CFP59

Fire Pump Drive Engines
CFP59 Series
Operation and Maintenance Manual
Doc. A042J557
September 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 cumminsfirepower.com to view the English version of 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.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.9 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.9 Coolant System Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.10 Charge Air Cooler (CAC) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.11 Lubricating Oil System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.12 Pre-Start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.13 Engine Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.14 Field Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Air Cleaner Filter and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.4 Engine Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.6 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.7 Electrical Supply and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.8 Crankcase Ventilation Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.9 Cooling Water Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.10 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.11 Engine Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.12 Engine Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.12.1 Crank Termination Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.12.2 Engine Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.3.12.3 Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.2 Turbocharger Mounting Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.3 Engine Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.6 Every Four Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6.1 Coolant Thermostat Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.6.2 Coolant Pump/Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
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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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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.
Cummins Fire Pump Drive Engine CFP59 1-1

Doc. A042J557, Rev. 09/2017
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.
1-2 Cummins Fire Pump Drive Engine CFP59

Doc. A042J557, Rev. 09/2017
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

Doc. A042J557, Rev. 09/2017
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

Doc. A042J557, Rev. 09/2017
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.

Doc. A042J557, Rev. 09/2017
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)

Doc. A042J557, Rev. 09/2017
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)

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Description
2.6 Fuel Supply and Drain
As shown in Figure 2-1, the fuel supply and return
connections are centrally located on the FPDP side.
Refer to the Engine Data Sheet in Section 8 - Compo-
nent Parts and Assemblies for the maximum allow-
able fuel tank supply locations above the fuel pump.
2.7 Fuel System

The fire pump drive engine is equipped with a fuel
system that provides fuel metering and timing based
on engine speed and load.

Doc. A042J557, Rev. 09/2017
Description
2.8 Engine Oil System NOTE: Typically engine oil has been added during
manufacture and testing procedures; however,
Figure 2-8 illustrates how the engine oil system lubri-
shipping restrictions can affect whether the oil is
cates moving internal engine parts (pistons, connect-
maintained in the engine or drained for shipping.
ing rods, valves, cam shafts, shafts, and bearings).
Check the oil level at the dipstick. Add oil as neces-
The oil pump circulates oil from the oil pan, through
sary to bring the oil level to the H (high) mark on the
the oil filter, and into engine areas where friction may
dipstick.
develop. Refer to the Cummins engine Operation and
Maintenance Manual for additional information.
14 15
16

12

CFP-010

1. Idler Gears 9. Combination Oil Filter
2. Check Valve 10. Filter Bypass Gears
3. Oil Pump 11. Oil Cooler
4. Pressure Regulator Valve 12. Crankshaft, Connecting Rod and Piston
5. Oil Return to Pan 13. Turbocharger
6. Oil Return to Pan 14. Piston Cooling
7. High Pressure Relief Valve 15. Rocker
8. Oil Thermostat 16. Camshaft
Figure 2-8 Engine Lubricating Oil System Flow Diagram (Typical)

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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)

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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)

Doc. A042J557, Rev. 09/2017
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.

Doc. A042J557, Rev. 09/2017
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 of the model-specific English manual.
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
NOTE: Cummins recommends using a good quality

semi-synthetic, molybdenum-fortified National Lubri-
cating Grease Institute (NLGI) #2 lithium complex
grease.

Doc. A042J557, Rev. 09/2017
Installation
An optional fuel pre-filter and a fuel filter/water sep- NOTE: The cooling water outlet piping from the heat
arator is integrated into the fuel delivery system of the exchanger should be one pipe size larger than the
fire pump drive engine. To ensure that the filter/sep- supply piping.
arator is free of water, open the fuel filter/water sep-
arator drain at the bottom of the filter and drain the 2. Check the pressure regulator setting on the
fuel into a container until no water is present. Dispose cooling loop with water flowing through the heat
of the contaminated fuel in accordance with local exchanger. The cooling loop is supplied by Cum-
environmental regulations. mins; both water pressure regulators have been
set at 276 kPa (40 psi) (or slightly less) water
pressure during manufacture and testing.
CAUTION
Due to the precise tolerances of diesel injection IMPORTANT: The manual water valves for the auto-
systems, it is extremely important that the fuel be matic loop should remain OPEN at ALL times. The
kept clean and free of dirt or water. Dirt or water in manual valves for the bypass loop should be
the system can cause severe damage to both the CLOSED during automatic (pump controller) opera-
fuel pump and the fuel injectors. tion. When running, the engine should stabilize
between temperatures identified on the Engine Data
Sheet. The flow rate may need to be adjusted to
WARNING maintain the desired engine temperature.
Do not mix gasoline, alcohol, gasohol, ethanol, or
methanol with diesel fuel. This mixture will cause NOTE: Excessively cold (4 °C to 23 °C [40 °F to 75
severe engine damage or explosion. °F]) cooling water flow can cause condensation
inside the charge air cooler.
CAUTION
IMPORTANT: Continuous operation with low coolant
Use ONLY no. 2 diesel (ASTM no. 2D) fuel. Any
temperature (below 70 °C [158 °F]) or high coolant
fuel other than no. 2 diesel fuel may affect emis-
temperature (above 107 °C [225 °F]) can damage the
sion levels. Any adjustment to compensate for
engine.
reduced performance with a fuel system using
alternate fuel is not warrantable. 3. Adjust the cooling water based on the water flow
rather than the water pressure. The flow is
3.6 Cooling Water Supply Installation dependent on the cooling water temperature.
IMPORTANT: The cooling water supply must be Refer to the Engine Data Sheet in Section 7 -
immediately available when the engine is started. Component Parts and Assemblies of the model-
Ensure that the supply line valves are in the OPEN specific English manual for details.
position.
4. To measure the water flow, use an appropriate-
NOTE: The flow rate of the cooling water should be sized container to measure the amount of water
as great as possible without exceeding the maximum and the elapsed time of the water to flow from
allowable pressure shown in the Engine Data Sheet the discharge pipe and then formulate the calcu-
in Section 7 - Component Parts and Assemblies of lations:
the model-specific English manual.
Flow rate = container size/ time to fill container.
To install the cooling water supply:
Example:
1. Provide a cooling water discharge line at the out- Time to fill a 20 gallon container = 15 seconds.
let of the engine coolant heat exchanger and
provide a cooling water supply line to the cooling 20 gallons divided by 15 seconds = 1.33 gallons per
water inlet per the Engine Data Sheet in Section second.
7 - Component Parts and Assemblies of the Multiply by 60 seconds = 80 gallons per minute (gpm)
model-specific English manual. (FLOW RATE)

Doc. A042J557, Rev. 09/2017
Installation
5. Adjust both pressure regulators to a pressure
that will provide a flow rate at or above the spec- WARNING
ifications listed in the Engine Data Sheet. Battery electrolyte (sulfuric acid) is highly caustic
and can burn clothing and skin. Wear impervious
neoprene gloves and safety goggles, or a full face
CAUTION shield, when working with the batteries.
When the cooling water piping is installed, adjust
both of the pressure regulator set points before IMPORTANT: Batteries must meet the requirement
operating the pump. Damage to the heat listed in the electrical system specifications. Batteries
exchanger may occur from improperly regulated may be supplied by Cummins as an option, or may be
cooling water supply pressure. supplied by the customer.
IMPORTANT: Monitor the oil pressure and coolant To properly install the batteries:
temperature gauges frequently. Refer to Lubricating
Oil System Specifications or Cooling System Specifi- 1. As shown in Figure 3-3 or Figure 3-4, install the
cations in the Engine Data Sheet in Section 7 - Com- Battery Cable Kit or equivalent customer-sup-
ponent Parts and Assemblies of the model-specific plied wiring. Install battery sets in a well-venti-
English manual for recommended operating pres- lated or otherwise protected location.
sures and temperatures. Shut off the engine if any
pressure or temperature does not meet the specifica-
tions. WARNING
NOTE: Maximum engine coolant temperature should Batteries can emit explosive gases during
not exceed the temperature listed on the Engine Data charging. Always ventilate the compartment
Sheet found in Section 7 - Component Parts and before servicing the batteries. To avoid arcing,
Assemblies of the model-specific English manual. remove the negative (-) battery cable first and
The coolant expansion pressure/fill cap must meet attach the negative (-) battery cable last.
the minimum pressure of 10 kPa (15 psi).
The engine coolant system contains a mixture of at

least 50% antifreeze and 50% water. The coolant
level should be maintained so it is visible in the
coolant level sight gauge.
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 of the model-spe-
cific English manual. RC and CCA definitions can be
found in SAE Standard J537. Refer to NFPA 20 and Figure 3-3 Series Battery Connection 12 VDC
FM 1333 standards for additional battery installation
information. 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.

