Cfp83 Series: Fire Pump Drive Engines

CFP83 SERIES
Operation & Maintenance Manual

Fire Pump Drive Engines
www.cumminsfirepower.com
Page ii
Foreword
This manual contains information for the correct operation and maintenance of a Cummins Fire Pump engine.
It also includes important safety information, engine and systems specifications, troubleshooting guidelines, and
listings of Cummins Authorized Repair Locations.
Read and follow all safety instructions. Refer to the General Safety Instructions in Section 1.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on
information in effect at the time of printing. Cummins Fire Power, Cummins NPower and Cummins Engine
Company, 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.
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. These parts can be
identified by the following trademarks:
NOTE: Warranty information is located in Section 11. Make sure you are familiar with the warranty or warranties
applicable to your engine.
© 2005 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.
Drawing No. 9777, Section 0, Rev. 02-07

Page iii
Index of Sections
Introduction ………………………………………………………………….……………….......................................... 1
Engine Identification …………………………………………………………………………… ................................... 2
Installation and Operation ………………………………………………………….………….. .................................. 3
Maintenance Guidelines ……………………………………………………….…………... ........................................ 4
Maintenance Procedures …………………………………………………………….................................................. 5
System Diagrams …………………………………………………………………………... ......................................... 6
Adjustment, Replace and Replacement……………………………............................... ....................................... 7
Service Literature …………………………………………………………………………… ........................................ 8
Service Assistance ………..………………………………………………………………... ........................................ 9
Maintenance Specifications ……………………………………............................................................................ 10
Warranty Information…………………………………………………………………………………….. .................... 11
Troubleshooting …………………………………………………………………………….. ...................................... 12
Assembly Drawings…………………………………………………………………………. ...................................... 13

Page iv
THIS PAGE INTENTIONALLY LET BLANK

Section 1 – Introduction Page 1-1
CFP83 Series
Section 1 – Introduction
Section Contents
Page
To the Owner and Operator .............................................................................................................1-3
About the Manual..............................................................................................................................1-3
How to Use the Manual ....................................................................................................................1-3
Symbols .............................................................................................................................................1-4
Illustrations .......................................................................................................................................1-5
General Safety Instructions .............................................................................................................1-6
General Cleaning Instructions ........................................................................................................1-8
Acronyms and Abbreviations..........................................................................................................1-14

Page 1-2 Section 1 – Introduction
CFP83 Series
THIS PAGE INTENTIONALLY LEFT BLANK

CFP83 Series
To the Owner and Operator

Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance
schedule recommendations outlined in Maintenance Guidelines in Section 4.
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil, coolant, and filters in the engine as specified in Maintenance Specifications in Section
10.
Cummins Fire Power, Cummins NPower and Cummins Engine Company, Inc use the latest technology and the
highest quality components to produce its engines. Cummins recommends using only genuine Cummins parts.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts
support. If a problem that can not be resolved by a Cummins Authorized Repair Location occurs, follow the
steps outlined in the Service Assistance in Section 9.
About the Manual

This manual contains information needed to operate and maintain an engine correctly as recommended by
Cummins Fire Power, Cummins NPower and Cummins Engine Company, Inc. Additional service literature
(troubleshooting and repair manual) can be ordered by filling out and mailing the Literature Order Form located
in Service Literature in Section 8.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the
U.S. customary in brackets.
Numerous illustrations and symbols are used to aid in understanding the meaning of the text. Refer to the
Symbols subsection in this section for a complete listing of symbols and their definitions.
Each section is preceded by a Section Contents to aid in locating information more quickly.
How to Use the Manual

This manual is organized according to intervals at which maintenance on the engine is to be performed. A table
that states the required intervals and the checks to be made is located in Section 4. Locate the interval at which
maintenance will be performed, then follow the steps given in the referenced section for all the procedures to be
performed. All the procedures done under previous maintenance intervals must be performed, also.
Keep a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or
hours, and which maintenance checks were performed is located in Section 4.
Refer to the Maintenance Specifications in Section 10 for specifications recommended by Cummins Engine
Company, Inc., for your engine. Specifications and torque values for each engine system are given in that
section.

CFP83 Series
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When
one of the symbols appears, it conveys the meaning define below:
WARNING. Serious personal injury or extensive property damage can result if the
warning instructions are not followed.
CAUTION. Minor personal injury can result or a part, an assembly, or the engine can
be damaged if the caution instructions are not followed.
INSPECTION is required.
Refer to another location in this manual or another publication for additional

information.
Indicates a REMOVAL or DISASSEMBLY step
LUBRICATE the part or assembly.
CLEAN the part or assembly.
TIGHTEN to a specific torque.
Indicates an INSTALLATION or an ASSEMBLY step
PERFORM a mechanical or time MEASUREMENT.
PERFORM an electrical MEASUREMENT.

CFP83 Series
Illustrations
The illustrations used in this manual are

intended to give an example of a problem, and
to show what to look for and where the problem
can be found.
Some of the illustrations are “generic” and might
not look exactly like the engine or parts used in
your application.
The illustrations can contain symbols to indicate
an action required, and an acceptable or not
acceptable condition.
The illustrations are also intended to show

repair or replacement procedures.
The illustration can differ from your application,
but the procedure given will be the same.

