Cummins/Onan CFP83-F30 Generator Set

⚠ Be sure to disengage the engine timing pin after locating top dead center to prevent damage to the engine timing pin.

Tools: Engine barring gear, Feeler gauge

1. Remove the air crossover tube, support clamps, hose clamp, and wastegate sensing line.
2. Remove the crankcase vent tube and remove the valve cover.
3. Locate top dead center for cylinder No. 1 by rotating the crankshaft while pressing on the engine timing pin.
4. Check/adjust the valves indicated for STEP A (I = intake; E = exhaust).
5. Tighten the rocker lever locknut and recheck valve clearance. Torque: 24 N•m [212 in-lb].
6. Disengage the timing pin; mark the vibration damper and rotate the crankshaft 360 degrees.
7. Set the valves indicated for STEP B; tighten the locknut and recheck the clearance.
8. Install a new rubber seal in the valve cover and new sealing o-rings on the capscrews.
9. Install the valve cover, wastegate sensing tube, and crankcase vent tube.

⚠ Do not exceed 120% of rated speed.

Tools: Signal generator (0.25 to 120 VAC RMS)

1. Lower the cover on the engine's local control panel.
2. Disconnect the engine speed sensor signal from PICK-UP terminals 1 and 2.
3. Connect a signal generator capable of providing 0.25 to 120 VAC RMS proportional to the engine's rated speed.
4. Remove the calibrating screw cover from the electronic overspeed switch.
5. Turn the potentiometer screw clockwise to increase trip speed, counter-clockwise to reduce trip speed.
6. Adjust until the OVERSPEED light is just illuminated at the desired setpoint.
7. Replace the screw cover, disconnect the signal generator, reset the light, and reconnect the speed sensor input.

⚠ Batteries can emit explosive gases. Always ventilate the compartment before servicing the batteries.

⚠ Acid is extremely dangerous.

Tools: Hydrometer, Refractometer

1. Use a hydrometer to measure the specific gravity of each cell.
2. Check the battery fluid column in the refractometer to determine the state of charge of each battery cell.
3. If charge is low, charge the batteries.
4. Replace the battery if it will not charge to the manufacturer's specifications.

⚠ If leakage is detected, the heat exchanger must be replaced.

Tools: 1-1/4" NPT pipe plug, 700 kPa [100 psi] pressure gauge

1. Install a 1-1/4" NPT pipe plug at the raw water outlet of the heat exchanger.
2. Install a pressure test setup with a 700 kPa [100 psi] pressure gauge at the 1" NPT raw water inlet.
3. Apply air pressure at 621 kPa [90 psig].
4. Isolate the pressure source and monitor the pressure gauge for 5 minutes.
5. Release the pressure, then remove the pipe plug and the test setup.

⚠ Do not remove the pressure cap from a hot engine.

Tools: Thermocouple or temperature gauge (optional)

1. Start the engine and allow it to approach operating temperature.
2. Monitor the operation of the thermostat; initial opening temperature MIN 81°C [178°F], MAX 83°C [181°F].
3. Stop the engine when the coolant starts to flow.
4. If the coolant does not start flowing in the initial opening range, the thermostat must be replaced.
5. Install the heat exchanger hose and tighten the hose clamp.

⚠ Fuel is flammable.

⚠ Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.

1. Loosen the banjo connector bleed screw at the fuel filter housing.
2. Operate the plunger on the fuel lift pump until the fuel flowing from the fitting is free of air.
3. Tighten the bleed screw. Torque: 9 N•m [80 in-lb].

⚠ Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area.

⚠ Do not open the high-pressure fuel system with the engine running.

1. Close any OEM fuel valves (if equipped) to prevent fuel from draining or siphoning.
2. Clean the area around the fuel filter head and remove the filters.
3. Clean the gasket surface of the filter head and replace the o-ring.
4. Fill the 10-micron water stripping (suction side) fuel filter with clean fuel.
5. Do not fill the 10-micron (pressure side) fuel filter; prime using the fuel lift pump instead.
6. Lubricate the o-ring seal with clean lubricating oil.
7. Install the filter as specified by the filter manufacturer.
8. Open the fuel supply and return valves, if equipped.
9. Once the engine is started, slowly increase engine speed while air is purged from the fuel plumbing.

⚠ Avoid direct contact of hot oil with your skin.

⚠ If no oil pressure is noted within 15 seconds after the engine is started, shut down the engine.

⚠ Used engine oil can be carcinogenic.

Tools: Oil filter wrench, Container that can hold at least 20 liters [21.1 qt]

1. Operate the engine until the water temperature reaches 60°C [140°F], then shut the engine off.
2. Remove the oil drain plug and drain the oil immediately.
3. Using an oil filter wrench, remove the filter and clean the gasket surface of the filter head.
4. Apply a light film of clean 15W-40 oil to the new filter gasket.
5. Fill the filter with clean 15W-40 oil.
6. Install the filter; tighten until the gasket contacts the filter head surface.
7. Clean and install the oil drain plug. Torque: 50 N•m [37 ft-lb].
8. Fill the engine with clean oil to the proper level using the fill tube on the side of the engine.
9. Operate the engine at idle to inspect for leaks at the filters and drain plug.
10. Stop the engine, wait approximately 15 minutes, then check the oil level and top off.

⚠ When closing the drain valve, do not over-tighten the valve. Over-tightening can damage the threads.

1. Use your hand to open the drain valve; turn it counterclockwise approximately 3½ turns until the valve drops down 25.4 mm [1 in] and draining occurs.
2. Drain the filter sump until clear fuel is visible.
3. Close the valve by lifting and turning it clockwise until hand-tight.
4. If more than 59 ml (2 oz) is drained, refill the filter to prevent hard starting.

⚠ Never use water alone for coolant.

⚠ Wait until the temperature is below 50°C [120°F] before removing the coolant system pressure cap.

Tools: Drain pan with a capacity of 20 liters [5 gal]

1. Drain the cooling system by opening the drain valve on the heat exchanger and removing the plug in the bottom of the water inlet.
2. Check for damaged hoses and loose or damaged hose clamps; replace as required.
3. Fill the system with a mixture of sodium carbonate and water (0.5 kg per 23 liters of water).
4. Operate the engine for 5 minutes with the coolant temperature above 82°C [180°F], then shut off and drain.
5. Fill the cooling system with clean water and operate for 5 minutes above 82°C [180°F]; drain.
6. Repeat flushing until the drained water is clean.
7. Fill with a mixture of 50-percent water and 50-percent ethylene glycol antifreeze.

1. Remove the air intake and the exhaust piping.
2. Look for damaged or cracked compressor or turbine blades.
3. Check that the turbocharger shaft spins freely.
4. If the compressor impeller is damaged, inspect the intake piping and filter element for damage.
5. Replace the turbocharger if damage is found; contact a Cummins Authorized Repair Location.
6. Install the air intake and the exhaust piping and tighten the clamps.

1. Disconnect the connector at the electric fuel solenoid (Fuel Shutoff Valve).
2. Press the MANUAL position on the AUTO/MANUAL rocker switch.
3. Crank the engine about two revolutions using either the CRANK BATT A or the CRANK BATT B switch positions.
4. Repeat a second time if oil pressure did not register on the gauge.
5. Reconnect the connector at the fuel injection pump solenoid (Fuel Shutoff Valve).