Doc. A042J557, Rev. 09/2017
Installation
Figure 3-4 Series Battery Connection 24 VDC
NOTE: Coat the terminals with petroleum jelly to off (FSO) and raw water solenoid are acti-
prevent corrosion. Install the cables and tighten the vated when voltage is present at TB-1. When
battery connections. TB-1 is removed while the engine is running,
the FPDP will command electronic engines to
3.8 Signal and Control Installation idle for up to three minutes.
The fire pump controller wires must be connected to
the terminal blocks (TBs) on the FPDP Interface Ter- b. TB-2 [Crank Termination Switch]: This B+
minal Strip and on the Battery Charger Interface. To signal is provided by the FPDP to inform the
complete the signal and control installation: pump controller that the engine is running.
Crank Termination indicates that the engine
1. Ensure that the fire pump controller is properly has started and that the crank command from
installed and configured per the manufacturer’s the fire pump controller should stop immedi-
instructions. ately.
2. Complete the fire pump controller wiring (cus- c. TB-3 [Overspeed Switch]: This B+ signal is
tomer-supplied) per the manufacturer’s instruc- provided by the FPDP when the engine
tions. speed has exceeded 115% of the rated
engine speed. When overspeed occurs, the
3. Ensure electrical continuity and adequate insula- ECM keyswitch or FSO outputs and the raw
tion resistance for the installed wiring. Refer to water cooling loop solenoid are immediately
Section 4.3.1.1 Engine Setup Screen to conduct deactivated in an attempt to stop the fire
a Terminal Block Test from the FPDP. pump drive engine. The FPDP will not allow
the engine to be restarted until after the over-
3.8.1 FPDP Interface Terminal Strip speed alarm has been reset.
As shown in Figure 3-5, the TBs between the fire
d. TB-4 [Low Lubricant Pressure Switch]: A
pump controller and the fire pump driver are standard
ground path is provided by the FPDP when
UL and FM controller terminals and follow a direct
one-to-one correspondence (some TBs are optional): the oil pressure has dropped below the 16 psi
(110 kPa) set point when the engine is run-
a. TB-1 [Run Solenoid Circuit]: This B+ signal ning. A ground path is also provided to indi-
is necessary for fire pump operations while in cate low oil pressure when the engine is NOT
the FPDP is in AUTO mode. The Electronic running.
Control Module (ECM) keyswitch/Fuel Shut-

Doc. A042J557, Rev. 09/2017
Installation
f. TB-9 [Main Battery Contactor One Coil or
Battery Relay One Coil]: This B+ signal is
driven from the fire pump controller to contac-
tor A when desiring to crank the engine from
Battery A. Current in this circuit shall not
exceed 10A continuous.
g. TB-10 [Main Battery Contactor Two Coil or

Battery Relay Two Coil]: This B+ signal is
driven from the fire pump controller to contac-
tor B when desiring to crank the engine from
Battery B. Current in this circuit shall not
exceed 10A continuous.
h. TB-301 [ECM Switch]: Not applicable to

mechanical engines.
i. TB-302 [Fuel Injection Malfunction (FIM)]:

Not applicable to mechanical engines.
j. TB-303 [ECM Warning]: Not applicable to

mechanical engines.
k. TB-304 [ECM Failure]: Not applicable to

mechanical engines.
l. TB-305 [Custom Output 1]: A ground path is

provided by the FPDP when the custom
alarm is configured and activated.
NOTE: If an Air Shutoff Valve is purchased, TB-305 is

reserved for valve position feedback.
m. TB-306 [Custom Output 2]: A ground path is

n. TB-307 [Custom Output 3]: A ground path is

Thermocouple Input o. TB-310 [Raw Water High Inlet Tempera-

ture] - not applicable on radiator-cooled
models: A ground path is provided by the
FPDP when high raw water temperature is
Figure 3-5 FPDP Interface Terminal Strip sensed.
e. TB-5 [High Engine Temperature Signal]: A p. TB-311 [Clogged Raw Water Coolant Loop
ground path is present when the engine is Strainer] - not applicable on radiator-cooled
running and the coolant temperature is at or models: A ground path is provided by the
above 212 °F (100 °C). FPDP when the raw water supply restriction
is sensed.

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Installation
q. TB-312 [Low Engine Temperature Signal]: To complete the battery signal connections:
A ground path is provided by the FPDP when
the engine coolant falls below 100 °F (37.8 1. Provide the initial charge on the redundant bat-
°C). teries per the battery charger’s instructions.
r. Type K Thermocouple Input - optional: The 2. Check that both voltmeters on the FPDP indicate
screws to the Type K thermal couple input the approximate battery voltage.
may be loosened for installation of an
exhaust temperature. NOTE: Both sets of batteries can be used for starting
the engine in the event that one set is low.
3.8.2 Battery Charger Interface
As shown in Figure 3-6, the Battery Charger Interface 3.9 Coolant System Preparation
provides power to the fire pump controller, as well as The fire pump drive engine cooling and lubrication
provides charging current to the fire pump drive system was initially filled during manufacture and
engine batteries. The Battery Charger Interface testing. To properly prepare the coolant system:
includes:
a. TB-6 [Battery A Positive]: The fire pump CAUTION

controller senses Battery A charge state and
Ensure that all coolant systems have been filled
charges Battery A through TB-6.
to the proper level before operation by checking
the coolant level sight gauge on the heat
b. TB-8 [Battery B Positive]: The fire pump
exchanger.
controller senses Battery B charge state and
charges Battery B through TB-8. 1. Inspect the engine coolant hoses and hose
clamps and ensure that all coolant hoses and
c. TB-11 [Battery A and Battery B Negative]: clamps are properly installed and water tight.
The fire pump controller uses TB-11 as a
ground reference for incoming power, as well 2. Ensure that the engine coolant heater maintains
as to charge the fire pump drive engine bat- an engine coolant temperature of 49 °C (120 °F)
teries. or above.
NOTE: This is not intended to create a fully isolated 3. Ensure that coolant is present in the engine
battery negative or ground system. Current in each coolant heater before plugging the heater
terminal block shall not exceed 30A continuous. 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
turbocharger before entering the air intake manifold.
Inspect the CAC piping and hoses for loose/missing

hose clamps, hose punctures, leaking manifold seals,
or corrosion. Torque the hose clamps to the recom-
mended torque value.
Figure 3-6 Battery Charger Interface

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Installation
Refer to the Engine Data Sheet in Section 7 - Compo- 3. Check that all hoses and tubes are properly
nent Parts and Assemblies of the model-specific installed.
English manual.
4. Check that all electrical connections are properly
3.11 Lubricating Oil System Preparation installed.
The fire pump drive engine and turbocharger were
initially lubricated during manufacture and testing. To 5. Check that the fire pump drive engine is properly
prepare the lubricating oil system for operation: installed per the pump manufacturer’s instruc-
tions, is correctly aligned, and is free to rotate.
1. Check the oil level using the dip stick before
operating the fire pump drive engine. 6. Lubricate the grease fittings on the axillary drive
shaft.
2. Fill the oil fill port to the “H” mark on the dipstick
with lubricating oil. NOTE: Use the same type of oil as used in normal
operation. Cummins Inc. recommends Premium
NOTE: Do not use special “break-in” lubricating oils Blue® 15W-40 oil for most climates.
for new or rebuilt Cummins engines. Use the same
type of oil during the “break-in” as used during normal After completing preliminary set-up procedures,
operation. perform the engine start test as outlined in detail in
Section 4 - Operation.
CAUTION WARNING
Some regulatory and shipping restrictions may
require that all lubricants, fuels, and coolants be Before operating the equipment, complete all
drained for transport. Ensure that all cooling and safety checks, remove all tools and foreign
lubrication systems have been filled to the proper objects from the equipment, and ensure that all
level before operation. guards are in place and securely fastened. Alert
area personnel that the equipment will be start-
NOTE: Using multi-viscosity lubricating oil can ing. Unintentional equipment start-up or contact
improve oil consumption control and improve engine with exposed or moving components can cause
cranking in cold temperatures while maintaining lubri- personal injury or equipment damage.
cation at high operating temperatures. Cummins Inc.
recommends Premium Blue® 15W-40 oil for most cli-
mates. CAUTION
If the oil pressure is not displayed on the gauge
NOTE: Ensure that all cooling and lubrication or if the low oil pressure message is displayed
systems have been filled to the proper level before within fifteen seconds, STOP THE ENGINE IMME-
operation. DIATELY! Continued operation without proper
lubrication will cause engine damage.
IMPORTANT: Cummins recommends that provisions
be made within the VSPLC connection line to account 3.13 Engine Monitoring
for any engine vibration and movement. When the engine starts, it is important to monitor the
displays:
3.12 Pre-Start Inspections
Prior to starting the fire pump drive engine for the first 1. Immediately check that water flow is established
time, perform a visual inspection: through the coolant heat exchanger. The water
flow should be established immediately, but
1. Check that there is no apparent damage and some delay may occur before the flow exits the
that all components are installed. heat exchanger drain connection.
2. Check that the drive belt is properly installed. NOTE: Ensure that cooling water is flowing through
the heat exchanger and the water pressure shown on
the local pressure gauge is no more than 414 kPa (60