CFP83 Series
General Safety Instructions
WARNING
Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily
injury or death.
• Read and understand all of the safety precautions and warnings before performing any repair. This list
contains the general safety precautions that must be followed to provide personal safety. Special safety
precautions are included in the procedures when they apply.
• Make sure the work area surrounding the product is dry, well lit, ventilated; free from clutter, loose tools,
parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair
work. Put a "Do Not Operate" tag on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate
the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property
damage, or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper
stands to support the product before performing any service work.
• Relieve all pressure in the air, oil, and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause
personal injury.
• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or
more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the
correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary.
The lifting hooks must not be side-loaded.
• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated
contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water.
In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes.
IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

CFP83 Series
General Safety Instructions (Cont.)

• Naphtha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH
OF CHILDREN.
• To avoid burns, be alert for hot parts on products that have just been turned OFF, and hot fluids in lines,
tubes, and compartments.
• Always use tools that are in good condition. Make sure you understand how to use them before performing
any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener
of lesser quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your
functioning.
• Some state and federal agencies in the United States of America have determined that used engine oil can
be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil. Dispose of waste oil in accordance with applicable requirements.

CFP83 Series
General Cleaning Instructions
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive
material in oil passages can cause bearing and bushing failures that can progress to major component
damage beyond reuse. This is particularly true of main and rod bearings.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner
beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner
material which can cause early cylinder wear-out or piston ring failures.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal
injury.
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston,
piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal
and result in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger
shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic
beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or
steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate
the tank and any other engine parts cleaned in the tank. Contaminated parts may cause failures from
abrasive wear.
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the
engine can be damaged due to increased parts clearance or inadequate surface finish on parts that
move against other parts.

CFP83 Series
Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they
have to appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to
forming a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface.
Gaskets are designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded
gaskets are those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal
portion forms a metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the
parts are better removed with a blunt-edged scraper on the spots rather than spending time polishing the whole
surface with an air sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to
prevent sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has
been in place a long time, has been overheated or the purpose of the release agent has been defeated by the
application of some sealant. The object however is just to remove the gasket without damaging the surfaces of
the mating parts without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the
carbon build-up above the top ring and in the ring grooves. There is more information on bead blasting and
piston cleaning later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean
metal is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out)
will be destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly.
A medium bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be
just as quick and there will be less damage. Yes, one must look carefully for broken wires after the piston is
removed but the wires are more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If
possible, leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off
along with any attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before
installation. Make sure parts are lubricated with clean oil before installation. They do not need to be oiled all over
but do need oil between moving parts (or a good lube system priming process conducted before cranking the
engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted
again so all that needs happen is remove any loose paint.

CFP83 Series
Using Abrasive Pads and Abrasive Paper

The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are
all supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive
material in oil passages can cause bearing and bushing failures that can progress to major component
damage beyond reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine
or component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks
or counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially
assembled engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum
oxide particles, silicon carbide, or sand or some other similar hard material. These particles are harder than
most of the parts in the engine. Since they are harder, if they are pressed against softer material they will either
damage the material or become embedded in it. These materials fall off the holding media as the product is
used. If the products are used with power equipment the particles are thrown about the engine. If the particles
fall between two moving parts, damage to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but
larger than the running clearance then damage will occur when the parts move relative to each other (engine
started). While the engine is running and there is oil pressure, particles that are smaller than the bearing
clearance are likely to pass between the parts without damage and be trapped in the oil filter. However, particles
larger than the bearing clearance will remove material from one part and can become embedded in one of the
parts. Once embedded in one part it will abrade the other part until contact is no longer being made between the
two parts. If the damage sufficiently degrades the oil film, the two parts will come into contact resulting in early
wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the
engine as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those
located downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles
and debris with compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean
and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage
the gasket surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member
bonded to the steel). What little sealing material that can adhere is best removed with a blunt-edged scraper or
putty knife. Cleaning gasket surfaces where an edge-molded gasket is used with abrasive pads or paper is
usually a waste of time.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner
beyond reuse. The surface finish will be damaged and abrasive particles can be forced into the liner
material which can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really
necessary because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and
clean as much of the surface as possible with the tool but clean around the oil hole/opening by hand so as to
prevent contamination of the drilling. Then remove the tape or plug and clean the remaining area carefully and
without the tool. DO NOT use compressed air to blow the debris out of oil drilling on an assembled engine! More
likely than not, the debris can be blown further into the drilling. Using compressed air is fine if both ends of the
drilling are open but that is rarely the case when dealing with an assembled engine.

CFP83 Series
Cleaning Gasket Surfaces

The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the
part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is
used, check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part
of the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air
powered gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning

Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons.
See Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to
90 to 95 °C (180 to 200 °F). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best
results. Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's
instructions. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush
or scraper before putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When
possible, steam clean the parts before putting them in the cleaning tank.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s
recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal
injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These
cleaners should not be heated to temperature in excess of 77 °C (170 °F). The solution begins to break down at
temperatures in excess of 82 °C (180 °F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic
components. They often do not do a good job of removing deposits from the ring groove and are costly to
dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high
alkaline solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further
away from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper
before putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use
hot high pressure water or steam clean the parts before putting them in the cleaning tank. Removing the
heaviest dirt before placing in the tank will allow the cleaner to work more effectively and the cleaning agent will
last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all
the capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The
rust proofing compound must be removed from the parts before assembly or installation on the engine.

