CFP83

SERIES
Operation & Maintenance Manual
Fire Pump Drive Engines

www.cumminsfirepower.com Doc 24809

Rel. 05/2016
 This manual contains proprietary information to equipment produced by Cummins Fire
Power or Cummins Inc. and is being supplied solely for the purpose of operating,
maintaining, and servicing the fire pump drive engine purchased from Cummins Fire Power.

© Copyright 2016, Cummins Inc.

Warranty Information

Cummins Fire Power

Limited Warranty

Fire Pump Package

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

Warranty Period:
The warranty start date for stationary Product is the date of initial start up, demonstration or 18 months
after factory ship date, whichever is sooner.

Base Warranty Duration (whichever occurs first): 2 years/2000 hours.

Cummins Fire Power Responsibilities:

In the event of a failure of the Product during the warranty period due to defects in material or
workmanship, Cummins Fire Power will only be responsible for the following costs:
x All parts and labor required to repair the Product.
x Reasonable travel expenses to and from the Product site location.
x Maintenance items that are contaminated or damaged by a warrantable failure.
Owner Responsibilities:
The owner will be responsible for the following:
x Notifying Cummins Fire Power distributor or dealer within 30 days of the discovery of failure.
x Installing, operating, commissioning and maintaining the Product in accordance with Cummins
Fire Power’s published policies and guidelines.
x Providing evidence for date of commissioning.
x Providing sufficient access to and reasonable ability to remove the Product from the installation in
the event of a warrantable failure.
In addition, the owner will be responsible for:
x Incremental costs and expenses associated with Product removal and reinstallation resulting from
difficult or non-standard installations.
x Costs associated with Fire Watch Protection during Product being repaired.
x Costs associated with labor overtime and premium shipping requested by the owner.
x All downtime expenses, fines, all applicable taxes, and other losses resulting from a warrantable
failure.
Limitations:
This limited warranty does not cover Product failures resulting from:
x Inappropriate use relative to designated power rating or application guidelines.
x Normal wear and tear, negligence, accidents or misuse.
x Improper and/or unauthorized installation.
x Lack of maintenance or unauthorized repair.
x Noncompliance with any Cummins Fire Power published guideline or policy.
x Use of improper or contaminated fuels, coolants or lubricants.
x Improper storage before and after commissioning.
x Owner’s delay in making Product available after notification of potential Product problem.
x Replacement parts and accessories not authorized by Cummins Fire Power.
x Owner or operator abuse or neglect such as: operation without adequate coolant or lubricants;
over-fueling; over-speeding; lack of maintenance to lubricating, cooling or air intake systems; late
servicing and maintenance; improper storage, starting, warm-up, run-in or shutdown practices, or
for progressive damage resulting from a defective warning device.
x Damage to parts, fixtures, housings, attachments and accessory items that are not part of the fire
pump package.

Cummins Fire Power 875 Lawrence Drive De Pere, WI 54115 Phone 920 337 9750 www.cumminsfirepower.com
Limitations (cont.):
This limited warranty does not apply to:
x Costs of maintenance, adjustments, installation, commissioning or start-up.
x Starting batteries and enclosures.
x Components added to the Product after shipment from Cummins Fire Power.
x Block heaters are warranted for 1 year from date in service
Please contact your local Cummins NPower Distributor for clarification concerning these limitations.

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

Cummins Fire Power Right to Failed Components:

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

THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY
CUMMINS FIRE POWER IN REGARD TO THE PRODUCT. CUMMINS FIRE POWER
MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT
IS CUMMINS FIRE POWER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL
DAMAGES.
This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited
warranty gives the owner specific rights that may vary from state to state or from jurisdiction to
jurisdiction.

C 8 11 920 33 9 0 f
 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 Digital Panel (FPDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Fire Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Cooling Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Fuel Supply and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.8 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.9 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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
3.9 Coolant System Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.10 Charge Air Cooler (CAC) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.11 Lubricating Oil System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.12 Pre-Start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.13 Engine Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.14 Field Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Section 4 - Controls
4.1 Fire Pump Digital Panel (FPDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Fault Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.3 Scroll UP and DOWN Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.4 ENTER Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.5 MENU Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.6 Overspeed RESET/STOP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.7 Battery “A” and “B” Voltmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.8 Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.9 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.10 ECM A/B Selector Switch and Indicator Lamps - Applicable on Electronic Engines . . . . . . . . . . 4-2

Fire Power Pump Engine CFP83 TOC-1

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Table of Contents
4.1.11 Crank Battery A and B Momentary Start Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.12 Automatic or Manual Mode of Operation Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.13 Coolant Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.14 Engine Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.15 Engine Overspeed Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.16 ECM Fault Code Lamps - Applicable on Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.17 Engine STOP Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.18 Engine Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.19 Contractor Access Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.20 Engine ECM Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.21 Engine Harness Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2 Electronic Control Module (ECM) - Applicable on Electronic Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Section 5 - Operation
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Starting and Stopping Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 Local Starting/Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.2 Emergency Starting/Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Fire Pump Digital Panel (FPDP) Screens and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3.1 Engine Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Overspeed Test Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 RPM INC/DEC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.4 Parameter Units Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.5 Display Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.6 Analog Values Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.7 Autoswitch Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Section 6 - Maintenance
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Engine Operation Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Weekly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Air Cleaner Filter and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.4 Engine Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.6 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.7 Electrical Supply and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.8 Crankcase Ventilation Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.9 Cooling Water Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.10 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.11 Engine Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.12 Engine Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.12.1 Crank Termination Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.12.2 Engine Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.13 Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.2 Turbocharger Mounting Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.3 Engine Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.4 Fuel Pumps and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.5 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.4.6 Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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6.4.7 Coolant Pump/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.8 Raw Water Zinc Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.4.9 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.4.10 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5 Every Two Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.1 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.5.2 Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.6 Every Four Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.6.1 Coolant Thermostat Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.6.2 Coolant Pump/Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Section 7 - Troubleshooting
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Engine Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Engine Cranks But Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Starts But Continues to Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.5 Engine Will Not Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6 Low Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Section 8 - Component Parts and Assemblies

8.1 Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Routine Service and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Emergency Repairs and Technical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.4 Recommended Spare Parts Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.5 Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

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Table of Contents

TOC-4 Fire Power Pump Engine CFP83

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 Section 1 - Safety
1.1 Introduction • Never attempt to manually clean a machine
while it is operating or in standby mode.
Cummins Fire Power engine manuals should be con-
sidered part of the equipment. Keep the manuals with
• Never open ports on tanks or piping while the
the equipment. If the equipment is traded or sold,
engine is operating. Contact with pressurized
give the manuals to the new owner.
agents can cause severe personal injury.
All personnel responsible for operation and mainte-
• Relieve all pressure in the air, oil, and the cool-
nance of the equipment should read and thoroughly
ing systems before any lines, fittings, or related
understand this manual.
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.

Fire Power Pump Engine CFP83 1-1

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Safety

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

1-2 Fire Power Pump Engine CFP83

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 Section 2 - Description
2.1 Introduction
This manual contains information for the correct oper- WARNING
ation and maintenance of a Cummins fire pump drive Injury may result and warranty is voided if fuel
engine. Read and follow all safety instructions in rate, revolutions per minute (RPM), or altitudes
Section 1 - Safety. Keep this manual with the equip- exceed published maximum values for this model
ment. If the equipment is traded or sold, give the and application.
manual to the new owner.
2.2 Fire Pump Digital Panel (FPDP)
Cummins fire pump drive engines have been The Fire Pump Digital Panel (FPDP) is mounted on
designed and tested in accordance with National Fire the left hand side (or right hand side - optional) on the
Protection Association (NFPA) 20 guidelines. flywheel end of the engine and contains controls for
starting the engine, monitoring engine performance,
No deviations are permitted without prior written and controlling fire pump drive engine operation.
approval. These engines are to be used only for fire Section 4 - Controls illustrates the FPDP in detail.
protection applications. Figure 2-1 and Figure 2-2
provide visual descriptions of the engine components Each engine is equipped with an electronic over-
for this fire pump drive engine. speed control which activates the fuel pump solenoid
valve or the Engine Control Module (ECM) ignition to
shut off the engine when the RPM exceeds a preset
NOTE: Refer to the Engine Data Sheet in Section 8 - limit of 115% of rated speed. The overspeed control
Component Parts and Assemblies for emission senses engine speed during the start cycle and stops
levels. the starting motor cranking cycle.

Cummins Fire Power, Cummins NPower, and All Cummins fire pump drive engines are shipped
Cummins Inc. reserve the right to make changes at from the factory adjusted to the requested operating
any time. If any differences are found between an speed (in RPM). Final operating speed adjustment
engine and the information in this manual, contact the must be made during the in-service inspection to
local Cummins Authorized Repair Location. obtain the required operating speed specified by the
The latest technology and the highest quality compo- pump manufacturer.
nents were used to produce this engine. Cummins
fire pump drive engines as packaged units (engine 2.3 Fire Pump Controller
and accessories) have been approved by Factory The fire pump controller starts the engine automati-
Mutual (FM) Approvals and listed by Underwriters cally when a remote fire demand signal is initiated
Laboratories (UL), Inc. and Underwriters Laboratories and automatically shuts down the engine when the
of Canada (ULC). When replacement parts are fire demand signal is discontinued. The engine may
needed, we recommend using only genuine also be started locally in the MANUAL mode and shut
Cummins or ReCon® exchange parts. down using the FPDP STOP button. The fire pump
controller is not supplied by Cummins Fire Power or
Cummins Inc.

Fire Power Pump Engine CFP83 2-1

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Description
.

1
1

2
1

1


4


7



CFP-003-1
1. Air Cleaner Assembly 8. Cooling Water Manifold
2. Air Cleaner Service Indicator 9. Heat Exchanger Cooling Water Discharge
3. Terminal Box 10. Coolant Heat Exchanger
4. Fire Pump Digital Panel (FPDP) 11. Coolant Expansion Line
5. Engine Aftercooler 12. Coolant Pressure/Fill Cap
6. Fuel Return Line 13. Exhaust Flex Connection
7. Fuel Supply Line 14. Turbocharger
Figure 2-1 Engine Components - Fire Pump Digital Panel (FPDP) Side (typical)

2-2 Fire Power Pump Engine CFP83

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 Description

15 1

14 4

13

5
6
7
8
9
12 10
11
CFP-004-1

1. Upper Coolant Hose/Tube 9. Engine Coolant Heater

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

Fire Power Pump Engine CFP83 2-3

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Description
2.4 Air Intake System Engine coolant is circulated through the integral after-
cooler on the engine.
The air intake system supplies combustion air to the
fire pump drive engine cylinders. The air filter pre- IMPORTANT: Cooling water piping will be supplied
vents particulate matter from entering the air intake. by Cummins Fire Power as shown in the drawings in
Figure 2-3 shows how the combustion air is drawn Section 8 - Component Parts and Assemblies. Refer
into the system. Combustion air drawn into the to NFPA 20 for installation requirements.
system by the turbocharger is directed through the
engine aftercooler before entering the cylinders. When the cooling water piping is installed:

1. Adjust both pressure regulator set points of the

cooling water manifold before operating the
pump.

2. Ensure that the bypass line (the upper line) is

closed.

3. Ensure that the normal water inlet line valve is

open. The lower line with the solenoid valve is
the normal inlet line.

