CUMMINS Fire Pump Drive Engines, CFP9E SERIES Operation & Maintenance Manual
CFP9E SERIES
Operation & Maintenance Manual
Fire Pump Drive Engines
www.cumminsfirepower.com
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-i
Table of Contents
Warranty Information
Section 1 - Safety
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section 2 - Description
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Fire Pump Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Operator Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 Overspeed Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Operating Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Fire Pump Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Raw Water Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.7 Fuel Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.7.1 Fuel Supply and Drain Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.8 High Pressure Common Rail (HPCR) Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.9 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.10 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Section 3 - Installation
3.1 Receiving and Handling Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Damage During Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.2 Claim Filing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Fuel Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Fuel System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.2 Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Raw Water Supply Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.1 Install Raw Water Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.5 Battery Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5.1 Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5.2 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5.3 Auxiliary Battery Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.6 Signal and Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.7 Coolant System Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.8 Charge Air Cooler System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.9 Engine Oil System Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.10 Pre-Start Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.11 Engine Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.11.1 Engine Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.11.2 Engine Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-ii
Table of Contents
Section 4 - Controls
4.1 Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Coolant Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Engine Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.3 Tachometer and Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.4 Battery A and B Voltmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.5 Circuit Breaker Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.6 AUTO/MANUAL Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.7 Overspeed Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.8 Engine Overspeed Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.9 Overspeed RESET/STOP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.10 High Coolant Temperature Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.11 Low Oil Pressure Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.12 CRANK BATT A/B Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.1.13 ECM Fault Code Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.14 ECM A/B Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 Electronic Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.1 ECM Data Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Overspeed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 Raw Water Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 Engine Protection System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.5.1 Engine Protection Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Section 5 - Operation
5.1 Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 General Operating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 Remote Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.4 Local Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.5 Emergency Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.6 Engine Operating Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.7 Overspeed Set Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.8 Crank Terminate Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.9 ECM Fault Code Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.10 Isolated Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.10.1 Integrated Acceptance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Section 6 - Maintenance
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Engine Operation Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Weekly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 General Walk Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Air 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 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.6 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.7 Electrical Supply and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.8 Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.9 Clean Raw Water Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.10 Check Battery Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.11 Engine Run Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.3.12 Engine Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Table of Contents
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-iii
6.3.13 Check Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3.14 Air Cleaner Service Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4 Annual Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.1 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.2 Turbocharger Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.4.3 Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.4.4 Inspect Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.5 Engine Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4.6 Change Fuel Filter of Filter/Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.4.7 Output Shaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.4.8 Engine Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.4.8.1 Crank Termination Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.4.8.2 Engine Speed Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4.8.3 Overspeed Set Point Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4.9 Coolant Pump/Alternator Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.4.10 Coolant Pump/Alternator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4.11 Heat Exchanger Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4.12 Turbocharger Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.5 Every 2 Years or 2000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5.1 Water Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5.2 Drain and Flush Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.6 Every 4 Years or 5000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.6.1 Coolant Thermostat Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.6.2 Coolant Pump/Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.6.3 Charge Air Cooler (CAC) Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.6.3.1 Charge Air Heat Exchanger Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Section 7 - Troubleshooting
7.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 Alternator Overcharging with the Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.1.2 Neither Battery is Charging with the Engine Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.1.3 Only One Battery is Charging with the Engine Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.1.4 Voltage Indications Differ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.1.5 Coolant Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.1.6 Excessive Coolant Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.1.7 Coolant Temperature Above Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.1.8 Coolant Temperature Below Normal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.1.9 Raw Water Drain Steaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.1.10 Raw Water Solenoid Valve fails to Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.1.11 Auto Start failure - Does not Crank on BATT A or B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.1.12 Auto Start failure - Cranks but does not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.1.13 Auto Start failure - Engine Starts but Crank Terminate Does Not Occur . . . . . . . . . . . . . . . . . . 7-19
7.1.14 Manual Start Failure from Solenoid Lever - Does not Crank on A or B . . . . . . . . . . . . . . . . . . . 7-20
7.1.15 Manual Start Failure from Control Panel - Does not Crank on A or B . . . . . . . . . . . . . . . . . . . . 7-20
7.1.16 Engine Cranks Normally But Will Not Start (No Exhaust Smoke). . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.1.17 Engine Cranks Slowly But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.1.18 Engine Stops During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.1.19 Engine Will Not Reach Rated Speed (RPM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.1.20 Engine Will Not Shut Off Remotely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.1.21 Engine Will Not Shut Off Locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.1.22 Fuel Consumption is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.1.23 Fuel or Engine Oil Leaking From Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.1.24 Engine Oil is Contaminated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-iv
Table of Contents