CFP83 Series
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good
method for cleaning the oil drillings and coolant passages.
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot
steam can cause serious personal injury.
Do not steam clean the following components:
• Electrical Components
• Wiring Harnesses
• Injectors
• Fuel Pump
• Belts and Hoses
• Bearings (ball or taper roller)
• Electronic Control Module (ECM)
• ECM Connectors
Plastic Bead Cleaning

Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part.
Cummins Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine
part. Never use sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the
media manufacturer's recommendations can cause excess dust and can embed in engine parts that can result
in premature failure of components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning
process is controlled by the use of plastic beads, the operating pressure and cleaning time.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston,
piston skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal
and result in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger
shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic
beads. Remove the foreign material and plastic beads with compressed air, hot high pressure water or
steam before placing them in tanks or cleaners. The foreign material and plastic beads can contaminate
the tank and any other engine parts cleaned in the tank. Contaminated parts may cause failures from
abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure
any bead blasting media on piston pin bores or aluminum skirts.

CFP83 Series
Plastic Bead Cleaning (Cont)

Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part
and cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
Bead size: U.S. size Number 16 — 20 for piston cleaning with plastic bead media, Part Number 3822735
Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the
engine can be damaged due to increased parts clearance or inadequate surface finish on parts that
move against other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure
is too high or the blast is being held on one spot too long. The blast operation must not disturb the metal
surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell
blasting produces a great amount of dust particularly when the pressure if the air pressure on the blasting
machine is increased above media manufacturer's recommendation. Cummins Inc. recommends not using
walnut shell media to clean engine parts due to the risk media embedment and subsequent contamination of the
engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too
easily embedded into the material particularly in soft materials and when air pressures greater than media
manufacturer's recommend are used. The glass is an abrasive so when it is in a moving part, that part is
abrading all the parts in contact with it. When higher pressures are used the media is broken and forms a dust of
a very small size that floats easily in the air. This dust is very hard to control in the shop, particularly if only
compressed air (and not hot water) is used to blow the media after it is removed from the blasting cabinet
(blowing the part off inside the cabinet may remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher
pressure washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the
pistons first then use the plastic bead method to safely remove the carbon remaining in the grooves (instead of
running the risk of damaging the surface finish of the groove with a wire wheel or end of a broken piston ring.
Make sure the parts are dry and oil free before bead blasting to prevent clogging the return on the blasting
machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under
the unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at
one-place too long causes the metal to heat up and be moved around. Remember that the spray is not just
hitting the dirt or carbon. If the machining marks on the piston groove or rim have been disturbed then there has
not been enough movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle
across the seat surface and radius rather than straight at them. The object is to remove any carbon build up and
continuing to blast to remove the stain is a waste of time.

CFP83 Series
Acronyms and Abbreviations

AFC Air Fuel Control in. Inch
Amp Ampere in-lb Inch Pound
API American Petroleum Institute kg Kilograms
ASA Air Signal Attenuator kPa Kilopascal
ASTM American Society of Testing and Materials l Liter
AWG American Wire Gauge lb. pound
C Celsius lbf. Pound force
C.I.D. Cubic Inch Displacement m Meter
CAC Charge Air Cooler ml Milliliter
CARB California Air Resources Board mm Millimeter
cc Cubic Centimeter MPa Megapascal
cm Centimeter MPH Miles Per Hour
CPL Control Parts List MPQ Miles Per Quart
cSt Centistokes N Newton
D. Diameter N•m Newton-meter
DCA Diesel Coolant Additive OEM Original Equipment Manufacturer
E.C.S. Emission Control System oz. Ounce
ECM Electronic Control Module ppm Parts Per Million
EPA Environmental Protection Agency psi Pounds Per Square Inch
EPS Engine Position Sensor PTO Power Takeoff
F Fahrenheit qt Quart
FSO Fuel Shut-Off RPM Revolutions Per Minute
FSOS Fuel Shut-Off Switch S.A.E. Society of Automotive Engineers
ft-lb Foot-Pound STC Step Timing Control
GAL Gallon (US) TDC Top Dead Center
H2O Water US United States of America
Hg Mercury V Volt
HP Horsepower VS Variable Speed

Section 2 – Engine Identification Page 2-1
CFP83 Series
Section 2 - Engine Identification

Section Contents
Page
Fire Pump Engines .............................................................................................................................................2-3
Overspeed Switches...........................................................................................................................................2-3
Operating Speed .................................................................................................................................................2-3
Control System ...................................................................................................................................................2-3
External Engine Components and Views.........................................................................................................2-4
Instrument Panel.................................................................................................................................................2-9
Fire Pump Engine Data Tag .............................................................................................................................2-10
Factory Setting Tag ..........................................................................................................................................2-10
Fuel Injection Pump Dataplate ........................................................................................................................2-11

Page 2-2 Section 2 – Engine Identification
CFP83 Series

Section 2 - Engine Identification Page 2-3
CFP83 Series
Fire Pump Engines

Cummins’ complete line of fire pump engines have been approved as packaged units (engine and all
accessories) by Factory Mutual Research and listed by Underwriter’s Laboratories, Inc. and Underwriter’s
Laboratories of Canada. Because of the lengthy and expensive process to design and produce a fire pump
engine that meets these requirements, no deviations are permitted without approval. These engines are to be
used only for fire protection applications.
Overspeed Switches
Each engine is equipped with an overspeed switch which will activate the fuel pump solenoid valve and shut off
the engine when the RPM exceeds a present limit. The overspeed switch senses engine speed during the start
cycle and stops the starting motor cranking cycle. The overspeed switch must be adjusted to the required speed
limit during the in-service inspection.
Operating Speed
All Cummins fire pump engines are shipped from the factory with the operating speed adjusted to the lowest
approved operating speed. Final operating speed adjustment must be made at the time of the in-service
inspection to obtain the required fire pump operating speed specified by the pump manufacturer.
Control System
The function of a fire pump controller is to start the engine. These controllers are more sophisticated than
standard industrial controllers because they include special items for fire pumps. Several options are available:
The automatic start controller can be used for either automatic or manual stop after the fire demand signal is
removed.
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 keep all pumps from starting simultaneously.
NOTE: Fire pump controllers are not supplied by Cummins Fire Power, or Cummins Engine Company, Inc.