4. Ensure that the pressure gauge isolation valve is

open.

IMPORTANT: Monitor the oil pressure and coolant

temperature gauges frequently. Refer to Lubricating
Oil System Specifications or Cooling System Specifi-
cations in the Engine Data Sheet in Section 8 - Com-
CFP_400
ponent Parts and Assemblies for recommended
operating pressures and temperatures. Shut off the
engine if any pressure or temperature does not meet
the specifications.
1. Filtered Air NOTE: Maximum engine coolant temperature should
2. Turbocharger Compressor not exceed the temperature listed on the Engine Data
3. Air Crossover Tube Sheet found in Section 8 - Component Parts and
4. Engine Aftercooler Assemblies. The coolant expansion pressure/fill cap
5. Intake Valve Port must meet the minimum pressure of 10 kPa (15 psi).
Figure 2-3 Air Intake Flow Diagram (typical)
The engine coolant system contains a mixture of at
least 50% antifreeze and 50% water. The coolant
2.5 Cooling Water System
level should be maintained so it is visible in the
Figure 2-4 illustrates a typical cooling water manifold coolant level sight gauge.
and Figure 2-5 shows the path of water through the
engine cooling system. Water entering the cooling
system through the cooling water inlet first circulates CAUTION
through the heat exchanger, cooling the compressed Continuous operation with low coolant tempera-
air from the turbocharger outlet ducting. Note that the ture (below 70 °C [158 °F]) or high coolant tem-
charge air cooler (CAC) and fuel heat exchanger are perature (above 107 °C [225 °F]) can damage the
not included in this engine model. engine. Verify the cooling water pressure and
NOTE: The cooling water supply must be immedi- flow to maintain a consistent operating tempera-
ately available when the engine is started. ture.

2-4 Fire Power Pump Engine CFP83

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 Description

8. Post Strainer Pressure Sensor

1. Bypass Water Pressure Regulator 9. Normal Water Pressure Regulator
2. Bypass Water Strainer 10. Normal Water Solenoid Valve
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
Figure 2-4 Cooling Water Manifold (typical)

Fire Power Pump Engine CFP83 2-5

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Description

2 3

2 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. Combustion Air Intake Manifold
Figure 2-5 Engine Cooling System Flow Diagram (typical)

2-6 Fire Power Pump Engine CFP83

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 Description
2.6 Fuel Supply and Drain NOTE: Typically engine oil has been added during
manufacture and testing procedures; however,
The fuel supply and return connections are centrally
shipping restrictions can affect whether the oil is
located on the FPDP side. Refer to the Engine Data
maintained in the engine or drained for shipping.
Sheet in Section 8 - Component Parts and Assem-
Check the oil level at the dipstick. Add oil as neces-
blies for the maximum allowable fuel tank supply
sary to bring the oil level to the H (high) mark on the
locations above the fuel pump.
dipstick.
2.7 Fuel System
2.9 Exhaust System
The fire pump engine is equipped with a fuel system
Figure 2-7 shows how the exhaust system removes
that provides fuel metering and timing based on tem-
engine exhaust from the cylinders after the combus-
perature, altitude, pressure, and throttle position.
tion process. The exhaust discharges from the
exhaust manifold, passes through (drives) the turbo-
2.8 Engine Oil System charger, and exits through the exhaust connection.
Figure 2-6 illustrates how the engine oil system lubri-
cates moving internal engine parts (pistons, piston
arms, valves, cam shafts, shafts, and bearings). The
oil pump circulates oil from the oil pan, through the oil
filter, and into engine areas where friction may
develop. Refer to the Cummins Engine Operation
and Maintenance Manual for additional information.






     
CFP-010

1. Oil Pump 7. Oil Cooler

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

Fire Power Pump Engine CFP83 2-7

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Description

CFP-008

1. Exhaust Valve Ports 3. Turbocharger Turbine

2. Engine Exhaust Manifold
Figure 2-7 Flow Diagram - Exhaust System (typical)

2-8 Fire Power Pump Engine CFP83

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

3.2 Receiving and Handling

CAUTION
Cummins Fire Power fire pump drive engines are pre- Ensure that the lifting device is capable of safely
assembled and tested before shipment. Parts not lifting the weight of the engine or the combined
shipped attached to the engine are sometimes weight of the assembled pump base, drive line,
shipped individually. The equipment was thoroughly and pump. Do not use the engine lifting points for
inspected and prepared for shipping before it was assembly!
turned over to 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.

Fire Power Pump Engine CFP83 3-1

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

3.5 Fuel Supply Installation

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

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

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 8 - Component Parts and
Assemblies.

NOTE: DO NOT use copper or galvanized pipe for

the fuel return or supply lines.

The fire pump drive engine fuel system has been

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

3-2 Fire Power Pump Engine CFP83

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 Installation
of the contaminated fuel in accordance with local IMPORTANT: The manual water valves for the auto-
environmental regulations. matic loop should remain OPEN at ALL times. The
manual valves for the bypass loop should be
CLOSED during automatic (pump controller) opera-
CAUTION tion. When running, the engine should stabilize
Due to the precise tolerances of diesel injection between temperatures identified on the Engine Data
systems, it is extremely important that the fuel be Sheet. The flow rate may need to be adjusted to
kept clean and free of dirt or water. Dirt or water in maintain the desired engine temperature.
the system can cause severe damage to both the
fuel pump and the fuel injectors. NOTE: Excessively cold (4 °C to 23 °C [40 °F to 75
°F]) cooling water flow can cause condensation
inside the charge air cooler.
WARNING
Do not mix gasoline, alcohol, gasohol, ethanol, or IMPORTANT: Continuous operation with low coolant
methanol with diesel fuel. This mixture will cause temperature (below 70 °C [158 °F]) or high coolant
severe engine damage or explosion. temperature (above 107 °C [225 °F]) can damage the
engine.
CAUTION 3. Adjust the cooling water based on the water flow
Use ONLY no. 2 diesel (ASTM no. 2D) fuel. Any rather than the water pressure. The flow is
adjustment to compensate for reduced perfor- dependent on the cooling water temperature.
mance with a fuel system using alternate fuel is Refer to the Engine Data Sheet in Section 8 -
not warrantable. Component Parts and Assemblies for details.

3.6 Cooling Water Supply Installation 4. To measure the water flow, use an appropriate-
sized container to measure the amount of water
IMPORTANT: The cooling water supply must be
and the elapsed time of the water to flow from
immediately available when the engine is started.
the discharge pipe and then formulate the calcu-
Ensure that the supply line valves are in the OPEN
lations:
position.
Flow rate = container size/ time to fill container.
NOTE: The velocity of the cooling water should be as
great as possible without exceeding the maximum
Example:
allowable pressure shown in the Engine Data Sheet
in Section 8 - Component Parts and Assemblies. Time to fill a 20 gallon container = 15 seconds.
20 gallons divided by 15 seconds = 1.33 gallons per
To install the cooling water supply:
second.
1. Provide a cooling water discharge line at the out- Multiply by 60 seconds = 80 gallons per minute (gpm)
let of the engine coolant heat exchanger and (FLOW RATE)
provide a cooling water supply line to the cooling
water inlet per the Engine Data Sheet in Section
8 - Component Parts and Assemblies. 5. Adjust both pressure regulators to a pressure
that will provide a flow rate at or above the spec-
NOTE: The cooling water outlet piping from the heat ifications listed in the Engine Data Sheet.
exchanger should be one pipe size larger than the
supply piping.
CAUTION
2. Check the pressure regulator setting on the When the cooling water piping is installed, adjust
cooling loop with water flowing through the heat both of the pressure regulator set points before
exchanger. The cooling loop is supplied by operating the pump. Damage to the heat
Cummins Fire Power; both water pressure regu- exchanger may occur from improperly regulated
lators have been set at 207 kPa (30 psi) (or cooling water supply pressure.
slightly less) water pressure during manufacture
and testing.

Fire Power Pump Engine CFP83 3-3

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Installation
3.7 Battery Installation 1. As shown in Figure 3-3 or Figure 3-4, install the
Battery Cable Kit or equivalent customer-sup-
Redundant sets of batteries must be supplied for the
plied wiring. Install battery sets in a well-venti-
required operating voltage. The minimum recom-
lated or otherwise protected location.
mended 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 8 - Component WARNING
Parts and Assemblies. RC and CCA definitions can Batteries can emit explosive gases during
be found in SAE Standard J537. Refer to NFPA 20 for charging. Always ventilate the compartment
additional battery installation information. before servicing the batteries. To avoid arcing,
remove the negative (-) battery cable first and
attach the negative (-) battery cable last.
WARNING
Battery electrolyte (sulfuric acid) is highly caustic
and can burn clothing and skin. Wear impervious
neoprene gloves and safety goggles, or a full face
shield, when working with the batteries.

CAUTION
DO NOT connect battery charging cables to any
electronic control system component. This can
damage the electronic control system.
IMPORTANT: Batteries must meet the requirement
listed in the electrical system specifications. Batteries
may be supplied by Cummins Fire Power or
Cummins Inc. as an option, or may be supplied by the
customer.
Figure 3-3 Series Battery Connection 12 VDC
To properly install the batteries:

Figure 3-4 Series Battery Connection 24 VDC

3-4 Fire Power Pump Engine CFP83

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

3. Locate the batteries near the engine or increase

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

4. Check the battery cables and connections.

NOTE: Coat the terminals with petroleum jelly to

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

3.8 Signal and Control Installation

The fire pump controller wires must be connected to
the terminal blocks (TBs) on the FPDP Interface Ter-
minal Strip (shown in Figure 3-5). To complete the
signal and control installation:

1. Ensure that the fire pump controller is properly

installed and configured per the manufacturer’s
instructions.

2. Complete the fire pump controller wiring (cus-

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

3. Ensure electrical continuity and adequate insula-

tion resistance for the installed wiring.