7.1.25 Engine Oil Consumption is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.1.26 Engine Oil in the Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.1.27 Engine Overspeed Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.1.28 Tachometer Does not Indicate Engine Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Section 8 - Component Parts and Assemblies
8.1 Part Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Routine Service and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.3 Emergency Repairs and Technical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.4 Recommended Spares Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Index
Table of Contents
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-v
List of Figures
Figure 2-1 Heat Exchanger Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2 Raw Water Cooling Loop Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-3 Engine Components - Instrument Panel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-4 Engine Components - Turbocharger Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-5 Engine Overspeed Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-6 Turbocharger and Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-7 Engine Air Intake and Charge Air Cooling Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-8 Engine Cooling System Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-9 Fuel System Components - High Pressure Common Rail (HPCR) . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-10 Flow Diagram - Engine Lubricating Oil System (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-11 Flow Diagram - Exhaust System (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-12 Turbocharger Exhaust Flow Diagram (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 3-1 Engine Lifting lugs (Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2 Drive Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-3 Drive Coupling Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-4 Fuel Line Supply and Return Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-5 Engine Fuel System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-6 Raw Water Cooling Loop Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-7 Cooling Loop Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-8 Series Battery Connection - 24 VDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-9 Termination Blocks and Wiring Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-10 Coolant Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-11 Coolant Circulation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-12 Engine Coolant Expansion Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-13 Charge Air Cooler Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-14 Turbocharger and CAC Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-15 Oil Filter and Oil Level Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-16 Turbocharger Oil Line Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-17 Turbocharger Turbine Wheel (typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-18 Operator’s Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-19 Operator’s Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-20 Manual Starter Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 4-1 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-2 Operator Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-3 Engine Settings Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-4 ECM Selector Panel and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-5 Electronic Control module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-6 Engine Overspeed Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 4-5
Figure 4-7 Raw Water Flow Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 5-1 Instrument Panel Switch Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Figure 5-2 ECM Selector Panel and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-3 Raw Water Manual Valves (open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-4 Manual Starter Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Figure 5-5 ECM Diagnostic Reader Plug-ins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-6 Instrument Panel Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 6-1 Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
TOC-vi
Table of Contents
Figure 6-2 Heat Exchanger Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Figure 6-3 Oil Level Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-4 Engine Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Figure 6-5 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-6 Raw Water Wye Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-7 Optional 24 VDC Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Figure 6-8 Engine Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Figure 6-9 Air Cleaner Service Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-10 Electrical Control Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-11 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Figure 6-12 Engine Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Figure 6-13 Fuel Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Figure 6-14 Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-15 Oil Filter and Oil Level Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-16 Fuel Filter or Filter/Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Figure 6-17 Drive Coupling Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Figure 6-18 Engine Overspeed Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Figure 6-19 Coolant Pump/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Figure 6-20 Turbocharger Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Figure 6-21 Turbocharger Turbine Wheel (typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Figure 6-22 Engine Coolant Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Figure 6-23 Filter Housing Gasket Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Figure 6-24 Thermostat Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Figure 6-25 Coolant Pump/Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Figure 6-26 Coolant Filter & Shut-off Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Figure 6-27 Cooling Loop and Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Figure 6-28 Charge Air Tubing Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
This manual contains proprietary information to equipment produced by Cummins Fire
Power or Cummins, Inc. and is being supplied solely for the purpose of operating,
maintaining and servicing the fire pump engine purchased from Cummins Fire Power.
© Copyright 2008, Cummins Fire Power
Warranty Information
LIMITED WARRANTY
EXCLUSIVE EXPRESS LIMITED WARRANTY: Cummins Fire Power (CFP), division of Cummins NPower,
LLC expressly warrants to the original end consumer only that, for a period not to exceed the earlier of two (2)
years or 2000 hours of use from the start-up date (or, if the original end consumer fails to register as purchaser
with CFP, six (6) months from CFP shipment date), the diesel fire pump drivers, manufactured and sold by
CFP, shall be free from defects in material and workmanship when used and serviced in accordance with the
Operations and Maintenance manual for the applicable Cummins Fire Pump engine model (the “Exclusive
Warranty”). The Exclusive Warranty is nontransferable and shall immediately terminate and be of no further
force or effect upon the sale, lease, assignment, transfer or other disposition by an original end consumer of a
Cummins Fire Pump engine that contains a diesel fire pump driver covered by this Exclusive Warranty.
Nothing contained herein shall be construed to extend the Exclusive Warranty, and the Exclusive Warranty
shall not be extended, to:
• Maintenance, adjustment, installation or start-up costs;
• Diesel fire pump driver failure due to normal wear, accident, misuse, abuse, neglect, improper installation
or a defect attributable to a Cummins Fire Pump engine;
• Alterations or modifications not authorized in writing by CFP;
• Additional components added to a diesel fire pump driver package subsequent to shipment of the
engine; or
• Starting batteries
• Coolant heaters are covered for 12 months.
DISCLAIMER OF WARRANTIES: Except for the Exclusive Warranty provided above, which is in lieu of all
other express and implied warranties, CFP EXPRESSLY DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION AND EXCLUSION OF REMEDIES: All claims under this Exclusive Warranty shall be deemed
waived by the original end consumer if not submitted to CFP or an authorized distributor within thirty (30) days
of initial discovery that a diesel fire pump driver is not conforming to the Express Warranty. The original end
consumer’s remedy under this Exclusive Warranty is limited, in CFP’s reasonable discretion, to repair, replacement or other appropriate adjustment of a nonconforming diesel fire pump driver determined, upon CFP’s
inspection, to have been properly installed, maintained and operated in accordance with the Operations and
Maintenance manual furnished by CFP. IN ANY EVENT, CFP SHALL NOT BE LIABLE FOR INCIDENTAL
OR CONSEQUENTIAL DAMAGES.
The Cummins Industrial Warranty covers the base engine for a period of time not to exceed the earlier of two
(2) years or 2000 hours of operation from the date of delivery and start-up of the engine. Reference bulletin
numbers 3381321 US/Canada & 3381322 Outside US/Canada. Cummins Fire Power components are warranted for a period of time not to exceed the earlier of two (2) years or 2000 hours of operation from the startup date of the fire pump system, and the coverage includes travel time and mileage for the first year of the
Limited Warranty, and repair or replacement of parts and reasonable cost of labor. The Cummins Fire Power
Limited Warranty does not cover failures or damage due to abuse or neglect and including, but not limited to:
shipping damage, improper storage, improper installation, unauthorized modification or lack of maintenance.
Cummins Fire Power is not responsible for incidental or consequential damages.