CFP83 Series
External Engine Components and Views

The following illustrations show the locations of the major external engine components, and other service and
maintenance points. Some external components will be at different locations for different engine models.
Instrument Panel Side
3 2
5 4 1
6
17
7 16
8
9 15
10 11 12 13 14
1. Instrument Panel 7. Raw Water Outlet 13. Dipstick
2. Terminal Box 8. Raw Water Inlet 14. Lubricating Oil Fill
3. Charge Air Cooler 9. Flywheel Housing 15. Lift Pump
4. Turbocharger 10. Engine Support 16. Fuel Filter
5. Upper Water Hose/Tube 11. Electric Fuel Solenoid 17. Manual Start
6. Fuel Pump 12. Oil Pan Drain

CFP83 Series
Turbocharger Side
2
3 1
4
10
6 7
1. Top Tank Fill 6. Coolant Heater
2. Exhaust 7. Lubricating Oil Filter
3. Turbocharger and Exhaust Shield 8. Lower Water Hose/Tube
4. Air Cleaner Element 9. Alternator
5. Starter Motor 10. Heat Exchanger

CFP83 Series
Front View

CFP83 Series
Top View

CFP83 Series
Isometric Views

CFP83 Series
Instrument Panel
1. Battery “A” Voltmeter 8. Overspeed Warning Light

2. Battery “B” Voltmeter 9. Not used
3. Tachometer (with hour-meter) 10. Overspeed Reset Switch
4. Water Temperature Gauge 11. High Water Temperature Warning Light
5. Lubricating Oil Pressure Gauge 12. Low Oil Pressure Warning Light
6. Circuit Breaker 13. Battery A/B Switch
7. ON/OFF Switch (AUTO/MANUAL) 14. ECM Indicators (For Electronic Engine
Models)

CFP83 Series
Fire Pump Engine Data Tag

The Fire Pump Engine Data Tag is located at the
pump end of the engine just above the redundant
starter solenoids. Refer to Drawing 8708 (CFP83-F10,
F20, F30) or Drawing 8710 (CFP83-F40) in Section 13
for location details.
This tag shows specific information about your engine.
The engine serial number provides information for
ordering parts and service needs.
NOTE: The fire pump dataplate must not be changed

unless approved by Cummins Fire Power.
Factory Setting Tag

The Factory Setting Tag is located at the pump end of
the engine just above the redundant starter solenoids.
Refer to Drawing 8708 (CFP83-F10, F20, F30) or FACTORY SETTING
Drawing 8710 (CFP83-F40) in Section 13 for location
details.
This tag identifies to rated operating speed at the rated
horsepower. It also provides the over speed switch
setpoint. Both values are set at the factory.
Refer to Installation Instructions in Section 3 for
procedures to verify or adjust either setpoint.

CFP83 Series
Fuel Injection Pump Dataplate

The Bosch® fuel injection pump dataplate is located
on the side of the injection pump. It provides
information for fuel pump calibration.
The Cummins part number for the fuel pump-

governor combination is located on the governor
dataplate.

CFP83 Series

Section 3 – Installation and Operation Page 3-1
CFP83 Series
Section 3 – Installation and Operation

Section Contents
Page
Installation Overview..........................................................................................................................................3-3
Physical Engine Installation ..............................................................................................................................3-4
Fuel Supply Installation .....................................................................................................................................3-6
Fire Pump Installation ........................................................................................................................................3-6
Raw Water Supply Installation ..........................................................................................................................3-7
Battery and Electrical Installation...................................................................................................................3-13
Signal and Control Installation........................................................................................................................3-14
Coolant System Preparation ...........................................................................................................................3-15
Lubricating Oil System Preparation ...............................................................................................................3-18
Fuel System Preparation..................................................................................................................................3-19
Pre-Start Inspections........................................................................................................................................3-21
Pre-Lubricate the Engine (CFP83-F10, F20, F30) ..........................................................................................3-22
Pre-Lubricate the Engine (CFP83-F40) ...........................................................................................................3-23
Lubricate Zerk Fittings on Auxiliary Drive Shaft ...........................................................................................3-24
Check Engine to Pump Alignment..................................................................................................................3-25
Initial Start-Up ...................................................................................................................................................3-26
Initial Start .........................................................................................................................................................3-34
Second Start......................................................................................................................................................3-36
Rated Speed Setpoint Adjustment (CFP83-F10, F20, F30) ...........................................................................3-37
Rated Speed Setpoint Adjustment (CFP83-F40)............................................................................................3-39
Overspeed Setpoint Adjustment and Testing................................................................................................3-41
Crank Terminate Adjustment and Testing .....................................................................................................3-45
Isolated Acceptance Testing ...........................................................................................................................3-48
Integrated Acceptance Testing .......................................................................................................................3-48
General Operating Information .......................................................................................................................3-49
Normal Remote Starting Procedure................................................................................................................3-49
Normal Local Starting Procedure ...................................................................................................................3-50
Jumpering the Batteries...................................................................................................................................3-53
Operating the Engine .......................................................................................................................................3-54
Emergency Manual Starting Procedures .......................................................................................................3-55
Emergency Manual Mode Electric Start .........................................................................................................3-56

