGURABLE SWITCH INPUT 3
VBATT ASO RELAY GROUND
VCC VCC VCC U17(P2) 12 28
5 5
6
VCC
6 11 16 6 RS485 SHIELD
RS485 +
U8(CANH) 9
J1939 +
9 10 21 4 RS485 +
R65
U8(CANL) 10
J1939 -
10 22 22 5 RS485 -
P/N A042G195 J1939 SHIELD
RS485 -

DISPLAY BOARD 11 11
CAN GND C13 R1

RF1 C6
KEY / FSO COOLING LOOP PRESSURE TRANSDUCERS 5V SUPPLY
VCC
OVERRIDE SWITCH 23 23 A 5V SUPPLY
VBATT
COOLING LOOP PRESSURE PRE SIGNAL COOLING LOOP
U7 (PIN23) 7 25 C SIGNAL
PRE PRESSURE
B GROUND

C7
JP2 A 5V SUPPLY
COOLING LOOP PRESSURE POST SIGNAL COOLING LOOP
7 ENGINE STOP U7 (PIN24) 19 26 C SIGNAL
POST PRESSURE
8 B GROUND
LED 49

9
+10V
1 COOLING LOOP GROUND
COOLING LOOP TEMP SIGNAL
2 U7 (PIN5) 16 17 COOLING LOOP WATER TEMPERATURE

3 +10V VBATT C2

LED 57
ECM OVERRIDE SWITCH
RAW WATER SOL.

K8
4 2 GROUND
NC
RAW WATER SOLENOID B+
5 5 15 1 VBATT
(ENERGIZE TO RUN)

6 LED 51

11 U17(P5) MAG PICK-UP

MAG PICK-UP +
12 U7 (PIN13) 1 5
MAG PICK-UP -
10 13 6

C5
C GROUND
FSO B+
2 7 A HOLD B+ FUEL SHUT-OFF
B PULL-IN B+

OIL PRESSURE SIGNAL

U7 (PIN25) 14 8 OIL PRESSURE SENDER
COOLANT TEMP SIGNAL
+10V +10V +10V +10V U7 (PIN4) 3 9 WATER TEMPERATURE SENDER
LED 56

LED 55

LED 2

LED 1
K20

K19

K2

K1

U17(P4) U17(P3) U3(P1) U3(P0)

AUTO CAD
 DPEM OPTION
P/N 18487 DPEM
WIRE HARNESS P/N 18488 POWER BOARD +10V +10V +10V +10V
SS P/N 18485

LED 21

LED 20

LED 19

LED 18
C1 JP1

K14

K13

K12

K11
C2 J1 BATTERY A
BATTERY A 8 21 13 D13
BATTERY B VBATT U15(P3) U15(P2) U15(P1) U15(P0)
BATTERY B 9 23 14 D14
GROUND ENERGIZE TO STOP INPUT
U5(P0) TB-12
GROUND 10 22 1
GROUND SWITCH 1
TB-13
24 2
SWITCH 2
TB-14
POWER
SWITCH 3
CONFIGURABLE SWITCH INPUT 1 7 LED 17 TB-15
SWITCH 4
CONFIGURABLE SWITCH INPUT 2 1 TB-16
HEARTBEAT
COMMON
CONFIGURABLE SWITCH INPUT 3 2 TB-17
LED 8
JP8
RS485 SHIELD 6 28 3 +10V +10V +10V +10V

LED 25

LED 24

LED 23

LED 22
RS485 + 4 26 1 U19(A)

K18

K17

K16

K15
5 27 2 U19(B)

CUSTOMER CONNECTIONS
RS485 -

U15(P7) U15(P6) U15(P5) U15(P4)

*CONNECTS TO DPEM CONNECTOR ON SHEET 1*
CONFIG SWITCH INPUT 1 CONFIG SWITCH INPUT 2
R78
1 GROUND 1 GROUND
DROP A2
TEMPERATURE A
TB-18
2 SIGNAL 2 SIGNAL DROP A1 TEMPERATURE B
DROP A0 TB-19
TEMPERATURE C
TB-20
CONFIG SWITCH INPUT 3 EXHAUST TEMPERATURE
TB-21
SW1
COMMON
1 GROUND TB-22
2 SIGNAL

+10V +10V +10V +10V

LED 12

LED 11

LED 10
JP1

LED 9
K6

K5

K4

K3
TEMPERATURE A
3 16 U1(PIN2)
U9(P3) U9(P2) U9(P1) U9(P0)
TEMPERATURE B
5 17 U1(PIN3)
PRESSURE A
TB-23
TEMPERATURE C
7 18 U1(PIN4) PRESSURE B
TB-24
PRESSURE C
PRESSURE A TB-25
4 5 U1(PIN21)
PRESSURE D
TB-26
PRESSURE B COMMON
6 6 U1(PIN22) TB-27

PRESSURE C
8 7 U1(PIN23)
+10V +10V +10V +10V

LED 16

LED 15

LED 14

LED 13
K10
PRESSURE D

K9

K8

K7
10 8 U1(PIN24)

PRESSURE E U9(P7) U9(P6) U9(P5) U9(P4)

12 9 U1(PIN25)

PRESSURE F PRESSURE E
14 10 U1(PIN7) TB-28
PRESSURE F
TB-29
SWITCH 1
9 19 D3
U5(P1) TB-30
LED 3
SWITCH 2 TB-31
11 20 D5
U5(P2)
COMMON
LED 4 TB-32
SWITCH 3
13 21 D6
U5(P3)
LED 5
SWITCH 4
15 22 D8
U5(P4) JP3
LED 6
+ 1
U1(PIN5)
- 2 U8A

TYPE K THERMOCOUPLE
EXHAUST TEMPERATURE

AUTO CAD
P/N A042G197
CRANK A 12

BATTERY A 1

BATTERY ISOLATOR ALTERNATOR

ALTERNATOR EXCITE 14 B+
GND

CRANK B 13
S
STARTER

B+
BATTERY B 2

GND
FSO B+ 7

GROUND 3
GROUND 4

FSO
GROUND C
HOLD B+ A
PULL-IN B+ B

DPEM
GROUND 10
BATTERY A 8
BATTERY B 9
POS NEG POS NEG

P/N A042C868
BAT A BAT B ENGINE BLOCK
TB-6
TB-8
TB-11

AUTO CAD