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
1-1
Section 1 - Safety
1.1 Introduction
Cummin’s Fire Power and Engine Manuals should be
considered part of the equipment. Keep the manuals
with the equipment. If the equipment is traded or sold,
give the manuals to the new owner.
All personnel responsible for operation and maintenance of the equipment should read and thoroughly
understand this manual.
1.2 Advisory and Cautionary Statements
Advisory and Cautionary Statements are used
throughout this manual to call attention to special
information, correct operating procedures and to
safety precautions.
NOTE: A general advisory statement relating to
equipment operation and maintenance procedures
IMPORTANT: A specific advisory statement intended
to prevent damage to the equipment or associated
components.
Cautionary Statements consist of two levels:
WARNING
Indicates the presence of a hazard which CAN
cause severe personal injury.
CAUTION
Indicates the presence of a hazard which CAN
cause personal injury, or cause equipment
damage.
1.3 Safety Precautions
Warning: Read and understand all of the safety pre-
cautions and warnings before performing any repair.
This manual contains the general safety precautions
that must be followed to provide personal safety.
When they apply, special safety precautions are
included with operating procedures.
Warning: Perform a walk around inspection and alert
all area personnel that the equipment will be starting
before manual operation.
Warning: Do not operate faulty or damaged equipment. Ensure that all hoses, pipe connections,
clamps and guards are in place and securely fastened. Electrical components should be kept in good
working condition and repaired immediately by qualified personnel.
Warning: After performing maintenance, remove all
tools and foreign materials, reinstall and securely
fasten ALL guards, covers and protective devices.
Warning: Exposed in-running belt nips can cause
severe personal injury or dismemberment. Ensure
that guards are in place and securely fastened before
operation.
Warning: Rotating drive shafts can lacerate, dismember or cause strangulation. Keep hands, body
parts, long hair, or loose-fitting clothing clear at all
times.
Warning: Never attempt to manually clean a
machine while it is operating or in standby mode.
Warning: Never open ports on tanks or piping while
the engine is operating. Contact with pressurized
agents can cause severe personal injury.
Warning: Relieve all pressure in the air, oil, and the
cooling systems before any lines, fittings, or related
items are removed or disconnected.
Caution: Engine fuel is flammable when in contact
with electrical spark or flame sources. Remove all
sources of spark or flame from the work area.
Caution: Always use the same fastener part number
(or equivalent) when replacing fasteners.
Caution: Some state and federal agencies in the
USA have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity.
Dispose of waste oil in accordance with applicable
requirements.
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
1-2
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-1
Section 2 - Description
2.1 Introduction
This manual contains information for the correct operation and maintenance of a Cummins Fire Pump
Engine. Read and follow all safety instructions. Refer
to the General Safety Instructions in Section 1 -
Safety.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new
owner.
Cummins Fire Power, Cummins NPower and Cummins, Inc. reserve the right to make changes at any
time without obligation. If any differences are found
between an engine and the information in this
manual, contact the local Cummins Authorized
Repair Location.
1. Coolant Fill Cap
2. Coolant Expansion Tank
3. Coolant Heat Exchanger
4. Heat Exchanger Discharge
5. Charge Air Cooler (CAC) Heat Exchanger
Figure 2-1 Heat Exchanger Tanks
The latest technology and the highest quality components were used to produce this engine. When
replacement parts are needed, we recommend using
only genuine Cummins or ReCon® exchange parts.
2.2 Fire Pump Engines
Cummins complete line of fire pump engines have
been approved as packaged units (engine and all
accessories) by Factory Mutual Approvals and listed
by Underwriter’s Laboratories, Inc. and Underwriter’s
Laboratories of Canada.
1. 1” NPT Raw Water Inlet
2. Bypass Water Inlet Valve
3. Bypass Water Pressure Regulator
4. Bypass Water Outlet Valve
5. Pipe To Heat Exchanger
6. Water Supply Pressure Gauge
7. Pressure Gauge Isolation Valve
8. Normal Water Outlet Valve
9. Normal Water Solenoid Valve
10. Normal Water Pressure Regulator
11. Normal Water Wye Strainer
12. Bypass Water Wye Strainer
13. Normal Water Inlet Valve
Figure 2-2 Raw Water Cooling Loop Manifold
1
2
3
4
5
CFP9-001
1
2
3
4
6
5
7
8
9
10
11
12
13
CFP9-002
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-2
1. Coolant Fill Cap
2. Coolant Expansion Tank
3. Exhaust Flex Connection
4. Charge Air Cooler Hose
5. Terminal Box
6. Charge Air Cooler (CAC) Heat Exchanger
7. Air Cleaner Element
8. Engine Speed Setting Plates
9. Battery Starter Contactors
10. Manual Start Instruction Decal
11. Engine Supports
12. Flywheel Housing
13. Fuel Return Outlet
14. Raw Water Inlet
15. Fuel Inlet
16. Oil Pan and Drain
17. Operator Control Panel
18. Fuel Filter or Filter/Separator
19. Cooling Loop Manifold Piping
20. Electronic Control Modules (ECMs)
Figure 2-3 Engine Components - Instrument Panel Side
19
17
16
1
23
4
6
5
7
8
9
10
11
12
20
11
14
15
13
18
CFP9-003
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-3
1. Air Cleaner Element
2. Charge Air Cooler (CAC) Heat Exchanger
3. Exhaust Flex Connection
4. Upper Coolant Hose
5. Coolant Fill Cap
6. Coolant Expansion Tank
7. Coolant Heat Exchanger
8. Heat Exchanger Raw Water Discharge
9. Lower Coolant Hose/Tube
10. Alternator
11. Engine Heater
12. Engine Oil Filter
13. Starter Motor
14. Manifold Heat Shield
Figure 2-4 Engine Components - Turbocharger Side
This product meets Tier 3 emission levels. This turbocharged engine requires charge air cooling (CAC)
and fuel cooling.