4. The TBs between the fire pump controller and

the FPDP Interface Strip are standard UL and
FM controller terminals and follow a direct one-
to-one correspondence (some TBs are optional):

a. TB-1 [Run Solenoid Circuit]: This power

source is necessary for fire pump operations
while in the AUTO mode. Figure 3-5 FPDP Interface Terminal Strip

b. TB-2 [Crank Termination Switch]: This d. TB-4 [Low Lubricant Pressure Switch]:
signal is present when the engine is running. This zero VDC grounded signal is present
This signal indicates that the engine has when the oil pressure has dropped below the
started and that the crank command from the 83 ± 13 kPa (12 ± 2 psi) set point.
fire pump controller should stop immediately.
e. TB-5 [High Engine Temperature Signal]:
c. TB-3 [Overspeed Switch]: This signal is This zero VDC grounded signal is activated
present when the overspeed control module when the engine is running and the coolant
has operated. If this event occurs, the fire temperature is at or above 93 °C (200 °F).
pump drive engine will stop. The alarm will deactivate when the engine is

Fire Power Pump Engine CFP83 3-5

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Installation
running and the coolant temperature drops from the FPDP when a single ECM has
below 88 °C (190 °F). failed.

f. TB-6 [Battery One Positive]: The fire pump n. TB-304 [Electronic Control Module
controller senses Battery A charge state and Failure]: Battery negative signal driven from
charges Battery A through this heavy gauge the FPDP when both ECMs have failed.
wire.
o. TB-310 [Raw Water High Inlet Tempera-
g. TB-8 [Battery Two Positive]: The fire pump ture]: Battery negative signal driven from the
controller senses Battery B charge state and FPDP when high raw water temperature is
charges Battery B through this heavy gauge sensed.
wire.
p. TB-311 [Clogged Raw Water Coolant Loop
h. TB-9 [Main Battery Contactor One Coil or Strainer] - not applicable on radiator-cooled
Battery Relay One Coil]: The battery posi- models: Battery negative signal driven from
tive signal is driven from the fire pump con- the FPDP when the raw water supply restric-
troller to contactor A when desiring to crank tion is sensed.
from Battery A. Current in this circuit shall not
exceed 10A continuous. q. TB-312 [Low Engine Temperature Signal]:
Battery negative signal driven from an engine
i. TB-10 [Main Battery Contactor Two Coil or temperature switch when engine coolant
Battery Relay Two Coil]: The battery posi- reaches or falls below 43.3 ± 2.78 °C (110 ± 5
tive signal is driven from the fire pump con- °F). The signal will be removed when the
troller to contactor B when desiring to crank coolant temperature reaches or exceeds 60 ±
from Battery B. Current in this circuit shall not 2.78 °C (140 ± 5 °F).
exceed 10A continuous.
5. Provide the initial charge on the redundant bat-
j. TB-11: Connect the common ground and teries per the battery charger’s instructions.
battery negative for both Battery A and
Battery B from between the fire pump control- 6. Check that both voltmeters on the FPDP indicate
ler and engine. This is not intended to create the approximate battery voltage. Both sets of
a fully isolated battery negative or ground batteries can be used for starting the engine in
system. Current in this circuit shall not the event that one set is low.
exceed 20A continuous.
3.9 Coolant System Preparation
NOTE: Terminals 301 through 312 shall be electri-
The fire pump drive engine cooling and lubrication
cally isolated from the ECM.
system was initially filled during manufacture and
testing. To properly prepare the coolant system:
k. TB-301 [Electronic Control Module
Switch]: Battery negative signal driven from
the FPDP when the engine is operating on
Engine Control Module (ECM) B.
CAUTION
Ensure that all coolant systems have been filled
l. TB-302 [Fuel Injection Malfunction]: to the proper level before operation by checking
Battery negative signal driven from the FPDP the coolant level sight gauge on the heat
when either of the ECMs triggers a fault code exchanger.
which can affect performance of the Fuel
1. Inspect the engine coolant hoses and hose
Injection System. See Section 7 - Trouble-
clamps and ensure that all coolant hoses and
shooting for possible fault causes and solu-
clamps are properly installed and water tight.
tions.
2. Ensure that the engine coolant heater maintains
m. TB-303 [Electronic Control Module
an engine coolant temperature of 49 °C (120 °F)
Warning]: Battery negative signal driven
or above.

3-6 Fire Power Pump Engine CFP83

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 Installation
3. Ensure that coolant is present in the engine cation at high operating temperatures. Cummins Inc.
coolant heater before plugging the heater recommends Premium Blue® 15W-40 oil for most cli-
element into a dedicated circuit. mates.

WARNING CAUTION
Do not remove the pressure/fill cap from a hot Ensure that all cooling and lubrication systems
engine. Wait until the coolant temperature is have been filled to the proper level before opera-
below 50 °C (122 °F) before removing the pres- tion.
sure/fill cap. Heated coolant spray or steam can
cause personal injury. 3.12 Pre-Start Inspections
Prior to starting the fire pump drive engine for the first
3.10 Charge Air Cooler (CAC) Inspection time, perform a visual inspection:
The charge air cooler (CAC) system reduces the tem-
perature of the compressed combustion air from the 1. Check that there is no apparent damage and
turbocharger before entering the air intake manifold. that all components are installed.

Inspect the CAC piping and hoses for loose/missing 2. Check that the drive belt is properly installed.
hose clamps, hose punctures, leaking manifold seals,
or corrosion. Torque the hose clamps to the recom- 3. Check that all hoses and tubes are properly
mended torque value. Refer to the Engine Data installed.
Sheet in Section 8 - Component Parts and Assem-
blies. 4. Check that all electrical connections are properly
installed.
3.11 Lubricating Oil System Preparation
5. Check that the fire pump drive engine is properly
The fire pump drive engine and turbocharger were
installed per the pump manufacturer’s instruc-
initially lubricated during manufacture and testing. To
tions, is correctly aligned, and is free to rotate.
prepare the lubricating oil system for operation:
6. Lubricate the grease fittings on the auxillary
1. Check the oil level using the dip stick before
drive shaft.
operating the fire pump drive engine.
NOTE: Use the same type of oil as used in normal
2. Fill the oil fill port to the “H” mark on the dipstick
operation. Cummins Inc. recommends Premium
with lubricating oil.
Blue® 15W-40 oil for most climates.
NOTE: Do not use special “break-in” lubricating oils
After completing preliminary set-up procedures,
for new or rebuilt Cummins engines. Use the same
perform the engine start test as outlined in detail in
type of oil during the “break-in” as used during normal
Section 5 - Operation.
operation.

CAUTION WARNING
Some regulatory and shipping restrictions may Before operating the equipment, complete all
safety checks, remove all tools and foreign
require that all lubricants, fuels, and coolants be
objects from the equipment, and ensure that all
drained for transport. Ensure that all cooling and
lubrication systems have been filled to the proper guards are in place and securely fastened. Alert
area personnel that the equipment will be start-
level before operation.
ing. Unintentional equipment start-up or contact
NOTE: Using multi-viscosity lubricating oil can with exposed or moving components can cause
improve oil consumption control and improve engine personal injury or equipment damage.
cranking in cold temperatures while maintaining lubri-

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Installation
4. Inspect the engine for leaks, unusual noises, or
CAUTION other indications of incorrect operation.
If the oil pressure is not displayed on the gauge
or if the low oil pressure message is displayed 5. Shut off the engine by pressing and holding the
within fifteen seconds, STOP THE ENGINE IMME- overspeed RESET/STOP switch.
DIATELY! Continued operation without proper
lubrication will cause engine damage. 6. Shortly after the engine stops, check that the
water flow stops automatically.
3.13 Engine Monitoring
7. Correct any problems found during the inspec-
When the engine starts, it is important to monitor the tion before proceeding.
displays:
8. Check the engine lubricating oil level at the dip
1. Immediately check that water flow is established stick. Add oil, if necessary.
through the coolant heat exchanger. The water
flow should be established immediately, but 9. Check the coolant expansion tank level. Add
some delay may occur before the flow exits the coolant, if necessary.
heat exchanger drain connection.
10. Check the cooling water strainers. Clean the
NOTE: Ensure that cooling water is flowing through strainers according to the maintenance schedule
the heat exchanger and the water pressure shown on in Section 6 - Maintenance.
the local pressure gauge is no more than 414 kPa (60
psi). The minimum cooling water flow rate is identified 11. Perform engine speed control and safety system
in the Engine Data Sheet in Section 8 - Component tests per the instructions in Section 5 - Opera-
Parts and Assemblies. tion.
2. Ensure that the engine operating temperature
stabilizes between applicable ranges as identi-
3.14 Field Acceptance Testing
fied in the Engine Data Sheet in Section 8 - The required installation tests are outlined in the
Component Parts and Assemblies. NFPA 20 Standards and shall be performed to vali-
date automatic and manual operational requirements
3. Operate the engine for eight to ten minutes. for field acceptance testing.

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 Section 4 - Controls
4.1 Fire Pump Digital Panel (FPDP) Pressing the Overspeed RESET/STOP Switch after
correcting an engine overspeed shutdown resets the
The Fire Pump Digital Panel (FPDP) shown in Figure
overspeed control module, allowing subsequent
4-1 controls starting and monitoring engine perfor-
restarts of the fire pump drive engine.
mance, as well as the fire pump drive engine opera-
tion. In MANUAL mode, the panel remains active as
long as battery power is available. In AUTO mode, 1 2 3
the panel is active when battery power is present on
Terminal Block (TB) -1, otherwise it goes into
STANDBY mode after thirty minutes of no battery
voltage on TB-1. 18
17
4.1.1 Warning Lamp 4
The Warning Lamp (1) illuminates (yellow) in the 16
event that the Electronic Control Module (ECM) has 5
sensed a non-mission disabling fault.
15 6
4.1.2 Fault Indicator Lamp
The Fault Indicator Lamp (2) indicates Fuel Injection
Malfunction (FIM) and illuminates (red) in the event 7
that the ECM has detected a fuel injection fault or
14
primary sensor fault.

The FPDP also sends a ground signal to TB-302,

which sends a signal to set off an alarm on the fire
pump controller to indicate a FIM. 13 12 11 10 9 8 CFP-223
1. Warning Lamp
4.1.3 Scroll UP and DOWN Buttons 2. Fault Indicator Lamp
The scroll buttons are used to scroll UP (4) or DOWN 3. Battery “A” Voltmeter
(5) when inside the FPDP menus. 4. Scroll UP Button
5. Scroll DOWN Button
4.1.4 ENTER Button 6. ENTER Button
Press the ENTER button (6) when making selections 7. MENU Button
in the FPDP menu screen. 8. Overspeed RESET/STOP Switch
9. Battery “B” Voltmeter
4.1.5 MENU Button 10. Crank Battery B Momentary Start Button
Press the MENU button (7) on the FPDP display to 11. Crank Battery A Momentary Start Button
open the menu options. 12. ECM A/B Selector Switch & Indicator Lamps
13. AUTO/MAN Mode Switch & Indicator Lamps
4.1.6 Overspeed RESET/STOP Switch 14. Hour Meter
The overspeed RESET/STOP switch (8) is used to 15. Engine Oil Pressure Gauge
shut off the engine at the FPDP. Momentarily press- 16. Coolant Temperature Gauge
ing the switch removes the key switch for thirty sec- 17. Tachometer
onds. 18. Engine Overspeed Warning Lamp
Figure 4-1 Fire Pump Digital Panel (FPDP)

Fire Power Pump Engine CFP83 4-1

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Controls
4.1.7 Battery “A” and “B” Voltmeters The MANUAL mode is typically used for engine
The Battery “A” (3) and Battery “B” (9) Voltmeters setup, testing, and emergency and maintenance pro-
display the charge status - or Voltage Direct Current cedures.
(VDC) - of the relative battery connections.
The AUTO mode is used to start the engine by the
4.1.8 Tachometer fire pump controller. In the AUTO mode, the fire pump
The Tachometer (17) displays the engine speed in drive engine shuts down upon loss of signal power
revolutions per minute (RPM) whenever the engine is from the fire pump controller.
operating.
4.1.13 Coolant Temperature Gauge
4.1.9 Hour Meter The Coolant Temperature Gauge (16) displays the
The Hour Meter (14) maintains a running total of the engine coolant temperature in degrees Fahrenheit.
hours of operation (run time).
4.1.14 Engine Oil Pressure Gauge
4.1.10 ECM A/B Selector Switch and Indicator The Engine Oil Pressure Gauge (15) displays the
Lamps - Applicable on Electronic Engines engine oil pressure in pounds per square inch (PSI).
The ECM A/B selector switch and indicator lamps This gauge is independent of the low oil pressure
(12) illuminate in yellow, indicating which ECM is alarm.
being used to control the engine.
4.1.15 Engine Overspeed Warning Lamp
If ECM A (normal position) is selected, ECM A is con- The overspeed control module monitors engine
trolling the engine. speed. If the engine RPM exceed 115% rated speed,
the Engine Overspeed Warning Lamp (18) is illumi-
If ECM B (alternate position) is selected, ECM B is nated (yellow).
controlling the engine, and the FPDP will send a
ground signal to TB-301, which will send a signal to The FPDP will send a power signal to TB-3, which will
set off an alarm on the fire pump controller to indicate send a signal to set off an alarm on the fire pump con-
that the engine is operating on the alternate ECM. troller, indicating that an overspeed condition has
occurred.
4.1.11 Crank Battery A and B Momentary Start
Buttons The FPDP will automatically switch to MANUAL
The Crank Battery A (11) and Crank Battery B (10) mode and will shut the engine down. After the over-
momentary start buttons initiate an immediate engine speed has been reset by using the RESET/STOP
start (momentary start) using the selected A or B switch on the FPDP, the engine operation will revert
crank battery. to the original AUTO mode position.