Doc. A042J557, Rev. 09/2017
Installation
psi). The minimum cooling water flow rate is identified 8. Check the engine lubricating oil level at the dip
in the Engine Data Sheet in Section 7 - Component stick. Add oil, if necessary.
Parts and Assemblies of the model-specific English
manual. 9. Check the coolant expansion tank level. Add
coolant, if necessary.
2. Ensure that the engine operating temperature
stabilizes between applicable ranges as identi- 10. Check the cooling water strainers. Clean the
fied in the Engine Data Sheet in Section 7 - strainers according to the maintenance schedule
Component Parts and Assemblies of the model- in Section 5 - Maintenance.
specific English manual.
11. Perform engine speed control and safety system
3. Operate the engine for eight to ten minutes. tests per the instructions in Section 4 - Opera-
tion.
4. Inspect the engine for leaks, unusual noises, or
other indications of incorrect operation. 3.14 Field Acceptance Testing
The required installation tests are outlined in the
5. Shut off the engine by pressing and holding the NFPA 20 Standards and shall be performed to vali-
overspeed RESET/STOP switch. date automatic and manual operational requirements
for field acceptance testing.
6. Shortly after the engine stops, check that the
water flow stops automatically. NOTE: The maximum engine speed should only be
altered by a Cummins technician.
7. Correct any problems found during the inspec-
tion before proceeding.

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Installation

Doc. A042J557, Rev. 09/2017
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.

Doc. A042J557, Rev. 09/2017
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
5. Check that the engine starts and operates at the
rated speed.
1. Battery A Starter Contactor
IMPORTANT: Engine oil pressure must be indicated 2. Battery B Starter Contactor
on the gauge within fifteen seconds after starting.
Figure 4-3 Manual Starter Contactors

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Operation
The engine may be stopped locally by pressing the 4.3 Fire Pump Digital Panel (FPDP)
RESET/STOP button on the FPDP or by holding Screens and Adjustments in Automatic
down the red ENGINE STOP button on the left side of
Mode
the FPDP.
As shown in Figure 4-4, the FPDP consists of a
IMPORTANT: Upon release of the Engine STOP Liquid Crystal Display (LCD) touchpad that displays
Button, the fire pump drive engine will attempt to the fire pump drive engine tachometer, coolant tem-
restart, If there is still a “pump on demand” signal perature, oil pressure, Battery A voltage, Battery B
present from the FPDP. The engine must also be voltage and hour meter, as well as includes two soft
stopped at the fire pump controller. If the fuel solenoid keys:
does not open, use the fuel solenoid override located
on the fuel pump. Push the plunger in to run the fire • MENU Soft Key
pump drive engine. Monitor the engine, as needed.
To stop the fire pump drive engine, pull the plunger • SCREEN Soft Key
out.
For models CFP59 F15 and F25, use the fuel sole-
noid 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 to lock the fuel solenoid.
To stop the fire pump drive engine, turn the fuel sole-
noid counter-clockwise and push the handle in. Figure 4-4 FPDP User Interface Screen (Typical)
NOTE: Electronic engines display tachometer, engine

temperature and oil pressure values from J1939.
Mechanical engines display parameters via sensors
added by Cummins.
NOTE: When the key switch is not on, the coolant

temperature defaults to “0 °F” (or “0 °C”) and the oil
pressure defaults to “0 PSI” (or “0 kPa”).
The FPDP LCD will go into SLEEP MODE after

fifteen minutes of inactivity by the user. The FPDP
LCD will resume normal display features when the
user presses a hard button or touches the LCD
screen.

Doc. A042J557, Rev. 09/2017
Operation
4.3.1 The MENU Soft Key Press SUBMIT to access the Engine Setup screen,
If the operator presses the MENU Soft Key from the shown in Figure 4-7.
FPDP User Interface Screen, the Settings Menu
Screen appears as shown in .
Figure 4-7 Engine Setup Screen (Typical)

Figure 4-5 Settings Menu Screen (Typical)
As shown in Figure 4-8, the System Options sub
The Settings Menu provides options for further opera-
menu displays the custom configurations of the fire
tor input and monitoring of fire pump drive engine
pump drive engine. When active, the soft buttons turn
parameters. Press the corresponding soft key to
green in color and display “ON.” Conversely, the soft
access a sub-menu.
button will turn red in color and display “OFF”, if the
4.3.1.1 ENGINE SETUP Screen - SYSTEM feature is disabled.
OPTIONS
The fire pump drive engine was preconfigured with
custom options (if applicable) at the factory prior to
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).
Overspeed Shutdown – When active, the FPDP

Figure 4-6 Engine Setup Login Screen (Typical) shuts the engine fueling off when the engine speed

Doc. A042J557, Rev. 09/2017
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;

Doc. A042J557, Rev. 09/2017
Operation
2. Press the OVERSPEED TEST soft key from the To change the displayed units of measurement:
Settings Menu; and then
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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Operation
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: Additionally, there are two other ways to alert the
operator of a DPEM fault:
Menu), press the MENU Soft Key; and From the FPDP - As shown in Figure 4-14, the
warning symbol will illuminate and the overlay will
2. Press the ANALOG VALUES soft key from the activate in yellow with the text of the active fault
Settings Menu.
3. To exit the Analog Values menu, press the

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.
Figure 4-14 DPEM Fault Screen (Sample)
To access the DPEM Screen:
From the DPEM/remote location - The terminal
1. Starting at the User Interface Screen (Main block interface inside of the DPEM has been created
Menu), press the MENU Soft Key; and for connection to monitor alarms remotely. There is
an LED next to each terminal block that will also illu-
2. Press the DPEM soft key from the Settings minate if the relay is commanded closed.
Menu.
Each set of four relays has a common dry contact
To exit the DPEM Screen, press the RETURN soft associated for integration flexibility:
key.
• Terminal Blocks 13-16 (R1-R4) are dedicated to
switched inputs, with TB-17 being the common
contact

Doc. A042J557, Rev. 09/2017
Operation
• Terminal Blocks 18-21 (R5-R8) are dedicated to deactivate the Fault overlay, press the SCREEN Soft
temperature inputs, with TB-22 being the com- Key to make the overlay disappear from the LCD.
mon contact
Figure 4-16 shows the location of the Analog Values
• Terminal Blocks 23-26 (R9-R12) are dedicated overlay when you press the SCREEN Soft Key. The
to pressure inputs, with TB-27 being the com- Analog Values overlay background color displays in
mon contact gray.
• 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:
Figure 4-15 DPEM Lost Fault Screen (Sample)
• Exhaust temperature (when a pyrometer is
4.3.2 The SCREEN Soft Key installed and landed to the Power Board).
The SCREEN Soft Key, on the bottom right of the
• Cooling loop raw water temperature and strainer
LCD, deactivates and activates an overlay box which
status on FM-approved and UL-listed fire pump
lies atop the tachometer signal (the engine speed is
drivers.
still digitally displayed). The overlay is used to:
• J1939 parameters are not available on mechani-
• Automatically - Warn the operator of ECM and/or
cal engines. The oil temperature, intake manifold
DPEM faults, when applicable (see Section
temperature, and intake manifold pressure val-
4.3.1.5 Analog Values Screen); and/or
ues display as “NWF.”
• Operator-selected - Display additional analog
To deactivate the Analog Values overlay, press the
values not required by NFPA 20.
SCREEN Soft Key to make the overlay disappear
from the LCD.
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

Doc. A042J557, Rev. 09/2017
Section 5 - Maintenance
5.1 Introduction to the component manufacturer’s vendor supplied
Before performing maintenance procedures, read literature for specific maintenance recommendations.
and understand Section 1 - Safety of this manual.
Improper performance or lack of critical information 5.2 Engine Operation Reports
could result in personal injury or equipment damage. The engine must always be maintained in top
mechanical condition. Proper maintenance of the fire
Cummins encourages our customers to perform pump drive engine requires documenting regular
maintenance and repairs whenever necessary. running reports to include the following:
However, servicing complex components within the
normal warranty period may void the Cummins war- • Low engine oil pressure.
ranty and any specified warranty extended by the
manufacturer of Original Equipment Manufacturer • Engine surge.
(OEM) products. See the warranty information at the
beginning of this manual. • Erratic operation or frequent shutdowns.
Maintenance procedures should be performed by • Any warning lamps flashing or staying illumi-
skilled technicians who are familiar with the equip- nated.
ment, local regulations, and service procedures for
fire pump drive engine and pump systems. Improper • Abnormal coolant or oil temperature.
maintenance can damage the engine or the fire pump
drive engine, or cause severe personal injury. • Unusual engine noise or vibration.
The National Fire Protection Association (NFPA) 25 • Excessive smoke.