No deviations are permitted without prior written
approval. These engines are to be used only for fire
protection applications. Refer to Figure 2-1, Figure
2-2, Figure 2-3 and Figure 2-4.
2.3 Operator Control Panel
The operator control panel is mounted on the flywheel end on the left (fuel pump) side of the engine.
Refer to Section 4 - Controls for additional information.
The operator control panel contains controls for starting, monitoring engine performance and controlling
fire pump engine operation.
1
2
3
4
6
5
7
8
9
10
11
12
14
13
CFP9-004
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-4
2.3.1 Overspeed Switches
Each engine is equipped with an electronic overspeed module which activates the fuel pump solenoid
valve and ECM ignition to shut off the engine when
the RPM exceeds a preset limit. The overspeed
switch senses engine speed during the start cycle
and stops the starting motor cranking cycle. Refer to
Figure 2-5.
2.3.2 Operating Speed
All Cummins fire pump engines are shipped from the
factory adjusted to the requested operating speed
(RPM). Final operating speed adjustment must be
made during the in-service inspection to obtain the
required operating speed specified by the pump manufacturer.
1. Spring Clamp Terminal Blocks
2. Speed Increase/Decrease Toggle Switch
3. RESET Button
4. TEST Button
5. Diagnostic ON/OFF Toggle Switch
6. CRANK Termination or RUN Signal Indicator
LED (Factory Use Only)
7. Overspeed Indicator LED
8. Pre-wired Terminals
9. Crank Terminate Potentiometer Cover
10. Overspeed Potentiometer Cover
Figure 2-5 Engine Overspeed Control Module
2.4 Fire Pump Controller
Fire pump controller is not supplied by Cummins Fire
Power, or Cummins, Inc. The fire pump controller
starts the engine automatically when a remote fire
demand signal is initiated and automatically shuts
down the engine when the fire demand signal is discontinued.
The engine may be started locally in the Manual
Mode and shut down using the operator control panel
Stop Switch or by returning the switch back to automatic mode.
NOTE: Pressure recorders are available to provide a
permanent record of water pressure fluctuations and
engine starts. Sequential starting is available for
multiple-pump installations to prevent all pumps from
starting simultaneously.
2.5 Air Intake System
The Air Intake System supplies combustion air to the
fire pump engine cylinders. The air filter prevents particulate matter from entering the air intake. Combustion air drawn into the system by the turbocharger is
directed through the charge air cooler (CAC) heat
exchanger for cooling before entering the intake manifold where the charge air is mixed with fuel. Refer to
Figure 2-6 and Figure 2-7.
1. Turbocharger
2. Turbo Connection to Charge Air Cooler
3. Intake Air Cleaner
4. Valve Cover
5. Exhaust Manifold
6. Exhaust Flex Connection
Figure 2-6 Turbocharger and Exhaust Manifold
CFP9-040
1
2
3
4
6
5
CFP9-005
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-5
1. Turbocharger
2. Air Hose To Charge Air Cooler
3. Intake Air Cleaner
4. Charge Air Cooler (CAC) Heat Exchanger
5. Charge Air Cooler Hose
6. Combustion Air Intake Manifold
Figure 2-7 Engine Air Intake and Charge Air Cooling Flow Diagram
2.6 Raw Water Cooling System
The fire pump raw water supply provides cooling
water for the engine heat exchanger system. A waterto-air Charge Air Cooler (CAC) Heat Exchanger,
reduces the combustion air temperature at the intake
manifold. A low charge air temperature (requirement
of 60° C (140° F) (with 25° C (77° F) ambient) meets
emission levels, while improving engine performance
and efficiency.
1
2
3
4
6
5
CFP9-006
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-6
1. Coolant Heat Exchanger
2. Coolant Expansion Tank
3. Coolant Fill Cap
4. Charge Air Cooler
5. Fuel Cooling Heat Exchanger
6. Exhaust Manifold
7. Exhaust Flex Connection
8. Turbocharger
9. Air Filter
10. Engine Block
11. 185° F. Thermostat
12. Raw Water Inlet Pipe
13. Coolant Pump
14. Coolant Filter
15. Bypass Piping
16. Manual Shut-off Valve
17. Raw Water Wye Strainer
18. Raw Water Pressure Regulator
19. Raw Water Solenoid Valve
20. Raw Water Pressure Gauge
21. Raw Water Drain Line
22. Combustion Air Intake Manifold
Figure 2-8 Engine Cooling System Flow Diagram
2
3
4
22
8
6
9
10
11
13
14
1616
18
16
18
19
16
21
16
20
7
12
15
1
5
17
CFP9-007
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-7
Water entering the cooling system through the 1”
NPT raw water inlet, first circulates through the
charge air cooler heat exchanger, cooling the compressed air from the turbocharger outlet ducting. The
cooled combustion air exits the CAC outlet duct to the
engine air intake manifold. Refer to Figure 2-1, Figure
2-2 and Figure 2-7.
NOTE: The raw water supply must be immediately
available when the engine is started.