Crank A energizes battery contactor A and Crank B NOTE: The engine will not be allowed to restart auto-
energizes battery contactor B, depending on which matically from the fire pump controller until the FPDP
one is selected. is reset.

Both Crank A and Crank B buttons can be energized 4.1.16 ECM Fault Code Lamps - Applicable on
at the same time in the event both batteries are weak. Electronic Engines
The amber engine warning lamp and the red engine
4.1.12 Automatic or Manual Mode of Operation shutdown lamp alert the operator of an engine mal-
Indicator function:
The AUTO/MAN mode switch and indicator lamps
(13) show whether the engine starts and is controlled • An illuminated amber lamp indicates an engine
by the operator (MANUAL) or by an automatic signal malfunction that requires timely operator atten-
from the fire pump controller (AUTO). The lamp (yel- tion.
low) is illuminated on which mode is selected.
• An illuminated red lamp indicates an engine mal-
function that requires immediate and decisive
operator response.

4-2 Fire Power Pump Engine CFP83

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 Controls
A three- or four-digit diagnostic fault code will display power source, start contactors, magnetic pick-up,
on the FPDP which can then be used to help describe alternator, and other engine-related functions con-
the engine malfunction. Refer to the Fault Code Chart trolled by the FPDP.
in Section 7 - Troubleshooting.
4.2 Electronic Control Module (ECM) -
4.1.17 Engine STOP Button Applicable on Electronic Engines
The Engine STOP Button is located on the left side of
The ECM is an electronically operated fuel control
the FPDP enclosure and is used to stop the operation
system that also provides many operator and vehicle
of the engine in either manual or automatic mode.
or equipment features. It processes all of the inputs
The button must be pressed and held until the engine
and sends commands to the fuel system vehicle and
has shut down.
engine control devices. The base functions of the
control system include fueling and timing control, lim-
4.1.18 Engine Communications Port
iting the engine speed operating range between the
The Engine Communications Port plug-in is located
low- and high-idle set points, and reducing exhaust
on the left side of the FPDP enclosure and is used for
emissions while optimizing engine performance.
the communications connection port for Cummins
InsiteTM.
The ECM uses inputs from the operator and its
sensors to determine the fueling and timing required
NOTE: InsiteTM is a Cummins Inc. computer software
to operate at the desired engine speed.
tool used to monitor or report engine performance cri-
teria.
The ECM performs diagnostic tests on most of its cir-
cuits and will activate a fault code if a problem is
4.1.19 Contractor Access Port
detected in one of these circuits. Along with the fault
The contractor access knock-out is located on the
code identifying the problem, a snapshot of the
lower side of the FPDP enclosure. This is the only
engine’s operating parameters at the time of fault
25.4 cm (1 in) knock-out provided for the installing
activation is also stored in memory. Some fault codes
contractor to connect the fire pump controller to the
will cause a diagnostic lamp to activate to signal the
FPDP.
driver.
IMPORTANT: If this port is not used for the installa-
The ECM also communicates with service tools and
tion, all warranty on the fire pump drive engine will be
some other controllers.
void.

4.1.20 Engine ECM Power Supply

CAUTION
The Engine ECM Power Supply plug-in is located on
Normally, Cummins engines with ECMs have
the lower side of the FPDP enclosure. The power
derate and shutdown protection calibrated into
supply port supplies unswitched battery power to
the ECM. However, when the ECM on a Cummins
both ECM A and ECM B.
engine has no derate or shutdown protection, the
engine will run to destruction. Therefore, preven-
4.1.21 Engine Harness Connection
tive maintenance is essential.
Located on the lower side of the FPDP, the Engine
Harness Connection plug-in connects the panel to the

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Controls

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4-4 Fire Power Pump Engine CFP83

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 Section 5 - Operation
5.1 Introduction The engine may be stopped locally by pressing the
RESET/STOP button on the FPDP or by holding
This section outlines general operating information
down the red ENGINE STOP button on the left side of
for starting and stopping the fire pump drive engine,
the FPDP.
as well as instructions for navigating the menu
screens of the Fire Pump Digital Panel (FPDP). This
5.2.2 Emergency Starting/Stopping Procedure
manual is provided for your specific equipment and
should be considered a part of that equipment. All The engine will start automatically in the event of a
personnel responsible for the operation and mainte- fire emergency. However, if it fails to start automati-
nance of the equipment should read and thoroughly cally, the engine can be started locally. The following
understand this manual. procedure outlines an emergency manual mode
electrical start:

1. As shown in Figure 5-1, open the water bypass

WARNING valves in the cooling water supply piping or the
Before preparing the equipment for normal ser- emergency cooling supply.
vice, complete all safety checks, remove all tools
and foreign objects from the equipment, ensure
all guards are in place and securely fastened, and
alert area personnel that the equipment will be
starting.

5.2 Starting and Stopping Procedures

By default, the fire pump will turn on automatically in
the event of low system water pressure. The engine
will continue to operate as long as the RUN signal is
present. When the RUN signal is terminated by the
fire pump controller, the engine will stop.

For testing purposes, the fire pump drive engine can

Figure 5-1 Fire Pump Drive Engine Bypass Valve
be turned on and off locally using the buttons on the
FPDP (see Figure 4-1), If the engine fails to start
2. Verify that water is being discharged.
automatically in the event of a fire emergency, follow
the Emergency Starting/Stopping Procedure outlined
3. Press the AUTO/MAN mode switch on the FPDP
in Section 5.2.2.
to place the engine in MANUAL mode.
5.2.1 Local Starting/Stopping Procedure
4. As shown in Figure 5-2, open the FPDP panel
To start the engine locally from the FPDP:
door and slide the keyswitch override to the “UP”
1. Press the AUTO/MAN mode switch on the FPDP position. Verify that the green LED next to the
to place the engine in MANUAL mode. override switch is lit.

2. Press either the CRANK BATT A or CRANK

BATT B button to start the engine.

Fire Power Pump Engine CFP83 5-1

Doc. 24809, Rev. 05/2016
Operation
. pump drive engine. Turn the handle clockwise to lock
the fuel solenoid. To stop the fire pump drive engine,
turn the fuel solenoid counter-clockwise and push the
handle in.

Figure 5-2 FPDP Override Switch

1

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.

5. As shown in Figure 5-3, press downward on

either the Battery A or Battery B contactor lever
to start the engine. Battery Contactor Levers
a. If crank contactor lever A does not engage
the starter, repeat using crank contactor 1. Battery A Starter Contactor
lever B. 2. Battery B Starter Contactor

b. Release the contactor lever immediately after Figure 5-3 Manual Starter Contactor
the engine starts.
5.3 Fire Pump Digital Panel (FPDP)
IMPORTANT: If the engine does not start after three Screens and Adjustments
attempts, check the fuel supply system. Absence of As shown in Figure 5-4, the FPDP User Interface
blue or white exhaust smoke during cranking indi- Screen (main screen) shows the fire pump drive
cates that no fuel is being delivered. engine tachometer, coolant temperature, oil pressure,
Battery A voltage, Battery B voltage, hour meter, and
6. Check that the engine starts and operates at the fault codes (when present). The “MORE /\ \/” indica-
rated speed. tor at the top right of the screen signals the user to
toggle the UP or DOWN buttons to switch easily
NOTE: Engine oil pressure must be indicated on the between the FPDP User Interface Screen and the
gauge within fifteen seconds after starting. Analog Values Screen (see Section 5.3.6).

The engine may be stopped locally by pressing the NOTE: Electronic engines display J1939 tachometer,
RESET/STOP button on the FPDP or by holding engine temperature, and oil pressure. Mechanical
down the red ENGINE STOP button on the left side of engines display parameters via sensors added by
the FPDP. Cummins Fire Power.

IMPORTANT: If the fuel solenoid does not open, then NOTE: When the key switch is not on, the coolant
use the fuel solenoid override located above the fuel temperature defaults to “0 °F” (or “-18 °C”) and the oil
pump. Turn the fuel solenoid handle counter-clock- pressure defaults to “0 PSI” (or “0 kPa”).
wise to unlock and then pull the handle to run the fire

5-2 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Operation
. 5.3.1 Engine Setup Screen
As shown in Figure 5-6, the Engine Setup screen is
password protected and for Cummins Fire Power
internal use only.

(1*,1(6(783

3$66:25'
;;;

68%0,73$66:25'
5(7851720$,1

Figure 5-4 FPDP User Interface Screen (Typical)

Figure 5-6 Engine Setup Screen (Typical)
If the operator presses the MENU button from the
FPDP User Interface Screen, the Main Menu Screen 5.3.2 Overspeed Test Screen
appears as shown in Figure 5-5. Figure 5-7 shows the Overspeed Test Screen. To
simulate an overspeed for engine speed models
above 2250 RPM or for instances when over-pressur-
izing of sprinkler systems can cause damage:

1. Using the DOWN/UP arrow buttons, toggle

(1*,1(6(783 down to highlight “SIMULATE OVERSPEED”.
29(563(('7(67
530,1&'(&
2. Press ENTER.
3$5$0(7(581,76
',63/$<6(77,1*6
$1$/2*9$/8(6
$8726:,7&+
5(7851720$,1
29(563(('7(67
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PDNHD6HOHFWLRQ
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29(563(('6(732,17
530
CFP-224
$'-867(1*,1(63(('
Figure 5-5 Main Menu Screen (Typical) 6,08/$7(29(563(('
5(7851720$,1
This list shows the menu options for further operator XXXX
input and monitoring of engine parameters. To reach
(1*,1(63(('LQ530
any one of these submenu screens, use the UP or 6HOHFWLQJ7KLV,WHPDOORZVWKH83'2:1
DOWN buttons to highlight a desired screen and then NH\VWR,QF'HF6SHHGE\530
press ENTER.
CFP-225

Figure 5-7 Overspeed Test Screen (Example)