Standard outlines the maintenance tests to be per-
formed to validate automatic and manual operational • Excessive use of coolant, fuel, or engine oil.
requirements for field acceptance testing.
• Any fluid leaks.
Cummins recommends that the engine be maintained
according to the Cummins Operation and Mainte- • Loose, worn, or damaged parts.
nance Manual for that engine family.
The weekly running report also helps to make
NOTE: If your engine is equipped with a component provisions for more extensive maintenance, as the
or accessory not manufactured by Cummins Inc, refer reports indicate the necessity.

Doc. A042J557, Rev. 09/2017
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
NOTE: All maintenance and inspections intervals are accumulative. When performing annual maintenance,
also perform maintenance listed under daily, weekly, monthly, and three month intervals.

Doc. A042J557, Rev. 09/2017
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 of the
ditions. model-specific English manual.
5.3.1 General
Each week, a general walk-around inspection should
CAUTION
include the following areas: Never operate the engine without an air cleaner.
Intake air must be filtered to prevent dirt and
1. Check fluid levels before starting the engine. debris from entering the engine and causing pre-
Check oil pressure and coolant temperatures mature wear. Dirt or foreign objects could cause
frequently. Most engine problems give an early engine damage.
warning.
a. If the red indicator flag is at the raised posi-
tion in the window, clean or replace the air fil-
2. Look and listen for changes in engine perfor-
ter per the manufacturer’s recommendation
mance, sound, or appearance that will indicate
as required. Do not remove the felt washer
that service or repair is needed. Be alert for mis-
from the indicator. The felt washer absorbs
fires, vibration, excessive exhaust smoke, loss
moisture.
of power, or increases in oil or fuel consumption.
b. After the air cleaner has been serviced, push
3. Check the engine appearance for excessive
the flag in to reset the service indicator.
heat, wiring short circuits, excessive end-play,
vibrations, excessive wear, excessive abrasion,
IMPORTANT: See the Engine Data Sheet in Section
damaged electrical wiring, or loose electrical
7 - Component Parts and Assemblies of the model-
wiring.
specific English manual for maximum intake air
restriction.
4. Check the engine for odors of diesel fuel,
burning rubber, electrical system failure, exhaust
2. Check for corrosion under the clamps and hoses
fumes, or smoke.
of the intake system piping. Corrosion can allow
corrosive products and dirt to enter the intake
system. Disassemble and clean as required.
WARNING
Engine fuel is highly flammable and represents 3. Replace any damaged air filter or hoses and
an extreme hazard for fire or explosion when tighten loose clamps, as necessary, to prevent
exposed to electrical sparks or open flame. Clean the air system from leaking. Torque the hose
up spilled fuel immediately. Keep sources of elec- clamps to the recommended torque value. Refer
trical spark or open flame away from a fuel to the Torque Tables in Section 7 - Component
source. Parts and Assemblies.
5.3.2 Air Cleaner Filter and Piping
5.3.3 Cooling System
On a weekly basis, perform the following inspections:
1. Visually inspect the air intake filter and piping

CAUTION
daily for blockage, damage to piping, loose Do not remove a coolant pressure/fill cap from a
clamps, or punctures that can allow debris to hot engine. Shut down the engine and wait until
enter the engine. If there is a blockage, the ser- the coolant temperature is below 50 °C (120 °F)
vice indicator will be activated. Refer to Figure before removing the pressure cap. Heated
2-2. coolant spray or steam can cause severe per-
sonal injury.
NOTE: Turbocharged engines must be operated at
rated revolutions per minute (RPM) and full load to
check maximum intake air restriction.

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Maintenance
On a weekly basis, perform the following inspections and Assemblies. Replace damaged hoses and
on the cooling system: clamps as required.
1. Inspect the cooling water piping, coolant heat 6. Check the heat exchanger for leaks, damage,
exchanger tanks, charge air cooling system, and dirt buildup. Clean and repair as required.
engine coolant hoses, and hose clamps for
loose fittings, leaks, damage, and corrosion. 5.3.4 Engine Oil System
a. Tighten the hose clamps as necessary. WARNING

Perform the specific checks in this section only
b. Check for cracks, holes, or other damage. after the engine is fully stopped. Unless tests
Repair or replace as necessary. require engine operation, disconnect the battery
leads from the batteries (negative terminal first).
Contact with exposed or moving components can
CAUTION cause severe personal injury.
Never use a sealing additive to stop leaks in the
cooling system. This can result in cooling system Inspect the engine oil system on a weekly basis fol-
plugging and inadequate coolant flow, causing lowing these steps:
the engine to overheat.
1. For accurate dipstick readings, shut off the
2. With the coolant expansion tank at ambient tem- engine and wait approximately ten minutes to
perature, press down, unscrew, and remove the allow the oil in the upper portions of the engine
pressure cap as shown in Figure 2-1. to drain back into the crankcase.
a. Ensure that the coolant level is visible by 2. As shown in Figure 5-1, check the oil level at the
checking the coolant level sight gauge. engine dipstick.
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
Do not mix coolant brands or chemical solutions, 1. Oil Fill Port (on valve cover)
as this could damage the cooling system. Keep a 2. Oil Level Dipstick
record of the coolant concentration and manufac- 3. Engine Oil Filter
turer with the engine maintenance records.
Figure 5-1 Oil Level Dipstick
5. Check for soft, overly-pliant hoses, oxidation,
and loose hose clamps. Torque the hose clamps • If the oil level is greater than the high mark (H),
to the recommended torque value. Refer to the drain the excess oil and recheck the level.
Torque Tables in Section 7 - Component Parts

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Maintenance
• If the oil level is consistently below normal after a Check for leaks at all connections, welds, gaskets,
fill, check for leaks, loose or damaged gaskets, and joints. Make sure that the exhaust pipes are not
or oil in the coolant system. If the oil level is heating surrounding areas excessively. Repair any
below the low mark (L), add the equivalent type leaks immediately.
oil.
5.3.7 Electrical Supply and Controls
NOTE: Cummins recommends using Premium Blue Check the terminals on the starting batteries for clean
S.A.E. 15W-40 Multi-viscosity Lubricating Oil or and tight connections. Loose or corroded connections
equivalent. create resistance which can hinder starting. Inspect
the FPDP harness connections to be sure they are
5.3.5 Fuel System secure.
WARNING 5.3.8 Crankcase Ventilation Hose

Engine fuel is highly flammable and represents Inspect the crankcase ventilation hose for wear,
an extreme hazard for fire or explosion when damage, sludge, blockage, or dirt buildup (refer to
exposed to electrical sparks or open flame. Clean Figure 2-1). Clean the ventilation hose, if obstructed
up spilled fuel immediately. Keep sources of elec- or blocked. Replace a worn or damaged hose.
trical spark or open flame away from a fuel
source. 5.3.9 Cooling Water Strainers
As shown in Figure 5-2, the (two) cooling water
To inspect the fuel system: strainers should be cleaned weekly to remove sedi-
ment.
1. Shut off the engine.
To clean the normal line strainer, ensure that the
2. Inspect the fuel supply line, return line, filter and normal line valves are closed and the bypass line
fittings for cracks or abrasions. valves are open.
a. Ensure the lines are not rubbing against any- To clean the bypass line strainer, ensure that the
thing that could damage the fuel system bypass line valves are closed and the normal line
hoses. Repair any leaks or alter line routing valves are open.
to eliminate wear immediately.
For each cooling water strainer:
b. Relieve fuel line pressure by carefully
loosening the fuel inlet line. 1. Remove the plug.
NOTE: Refer to the Engine Data Sheet in Section 7 - 2. Inspect and remove any debris.
Component Parts and Assemblies of the model-
specific English manual for Cummins recommended 3. Install the strainer plugs.
replacement components.
4. When finished, open the normal line valves and
5.3.6 Engine Exhaust System close the bypass line valves for normal opera-
With the engine operating, inspect the entire exhaust tion.
system: exhaust manifold, exhaust flex pipe, muffler,
and piping.