The raw water from the CAC heat exchanger then
passes through the Fuel Cooling Heat Exchanger
and the Engine Coolant Heat Exchanger. The raw
water exits the Coolant Heat Exchanger through a
1-1/4” NPT discharge connection.
IMPORTANT: If the piping will be supplied by the
customer, provide raw water supply piping and components equivalent to components supplied by
Cummins Fire Power and as shown in Assembly Diagram, Raw Water Piping. Refer to National Fire Protection Association NFPA20 Chapter 11 for US
installation requirements. When choosing components for the raw water supply and bypass, ensure
that the internal cross sectional area of the component is at least as large as the recommended pipe
size.
When the raw water piping is installed, adjust both
pressure regulator set points before operating the
pump.
1. The upper line is the bypass line. The bypass
line outlet valve should be closed.
2. The lower line with the solenoid valve is the
normal inlet line. The pressure gauge isolation
valve must be open. The normal water inlet line
valve should be open.
IMPORTANT: Monitor the oil pressure and coolant
temperature gauges frequently. Refer to Lubricating
Oil System Specifications or Cooling System Specifications in the Engine Data Sheets for recommended
operating pressures and temperatures. Shut off the
engine if any pressure or temperature does not meet
the specifications.
Maximum engine coolant temperature should not
exceed 107° C (225° F). The coolant expansion pressure/fill cap must meet the minimum pressure of 10
kPa (15 psi).
The engine coolant system contains a mixture of at
least 50 percent antifreeze and 50 percent water. The
coolant level should be maintained just below the fill
neck of the coolant supply tank.
CAUTION
Continuous operation with low coolant temperature (below 70° C (158° F)) or high coolant temperature (above 107° C (225° F)) can damage the
engine. Verify raw water pressure and flow.
2.7 Fuel Cooling System
A fuel cooling heat exchanger maintains fuel temperature to meet the maximum allowable fuel inlet temperature (71° C (160° F)). Performance of the fuel
cooling system is critical to engine durability, performance and emissions compliance.
2.7.1 Fuel Supply and Drain Location
The fuel supply and return connections are located
on the rear (flywheel end) left (injection pump side)
engine support. Refer to Figure 2-9.
2.8 High Pressure Common Rail (HPCR)
Fuel System
The fire pump engine is equipped with an electronic
fuel system that delivers precise fuel quantities with
precise injection timing at high injection pressures.
The system consists of a high pressure pump (up to
1100 BAR) that supplies a common fuel rail and
accumulator manifold feeding 6 high-pressure electronic controlled injectors to provide precise fuel
metering and timing. The system is controlled by the
Engine Control module CM850 for fueling and timing
based on temperature, altitude, boost pressure, and
throttle position. Refer to Figure 2-9.
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-8
1. High Pressure Fuel Pump
2. Injector (4)
3. Fuel Cooling Heat Exchanger
4. Fuel Filter or Filter/Separator
5. ECM Selector Panel and Switch
6. Fuel Return Connection
7. Fuel Supply Connection
8. ECM Module A
9. Lift Pump (behind ECM A)
10. ECM Module B
Figure 2-9 Fuel System Components - High Pressure Common Rail (HPCR)
With the High Pressure Common Rail (HPCR) fuel
system, fuel priming is required for conditions such
as: initial start-up, running out of fuel and maintenance of fuel system components (i.e., filter change).
A 12 VDC fuel lift pump is standard.
NOTE: The system will prime a totally dry fuel system
in 120 seconds or less. Applications with remote fuel
tank requires a fuel lift pump (supplied). Lift pump run
time is limited to two minutes.
CFP9-009
1
2
7
9
10
2
3
8
6
5
4
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-9
1. Oil Pump
2. Pressure Regulator Valve
3. Oil Return To Pan
4. High Pressure Relief Valve
5. Oil Return To Pan
6. Oil Thermostat
7. Oil Cooler
8. Combination Oil Filter
9. Filter Bypass Gears
10. Idler Gears
11. Viscosity Sensor
12. Turbocharger
Figure 2-10 Flow Diagram - Engine Lubricating Oil System (typical)
2.9 Engine Oil System
The Engine Oil System lubricates moving internal
engine parts (pistons, piston arms, valves, cam
shafts, drive 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
Figure 2-10.
Typically engine oil has been added during manufacture and testing procedures, however, shipping
restrictions can affect whether the oil is maintained in
the engine or drained for shipment.
Check the oil level at the dipstick. Add oil as necessary to bring the oil level to the H (high) mark on the
dipstick.
2.10 Exhaust System
The exhaust system removes engine exhaust from
the cylinders after the combustion process.The
exhaust discharges from the exhaust manifold,
passes through (drives) the turbocharger, and exits
through the exhaust flex-pipe. Refer to Figure 2-11,
and Figure 2-12.
CFP9-010
1
2
3
4
7
5
8
9
10
12
6
11
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
2-10
1. Exhaust Valve Ports
2. Engine Exhaust Manifold
3. Combustion Air To Charge Air Cooler
4. Turbocharger Turbine
Figure 2-11 Flow Diagram - Exhaust System (typical)
1. Wastegate Actuator Cylinder
2. Exhaust Flow to Flex Pipe
3. Combustion Air To Charge Air Cooler
4. Wastegate OPEN
5. Wastegate CLOSED
Figure 2-12 Turbocharger Exhaust Flow Diagram (typical)
1
2
3
4
CFP9-008
1
2
3
4
5
1
3
2
CFP9-011
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-1
Section 3 - Installation
3.1 Receiving and Handling Information
Cummins Fire Power Pump Engines are pre-assembled and tested before shipment. Parts not shipped
attached to the engine are sometimes shipped individually. The equipment was thoroughly inspected
and prepared for shipping before it was turned over to
the carrier.