Fire Power Pump Engine CFP83 5-3

Doc. 24809, Rev. 05/2016
Operation
3. A six-second timer will begin a countdown at the 5.3.5 Display Settings Screen
bottom of the screen and all buttons will be The Display Settings Screen (shown in Figure 5-10)
locked out, except for RESET/STOP. enables adjustments to the backlight and contrast for
optimal viewing in varying lighting environments. The
The simulation test temporarily lowers the FPDP version number of the FPDP software will also be
overspeed setpoint to below the engine speed. Upon indicated on this screen.
completion of the overspeed simulation, the FPDP
reverts back to its previous operating parameters.
',63/$<6(77,1*6
5.3.3 RPM INC/DEC Screen
NOTE: This screen appears but does not function for 9HUVLRQ1XPEHU
mechanical engines. 9HUVLRQ'DWH0DU
&RQILJXUDWLRQ BBB

%$&./,*+73(5&(17>@
530,1&'(&6&5((1
530,1&'(&6&5((1 &2175$673(5&(17>@
5$7('63(('
5$7('63((' 5(7851720$,1
530
530
$'-867(1*,1(63(('
$'-867(1*,1(63(('
5(7851720$,1
5(7851720$,1
CFP-228
XXXX
)81&7,21127$9$,/$%/()257+,6(1*,1(
Figure 5-10 Display Settings Screen (Typical)
(1*,1(63(('LQ530
(1*,1(63(('LQ530 5.3.6 Analog Values Screen
6HOHFWLQJWKLV,WHPDOORZVWKH83'2:1
6HOHFWLQJWKLV,WHPDOORZVWKH83'2:1
NH\VWR,QF'HF6SHHGE\530
NH\VWR,QF'HF6SHHGE\530 The Analog Values Screen shown in Figure 5-11
provides analog output values for battery voltages,
CFP-226 engine speed, water temperature, oil pressure,
exhaust temperature, cooling loop temperature,
Figure 5-8 Mechanical RPM INC/DEC Screen (Typ- cooling loop differential pressure, and hours of opera-
ical) tion. The Analog Values Screen may be accessed
either by toggling down and selecting ANALOG
5.3.4 Parameter Units Screen VALUES from the Main Menu Screen (Figure 5-5) or
The Parameter Units Screen shown in Figure 5-9 by using the UP and DOWN buttons from the FPDP
allows the operator to select Imperial or Metric units. User Interface Screen (Figure 5-4).
The default units of measure are degrees in
Fahrenheit and pounds per square inch (PSI).

ANALOG VALUES
R(7851720$,1
3$5$0(7(581,76
B$77(5< A: 0.0 Volts
7(03(5$785(6 B$77(5<B: 14.0 Volts
E1*,1(63((': 0 RPM
LQƒ) W$7(57(03: 70° F
LQƒ&
O,/35(6685(: 0 PSI
35(6685(6: E;+$8677(03: 0° F
LQ36, /2237(03: 0° F
LQN3D /223',))35(6 0 PSI
5(7851720$,1 380335(6685( 0 PSI
H2850(7(5: 0.1 Hrs

Figure 5-11 Analog Values Screen (Typical)

Figure 5-9 Parameter Units Screen (Typical)

5-4 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Operation
NOTE: The choice of Metric or Imperial values is
made using the Parameter Units screen.

NOTE: For exhaust temperature values less than $8726:,7&+6(77,1*

93 °C (200 °F) or not monitored, the value will be
displayed as 0°. For oil temperature values less than $8726:,7&+
24 °C (75 °F) or not monitored, the value will be ',6$%/(
displayed as 0°. (1$%/(

5.3.7 Autoswitch Screen 5(7851720$,1

The National Fire Protection Association (NFPA) 20
Standard, as well as Underwriters Laboratories (UL)
and Factory Mutual (FM) Standards, requires redun-
dancy for fire safety systems. If the autoswitch is Figure 5-12 Autoswitch Screen (Typical)
enabled and the selected ECM fails to start, the fire In the event that the FPDP experiences a loss of the
pump drive engine will automatically switch to the pressure signal, the engine will default to the rated
other ECM and restart. As shown in Figure 5-12, the speed.
Autoswitch Setting Screen allows the operator to
disable or enable this autoswitch capability.

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Operation

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5-6 Fire Power Pump Engine CFP83

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 Section 6 - Maintenance
6.1 Introduction
Before performing maintenance procedures, read
and understand Section 1 - Safety of this manual. 6.2 Engine Operation Reports
Improper performance or lack of critical information The engine must always be maintained in top
could result in personal injury or equipment damage. mechanical condition. The maintenance department
requires regular running reports to include the follow-
Cummins encourages our customers to perform ing:
maintenance and repairs whenever necessary.
However, servicing complex components within the • Low engine oil pressure.
normal warranty period may void the Cummins war-
ranty and any specified warranty extended by the • Engine surge.
manufacturer of Original Equipment Manufacturer
(OEM) products. See the Warranty Information • Erratic operation or frequent shutdowns.
section at the beginning of this manual.
• Any warning lamps flashing or staying illu-
Maintenance procedures should be performed by minated.
skilled technicians who are familiar with the equip-
ment, local regulations, and service procedures for • Abnormal coolant or oil temperature.
fire pump drive engine and pump systems. Improper
maintenance can damage the engine or the fire pump • Unusual engine noise or vibration.
drive engine, or cause severe personal injury.
• Excessive smoke.
The National Fire Protection Association (NFPA) 25
Standard outlines the maintenance tests to be per- • Excessive use of coolant, fuel, or engine oil.
formed to validate automatic and manual operational
requirements for field acceptance testing. • Any fluid leaks.

Cummins recommends that the engine be maintained • Loose, worn, or damaged parts.
according to the Cummins Operation and Mainte-
nance Manual for that engine family. The weekly running report also helps to make
provisions for more extensive maintenance, as the
NOTE: If your engine is equipped with a component reports indicate the necessity.
or accessory not manufactured by Cummins Inc, refer
to the component manufacturer’s vendor supplied The Fault Codes displayed on the Fire Pump Digital
literature for specific maintenance recommendations. Panel (FPDP) assist in recording operation irregulari-
ties. See Section 7 - Troubleshooting for a listing of
Fault Codes.

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Maintenance

Maintenance Chart
Task Period Page

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

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

Every 2 Years or 2000 Hours

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

Every 4 Years or 5000 Hours

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

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

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 Maintenance

Maintenance Record Form

Table 6-1.

Engine Serial Number: Engine Model:

Owner’s Name: Equipment Name/Number:

Hours or Time Check

Date Actual Hours Performed By Comments
Interval Performance

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Maintenance
6.3 Weekly Maintenance NOTE: Turbocharged engines must be operated at
rated revolutions per minute (RPM) and full load to
When the engine is running, be alert for mechanical
check maximum intake air restriction.
problems that could create unsafe or hazardous con-
ditions.
NOTE: Cummins recommends using an air cleaner
filter element as listed on the Engine Data Sheet in
6.3.1 General
Section 8 - Component Parts and Assemblies.
Each week, a general walk-around inspection should
include the following areas:

1. Check fluid levels before starting the engine.

CAUTION
Check oil pressure and coolant temperatures Never operate the engine without an air cleaner.
frequently. Most engine problems give an early Intake air must be filtered to prevent dirt and
warning. debris from entering the engine and causing pre-
mature wear. Dirt or foreign objects could cause
2. Look and listen for changes in engine perfor- engine damage.
mance, sound, or appearance that will indicate
a. If the red indicator flag is at the raised posi-
that service or repair is needed. Be alert for mis-
tion in the window, clean or replace the air fil-
fires, vibration, excessive exhaust smoke, loss
ter per the manufacturer’s recommendation
of power, or increases in oil or fuel consumption.
as required. Do not remove the felt washer
from the indicator. The felt washer absorbs
3. Check the engine appearance for excessive
moisture.
heat, wiring short circuits, excessive end-play,
vibrations, excessive wear, excessive abrasion,
b. After the air cleaner has been serviced, push
damaged electrical wiring, or loose electrical
the flag in to reset the service indicator.
wiring.
IMPORTANT: See the Engine Data Sheet in Section
4. Check the engine for odors of diesel fuel,
8 - Component Parts and Assemblies for maximum
burning rubber, electrical system failure, exhaust
intake air restriction.
fumes, or smoke.
2. Check for corrosion under the clamps and hoses
of the intake system piping. Corrosion can allow
WARNING corrosive products and dirt to enter the intake
Engine fuel is highly flammable and represents system. Disassemble and clean as required.
an extreme hazard for fire or explosion when
exposed to electrical sparks or open flame. Clean 3. Replace any damaged air filter or hoses and
up spilled fuel immediately. Keep sources of elec- tighten loose clamps, as necessary, to prevent
trical spark or open flame away from a fuel the air system from leaking. Torque hose clamps
source. to the recommended torque value. Refer to the
torque chart in Section 8 - Component Parts and
6.3.2 Air Cleaner Filter and Piping
Assemblies.
The frequency of cleaning or replacing the air cleaner
filter element is determined by the conditions in which 6.3.3 Cooling System
the engine operates. On a weekly basis, perform the
following inspections:
CAUTION
1. Visually inspect the air intake filter and piping Do not remove a coolant pressure/fill cap from a
daily for blockage, damage to piping, loose hot engine. Shut down the engine and wait until
clamps, or punctures that can allow debris to the coolant temperature is below 50 °C (120 °F)
enter the engine. If there is a blockage, the ser- before removing the pressure cap. Heated
vice indicator will be activated. Refer to Figure coolant spray or steam can cause severe per-
2-2. sonal injury.

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 Maintenance
On a weekly basis, perform the following inspections 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. 6.3.4 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 6-1, 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 6-1 Oil Level Dipstick
5. Check for soft, overly-pliant hoses, oxidation,
and loose hose clamps. Torque hose clamps to a. If the oil level is greater than the high mark
the recommended torque value. Refer to the (H), drain the excess oil and recheck the
torque chart in Section 8 - Component Parts and level.

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Maintenance
b. If the oil level is consistently below normal Check for leaks at all connections, welds, gaskets,
after a fill, check for leaks, loose or damaged and joints. Make sure that the exhaust pipes are not
gaskets, or oil in the coolant system. If the oil heating surrounding areas excessively. Repair any
level is below the low mark (L), add the leaks immediately.
equivalent type oil.
6.3.7 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
6.3.5 Fuel System secure.

WARNING 6.3.8 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. 6.3.9 Cooling Water Strainers
As shown in Figure 6-2, 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 8 - 2. Inspect and remove any debris.
Component Parts and Assemblies for Cummins rec-
ommended replacement components. 3. Install the strainer plugs.

6.3.6 Engine Exhaust System 4. When finished, open the normal line valves and
With the engine operating, inspect the entire exhaust close the bypass line valves for normal opera-
system: exhaust manifold, exhaust flex pipe, muffler, tion.
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 6-2 Cooling Water Strainer (typical)

6.3.10 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
6.3.11 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 5 - 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:

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Maintenance
1. Check that the engine oil pressure is indicated 6.3.12.2 Engine Speed Calibration
on the gauge within fifteen seconds after start- CFP83-F10, F20, and F30 Speed Adjustment
ing.
To adjust the speed on CFP83-F10, F20, and F30 fire
2. Check that the engine has attained a normal pump drive engines, follow these steps:
running temperature after running the engine for
a minimum of thirty minutes. 1. Start the engine.