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Maintenance
a. If the battery cables are corroded, remove
the battery cable clamps, starting with the
negative (-) battery cable.
b. Use a fine emery cloth or a wire brush to

clean the cable clamps and battery cables.
The metal should be shiny.
c. Wash the battery terminals with a solution of

baking soda and water (2 oz (1/4 cup) baking
1 soda to 0.94 liter (1 qt) of water).
2 d. Be careful to prevent the solution from enter-

ing the battery cells, and flush the batteries
with clean water when done.
e. After cleaning the connections, coat the ter-

minals with a light application of petroleum
1. Bypass Water Line Strainer jelly.
2. Normal Water Line Strainer
f. Reinstall and tighten the cable clamps.
Figure 5-2 Cooling Water Strainer (typical)
5.3.10 Batteries
WARNING
CAUTION Battery electrolyte (sulfuric acid) is highly caustic
and can burn clothing and skin, or cause blind-
Batteries can emit explosive gases during
ness. Wear protective clothing, impervious neo-
charging. To reduce the possibility of personal
prene gloves, safety goggles, or full-face shield
injury, always ventilate the battery compartment
when working with the batteries.
before servicing the batteries.
4. Check the electrolyte level in the batteries
monthly. If low, fill the battery cells to the bottom
CAUTION of the filler neck with distilled water.
To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the neg- 5. Check for continuity between terminals using a
ative (-) battery cable last. digital multimeter or other test equipment. Also
check the insulation resistance to ground.
For proper weekly maintenance of the batteries:
Correct any electrical faults.
1. Keep the batteries clean by wiping them with a
6. Reinstall the battery cables; attach the negative
damp cloth whenever dirt appears excessive.
(-) battery cable last.
2. Use a battery hydrometer to check the specific
5.3.11 Engine Test Run
gravity of the electrolyte in each battery cell. A
Start the engine at least once a week for a minimum
fully-charged battery will have a specific gravity
of thirty minutes with as much load as possible.
of 1.260. Charge the battery if the specific
Periods of no-load operation should be held to a min-
gravity reading is below 1.215.
imum, because unburned fuel tends to accumulate in
the exhaust system. Refer to the operating instruc-
3. Check the battery wiring and cable connections
tions in Section 4 - Operation.
for loose, corroded, worn, or damaged cables.
Check both connectors at the alternator, battery
Check that the engine starts and operates at the rec-
connections, and engine grounding lug (near the
ommended fire pump drive engine speed specifica-
starter motor).
tion and inspect the following:

Doc. A042J557, Rev. 09/2017
Maintenance
1. Check that the engine oil pressure is indicated 5.3.12.2 Engine Speed Calibration
on the gauge within fifteen seconds after start- If required, use this section to adjust the normal oper-
ing. ating speed to the nameplate value on the fire pump
drive engine.
2. Check that the engine has attained a normal
running temperature after running the engine for CFP59-F10, F20, F40, and F50 Speed Adjustment
a minimum of thirty minutes.
To adjust the speed on CFP59-F10, F20, F40, and
3. Observe that the engine is operating at the F50 fire pump drive engines, follow these steps:
proper operating speed. (If the engine is not
operating at the proper speed, see Section 1. Start the engine.
5.3.12 Engine Operation Checks.)
2. Observe that the engine starts and accelerates
4. Check for unusual engine noise. Listen for any to the currently adjusted speed setpoint.
unusual engine noise which can indicate that
service is required. 3. Locate the threaded bolts on each side of the
throttle bracket on the fuel pump side of the
5. Ensure that the oil pressure is greater than 69 engine (see Figure 5-3). To adjust the speed set-
kPa (10 psi). point to the rated speed, do the following:
6. Check that the coolant temperature is between • To increase the speed, turn the bolt on the left
70 °C (158 °F) and 107 °C (225 °F). side of the throttle bracket clockwise. The adjust-
ment of the bolt will pivot the throttle bracket
7. Check that both battery voltmeters indicate clockwise and allow more fuel through the pump
12 VDC for standard or 24 VDC for optional to speed up the engine.
operating systems.
NOTE: The bolt on the right side of the bracket is for
8. Check that the air filter service indicator has not maximum speed and may also need to be adjusted if
popped-up, indicating an air filter blockage. the maximum speed cannot be attained. Loosen the
Replace the air filter as required. lock nut and turn the bolt counter-clockwise to
increase speed. When the rated speed is correct,
End the test run by pressing and holding the over- tighten the lock nut against the stops.
speed RESET/STOP switch until the engine stops.
• To decrease the speed, turn the bolt on the left
5.3.12 Engine Operation Checks side of the throttle bracket counter-clockwise.
The following service inspections ensure that the The adjustment of the bolt will pivot the throttle
engine starts and operates properly under normal bracket counter-clockwise and allow less fuel
conditions. through the pump to slow down the engine.
When the rated speed is correct, tighten the locking

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

Doc. A042J557, Rev. 09/2017
Maintenance
b. When the rated speed is correct, tighten the
locking nuts against the stops.
4. Stop the engine.
5. Repeat Steps 1 through 4 until the desired

speed is attained.
Figure 5-3 Fire Pump Drive Engine Throttle

Bracket
CFP59-F15, F25, and F65 Speed Adjustment Figure 5-4 Fire Pump Drive Engine Linkage Rod
To adjust the speed on CFP59-F15, F25, and F65 fire 5.3.12.3 Engine Coolant Heater
pump drive engines, follow these steps: NOTE: Perform this inspection procedure twenty-four
hours after shutting off the engine.
1. Start the engine.
The engine coolant heater must maintain an engine
2. Observe that the engine starts and accelerates coolant temperature of 49 °C (120 °F) or above. The
to the currently adjusted speed setpoint. engine block must be warm to the touch (38 °C (100
°F)) in the water jacket areas (see Figure 2-2).
3. Locate the threaded linkage rod on the fuel
pump side of the engine (see Figure 5-4). If the heater does not appear to be working correctly,
Loosen the locking nuts against the stops on the contact a Cummins Authorized Repair Location.
outside of the threaded rod. To adjust the speed
setpoint to the rated speed, do the following:
a. To increase the speed, turn the rod upward

toward the engine. The adjustment of the rod
upward and toward the engine increases the
actual length of the rod to allow more fuel
through the pump to speed up the engine.
a. To decrease the speed, turn the rod down-

ward toward the floor. The adjustment of the
rod toward the floor decreases the actual
length of the rod to allow less fuel through the
pump to slow down the engine.

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Maintenance
5.4 Annual Maintenance 5.4.2 Turbocharger Mounting Nuts
All checks or inspections listed under previous main- As shown in Figure 5-5, check the turbocharger
tenance intervals must also be performed at the time mounting nuts and torque the mounting nuts to the
of the annual maintenance, in addition to those listed recommended torque value. Refer to the Torque
only under the annual maintenance interval. Tables in Section 7 - Component Parts and Assem-
blies.
5.4.1 Electrical Components
CAUTION 1
AVOID SERVICING complex components such 2
as: printed circuit boards, programmable control- 3
lers, and ECMs not specifically authorized by
Cummins Inc. Contact a Cummins Authorized
Repair Location before performing any extensive
maintenance.
4
CAUTION
To reduce the possibility of arcing, remove the
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 5
with the negative (-) cable first and check the follow-
ing:
1. Exhaust Flex Connection
1. Inspect the electrical wiring harness, electrical 2. Turbocharger
terminal connections, and electrical plug-ins for 3. Air Cleaner/Filter
secure, clean electrical contacts, worn or dam- 4. Service Indicator
aged insulation, burnt wires, broken wires, and 5. Air Cleaner Piping
loose connections (see Figure 2-1).
Figure 5-5 Turbocharger (typical)
a. Clean and tighten any loose electrical con-
5.4.3 Engine Supports
nections.
b. Repair or replace worn, damaged, burnt, or CAUTION

poorly insulated wiring immediately. Refer to Loose engine mount bolts or damaged brackets
Section 7 - Component Parts and Assem- can cause engine misalignment or excessive
blies of the model-specific English manual. vibration. These conditions can cause engine or
pump damage.
IMPORTANT: Refer to the vendor-supplied literature
Refer to Figure 2-1 for the location of the engine sup-
for recommended maintenance procedures.
ports and inspect all engine supports for cracks or
loose hardware. Check the torque on the engine
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.