1. Carefully remove the components from the shipping container. Remove crating, shipping tape,
braces and tie-downs.
2. Inspect the equipment for damage that may
have occurred in shipping.
3. Check each item carefully against the shipping
manifest or bill of lading.
3.1.1 Damage During Shipping
File a Claim For Damages with the carrier, if your
equipment was received damaged or not received at
all. Notify Cummins Fire Power, or Cummins Inc. as
soon as possible to determine if a replacement item
or repair is required.
3.1.2 Claim Filing Procedure
The following information is required if a claim is filed:
1. A Claim Statement describing the damaged or
lost merchandise and how the claim was determined.
2. A Bill of Lading or Freight Bill is required as proof
of who transported the freight.
3. A noted Freight Bill or Inspection Report Copy,
as evidence of loss or damage.
4. Invoice Copy or other documents establishing
the cost to you of the freight lost or damaged, or
an Invoice for Repairs.
3.2 Site Preparation
This section provides instructions for the initial installation, adjustment, and testing of the Cummins Fire
Pump Engine. Appropriate portions of this section
should be used when returning the engine to operation after overhaul or major maintenance.
The site should be clean and relatively level. Clear
the proposed equipment area of overhanging
obstructions and obstacles protruding from the floor.
Raw water piping should be installed by trained technicians, familiar with local, state and federal codes
and regulations, per the equipment layouts supplied
by Cummins Fire Power, or Cummins Inc.
3.2.1 Site Considerations
Refer to the general fire pump and engine layout
drawings for installation dimensions supplied with this
manual.
CAUTION
Avoid installation in a dusty or dirty environment.
Provide adequate physical protection from other
physical damage as may be present in the specific location.
Refer to National Fire Protection Association NFPA
20, Chapter 11 for US installation and applicable local
code requirements.
1. Lay out a designated center line on the site floor.
Find the center line of the engine drive shaft. Lay
out a center line on the cross frame members.
IMPORTANT: Ensure that the lifting device or forklift
is capable of handling the package weight and size
requirements.
2. If the engine is lifted separately, use the lifting
hooks (supplied with the engine) and a spreader
bar to position the engine. Refer to Figure 3-1.
If the engine is assembled with the drive line,
pump and mounting base, use the lifting points
provided on the mounting base or lift the entire
skid using an approved fork lift. Refer to the layout drawings supplied with this manual for lifting
points.
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-2
1. Lifting Lug
2. Lifting Spreader Bar
Figure 3-1 Engine Lifting lugs (Engine Only)
CAUTION
Ensure that the lifting device is capable of safely
lifting the weight of the engine or the combined
weight of the assembled pump base, drive line
and pump. Refer to the Bill of Lading for combined shipping weights.
3. Position the engine as required for the interface
with the fire pump, water piping, fuel piping,
exhaust and air system connections.
4. Position the engine center line to align the
engine drive shaft with the fire pump drive.
Ensure that the engine and pump are correctly
aligned.
a. Ensure engine position is centered on frame
side to side within ± .03 inch, by measuring
outside of frame side to engine support leg
mounting pad. (Compare two front engine
supports and two back engine supports).
b. Align engine center line to pump center line
within ± .03 inch. Refer to Figure 3-2.
c. The pump center line to the engine crank-
shaft center line (in vertical plane) is to be .25
inch: +0, -.25 inch offset.
d. Drive shaft mounting flanges must be
parallel.
1. Planes Must Be Parallel
2. Align Both Mounting Center lines to
± .03”
3. Distance to Equal Half of Total Travel
4. .25”: +0, -.25” Offset
Figure 3-2 Drive Coupling Alignment
5. Check that the fire pump is properly installed per
the pump manufacturer’s specifications.
6. Connect the exhaust piping to a safe location,
away from building air intake sources (air conditioners, windows, fresh air intake pipes, etc.).
Figure 3-3 Drive Coupling Grease Fittings
2
1
1
CFP9-012
2
4
1
3
90
°
90
°
TOP
SIDE
CFP9-013
CFP9-015
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-3
7. Check that the alternator/coolant pump drive belt
is properly installed.
8. Check that all hoses and tubes are properly
installed and all clamps secure.
9. Lubricate grease fittings on the drive shaft universal joint. Refer to Figure 3-3.
a. Wipe the grease fittings and grease gun noz-
zle with a clean cloth.
b. Add grease to the universal joint grease fit-
tings.
c. Wipe excess grease from the grease fittings.
NOTE: Cummins Fire Power, or Cummins Inc. recommends using a good quality semi-synthetic,
molybdenum-fortified NLGI #2 lithium complex
grease which protects from -54° to 400° F such as
Valvoline Durablend®.
NOTE: Some lubrication loss may occur during transport and storage. It is recommended that the drive
shaft be re-lubricated upon installation.
3.3 Fuel Supply Installation
1. Install an elevated no. 2 diesel fuel tank or other
fuel supply arrangement which is compatible
with ASTM no. 2 diesel fuel specifications.
1. Engine Pedestal Leg
2. 1/2” Fuel Return Connection
3. 5/8” Fuel Supply Connection
Figure 3-4 Fuel Line Supply and Return Hoses
NOTE: The fuel supply line at the fuel tank must be
higher than the fuel intake port on the engine fuel
filter or filter/separator. Ensure that the fuel system is
installed in a safe and effective manner.