3. Observe that the engine is operating at the 2. Observe that the engine starts and accelerates
proper operating speed. (If the engine is not to the currently adjusted speed setpoint.
operating at the proper speed, see Section
6.3.12 Engine Operation Checks.) 3. Locate the threaded linkage rod on the fuel
pump side of the engine (see Figure 6-3).
4. Check for unusual engine noise. Listen for any Loosen the locking nuts against the stops on the
unusual engine noise which can indicate that outside of the threaded rod. To adjust the speed
service is required. setpoint to the rated speed, do the following:

5. Ensure that the oil pressure is greater than 69 a. To increase the speed, loosen the lock nut
kPa (10 psi). and turn the bolt on the right side of the throt-
tle bracket clockwise. The adjustment of the
6. Check that the coolant temperature is between bolt will pivot the throttle bracket counter-
70 °C (158 °F) and 107 °C (225 °F). clockwise and will allow more fuel through
the pump to speed up the engine.
7. Check that both battery voltmeters indicate
12 VDC for standard or 24 VDC for optional b. To decrease the speed, loosen the lock nut
operating systems. and turn the bolt on the right side of the throt-
tle bracket counter-clockwise. The adjust-
8. Check that the air filter service indicator has not ment of the bolt will pivot the throttle bracket
popped-up, indicating an air filter blockage. clockwise and will allow less fuel through the
Replace the air filter as required. pump to slow down the engine.

End the test run by pressing and holding the over- c. When the rated speed is correct, tighten the
speed RESET/STOP switch until the engine stops. locking nut against the stop.

6.3.12 Engine Operation Checks 4. The threaded bolt on the left side of the throttle
The following service inspections ensure that the bracket is for maximum speed and may also
engine starts and operates properly under normal need to be adjusted if the maximum speed
conditions. cannot be attained by adjusting the threaded bolt
on the right side of the throttle bracket. Use the
same procedures outlined in Step 3 for the
WARNING threaded bolt on the left side of the throttle
Before equipment operation, ALL guards, covers, bracket, if necessary.
and protective devices MUST BE in place and
securely fastened. Serious personal injury could 5. Stop the engine.
result from contact with exposed or moving com-
ponents. 6. Repeat Steps 1 through 5 until the desired
speed is attained.
6.3.12.1 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.

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 Maintenance
Cummins Inc. Contact a Cummins Authorized
Repair Location before performing any extensive
maintenance.

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
with the negative (-) cable first and check the follow-
ing:

Throttle Bracket 1. Inspect the electrical wiring harness, electrical

terminal connections, and electrical plug-ins for
Figure 6-3 Fire Pump Drive Engine Threaded secure, clean electrical contacts, worn or dam-
Linkage Rod aged insulation, burnt wires, broken wires, and
loose connections (see Figure 2-1).
6.3.13 Engine Coolant Heater
NOTE: Perform this inspection procedure twenty-four a. Clean and tighten any loose electrical con-
hours after shutting off the engine. nections.

The engine coolant heater must maintain an engine b. Repair or replace worn, damaged, burnt, or
coolant temperature of 49 °C (120 °F) or above. The poorly insulated wiring immediately. Refer to
engine block must be warm to the touch in the water Section 8 - Component Parts and Assem-
jacket areas (see Figure 2-2). blies.

If the heater does not appear to be working correctly, IMPORTANT: Refer to the vendor-supplied literature
contact a Cummins Authorized Repair Location. for recommended maintenance procedures.

2. Inspect the function of all gauges, voltmeters,

6.4 Annual Maintenance
switches, and warning lamps on the FPDP.
All checks or inspections listed under previous main- Replace the FPDP if any are not functioning
tenance intervals must also be performed at the time properly.
of the annual maintenance, in addition to those listed
only under the annual maintenance interval. 3. Reinstall the battery cables; attach the negative
(-) battery cable last.
6.4.1 Electrical Components
6.4.2 Turbocharger Mounting Nuts
CAUTION As shown in Figure 6-4, check the turbocharger
AVOID SERVICING complex components such mounting nuts and torque the mounting nuts to the
as: printed circuit boards, programmable control- recommended torque value as specified in Section 8
lers, and ECMs not specifically authorized by - Component Parts and Assemblies.

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Maintenance

1
2
3

Fuel filter or Filter/Separator

CFP-058-1
5
Figure 6-5 Fuel Pumps (typical)
1. Exhaust Flex Connection
2. Turbocharger
3. Air Cleaner/Filter WARNING
4. Service Indicator Engine fuel is highly flammable and represents
5. Air Cleaner Piping an extreme hazard for fire or explosion when
exposed to electrical sparks or open flame. Clean
Figure 6-4 Turbocharger (typical)
up spilled fuel immediately. Keep sources of elec-
trical spark or open flame away from a fuel
6.4.3 Engine Supports
source.
CAUTION
Loose engine mount bolts or damaged brackets WARNING
can cause engine misalignment or excessive Do not open the fuel filter/water separator drain
vibration. These conditions can cause engine or valve or dismantle the fuel lines on the high-pres-
pump damage. sure fuel system with the engine running. High
pressure fuel spray from an operating engine can
Refer to Figure 2-1 for the location of the engine sup-
cause serious personal injury or fire hazard.
ports and inspect all engine supports for cracks or
loose hardware. Check the torque on the engine To change the fuel filters:
support mounting capscrews. Torque the engine
mounting cap screws to the support bracket. Refer to 1. Shut off the engine.
the torque table in Section 8 - Component Parts and
Assemblies for recommended torque values. 2. Close any fuel valves (if equipped) to prevent
fuel from draining or siphoning.
6.4.4 Fuel Pumps and Filters
As shown in Figure 6-5, inspect the fuel injection 3. Clean the area around the fuel filter or fuel/water
pump mounting nuts (including the support bracket) separator heads.
for loose or damaged hardware. Inspect the fuel line
hoses and fuel filters for wear, damage, loose fittings, NOTE: Refer to the Engine Data Sheet in Section 8 -
and leaks. Repair or replace damaged hoses and Component Parts and Assemblies for filter replace-
filters as required. ment recommendations.

4. Remove the spent filter canisters using a filter

wrench.

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 Maintenance
5. Clean the filter mounting head surfaces of IMPORTANT: If the engine oil is drained from the oil
sludge buildup and foreign particles. Ensure pan to make an engine repair, new oil must be used.
mating gasket surfaces are clean.

6. Lubricate the gasket seals with clean SAE WARNING

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

To change the oil and filter to remove the contami-

CAUTION nants suspended in the oil:
Mechanical over-tightening can distort the
threads or damage the filter element seal. 1. Operate the engine until the coolant temperature
reaches 70 °C (158 °F). Shut the engine off.
9. Press either the CRANK BATT A or CRANK
BATT B button to start the engine to allow the 2. Place an appropriate container under the oil pan
fuel to flow through the system. drain plug. Refer to the Engine Data Sheet in
Section 8 - Component Parts and Assemblies for
10. Depress the contactor switch for up to fifteen oil pan capacity.
seconds or until the engine starts. Repeat up to
three times, if necessary. 3. Remove the oil drain plug and drain the oil
immediately to make sure all the oil and sus-
pended contaminants are removed from the
CAUTION engine.
To prevent damage to the starter, do not engage
the starting motor more than fifteen seconds. 4. Remove the oil filter (see Figure 6-6) following
Wait fifteen seconds between each start attempt. these steps:

IMPORTANT: If the engine does not start after three a. Clean the area around the engine oil filter
attempts, check the fuel supply system. Absence of canister. Use a filter wrench to remove the fil-
blue or white exhaust smoke during cranking indi- ter.
cates no fuel is being delivered.
b. Remove and discard the O-ring seal if it has
NOTE: Engines used in fire pumps or standby service remained attached to the mounting flange.
are expected to immediately accelerate from crank to Clean the filter mounting flange with a clean
full load. lint-free cloth.

6.4.5 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.

Fire Power Pump Engine CFP83 6-11

Doc. 24809, Rev. 05/2016
Maintenance
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.

6.4.6 Drive Shaft

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

1. Remove the drive shaft guards.

2. Wipe the grease fittings and grease gun nozzle

1. Oil Fill Port (on valve cover) with a clean cloth to avoid contamination.
2. Oil Level Dipstick
3. Engine Oil Filter 3. Add grease to the drive shaft universal joint
grease fittings (see Figure 3-2).
Figure 6-6 Oil Filter and Oil Level Dipstick (Typical)
4. Wipe excess grease from the grease fittings.
6. Center the filter ring on the threaded mounting
nipple. Screw the filter canister onto the mount- NOTE: Cummins Inc recommends using a good
ing flange until the gasket is snug against the quality semi-synthetic, molybdenum-fortified NLGI #2
mounting flange. Then tighten an additional 1/4 lithium complex grease which protects from -47 to
turn. 204 °C (-54 to 400 °F).

6.4.7 Coolant Pump/Alternator Belt

CAUTION On some engine models, the pump and alternator
Mechanical over-tightening can distort the belt drives both the pump and alternator.
threads or damage the filter element seal.
To inspect the coolant pump and the alternator belt:
NOTE: Cummins recommends using oil filter replace-
ment parts as outlined in the Engine Data Sheet in 1. Press the AUTO/MAN button on the FPDP to
Section 8 - Component Parts and Assemblies. place the fire pump drive engine in MANUAL
operation.
7. Check and clean the oil pan drain plug threads
and sealing surface. Install the oil pan drain plug.
2. Disconnect both batteries at their terminals.
Torque the plug according to the Torque Chart in
Remove the negative (-) cable first.
Section 8 - Component Parts and Assemblies.
3. Remove the belt guard capscrews and the belt
8. Fill the engine to the proper level with clean, high
guard. Set aside for re-installation (see Figure
quality 15W-40 oil at the fill port.
6-7).

CAUTION
If no oil pressure is noted within fifteen seconds
after the engine is started, shut down the engine
to reduce the possibility of internal damage.

6-12 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Maintenance
NOTE: Belts with glazed or shiny surfaces indicate
    belt slippage. Correctly installed and tensioned belts
will show even pulley and belt wear.

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

 a. Use the Cummins belt tension gauge (Part

Number 3822524) to measure the drive belt

tension in the center span of the belt between
the idler and alternator pulleys. Ensure that

the belt tension is set to the specifications
outlined in the Engine Operation Manual.

b. Use the deflection method and measure the

belt tension in the center span of the belt
between the alternator and idler pulleys. If
the belt deflection is more than one belt thick-
1. Belt Guard ness per foot of pulley center-to-center dis-
2. Alternator Pulley tance, adjust the belt tension.
3. Drive Belt
4. Idler Pulley 6. Reinstall the battery cables; attach the negative
5. Coolant Pump Pulley (-) battery cable last.
6. Balancer Pulley
7. Belt Tensioner 6.4.8 Raw Water Zinc Anode
The zinc anode (see Figure 6-8) acts as a raw water
Figure 6-7 Coolant Pump/Alternator Belt (typical) filter and must be checked for erosion and replaced,
when necessary. If the anode has eroded more than
4. Visually inspect the belt for frayed, worn, missing fifty percent, it must be replaced.
pieces, or cracked belt surfaces. Check the belt
for intersecting cracks.