Page 3-2 Section 3 – Installation and Operation
CFP83 Series
Emergency Staring Manual Mode Non-Electric Start (CFP83-F10, F20, F30) ............................................ 3-58
Emergency Staring in Automatic Mode with Failed Fuel Shut-Off Solenoid............................................. 3-62
Emergency Manual Stopping Procedure....................................................................................................... 3-63
Starting Procedure - After Extended Shutdown or Oil Change .................................................................. 3-64

CFP83 Series
Installation Overview
The first part of this section provides instructions for the initial installation, adjustment, and testing of the
Cummins NPower Fire Pump engine. Appropriate portions of this section should also be used when returning
the engine to operation after overhaul or major maintenance. The second part details normal operations.

CFP83 Series
Physical Engine Installation

Location
Refer to Drawing CFP83 GEN in Section 13 for the general fire pump and engine layout.
Refer to the following drawings in Section 13 for the general fire pump engine power module assembly:
Model Drawing
CFP83-F10, F20, F30 Drawing 8708
CFP83-F40 Drawing 8710
WARNING
Do not operate a diesel engine where there are or can be combustible vapors. These vapors can be
sucked through the air intake system and cause engine acceleration and overspeeding, which can
result in a fire, an explosion, and extensive property damage. Numerous safety devices are available,
such as air intake shutoff devices, to minimize the risk of overspeeding in which an engine, because of
application, might operate in a combustible environment (from a fuel spill or gas leak, for example).
Cummins Engine Company, Inc. does not know how you will use your engine. The equipment owner and
operator, therefore, are responsible for safe operation in a hostile environment. Consult your Cummins
Authorized Repair Location for further information.
Install the fire pump engine in a sheltered environment protected from extremes of weather. Any enclosure must
protect the water supply from freezing. Ensure that the engine and electrical components are not exposed to
significant water dripping or sprays. 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 NFPA20-2003 Chapter 11 for additional installation requirements for installations in the
USA.)
Design the installation to meet the engine’s mounting requirements. Refer to General Engine Data in Section 10.
Install the engine on a stable level foundation that is designed for the load and vibration of pump operation.
Install the engine with ample room for servicing of the engine, the pump, fuel supply, and support systems.
Ensure that the engine location is free of any risk of exposure to combustible vapors.

CFP83 Series
Physical Engine Installation (Cont)
Physical Installation
Use the supplied lifting hooks on the engine to
position the engine.
Provide engine support as required to support
the wet weight specified in General Engine
Data in Section 10.
Position the engine as required for the interface
with the pump, piping, and electrical
connections.
Level the installation with shims as required.
Secure the engine to the support or floor.
Connect the exhaust piping.

CFP83 Series
Fuel Supply Installation

NOTE: Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for additional installation
requirements for installations in the USA. Ensure that the fuel system is installed in a safe and an effective
manner.
Install an elevated Diesel # 2 fuel tank or other fuel supply arrangement that meets the specifications listed in
Fuel System Specifications in Section 10.
Install a 3/8” NPT (minimum) fuel supply line to

the fire pump engine.
Install a 1/4“ NPT (minimum) fuel return line.
Route this line to the bottom of the fuel tank in
order to minimize the return head.
Provide a pre-filter on the fuel line to the fire
pump engine.
Size the fuel tank for the maximum expected 3/8” NPT FUEL SUPPY
full-load engine operation period with the initial
fuel level at the minimum level for refueling. 1/4” NPT FUEL RETURN
Fire Pump Installation

Install the customer supplied fire pump as per the pump manufacturer’s instructions and applicable code
requirements. Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for requirements for
installations in the USA. Ensure that the engine and pump are correctly aligned.

CFP83 Series
Raw Water Supply Installation

Overview
Raw water is used to cool the engine cooling fluid. Raw water is supplied from the fire pump prior to the pump
discharge flange. It is forced through a cooling loop by fire pump pressure to the heat exchanger. In the heat
exchanger, it flows through the tubes in the bundle and is discharged to an open waste cone. The raw water
supply must be immediately available when the engine is started.
Refer to the Cooling System Flow Diagrams in Section 6 for a simplified block diagram of the cooling water
system. Refer to Cooling System Specifications in Section 10 for pipe size requirements.
Refer to Drawing 9659 in Section 13 for the optional raw water piping manifold that is available from Cummins
Fire Power.
If the piping supplied by the customer, provide raw water supply piping and components equivalent to that can
be supplied by Cummins Fire Power and as shown in Assembly Diagram, Raw Water Piping in Section 6. Refer
to National Fire Protection Association NFPA20-2003 Chapter 11 for installation requirements for installations in
the USA. When choosing the components for the raw water supply and by-pass, care must be taken to 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 setpoints before operating the pump.
Damage to the heat exchanger may occur from improperly regulated raw water supply pressure.
Raw Water Supply and Drain without Cummins Raw Water Manifold (CFP83-F10, F20, and F30 Only)
NOTE: Raw water outlet piping from the heat

exchanger should be one pipe size larger than
the supply piping.
NOTE: The velocity of raw water should be as
great as possible without exceeding the
maximum shown on the appropriate engine data
sheet.
NOTE: Failure to comply will result in engine
overheat and failure.
Provide raw water supply to the engine side of
the heat exchanger.
Provide an open waste cone raw water drain at
the outside of the heat exchanger.