2. Size the fuel tank for the maximum expected fullload engine operation period with the initial fuel
level at the minimum level for refueling.
3. Install a 1/2“NPT (minimum) fuel return line.
Route this line to the bottom of the fuel tank in
order to minimize the return head. Refer to
Figure 3-4.
4. Install a 5/8” NPT (minimum) fuel supply line to
the fire pump engine.
NOTE: DO NOT use copper or galvanized pipe for
the fuel return or supply lines.
3.3.1 Fuel System Preparation
The fire pump engine fuel system has been primed
during manufacturing and test procedures. The
engine is equipped with an electric lift pump which
primes the fuel filter or filter/separator and high pressure fuel pump when the engine is cranked. Refer to
Figure 3-5.
A Water Separator must be integrated into the fuel
delivery system of the fire pump engine. A Fuel Filter/
Water Separator may be installed directly on the unit
in the primary fuel filter location, or a separate filter/
separator may be installed in the fuel delivery system
near the fire pump engine assembly.
1. Ensure that the filter/separator is free of water by
opening the fuel filter/water separator drain at
the bottom of the filter. Refer to 6.3.5 Fuel Sys-
tem Inspections for additional information.
2. Drain the fuel into a container until no water is
present. Dispose of the contaminated fuel in
accordance with local environmental regulations.
CAUTION
Due to the precise tolerances of diesel injection
systems, it is extremely important that the fuel be
kept clean and free of dirt or water. Dirt or water
in the system can cause severe damage to both
the fuel pump and the fuel injectors.
3
2
1
CFP9-041
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-4
1. High Pressure Fuel Pump
2. Fuel Filter or Filter/Separator
3. Fuel Return Connection
4. Fuel Supply Connection
5. Lift Pump (behind ECM A)
Figure 3-5 Engine Fuel System Components
3.3.2 Fuel Recommendations
WARNING
Do not mix gasoline, alcohol, gasohol, ethanol or
methanol with diesel fuel. This mixture will cause
severe engine damage or explosion.
CAUTION
Use ONLY no. 2 diesel (ASTM no. 2D) fuel. Any
adjustment to compensate for reduced performance with a fuel system using alternate fuel is
not warrantable.
3.4 Raw Water Supply Installation
Raw water circulated through the system cools the
charge air cooler (CAC) heat exchanger, the fuel
cooling heat exchanger, and the engine coolant heat
exchanger fluid. Raw water supplied from the fire
pump water source prior to the pump discharge
flange, is forced through the cooling system to the
various heat exchangers. Refer to Figure 3-6 and
Figure 3-7.
IMPORTANT: The raw water supply must be immediately available when the engine is started. Ensure
that the supply line valves are in the OPEN position.
CAUTION
When the raw water piping is installed, adjust
both pressure regulator set points before operating the pump. Damage to the heat exchanger may
occur from improperly regulated raw water
supply pressure.
3.4.1 Install Raw Water Piping
NOTE: The velocity of the raw water should be as
great as possible without exceeding the maximum
allowable pressure shown in the appropriate engine
data sheet.
1. Provide 1-1/4” NPT raw water discharge line at
the outlet of the engine coolant heat exchanger.
Refer to Figure 3-7.
1. 1” NPT Raw Water Inlet
2. Bypass Water Inlet Valve
3. Bypass Pressure Regulator/Strainer
4. Bypass Water Outlet Valve
5. Pipe To Heat Exchanger
6. Water Supply Pressure Gauge
7. Pressure Gauge Isolation Valve
8. Normal Water Outlet Valve
9. Solenoid Valve
10. Normal Pressure Regulator/Strainer
11. Normal Water Wye Strainer
12. Bypass Water Wye Strainer
13. Normal Water Inlet Valve
Figure 3-6 Raw Water Cooling Loop Manifold
CFP9-043
3
2
4
1
5
1
2
3
4
6
5
7
8
9
10
11
12
13
CFP9-002
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-5
NOTE: Raw water outlet piping from the heat
exchanger should be one pipe size larger than the
supply piping.
2. Provide a raw water supply line to the 1” NPT
raw water inlet.
NOTE: The water supply set points have been set by
the manufacturer during engine assembly and
testing.
3. Check the pressure regulator setting with water
flowing through the heat exchanger. If supplied
as an option from CFP, both water pressure regulators have been set at 207 kPa (30 psig) or
slightly less water pressure, during manufacture
and testing. The raw water should be adjusted
based on water flow rather than water pressure.
The flow is dependent on the raw water temperature. Refer to the engine curve and data sheets
for details.
4. Use a 5 gallon container to measure and time
the flow from discharge pipe.
Flow rate = time to fill container/container size.
Example: Time to fill 5 gallon container = 15 seconds.
Divide 15 by 5 = 3 (seconds per gallon).
Divide 60 seconds by 3 = 20 gallons per minute.
5. Adjust both pressure regulators to a pressure
that will provide a flow rate at or above the specifications.
The minimum raw water flow rate is 20 GPM @
50F, 30 GPM @ 70F, and 40 GPM @ 90F.
IMPORTANT: The manual water valves for the Automatic Loop should remain OPEN at ALL times. The
manual valves for the Bypass Loop should be
CLOSED during Automatic (pump controller) operation.