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

NOTE: Transverse cracks (across the belt width) are

acceptable. Longitudinal cracks (direction of belt
length) that intersect with transverse cracks are not
acceptable. Replace the belt if it is cracked, frayed, or
damaged.
Figure 6-8 Raw Water Zinc Anode (typical)
5. If the belt condition is acceptable, check the belt
tension. There are two ways to check the belt 6.4.9 Heat Exchanger
condition:
If internal leakage in the heat exchanger is sus-
pected, a heat exchanger pressure test may be per-
formed prior to removal from the engine.

Fire Power Pump Engine CFP83 6-13

Doc. 24809, Rev. 05/2016
Maintenance
NOTE: Use Teflon™ tape or other pipe sealant when 2. Remove the air intake and exhaust piping from
installing the test setup in order to prevent leaks. the turbocharger.

NOTE: The size of fittings required on the water 3. Inspect the turbocharger turbine wheel for
outlets and inlets are listed on the Engine Data Sheet cracks in the housing or turbine blades, missing
in Section 8 - Component Parts and Assemblies. blades, mechanical binding, eccentric motion, or
excessive end-play.
To test the heat exchanger pressure:
4. Replace the turbocharger if damage, excessive
1. Install an adapter at the cooling water outlet of end-play, binding, wear, or eccentric motion is
the heat exchanger. found. Contact a Cummins Authorized Repair
Location for replacement.
2. Install a pressure test setup with 689 kPa (100
psi) pressure gauge at the cooling water inlet to IMPORTANT: The turbocharger must be removed for
the heat exchanger. replacement or rebuild if the clearance is beyond the
limits, the housing is cracked, or the turbine wheel is
3. Apply air pressure at 414 kPa (60 psi). damaged.

a. Isolate the pressure source and monitor the 5. Reinstall the air intake filter and exhaust piping.
pressure gauge for five minutes. Tighten the clamps. Torque loosened clamps to
the recommended torque value. Refer to the
b. There should be no change in pressure for torque table in Section 8 - Component Parts and
the duration of the test. Assemblies.
4. After testing, release the pressure. Remove the
tubing adapters, plug, and test equipment.
6.5 Every Two Years
All checks or inspections listed under daily or previ-
5. If leakage is detected, the heat exchanger must ous maintenance intervals must also be performed at
be replaced. this time, in addition to those listed under this mainte-
nance interval.
6.4.10 Turbocharger
As shown in Figure 6-4, follow these steps to thor- 6.5.1 Coolant Pump
oughly inspect the turbocharger: Inspect the coolant pump for eccentric motion,
mechanical binding, excessive end play, seal
1. Visually inspect the air intake filter and piping damage, and excessive grease or coolant leakage
according to the steps outlined in Section 6.3.2. around the pump shaft.

NOTE: Turbocharged engines must be operated at Replace with a new or rebuilt pre-lubricated unit, as
rated revolutions per minute (RPM) and full load to necessary. Contact a Cummins Authorized Repair
check maximum intake air restriction. Location for replacement.

NOTE: Cummins recommends using an air cleaner 6.5.2 Cooling System

filter element as listed on the Engine Data Sheet in Figure 6-9 illustrates the cooling system. The cooling
Section 8 - Component Parts and Assemblies. system must be clean to work properly. If the system
shows excessive mineral buildup, particulate matter,
scale, oxidation, or oil contamination, drain and flush
CAUTION the cooling system. If the coolant is excessively dirty
Never operate the engine without an air cleaner. or is mixed with oil, contact a Cummins Authorized
Intake air must be filtered to prevent dirt and Repair Facility.
debris from entering the engine and causing pre-
mature wear. Dirt or foreign objects could cause
engine damage. WARNING
Do not remove the pressure/fill cap from a hot
engine. Shut down the engine and wait until the

6-14 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Maintenance
coolant temperature is below 50 °C (120 °F)
before removing the pressure cap. Heated
coolant spray or steam can cause severe per-
sonal injury.

1. Press the AUTO/MAN button on the FPDP to

place the fire pump drive engine in MANUAL
operation.

2. Disconnect both batteries at their terminals.

Remove the negative (-) cable first.

3. Press down, unscrew, and remove the coolant

expansion tank pressure/fill cap. The cap must
1
be removed to allow air to vent the cooling
system during the draining process.
2
4. Disconnect the engine coolant heater power
supply before draining the cooling system.
3
4
5
5. Place a container that will hold at least 57 liters
(15 gal) of liquid under the coolant drain valve.
1. Lower Coolant Tube
2. Coolant Drain Petcock
6. Ensure that the coolant filter shut-off valves are
3. Coolant Filter
OPEN.
4. Coolant Filter Shut-off Valve
5. Engine Coolant Heater
7. Open the drain petcock on the lower coolant
tube, allowing the coolant to drain into the waste Figure 6-9 Engine Coolant Drain
container.

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

under the engine coolant heater. Over-concentration of antifreeze or use of high-
silicate antifreeze can damage the engine. Do not
9. Disconnect either end of the engine heater use more than 50% antifreeze in the mixture
coolant hose and drain the engine heater. unless additional freeze protection is required.
Antifreeze at 68% concentration provides the
maximum freeze protection, and must never be
CAUTION exceeded under any condition. Antifreeze protec-
Coolant is toxic. Avoid prolonged and repeated tion decreases above 68%.
skin contact with used antifreeze - wash thor-
oughly after contact. Prolonged, repeated contact 11. When the flushing water has fully drained, use a
can cause skin disorders. Dispose of waste anti- filter wrench to remove the water coolant filter
freeze in accordance with local environmental from the filter housing.
regulations.
a. Clean the filter housing gasket mount of dirt
10. Flush with clean fresh water or heavy-duty heat buildup, oxidation, or particulate matter with a
exchanger cleaner. Follow the manufacturer’s clean cloth.
directions on the product container.
b. Coat the replacement filter gasket with a light
NOTE: Some cooling system cleaners or commercial coating of 15W-40 lubrication oil.
solvents require a soapy water rinse after use. Follow
the directions on the cleaning solution or solvent. 12. 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

Fire Power Pump Engine CFP83 6-15

Doc. 24809, Rev. 05/2016
Maintenance
mounting flange, then tighten an additional 1/4 glycol or propylene-glycol and Supplemental Coolant
turn. If using a soapy water solution, flush again Additive (SCA) required for wet-sleeved engines in
with clear water. Allow time for the water to fully most climates. Contact your local Cummins Autho-
drain. rized Repair Location for additional information.

CAUTION Table 6-2.

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

NOTE: Recommendations on filter replacements and 40% = -23 °C (-10 °F) 40% = -21 °C (-6 °F)
fill rates can be found on the Engine Data Sheet in
Section 8 - Component Parts and Assemblies. 50% = -37 °C (-34 °F) 50% = -33 °C (-27 °F)

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

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

NOTE: During filling, air must be vented from the

engine coolant passages. The air vents through the
CAUTION
coolant filler port. The fill rate can be found in the The system must be filled properly to prevent air
Engine Data Sheet in Section 8 - Component Parts locks. During filling, air must be vented from the
and Assemblies. engine coolant passages.

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

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

b. Re-install the expansion tank fill cap.

CAUTION
Use soft or distilled water in the coolant mixture. 16. Re-install the heater wiring.
Contaminants in hard water neutralize the corro-
sion inhibitor components. Water must not 17. Reinstall the battery cables; attach the negative
exceed 300-ppm hardness or contain more than (-) battery cable last.
100 ppm of either chloride or sulfate.
18. Operate the engine until it reaches a tempera-
ture of 82 °C (180 °F), and check for coolant
CAUTION leaks.
Never use a sealing additive to stop leaks in the
cooling system. This can result in cooling system 19. Ensure that the coolant level is just below the fill
blockage or restricted coolant flow, causing the neck and that the coolant heater is reconnected.
engine to overheat.
6.6 Every Four Years
NOTE: Cummins Inc. recommends using Fleet-
All maintenance checks and inspections listed in pre-
guard® ES COMPLEAT™ Ethylene-Glycol (EG) or vious maintenance intervals must also be performed
Fleetguard® Propylene-Glycol (PG) Plus™ Anti- at this time.
freeze/Coolants. Both products are available in con-
centrated or pre-mixed formulations. Use a 50% Cummins recommends performing maintenance on
concentration level (40% to 60% range) of ethylene- valve lash settings.

6-16 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Maintenance
6. Replace the thermostat flange and cap screws.
CAUTION
Disconnect both batteries (negative cable first)
before performing service on the fire pump drive
engine or on any of its controls. Wear safety
glasses when disconnecting batteries!

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

6.6.1 Coolant Thermostat Removal/Installation

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

1. Hose Clamps
CAUTION 2. Upper Coolant Hose
3. Thermostat Housing
Always use the correct thermostat, and never
operate the engine without a thermostat installed. Figure 6-10 Thermostat Housing (typical)
The engine can overheat if operated without a
thermostat because the path of least resistance 6.6.2 Coolant Pump/Alternator Belt Replacement
for the coolant is through the bypass to the pump Referring to Figure 6-7, replace the coolant pump/
inlet. alternator belt if it is cracked, frayed, or has pieces of
material missing.
1. Remove the upper coolant hose clamps and
upper coolant hose at the thermostat housing. 1. Remove the belt guard.
2. Use a 3/8” drive ratchet or breaker bar to rotate
2. Remove the (2) thermostat housing flange cap the tensioner arm away from the belt and
screws and the thermostat flange (see Figure remove the belt.
6-10).
3. Check the belt tensioner cap screw torque. For
3. Remove the thermostat and gasket from the recommended torque values, refer to the torque
housing. table in Section 8 - Component Parts and
Assemblies.
4. Clean the housing flange faces of dirt buildup,
oxidation, and sludge. 4. Check the tensioner arm, pulley, and stops for
cracks. If any cracks are noticed, the tensioner
5. If still in good condition, re-install the thermostat must be replaced.
in the housing.
5. Verify that the tensioner arm stop is not in
IMPORTANT: Inspect the seal on the thermostat contact with the spring casing stop. If either stop
housing flange surface and - if damaged or cracked - is touching, the tensioner must be replaced.
apply a new seal.
6. Inspect the tensioner for evidence of the ten-
NOTE: Recommendations on thermostat replace- sioner arm contacting the tensioner cap.
ment components can be found on the Engine Data If there is evidence of the two areas making con-
Sheet in Section 8 - Component Parts and Assem- tact, the pivot tube bushing has failed and the
blies. tensioner must be replaced.

Fire Power Pump Engine CFP83 6-17

Doc. 24809, Rev. 05/2016
Maintenance
7. Check the tensioner bearing. 9. After checking the torque, use a 3/8” drive
ratchet or breaker bar to rotate the tensioner
a. Rotate the belt tensioner pulley. The pulley
slowly away from the area of belt contact.
should spin freely with no mechanical bind-
ing, eccentric motion, or excessive end-play. 10. Install the replacement drive belt.
b. If the arm rotates with mechanical binding,
eccentric movement, or excessive end play, CAUTION
replace the tensioner. To prevent pulley or belt damage, do not roll a
8. Inspect the clearance between the tensioner belt over the pulley or pry it on with a tool. Move
spring case and the tensioner arm for uneven the tensioner arm away from the belt area before
bearing wear. installing the drive belt.