Doc. A042J557, Rev. 09/2017
Maintenance
5.4.4 Fuel Pumps and Filters 3. Clean the area around the fuel filter or fuel/water
As shown in Figure 5-6, inspect the fuel injection separator heads.
pump mounting nuts (including the support bracket)
for loose or damaged hardware. Inspect the fuel line NOTE: Refer to the Engine Data Sheet in Section 7 -
hoses and fuel filters for wear, damage, loose fittings, Component Parts and Assemblies of the model-
and leaks. Repair or replace damaged hoses and specific English manual for filter replacement recom-
filters as required. mendations.
4. Remove the spent filter canisters using a filter

wrench.
5. Clean the filter mounting head surfaces of

sludge buildup and foreign particles. Ensure
mating gasket surfaces are clean.
6. Lubricate the gasket seals with clean SAE

15W-40 lubricating oil.
7. 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
mounting flange, then tighten an additional 1/4
turn.
Fuel filter or Filter/Separator
8. Open the fuel supply valves (if equipped).
CFP-058-1
Figure 5-6 Fuel Pumps (typical) CAUTION

Mechanical over-tightening can distort the
threads or damage the filter element seal.
WARNING
Engine fuel is highly flammable and represents 9. Press either the CRANK BATT A or CRANK
an extreme hazard for fire or explosion when BATT B button to start the engine to allow the
exposed to electrical sparks or open flame. Clean fuel to flow through the system.
up spilled fuel immediately. Keep sources of elec-
trical spark or open flame away from a fuel 10. Depress the contactor switch for up to fifteen
source. seconds or until the engine starts. Repeat up to
three times, if necessary.
WARNING
Do not open the fuel filter/water separator drain CAUTION
valve or dismantle the fuel lines on the high-pres- To prevent damage to the starter, do not engage
sure fuel system with the engine running. High the starting motor more than fifteen seconds.
pressure fuel spray from an operating engine can Wait fifteen seconds between each start attempt.
cause serious personal injury or fire hazard.
IMPORTANT: If the engine does not start after three
To change the fuel filters: attempts, check the fuel supply system. Absence of
blue or white exhaust smoke during cranking indi-
1. Shut off the engine. cates no fuel is being delivered.
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.

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Maintenance
5.4.5 Engine Oil and Filter c. Apply a light film of 15W-40 lubricating oil to
Engine oil becomes contaminated and essential oil the replacement filter gasket before installing
additives are depleted with use. The amount of con- the filter.
tamination is related to the total amount of fuel and oil
consumed. Change the oil at least once annually. 5. Fill the oil filter with a high-quality 15W-40 multi-
viscosity lubricating oil, such as Premium Blue®,
NOTE: For composite oil pans, always use a new or its equivalent.
sealing washer on the oil drain plug. Hold the external
locking nut in place while tightening the oil drain plug.
IMPORTANT: If the engine oil is drained from the oil

pan to make an engine repair, new oil must be used.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin. Some
state and federal agencies have determined that
used engine oil can be carcinogenic. Prolonged,
repeated contact can cause skin disorders or
other bodily injury. Wash thoroughly after con-
tact. Avoid inhalation of vapors and ingestion of
used engine oil. Dispose of the oil in accordance
with local environmental regulations.
To change the oil and filter to remove the contami-

nants suspended in the oil:
1. Operate the engine until the coolant temperature 1. Oil Fill Port (on valve cover)
reaches 70 °C (158 °F). Shut the engine off. 2. Oil Level Dipstick
3. Engine Oil Filter
2. Place an appropriate container under the oil pan
drain plug. Refer to the Engine Data Sheet in Figure 5-7 Oil Filter and Oil Level Dipstick (Typical)
Section 7 - Component Parts and Assemblies of
the model-specific English manual for oil pan 6. Center the filter ring on the threaded mounting
capacity. nipple. Screw the filter canister onto the mount-
3. Remove the oil drain plug and drain the oil mounting flange. Then tighten an additional 1/4
immediately to make sure all the oil and sus- turn.
pended contaminants are removed from the
engine.
CAUTION
4. Remove the oil filter (see Figure 5-7) following Mechanical over-tightening can distort the
these steps: threads or damage the filter element seal.
a. Clean the area around the engine oil filter NOTE: Cummins recommends using oil filter replace-
canister. Use a filter wrench to remove the fil- ment parts as outlined in the Engine Data Sheet in
ter. Section 7 - Component Parts and Assemblies of the
model-specific English manual.
b. Remove and discard the O-ring seal if it has
remained attached to the mounting flange.
Clean the filter mounting flange with a clean
lint-free cloth.

Doc. A042J557, Rev. 09/2017
Maintenance
7. Check and clean the oil pan drain plug threads To inspect the coolant pump and the alternator belt:
and sealing surface. Install the oil pan drain plug.
Torque the plug according to the Torque Tables 1. Press the AUTO/MAN button on the FPDP to
in Section 7 - Component Parts and Assemblies. place the fire pump drive engine in MANUAL
operation.
8. Fill the engine to the proper level with clean, high
quality 15W-40 oil at the fill port. 2. Disconnect both batteries at their terminals.
Remove the negative (-) cable first.
CAUTION 3. Remove the belt guard capscrews and the belt

If no oil pressure is noted within fifteen seconds guard. Set aside for re-installation (see Figure
after the engine is started, shut down the engine 5-8).
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

with a clean cloth to avoid contamination. 1. Belt Guard
2. Alternator Pulley
3. Add grease to the drive shaft universal joint 3. Drive Belt
grease fittings (see Figure 3-2). 4. Idler Pulley
5. Coolant Pump Pulley
4. Wipe excess grease from the grease fittings. 6. Balancer Pulley
7. Belt Tensioner
NOTE: Cummins Inc recommends using a good
quality semi-synthetic, molybdenum-fortified NLGI #2 Figure 5-8 Coolant Pump/Alternator Belt (typical)
lithium complex grease which protects from -47 to
204 °C (-54 to 400 °F). 4. Visually inspect the belt for frayed, worn, missing
pieces, or cracked belt surfaces. Check the belt
for intersecting cracks.
CAUTION
5.4.7 Coolant Pump/Alternator Belt Belt damage can be caused by: incorrect tension,
On some engine models, the pump and alternator incorrect size or length, pulley misalignment,
belt drives both the pump and alternator. incorrect installation, severe operating environ-
ment, and/or oil or grease on the belt or pulley.

Doc. A042J557, Rev. 09/2017
Maintenance
NOTE: Transverse cracks (across the belt width) are
acceptable. Longitudinal cracks (direction of belt
length) that intersect with transverse cracks are not
acceptable. Replace the belt if it is cracked, frayed, or
damaged. Zinc Anode
5. If the belt condition is acceptable, check the belt

tension. There are two ways to check the belt
condition:
NOTE: Belts with glazed or shiny surfaces indicate

belt slippage. Correctly installed and tensioned belts
will show even pulley and belt wear.
Figure 5-9 Raw Water Zinc Anode (typical)

CAUTION
Disconnect the batteries (negative cable first) 5.4.9 Heat Exchanger
before performing service on the fire pump drive If internal leakage in the heat exchanger is sus-
engine or on any of its controls. pected, a heat exchanger pressure test may be per-
formed prior to removal from the engine.
• Use the Cummins belt tension gauge (Part Num-
ber 3822524) to measure the drive belt tension NOTE: Use Teflon™ tape or other pipe sealant when
in the center span of the belt between the idler installing the test setup in order to prevent leaks.
and alternator pulleys. Ensure that the belt ten-
sion is set to the specifications outlined in the NOTE: The size of fittings required on the water
Engine Operation Manual. outlets and inlets are listed on the Engine Data Sheet
in Section 7 - Component Parts and Assemblies of
• Use the deflection method and measure the belt the model-specific English manual.
tension in the center span of the belt between
the alternator and idler pulleys. If the belt deflec- To test the heat exchanger pressure:
tion is more than one belt thickness per foot of
pulley center-to-center distance, adjust the belt 1. Install an adapter at the cooling water outlet of
tension. the heat exchanger.
6. Reinstall the battery cables; attach the negative 2. Install a pressure test setup with 689 kPa (100
(-) battery cable last. psi) pressure gauge at the cooling water inlet to
the heat exchanger.
5.4.8 Raw Water Zinc Anode
The zinc anode (see Figure 5-9) acts as a raw water 3. Apply air pressure at 414 kPa (60 psi).
filter and must be checked for erosion and replaced,
when necessary. If the anode has eroded more than a. Isolate the pressure source and monitor the
fifty percent, it must be replaced. pressure gauge for five minutes.
b. There should be no change in pressure for

the duration of the test.
4. After testing, release the pressure. Remove the

tubing adapters, plug, and test equipment.
5. If leakage is detected, the heat exchanger must

be replaced.