CFP83 Series
Raw Water Supply Installation (Cont)

Raw Water Supply & Drain without Cummins Raw Water Manifold (CFP83-F40 Only)
NOTE: Raw water outlet piping from the heat

exchanger should be one pipe size larger than
the supply piping.
NOTE: The velocity of raw water should be as
great as possible without exceeding the
maximum shown on the appropriate engine data
sheet.
NOTE: Failure to comply will result in engine
overheat and failure.
Provide raw water supply to the Charge Air
Cooler water inlet.
Provide an open waste cone raw water drain at
the outside of the heat exchanger.
Raw Water Supply and Drain with Cummins Raw Water Manifold
NOTE: Raw water outlet piping from the

heat exchanger should be one pipe size
larger than the supply piping.
NOTE: The velocity of raw water should
be as great as possible without exceeding
the maximum shown on the appropriate
engine data sheet.
NOTE: Failure to comply will result in
engine overheat and failure.
Provide raw water supply to the raw water
manifold inlet.
Provide an open waste cone raw water
drain at the outside of the heat
exchanger.

CFP83 Series
Check Raw Water Pressure Regulator Setpoints (CFP83-F10, F20, and F30 Only)
NOTE: Adapt this procedure to the actual

installation if a Cummins raw water manifold is
not supplied.
Temporarily remove the raw water inlet piping
from the engine coolant heat exchanger. Refer
to Drawing 9637 in Section 13.
Temporarily remove the raw water supply
piping from the fire pump to the manifold.
Temporarily supply an alternate source of raw
water to the inlet to the raw water manifold.
The temporary water supply pressure should
exceed 414 kPa [60 psig].

CFP83 Series

Check Raw Water Pressure Regulator Setpoints (CFP83-F10, F20, and F30 Only) (Cont)
Provide temporary drain piping at the raw water

manifold outlet.
If closed, open the pressure gauge isolation
valve.
NOTE: The normal line has the solenoid valve.
The bypass line does not.
If open, close the normal line inlet valve.
Open the bypass line inlet and outlet valves.
Apply water pressure to the raw water
manifold.
NOTE: The heat exchanger is rated at 414 kPa
[60 psig].
Adjust the bypass pressure regulator for 414
kPa [60 psig] or slightly less.
Close the bypass line inlet valve.
NOTE: Use the correct voltage for unit.
Provide a temporary 12 VDC standard (24
VDC optional) power source for the solenoid
valve at Pin 13 and Pin 17. Refer to Drawing
10423 Sheet 1 in Section 13.
Open the normal line inlet and outlet valves.
Adjust the normal pressure regulator for 414
Remove the power jumper and reconnect the
wiring.
Re-install the raw water piping from the
manifold to the engine. Refer to Drawing 9637
in Section 13.
Test the pressure regulator setpoints with
water flowing through the heat exchanger. Trim
the setpoints if required.
Remove the temporary water supply to the
manifold.
Re-install the raw water piping at the pump.

CFP83 Series

Check Raw Water Pressure Regulator Setpoints (CFP83-F40 Only)
NOTE: Adapt this procedure to the actual

installation if a Cummins raw water manifold is
not supplied.
Temporarily remove raw water inlet piping at
the charge air cooler. Refer to Drawing 10712
in Section 13.
Provide temporary drain piping at the raw water
manifold outlet.
If closed, open the pressure gauge isolation
valve.
NOTE: The normal line has the solenoid valve.
The bypass line does not.
If open, close the normal line inlet valve.
Open the bypass line inlet and outlet valves.
NOTE Temporary water supply pressure
should exceed 414 kPa [60 psig].
Provide temporary water supply piping to the
raw water manifold.
Adjust the bypass pressure regulator for 414
Close the bypass line inlet valve.
NOTE: Use the correct voltage for unit.
Provide a temporary 12 VDC standard (24
VDC optional) power source for the solenoid
valve at Pin 13 and Pin 17. Refer to Drawing

CFP83 Series

Check Raw Water Pressure Regulator Setpoints (CFP83-F40 Only) (Cont)
Open the normal line inlet and outlet valves.

Adjust the normal pressure regulator for 414
Remove the power jumper and reconnect the
wiring.
Re-install the raw water piping from the
manifold to the charge air cooler. Refer to
Drawing 10712 in Section 13.
Test the pressure regulator setpoints with
water flowing through the heat exchanger. Trim
the setpoints if required.
Remove the temporary water supply to the
manifold.
Re-install the raw water piping at the pump.