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

6-18 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Section 7 - Troubleshooting
7.1 Introduction
The following information is intended as a guide for CAUTION
some common non-technical equipment problems. AVOID SERVICING complex components such
The first part of this section includes troubleshooting as: printed circuit boards, programmable
charts that cross-reference the problem, the possible controllers, and ECMs not specifically authorized
cause, and the solution. The second section includes by Cummins Inc. Contact the Cummins Fire
complete Fault Code charts outlining a numerical Power Customer Service Department toll free at
listing of fault codes and their descriptions. 1-800-343-7357 before performing any extensive
maintenance.
Many problems can be resolved using corrective
maintenance, adjustment, or minor repair. Refer to
the vendor supplied literature, electrical schematics, CAUTION
and mechanical prints for additional information. Never climb or stand on the equipment frame,
guards, or enclosures. Contact with exposed or
For engine-related issues, refer to the engine Opera- moving components can cause personal injury or
tion and Maintenance Manual or contact the equipment damage.
Cummins Customer Assistance Center at 1-800-
DIESELS (1-800-343-7357).

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

Fire Power Pump Engine CFP83 7-1

Doc. 24809, Rev. 05/2016
Troubleshooting

This page is intentionally left blank.

7-2 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Troubleshooting

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7-3
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
Troubleshooting

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7-4
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
 Troubleshooting

Engine Cranks But Will Not Start (continued)

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7-5
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
Troubleshooting

7.4 Engine Starts But Continues to Crank

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7-6
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
 Troubleshooting

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7-7
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
Troubleshooting
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7-8 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Troubleshooting

7.7 Fault Codes

NOTE: Fault codes are not displayed on the FPDP for mechanical engines.

7-9
Fire Power Pump Engine CFP83
Doc. 24809, Rev. 05/2016
Troubleshooting

This page is intentionally left blank.

7-10 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Section 8 - Component Parts and Assemblies
8.1 Ordering Parts Check the telephone directory yellow pages or refer
to the directory in this section for the nearest
Replacement parts for the Cummins Inc. equipment
Cummins Authorized Repair Location.
are manufactured to the same quality standards and
specifications as the original equipment. Unapproved
substitution may result in poor performance, reduced 8.3 Emergency Repairs and Technical
service life, lost production, or unsafe operation. Service
The Cummins Customer Assistance Center provides
Cummins Inc. relies on the best and most cost effec- a 24-hour, toll free telephone number to aid in techni-
tive shipping methods, unless specific instructions or cal and emergency service when a Cummins Autho-
requirements are requested by the customer. When rized Repair Location cannot be reached or is unable
ordering parts, please be prepared to provide the fol- to resolve an issue with a Cummins product.
lowing information.
If assistance is required, call Toll-Free: 1-800-
• Model and serial number. DIESELS (1-800-343-7357). Includes all 50 states,
Bermuda, Puerto Rico, Virgin Islands, and the Baha-
• Part description by name or number. mas.

• Quantity required. Outside of North America contact your Regional

Office. Telephone numbers and addresses are listed
• Purchase order number. in the International Directory.

NOTE: A purchase order number is desirable, even if Refer also to the Cummins Inc. web site at www.cum-
the part(s) are supplied on a Returned Goods Autho- mins.com.
rization (RGA) issue number. A purchase order
number helps Cummins NPower Inc. and its 8.4 Recommended Spare Parts Inventory
customer track the parts and necessary credits.
To minimize downtime and increase productivity,
Cummins Inc. recommends maintaining a stock of
8.2 Routine Service and Parts spare parts critical to uninterrupted engine operation.
Personnel at Cummins Authorized Repair Locations Shipping costs can be lower using ground transporta-
can assist you with the correct operation and service tion rather than overnight or next day air freight. For
of your engine. Cummins has a worldwide service this reason Cummins Inc. can provide a list of recom-
network of more than 5,000 Distributors and Dealers mended spare parts. Contact a Cummins Authorized
who have been trained to provide sound advice, Repair Location for additional information.
expert service, and complete parts support.

Fire Power Pump Engine CFP83 8-1

Doc. 24809, Rev. 05/2016
Component Parts and Assemblies
CFP83 Engine Data Sheet
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8-2 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Component Parts and Assemblies
CFP83 Engine Data Sheet (Continued)

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Fire Power Pump Engine CFP83 8-3

Doc. 24809, Rev. 05/2016
Component Parts and Assemblies
CFP83 Engine Data Sheet (Continued)

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8-4 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Component Parts and Assemblies
Torque Table

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

Fire Power Pump Engine CFP83 8-5

Doc. 24809, Rev. 05/2016
Component Parts and Assemblies
Torque Table (Continued)

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

8-6 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 Component Parts and Assemblies
8.5 Assembly Drawings
The most current revisions to these drawings and re-
lated documents are accessible at: http://www.cum-
minsfirepower.com/products.html

Drawing Revision Change

Description
No. Level Date
General Layout, Fire Pump, CFP83 26726 -
Drawing, Installation, Fire Pump, CFP83-F10/20/30 (6CTA8.3) 26110 G 3/16
Options, Engine, G-Drive, CFP83-F10/20/30 (6CTA8.3) 8738 D
Assembly, Heat Exchanger 8919 J
Assembly, Air Intake and Rear Mounting 26567 C
Assembly, Coolant Heater A042A161 C
Assembly, Sensor Package 9574 D
Assembly, Solenoid Override 9830 A
Assembly, Control Panel Mounting 21249 -
Assembly, All Components Top-level:
Assembly, Panel, Digital Mechanical 22793 A
Assembly, Harness 23930 B
Cables, Battery Contactors 8824-12 A
Battery Contactors, 4B, 6B, 6C, QSB 24234 B
Kit, Fuel Lines A042B473 A
Misc. Piping, Cooling Loop, Raw Water 26288 D 3/16
Assembly, Raw Water Cooling Loop, 3/4" Vertical 21511 A
Assembly, Raw Water Cooling Loop, 3/4" Horizontal 12V 21509 B
Assembly, Raw Water Cooling Loop, 3/4" Horizontal 24V 21510 B
Misc. Piping, Cooling Loop, Sea Water A042A409 -
Assembly, Sea Water Cooling Loop, 3/4" Vertical 21512 B
Assembly, Sea Water Cooling Loop, 3/4" Horizontal 12V 21438 C
Assembly, Sea Water Cooling Loop, 3/4" Horizontal 24V 21439 C
Assembly, Stub-Shaft, SAE#3, 2.25" QSB, QSC, 4B, 6B, 6C 8619 D
Schematic, Control Panel, Mechanical 16122 B

Fire Power Pump Engine CFP83 8-7

Doc. 24809, Rev. 05/2016
Component Parts and Assemblies

This page is intentionally left blank.

8-8 Fire Power Pump Engine CFP83

Doc. 24809, Rev. 05/2016
 CONNECTOR WIRE INSERTION VIEW
C1 C2 C3 C6 C4 C5 C7 C8 C7-A C9
A
A B C
2 1 B
A B C
C

CONTACTOR A

"CR A GND" "BATT A+"

W14
W12 W11
"CR B +"
W15 "CR A+"
"CR B GND" W13
CONTACTOR B
"BATT A+"
W10

7" 9"
W16
7" 5"
"BATT B +" 9"
5" 5"

W17 5" 10"

"EXCITE" "BATT B +"

C4
7"
SPL C SPL B SPL D SPL A
10"
W18
"ALT GND" 10" 33" 6" 2" 10"
10" 7" 8" 10"
10" 7" 8"
7" 7" "DPEM POWER"
W19 C8
"ALT BATT +" W20
9" C9-A
W22 W6
"LOW H20 TEMP" "FSO PULL-IN" "BATT A +"
"ALT GND +" W9 C9
W21 "BATT B +"
"STARTER GND +" W8 W7
"ALT BATT +" "EXCITE"
12"
BATTERY ISOLATOR
W1
3"
MAG PICKUP 5" 15" C1
3"
W2
"WTS"
WATER TEMP SWITCH
12"
W3 C6
"WTG"
WATER TEMP SENDER
8" C7
4" 6"
C7-A SPLICE DETAIL
6" 17B
"RS-485" 17 17C
SPL A
17A
8" 4" 17F
17D
17E
17G 33
34
C5 "OPS"
OIL PRESSURE SWITCH
C3 5" 6" SPL B 21A
"FSO" 21
FUEL SHUT-OFF 21B

4"
30" 7"
SPL C 1
W25 29 31
"CL POST-PRESS" 35

NOTES:
1) LOOM WITH BLACK NYLON BRAID W/ RED TRACERS, 28 MIL MINIMUM. 7" 14"
2) PROMINENTLY LABEL ALL CONNECTORS AS "INDICATED".
13" SPL D 2
30 32
3) ALL SPLICES TO BE FITTED WITH GLUED HEATSHRINK.
W5 36
W4 "OPG"
4) ALL DIMENSIONS SHOWN ARE MEASURED FROM THE REAR OF THE CONNECTOR
(WIRE ENTRY VIEW). 27" 5" "GND" OIL PRESSURE SENDER
5) SEE SHEET 2 FOR THE WIRE TO/FROM LIST. W24
6) RUN BRAID OVER THE BOOT AT LEAST 1" ON ALL CONNECTORS WITH BOOST TO C2
"CL PRE-PRESS"
PREVENT THE BRAID FROM SLIPPING BACK.
"RAW WATER"
7) USE A 3" LONG GLUED HEATSHRINK ON ALL RING TERMINALS AND RUN THE BRAID W23
1
2 WAY UP THE HEATSHRINK. "CL TEMP"
8) USE GLUED HEAT SHRINK ON CONNECTORS C4 & C5 TO ACT AS A BOOT. MAKE
SURE HEAT SHRINK COVERS BACK OF CONNECTOR AND BRAID RUNS 21 WAY UP
THE HEATSHRINK.
AUTO CAD
9) COMPONENTS MAY BE SUBSTITUTED AS LONG AS FIT, FORM, FUNCTION AND
REGULATORY STANDARDS ARE MET OR EXCEEDED.
AUTO CAD
 SPLICE C
1 1
SPLICE D
2 2

FSO PULL-IN W20 20

STARTER GND + W21 3 3 4

ALT GND W22 16 17C 3

11 12

12 13

BATTERY A+ W10 18 21 14

BATTERY A+ W11 29

COIL GROUND W12 17D W1 4 5

MAGNETIC PICKUP
COIL SIGNAL W13 11 W2 5 6

A 6 6 7

COIL SIGNAL W14 12 B 20

SPLICE A
COIL GROUND W15 17E C 17F 17 W4
BATTERY B+ W16 30

BATTERY B+ W17 19 A 17A

B 14

C 9 9 10

BATTERY B+ W9 19

ALT BATT + W8 15 21 A 14

EXCITE W7 21B SPLICE B B 10 10 11

BATTERY A+ W6 18 21A

1 13 13 15

2 17B

ALT GND W18 16

A
ALT BATT + W19 15
B 25 25 19

C 17G
C 21A
WATER TEMP SENDER W3 8 9

W5 7 8

1 31
A 22 21
2 32
B 23 22
3 33
C 24 16
4 34

5 35

6 36
TEMPERATURE W23 26 17

PRE-PRESSURE W24 27 25

POST-PRESSURE W25 28 26

AUTO CAD