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Maintenance
5.4.10 Turbocharger 5.5 Every Two Years
As shown in Figure 5-5, follow these steps to thor- All checks or inspections listed under daily or previ-
oughly inspect the turbocharger: ous maintenance intervals must also be performed at
this time, in addition to those listed under this mainte-
1. Visually inspect the air intake filter and piping nance interval.
according to the steps outlined in Section 5.3.2.
5.5.1 Coolant Pump
NOTE: Turbocharged engines must be operated at Inspect the coolant pump for eccentric motion,
rated revolutions per minute (RPM) and full load to mechanical binding, excessive end play, seal
check maximum intake air restriction. damage, and excessive grease or coolant leakage
around the pump shaft.
NOTE: Cummins recommends using an air cleaner
filter element as listed on the Engine Data Sheet in Replace with a new or rebuilt pre-lubricated unit, as
Section 7 - Component Parts and Assemblies of the necessary. Contact a Cummins Authorized Repair
model-specific English manual. Location for replacement.
5.5.2 Cooling System

CAUTION Figure 5-10 illustrates the cooling system. The
Never operate the engine without an air cleaner. cooling system must be clean to work properly. If the
Intake air must be filtered to prevent dirt and system shows excessive mineral buildup, particulate
debris from entering the engine and causing pre- matter, scale, oxidation, or oil contamination, drain
mature wear. Dirt or foreign objects could cause and flush the cooling system. If the coolant is exces-
engine damage. sively dirty or is mixed with oil, contact a Cummins
Authorized Repair Facility.
2. Remove the air intake and exhaust piping from
the turbocharger.
3. Inspect the turbocharger turbine wheel for

WARNING
cracks in the housing or turbine blades, missing Do not remove the pressure/fill cap from a hot
blades, mechanical binding, eccentric motion, or engine. Shut down the engine and wait until the
excessive end-play. coolant temperature is below 50 °C (120 °F)
before removing the pressure cap. Heated
4. Replace the turbocharger if damage, excessive coolant spray or steam can cause severe per-
end-play, binding, wear, or eccentric motion is sonal injury.
found. Contact a Cummins Authorized Repair
1. Disconnect both batteries at their terminals.
Location for replacement.
Remove the negative (-) cable first.
IMPORTANT: The turbocharger must be removed for
2. Press down, unscrew, and remove the coolant
replacement or rebuild if the clearance is beyond the
expansion tank pressure/fill cap. The cap must
limits, the housing is cracked, or the turbine wheel is
be removed to allow air to vent the cooling
damaged.
system during the draining process.
5. Reinstall the air intake filter and exhaust piping.
3. Disconnect the engine coolant heater power
Tighten the clamps. Torque the loosened clamps
supply before draining the cooling system.
to the recommended torque value. Refer to the
Torque Tables in Section 7 - Component Parts
4. Place a container that will hold at least 57 liters
and Assemblies.
(15 gal) of liquid under the coolant drain valve.
5. Ensure that the coolant filter shut-off valves are

OPEN.

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Maintenance
6. Open the drain petcock on the lower coolant
tube, allowing the coolant to drain into the waste
container.
7. When the system is empty, move the container

under the engine coolant heater.
8. Disconnect either end of the engine heater

coolant hose and drain the engine heater.
CAUTION
Coolant is toxic. Avoid prolonged and repeated
skin contact with used antifreeze - wash thor- 1
oughly after contact. Prolonged, repeated contact
can cause skin disorders. Dispose of waste anti- 2
freeze in accordance with local environmental
regulations.
3
9. Flush with clean fresh water or heavy-duty heat 4
5
exchanger cleaner. Follow the manufacturer’s
directions on the product container. 1. Lower Coolant Tube
2. Coolant Drain Petcock
NOTE: Some cooling system cleaners or commercial 3. Coolant Filter
solvents require a soapy water rinse after use. Follow 4. Coolant Filter Shut-off Valve
the directions on the cleaning solution or solvent. 5. Engine Coolant Heater
Figure 5-10 Engine Coolant Drain
CAUTION
11. Center the filter ring on the threaded mounting
Over-concentration of antifreeze or use of high-
nipple. Screw the filter canister onto the mount-
silicate antifreeze can damage the engine. Do not
use more than 50% antifreeze in the mixture
mounting flange, then tighten an additional 1/4
unless additional freeze protection is required.
turn. If using a soapy water solution, flush again
Antifreeze at 68% concentration provides the
with clear water. Allow time for the water to fully
maximum freeze protection, and must never be
drain.
exceeded under any condition. Antifreeze protec-
tion decreases above 68%.
10. When the flushing water has fully drained, use a CAUTION
filter wrench to remove the water coolant filter Mechanical over-tightening can distort the
from the filter housing. threads or damage the filter element seal.
a. Clean the filter housing gasket mount of dirt NOTE: Recommendations on filter replacements and
buildup, oxidation, or particulate matter with a fill rates can be found on the Engine Data Sheet in
clean cloth. Section 7 - Component Parts and Assemblies of the
model-specific English manual.
b. Coat the replacement filter gasket with a light
coating of 15W-40 lubrication oil. 12. Reconnect the engine heater coolant hose and
close the drain petcock on the lower coolant
tube.

Doc. A042J557, Rev. 09/2017
Maintenance
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 of the model-specific English engine coolant passages.
manual.
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
15. Re-install the heater wiring.
Use soft or distilled water in the coolant mixture.
Contaminants in hard water neutralize the corro-
sion inhibitor components. Water must not
exceed 300-ppm hardness or contain more than
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 18. Ensure that the coolant level is just below the fill
cooling system. This can result in cooling system neck and that the coolant heater is reconnected.
blockage or restricted coolant flow, causing the
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
at this time.
Fleetguard® Propylene-Glycol (PG) Plus™ Anti-
freeze/Coolants. Both products are available in con-
Cummins recommends performing maintenance on
centrated or pre-mixed formulations. Use a 50%
valve lash settings.
concentration level (40% to 60% range) of ethylene-
glycol or propylene-glycol and Supplemental Coolant
Additive (SCA) required for wet-sleeved engines in
most climates. Contact your local Cummins Autho-
CAUTION
Disconnect both batteries (negative cable first)
rized Repair Location for additional information.
before performing service on the fire pump drive
engine or on any of its controls. Wear safety
glasses when disconnecting batteries!
Table 5-2.
Ethylene-Glycol Propylene-Glycol CAUTION

Valve lash maintenance should be performed by a
40% = -23 °C (-10 °F) 40% = -21 °C (-6 °F) skilled technician. Improper maintenance can
50% = -37 °C (-34 °F) 50% = -33 °C (-27 °F) damage the engine or cause severe personal
injury. Contact your local Cummins Authorized
60% = -54 °C (-65 °F) 60% = -54 °C (-65 °F) Repair Location before performing any extensive
maintenance.
68% = -71 °C (-96 °F) 68% = -63 °C (-82 °F)

Doc. A042J557, Rev. 09/2017
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
instructions.
CAUTION
Always use the correct thermostat, and never
operate the engine without a thermostat installed.
The engine can overheat if operated without a
thermostat because the path of least resistance
for the coolant is through the bypass to the pump
inlet.
1. Remove the upper coolant hose clamps and

upper coolant hose at the thermostat housing.
3 2 1
2. Remove the (2) thermostat housing flange cap
screws and the thermostat flange (see Figure
5-11). 1. Hose Clamps
2. Upper Coolant Hose
3. Remove the thermostat and gasket from the 3. Thermostat Housing
housing. Figure 5-11 Thermostat Housing (typical)
4. Clean the housing flange faces of dirt buildup,
oxidation, and sludge. 5.6.2 Coolant Pump/Alternator Belt Replacement
Referring to Figure 5-8, replace the coolant pump/
5. If still in good condition, re-install the thermostat alternator belt if it is cracked, frayed, or has pieces of
in the housing. material missing.
IMPORTANT: Inspect the seal on the thermostat
1. Remove the belt guard.
housing flange surface and - if damaged or cracked -
apply a new seal. 2. Use a 3/8” drive ratchet or breaker bar to rotate
the tensioner arm away from the belt and
NOTE: Recommendations on thermostat replace- remove the belt.
ment components can be found on the Engine Data
3. Check the belt tensioner cap screw torque. For
Sheet in Section 7 - Component Parts and Assem-
recommended torque values, refer to the Torque
blies of the model-specific English manual.
Tables in Section 7 - Component Parts and
6. Replace the thermostat flange and cap screws. Assemblies.
4. Check the tensioner arm, pulley, and stops for
cracks. If any cracks are noticed, the tensioner
must be replaced.
5. Verify that the tensioner arm stop is not in
contact with the spring casing stop. If either stop
is touching, the tensioner must be replaced.
6. Inspect the tensioner for evidence of the ten-
sioner arm contacting the tensioner cap.
If there is evidence of the two areas making con-
tact, the pivot tube bushing has failed and the
tensioner must be replaced.
7. Check the tensioner bearing.