NOTE: When running, the engine should stabilize
between 180° F and 185° F. The flow rate may need
to be increased if the temperature stabilizes above
this range. Do not exceed 60 psi.
NOTE: Excess cold (40° F to 75° F) raw water flow
can cause condensation inside the charge air cooler.
1. Charge Air Cooler (CAC) Heat Exchanger
2. Fuel Cooling Heat Exchanger
3. 1” NPT Raw Water Inlet
4. 1-1/4” NPT Raw Water Discharge
5. Coolant Heat Exchanger
6. Coolant Expansion Tank
Figure 3-7 Cooling Loop Heat Exchangers
IMPORTANT: Continuous operation with low coolant
temperature (below 70° C (158° F)) or high coolant
temperature (above 107° C (225° F)) can damage the
engine.
3.5 Battery Selection
The minimum recommended reserve capacity (SAE
RC) and cold cranking ampere (SAE CCA) values for
a particular engine can be found on the engine curve
and data sheets. RC and CCA definitions can be
found in SAE standard J537. All battery information is
for lead/acid batteries.
3.5.1 Battery Requirements
One set of batteries must be supplied for the standard 12VDC operating voltage. Two redundant sets
of batteries must be supplied for the optional 24 VDC
operating voltage. Refer to National Fire Protection
Association, NFPA 20, Chapter 11 and Section 1 Safety of this manual for additional battery installation
information.
6
5
4
1
3
2
CFP9-042
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-6
Figure 3-8 Series Battery Connection - 24 VDC
IMPORTANT: Batteries must meet the requirement
listed in Electrical System Specifications. Batteries
may be supplied by Cummins Fire Power, or
Cummins Inc. as an option or may be supplied by the
customer.
WARNING
Battery electrolyte (sulfuric acid) is highly caustic
and can burn clothing, and skin. Wear impervious
neoprene gloves, and safety goggles or full face
shield, when working with the batteries. Always
disconnect the negative battery cable first and
reconnect it last.
CAUTION
Do not connect battery charging cables to any
electronic control system component. This can
damage the electronic control system.
NOTE: Use the inductive charging-cranking systems
analyzer, Cummins Part Number 3377193, to test the
output amperage of either maintenance-free or conventional vent cap batteries. Follow the instructions
provided with the test equipment.
3.5.2 Battery Installation
Install the Loose Wire Kit per instructions on
Cummins Drawing 9768. If purchased, install the
optional Battery Cable Kit (Cummins Fire Power Part
No. 9614). Otherwise, install equivalent customer
supplied wiring. Install battery sets in a well ventilated
or otherwise protected location.
NOTE: There are two possible heavy-duty battery
connections: Battery terminal and clamp or threaded
battery terminal and nut.
1. Provide adequate room for servicing or replacing
the batteries. Provide protection from extremes
of temperature and weather.
2. Locate the batteries near the engine or increase
the size of the conductors as required by applicable codes. Ensure that the batteries are configured properly for standard 12 VDC operations
or optional 24 VDC operations. Refer to Figure
3-8.
3. Check the battery cables and connections.
NOTE: Coat the terminals with petroleum jelly to
prevent corrosion. Install the cables and tighten the
battery connections.
3.5.3 Auxiliary Battery Starting
If a battery charging system is not provided, the
engine can be started using charged batteries.
NOTE: For maintainable lead acid batteries supplied
by Cummins Fire Power, or Cummins Inc., check the
state of charge by measuring battery cell specific
gravity. Refer to Battery Testing in Section 6 - Mainte-
nance for additional information.
WARNING
Batteries can emit explosive gases during charging. Always ventilate the compartment before servicing the batteries. Remove sources of spark or
open flame. To avoid arcing, remove the negative
(-) battery cable first and attach the negative (-)
battery cable last.
3.6 Signal and Control Installation
This section explains how to connect the controller
wires to the terminal block.
CAUTION
If the batteries have been installed prior to the
control wiring, disconnect the negative cable first
and then disconnect the positive battery lead.
Install the cables with the positive cable first and
the negative cable last before testing.
CFP9-014
Fire Power Pump Engine CFP9E
Doc. 9778, Rev. 10-08
3-7
NOTE: Install signal and control wiring at Terminal
Board TB. Refer to the terminal wiring schematic
decal on the inside of the instrument enclosure.
1. Ensure that the fire control system is properly
installed and configured per the manufacturer’s
instructions. Refer to the Wiring Schematic
Drawings provided with the pump manual.
2. Complete the fire pump controller wiring (customer supplied) per the manufacturer’s instructions.
Figure 3-9 Termination Blocks and Wiring Decal
3. Connect the following wires to the Fire Pump
Engine Instrument Panel per the engine electrical diagrams. Refer to Figure 3-9.
a. TB-1: Connect the Control Power from the
Fire Pump Controller. This power source is
necessary for fire pump operations while in
the AUTO Mode.
INSERT FLAT SCREW DRIVER
INTO THE SQUARE HOLE
PRY OPEN THE SPRING
CLAMP WITH THE
SCREW DRIVER
INSERT THE STRIPPED
LEAD WIRE INTO THE
ROUND HOLE.
RELEASE THE SCREW DRIVER.
VERIFY THAT THE
STRIPPED PORTION OF
THE LEAD WIRE (AND
NOT THE INSULATION)
IS CLAMPED BY LIGHTLY
TUGGING ON THE WIRE.
STRIP LENGTH
1/2 INCH
303
302
301
12
11
10
9
8
7
6
5
4
3
2
1
CFP9-044
Loading...