CFP83 Series
Battery and Electrical Installation

Overview
Two redundant sets of batteries must be supplied for the selected operating voltage (standard 12 VDC or
optional 24 VDC).
Batteries must meet the requirement listed in Electrical System Specifications in Section 10.
Batteries may be supplied by Cummins Fire Power as an option or may be supplied by the customer.
Refer to National Fire Protection Association NFPA20-2003 Chapter 11 for battery and battery charger
requirements for installations in the USA.
Battery Installation
Install the redundant sets of batteries in a well ventilated or otherwise protected location. Provide adequate
room for servicing or replacing the batteries. Provide protection from extremes of temperature and weather.
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 either 12 VDC or 24 VDC operations as appropriate.
Battery Wiring Installation

NOTE: Install the wiring in accordance with applicable codes and specifications.
Install the Loose Wire Kit wires. Refer to Drawing 9767 in Section 13.
If purchased, install the optional battery cable kit (Cummins Fire Power Part No. 9609). Otherwise, install
equivalent customer supplied wiring.

CFP83 Series
Signal and Control Installation

NOTE: Install signal and control wiring at Terminal Board TB. Refer to Drawing 10423 Sheet 1 in Section 13.
Ensure that the fire control system is properly installed and configured as per the manufacturer’s instructions.
Complete the customer-supplied fire pump controller wiring as per the manufacturer’s instructions.
NOTE: Do not connect more than two wires at any point on the fire pump engine control panel terminal board. If
necessary, add a grounding terminal board at the fire control system.
Connect the control power from the fire pump controller at TB-1 (+) and TB-11 (-). This power source is
necessary for fire pump operations while in the AUTO mode.
Connect the two redundant crank signals from the fire pump controller to TB-9 (Crank Battery A) and to TB-10
(Crank Battery B). Connect the signal ground to TB-11.
Connect the Crank Terminate input to the fire pump controller from TB-2 with signal ground at TB-11. This 12 or
24 VDC signal is present when the engine is running. This signal indicates that the engine has started and that
the crank command from the fire pump controller should stop immediately.
Connect the remote overspeed alarm input to the fire pump controller from TB-3. This 12 or 24 VDC signal is
present when the overspeed switch has operated. If this event occurs, the fire pump engine will stop. The local
RESET button must be pressed in order to restart the engine.
Connect the Low Oil Pressure alarm input to the fire pump controller from TB-5. This 0 VDC grounded signal is
present when the oil pressure has dropped below the 110 kPa [16 PSIG] setpoint. The engine will continue to
operate but immediate attention is necessary in order to prevent excessive damage to the engine or
catastrophic engine failure.
Connect the High Water Temperature alarm input to the fire pump controller from TB-5. This 0 VDC grounded
signal is present when the engine is running and the coolant temperature has risen above the 93 oC [200 oF]
setpoint. The engine will continue to operate but immediate attention is necessary in order to prevent excessive
damage to the engine or catastrophic engine failure.
If used, provide permanently installed redundant battery charging systems with connections at TB 6 and TB-8
(+) and TB-11 (-). TB-6 (+) and TB-8 (+) and TB-11 (-) should also be used for remote battery voltage
indications at the fire control system or elsewhere.
Ensure electrical continuity and adequate insulation resistance for the installed wiring.
Provide the initial charge on the redundant batteries as per the battery charger’s instructions.
Check that both voltmeters on the local control panel indicate the approximate battery voltage.

CFP83 Series
Coolant System Preparation

Check Cooling System Integrity
NOTE: Refer to Drawing 8708 (CFP83-F10,
F20, F30) or Drawing 8710 (CFP83-F40) in
Section 13 for hose arrangement.
Check that all coolant hoses are properly
installed and that the clamps are tight.
Check that the coolant drain petcock is closed.
CAUTION
The valve must be in the ON position to
prevent engine damage.
Check that the coolant filter valve is open. If
required, turn the shutoff to the ON position by
rotating the knob from horizontal to vertical in
the direction shown.
CFP83-F10, F20, F30 Only

Open the aftercooler coolant vent.

CFP83 Series
Coolant System Preparation (Cont)
Add Coolant
Remove the pressure cap from the heat
exchanger.
Refer to Cooling System Specifications and

Coolant Recommendations and Specifications
in Section 10.
NOTE: Use a mixture of at least 50 percent
antifreeze and 50 percent water.
NOTE (CFP83-F10, F20, F30 Only): Close the
coolant vent when coolant level reaches the
vent.
Add coolant until the coolant level is just below
the fill tube in the coolant heat exchanger.
Check for leaks. Correct any leaks.
Install the pressure cap on the heat exchanger.
Check Raw Water Supply Lineup
CAUTION
The raw water lines to and from the fire
pump must be open, and there must be
sufficient water to the heat exchanger when
the engine has started. Insufficient water
supply will cause overheating, resulting in
engine failure.
Check that the pressure gauge isolation valve
is open.

CFP83 Series
Coolant System Preparation (Cont)

NOTE: The right line is the bypass line. The left
line with the solenoid valve is the normal line.
Check that the bypass line outlet valve is
closed.
Check that the normal line inlet valve is open.
Check that the normal line outlet valve is open.

CFP83 Series
Lubricating Oil System Preparation

Add Lubricating Oil
NOTE: For oil requirements, refer to Lubricating
Oil System Specifications and Lubricating Oil
Recommendations and Specifications in Section
10. No change in oil viscosity or type is needed
for new or newly rebuilt engines.
Fill the crankcase with lubricating oil to the “H”
(high) mark on the dipstick.
Prime the Turbocharger
CAUTION
New turbochargers must be pre-lubricated
before startup. Failure to pre-lube the
turbochargers will result in turbocharger
bearing failure.
Remove the air intake filter assembly. Refer to
Intake Air Filter Removal/Installation in Section
7.
Remove the turbocharger oil inlet line from the
turbocharger bearing housing.
NOTE: Rotate the turbine wheel to allow oil to

enter the bearing housing. Any excess oil will
drain through the oil drain line.
Lubricate the bearings by pouring 59 to 89 ml [2
to 3 oz] of clean engine lubricating oil into the
turbocharger oil supply line fitting.
Tighten the oil supply line.
Torque Value: 24 N•m [18 ft-lb]
Install the air intake filter assembly. Refer to
Intake Air Filter Removal/Installation in Section
7.