Doc. A042J557, Rev. 09/2017
Maintenance
a. Rotate the belt tensioner pulley. The pulley
should spin freely with no mechanical bind- CAUTION
ing, eccentric motion, or excessive end-play. To prevent pulley or belt damage, do not roll a
b. If the arm rotates with mechanical binding, belt over the pulley or pry it on with a tool. Move
eccentric movement, or excessive end play, the tensioner arm away from the belt area before
replace the tensioner. installing the drive belt.
8. Inspect the clearance between the tensioner 11. Check the location of the drive belt on the belt
spring case and the tensioner arm for uneven tensioner pulley. The belt should be centered on,
bearing wear. or centered close to, the middle of the pulley.
If the clearance exceeds 3 mm (0.12 in) at any 12. Reinstall the belt guard.
point, the tensioner must be replaced as a com-
plete assembly. Contact a Cummins Authorized CAUTION
Repair Location for replacement. Unaligned belts, either too far forward or back-
NOTE: Experience has shown that tensioners gener- ward, can cause belt wear, belt roll-off failures or
ally will show a larger clearance gap near the lower increase uneven tensioner bushing wear.
portion of the spring case, resulting in the upper
portion rubbing against the tensioner arm. Always
replace the belt when a tensioner is replaced.
9. After checking the torque, use a 3/8” drive
ratchet or breaker bar to rotate the tensioner
slowly away from the area of belt contact.
10. Install the replacement drive belt.

Doc. A042J557, Rev. 09/2017
Section 6 - Troubleshooting
6.1 Introduction injury or death.
The following information is intended as a guide for
some common non-technical equipment problems.
The first part of this section includes troubleshooting
CAUTION
charts that cross-reference the problem, the possible AVOID SERVICING complex components such
cause, and the solution. The second section includes as: printed circuit boards, programmable
complete Fault Code charts outlining a numerical controllers, and ECMs not specifically authorized
listing of fault codes and their descriptions. by Cummins Inc. Contact the Cummins Customer
Service Department toll free at 1-800-343-7357
Many problems can be resolved using corrective before performing any extensive maintenance.
maintenance, adjustment, or minor repair. Refer to
the vendor supplied literature, electrical schematics,
and mechanical prints for additional information.
CAUTION
Never climb or stand on the equipment frame,
For engine-related issues, refer to the engine Opera- guards, or enclosures. Contact with exposed or
tion and Maintenance Manual or contact the moving components can cause personal injury or
Cummins Customer Assistance Center at 1-800- equipment damage.
CUMMINSTM (1-800-286-6467).
WARNING
The status checks should be performed ONLY by
a qualified technician. Contact with exposed elec-
trical components could cause extreme personal

Doc. A042J557, Rev. 09/2017
Troubleshooting
6.2 Engine Will Not Start
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6-2
Cummins Fire Pump Drive Engine CFP59
Doc. A042J557, Rev. 09/2017
Troubleshooting
6.3 Engine Cranks But Will Not Start
6<03720
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6-3
Doc. A042J557, Rev. 09/2017
Troubleshooting
Engine Cranks But Will Not Start (cont.)
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6-4
Doc. A042J557, Rev. 09/2017
Troubleshooting
6.4 Engine Starts But Continues to Crank
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6-5
Doc. A042J557, Rev. 09/2017
Troubleshooting
6.5 Engine Will Not Stop
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6-6
Doc. A042J557, Rev. 09/2017
Troubleshooting
6.6 Low Battery Voltage
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6-7
Doc. A042J557, Rev. 09/2017
Troubleshooting

Doc. A042J557, Rev. 09/2017
Section 7 - Component Parts and Assemblies
7.1 Ordering Parts If assistance is required, call Toll-Free: 1-800-CUM-
Replacement parts for the Cummins Inc. equipment MINSTM (1-800-286-6467). 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. website at 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
number helps Cummins and its customer track the The following pages outline applicable reference
parts and necessary credits. material for the CFP59 fire pump drive engine. Table
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 cumminsfirepower.com. Table
can assist you with the correct operation and service 7-2. Cap Screw Markings and Torque Tables outlines
of your engine. Cummins has a worldwide service the recommended cap screw markings and torque
network of more than 5,000 Distributors and Dealers 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.

Doc. A042J557, Rev. 09/2017
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 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
Doc. A042J557, Rev. 09/2017
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-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
Doc. A042J557, Rev. 09/2017
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)
CFP59 F-40
Output - BHP (kW) 150 (112) 171 (128)
CFP59 F-50
Output - BHP (kW) 164 (122) 188 (140)
7-4
Doc. A042J557, Rev. 09/2017
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 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
Doc. A042J557, Rev. 09/2017
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
Doc. A042J557, Rev. 09/2017
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
Doc. A042J557, Rev. 09/2017
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
7-8
Doc. A042J557, Rev. 09/2017
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
7-9
Doc. A042J557, Rev. 09/2017
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
Doc. A042J557, Rev. 09/2017
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

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Fire Pump Drive Engines

Operation and Maintenance Manual

Please visit us at cumminsfirepower.com to view the English version of this

This product has been manufactured under the controls established by a

© Copyright 2017, Cummins Inc.

Cummins Fire Pump Drive Engine CFP59 TOC-1

TOC-2 Cummins Fire Pump Drive Engine CFP59

Section 7 - Component Parts and Assemblies

Cummins Fire Pump Drive Engine CFP59 TOC-3

This page is intentionally left blank.

TOC-4 Cummins Fire Pump Drive Engine CFP59

Cummins Fire Pump Drive Engine CFP59 1-1

1-2 Cummins Fire Pump Drive Engine CFP59

2.2 Fire Pump Controller

Cummins Fire Pump Drive Engine CFP59 2-1

1. Air Cleaner Assembly 11. Engine Oil Dipstick

2-2 Cummins Fire Pump Drive Engine CFP59

1. Manifold Heat Shield 9. Battery Starter Contactor A

Cummins Fire Pump Drive Engine CFP59 2-3

2-4 Cummins Fire Pump Drive Engine CFP59

Cummins Fire Pump Drive Engine CFP59 2-5

• red - when the engine oil pressure is below 16

2.3.12 Coolant Temperature Gauge

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

• red - when the coolant temperature is greater

2.3.13 Overspeed Warning Indicator

2-6 Cummins Fire Pump Drive Engine CFP59

9. Normal Water Pressure Regulator

Cummins Fire Pump Drive Engine CFP59 2-7

1. Coolant Heat Exchanger 11. Coolant Pump

2-8 Cummins Fire Pump Drive Engine CFP59

2.7 Fuel System

Cummins Fire Pump Drive Engine CFP59 2-9

2-10 Cummins Fire Pump Drive Engine CFP59

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

Cummins Fire Pump Drive Engine CFP59 2-11

1. Combustion Air to Low Temperature

2-12 Cummins Fire Pump Drive Engine CFP59

3.2 Receiving and Handling

c. Ensure that the pump center line to the

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

Cummins Fire Pump Drive Engine CFP59 3-1

3.5 Fuel Supply Installation

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

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

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

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

NOTE: For fuel line specifications, refer to the Engine

NOTE: DO NOT use copper or galvanized pipe for

The fire pump drive engine fuel system has been

NOTE: Cummins recommends using a good quality

3-2 Cummins Fire Pump Drive Engine CFP59

Cummins Fire Pump Drive Engine CFP59 3-3

The engine coolant system contains a mixture of at

3.7 Battery Installation

3. Locate the batteries near the engine or increase

4. Check the battery cables and connections.

3-4 Cummins Fire Pump Drive Engine CFP59

Figure 3-4 Series Battery Connection 24 VDC

Cummins Fire Pump Drive Engine CFP59 3-5