Cummins/Onan CFP7E Generator Set

Tools: Cummins belt tension gauge Part No. 3822524

1. Disconnect both batteries, negative cable first.
2. Check drive belt tension.
3. Use Cummins belt tension gauge Part No. 3822524.
4. Measure tension in center span between alternator and idler pulleys.
5. Belt tension should be between 18 - 149 N-m (60-110 ft-lb).
6. Deflection method: apply 110 N-m (25 ft-lb) force on belt.
7. If deflection exceeds one belt thickness per foot, adjust tension.

1. Open engine control panel and remove crank terminate potentiometer cover.
2. Crank Terminate Potentiometer is the upper of two potentiometers.
3. This is a 30-turn potentiometer.
4. Rotate potentiometer 30 turns counterclockwise to set zero.
5. Turn potentiometer 14 turns clockwise.
6. Replace cover. Set at approximately 650 rpm.

⚠ Never switch from ECM-A to ECM-B while engine is running.

1. Remove cap screw from operator instrument face plate.
2. Start engine using local start method.
3. Observe engine accelerates to speed set point on Factory Settings Plate.
4. Move Engine Speed Toggle Switch to INC or DEC position as required.
5. Each brief toggle movement changes idle speed by 10 RPM.
6. Repeat steps for ECM A and ECM B subsystems.
7. Close panel and tighten enclosure cap screw.

⚠ The maximum engine speed should only be altered by a Cummins technician.

1. Start the engine.
2. Observe that the engine accelerates to the currently adjusted speed setpoint.
3. Locate the threaded linkage rod on the fuel pump side of the engine.
4. Loosen the locking nuts against the stops on the threaded rod.
5. To increase speed, turn the bolt on the right side of the throttle bracket clockwise.
6. To decrease speed, turn the bolt counter-clockwise.
7. When the rated speed is correct, tighten the locking nut against the stop.
8. Adjust the left-side threaded bolt for maximum speed if needed.
9. Stop the engine and repeat until the desired speed is attained.

⚠ Engine overspeed trip stops engine immediately.

1. Open engine instrument panel and remove Overspeed Potentiometer Cover.
2. Place AUTO/MANUAL Mode Switch in MANUAL position.
3. Start engine and adjust speed to system design pump speed.
4. Press and hold test button. Slowly turn Overspeed Potentiometer counterclockwise until engine stops.
5. Keep test button depressed during adjustment.
6. Press Reset button on speed switch or front panel.
7. Final pump speed is typically set while pump is flowing 150%.

⚠ Use Teflon tape or pipe sealant when installing test setup.

Tools: pressure gauge 689 kPa (100 psi)

1. Install an adapter at the cooling water outlet of the heat exchanger.
2. Install a pressure test setup with 689 kPa (100 psi) gauge at the cooling water inlet.
3. Apply air pressure at 276 kPa (40 psi).
4. Isolate pressure source and monitor gauge for five minutes.
5. Release pressure and remove test equipment.

1. From the User Interface screen press the MENU soft key.
2. Press the OVERSPEED TEST soft key from the Settings Menu.
3. Press the RUN soft button.
4. When the dialog box appears, proceed with the test and select Yes.
5. When the timer expires, ENGINE OVERSPEED flashing in red appears at the top of the FPDP screen.
6. The engine will enter MANUAL mode until reset.
7. Press the RESET/STOP switch on the FPDP to reset the fire pump drive engine.

Tools: Digital multimeter

1. From the User Interface screen press the MENU soft key.
2. Press the ENGINE SETUP soft key from the Settings menu.
3. Enter password 806 in the Engine Setup Login screen.
4. Press the TERMINAL BLOCKS soft key from the Engine Setup menu.
5. Press the soft key corresponding to the terminal block requiring verification.
6. Press the RETURN soft key to exit the Terminal Block Test menu.

⚠ Battery electrolyte (sulfuric acid) is highly caustic.

⚠ Batteries can emit explosive gases during charging.

⚠ Remove the negative (-) battery cable first and attach it last.

Tools: Neoprene gloves, Safety goggles or full face shield

1. Install the battery cable kit or equivalent customer-supplied wiring.
2. Install battery sets in a well-ventilated or otherwise protected location.
3. Provide adequate room for servicing or replacing the batteries.
4. Locate the batteries near the engine or increase conductor size as required.
5. Check the battery cables and connections.
6. Coat the terminals with petroleum jelly to prevent corrosion.

⚠ The cooling water supply must be immediately available when the engine is started.

⚠ Do not operate without a pressure cap.

Tools: Appropriate-sized container

1. Provide a cooling water discharge line at the heat exchanger outlet and a supply line to the cooling water inlet.
2. Check the pressure regulator setting on the cooling loop with water flowing through the heat exchanger.
3. Adjust the cooling water based on water flow rather than water pressure.
4. Measure the water flow using a container and elapsed time.
5. Adjust both pressure regulators to provide flow at or above specifications.

⚠ Do not use the engine lifting points for assembly!

Tools: Lifting device, Grease gun

1. Ensure the engine and pump are correctly aligned.
2. Verify engine position centered on frame side to side within +/- .76 mm (.03 in).
3. Align engine center line to pump center line within +/- .76 mm (.03 in).
4. Ensure pump center line to engine crankshaft center line (vertical) is 2 degrees +/- 1 degree.
5. Ensure drive shaft mounting flanges are parallel.
6. Lubricate the grease fittings on the drive shaft universal joint.
7. Check engine is installed per pump manufacturer's specifications.

⚠ Do not use copper or galvanized pipe for the fuel return or supply lines.

⚠ Do not mix gasoline, alcohol, gasohol, ethanol, or methanol with diesel fuel.

Tools: Container for contaminated fuel

1. Install an elevated no. 2 diesel fuel tank or equivalent compatible with ASTM no. 2 diesel specifications.
2. Size the fuel tank for the maximum expected full-load operation period.
3. Install a fuel return line routed to the bottom of the fuel tank.
4. Install a fuel supply line to the fire pump drive engine.
5. Open the fuel filter/water separator drain and drain until no water is present.