CFP83 Series
Fuel System Preparation

Fill the Fuel Filter
Unscrew the combination fuel filter assembly
and remove it from the engine.
If open, close the water separator drain cock.

Refer to Drain Fuel-Water Separator in
Section 5.
Lubricate the o-ring seal with clean
lubricating oil.
NOTE: Refer to Fuel Recommendations and
Specifications in Section 10 for fuel
requirements.
Fill the fuel element with fuel.
CAUTION
Mechanical over-tightening will distort the
threads, filter element seal or filter can.
Install the filter on the filter head.
Tighten the filter until the gasket contacts the
filter head surface.
Tighten the filter an additional one-half to
three-fourths of a turn, or as specified by the
filter manufacturer.

CFP83 Series
Fuel System Preparation (Cont)
Fill the Fuel Tank

Check that the fuel tank and piping is clean.
Fill the fuel tank with Number 2 Diesel fuel.
Bleed the air from the fuel supply line to the
fire pump engine.
Fill the fuel lines to the engine and fill the fuel
pre-filter.
Tighten all fuel supply line fittings to stop
possible suction leaks.
Bleed the Engine Fuel Lines

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

CFP83 Series
Pre-Start Inspections
Perform a visual inspection as follows:
• Check that there is no apparent damage and that all components are installed.
• Check that the drive belt is properly installed.
• Check that all hoses and tubes are properly installed.
• Check that all electrical connections are properly installed.
• Check that the fire pump is properly installed as per the pump manufacturer’s instructions, is correctly
aligned, and is free to rotate.

CFP83 Series
Pre-Lubricate the Engine (CFP83-F10, F20, F30)

Disconnect the connector at the electric fuel
solenoid (Fuel Shutoff Valve).
Press the MANUAL position on the

AUTO/MANUAL rocker switch.
NOTE: Monitor engine oil pressure on the local
control panel. Some pressure indication is
expected. Also, the low oil pressure light should
go off.
Crank the engine about two revolutions using
either the CRANK BATT A or the CRANK BATT
B switch positions.
Repeat a second time if oil pressure did not
register on the gauge.
NOTE: Troubleshoot as per Lubricating Oil
Pressure Low in Section 12 if oil pressure did not
When pre-lubrication has been accomplished,

reconnect the connector at the fuel injection
pump solenoid (Fuel Shutoff Valve).

CFP83 Series
Pre-Lubricate the Engine (CFP83-F40)

Check content, option info not found/available

solenoid.

NOTE: Monitor engine oil pressure on the local
control panel. Some pressure indication is
expected.
Crank the engine about two revolutions using
either the CRANK BATT A or the CRANK BATT
B switch positions.
Repeat a second time if oil pressure did not
NOTE: Troubleshoot as per Lubricating Oil
Pressure Low in Section 12 if oil pressure did not
When pre-lubrication has been accomplished,

reconnect the connector at the fuel injection
pump solenoid.

CFP83 Series
Lubricate Zerk Fittings on Auxiliary Drive Shaft

Some lubrication loss may occur during
transport and storage. It is recommended
that all drive shafts be re-lubricated upon
installation.
Grease zerk fittings as shown.
See Lubricating Oil Recommendations
and Specifications in Section 10 for
grease specifications.

CFP83 Series
Check Engine to Pump Alignment

Ensure engine position is centered on
Frame side to side within +-1/32”, by
measuring outside of frame side to engine
support leg mounting pad. (Compare two
front engine supports and Two back
engine supports).
Align engine centerline to pump centerline

within +-1/32”.
The pump centerline to the engine crank

centerline (in vertical plane) is to be ½”
+0, -1/4” offset.
NOTE: The slip joint must rest in the
middle third of its travel when installed.
SIDE VIEW
Auxiliary Drive shaft mounting flanges

must be parallel within 1.5 degrees. 90°
90°
TOP VIEW

CFP83 Series
Initial Start-Up
NOTE: Contact personnel responsible for the fire protection system before starting and to obtain approval to
service or repair the system.
Check the Raw Water Valves
CAUTION
The raw water lines to and from the fire
pump must be open, and there must be
sufficient water to the heat exchanger when
the engine has started. Insufficient water
supply will cause overheating, resulting in
engine failure.
Align raw water supply to the raw water supply
valves.
Align drainage from the heat exchanger raw
water outlet.
Open the raw water supply valves as shown.
Check the Engine Coolant Supply

Close all cooling system drains.
Verify that the vents are opened.

CFP83 Series
Initial Start-Up (Cont)

Remove the coolant tank cap.
Check coolant level.
Cold coolant level should be between the bottom
of the tube and above the top of the heat
exchange coils.
Add coolant if necessary. Use a mixture of at

least 50 percent antifreeze and 50 percent
water.
Replace the coolant tank cap.
Make a visual check for coolant leaks.
Prime the Fuel System:

Fill the fuel filter (see Fuel Recommendations
and Specifications in Section 10).
Remove the fuel pump suction line and wet the

gear pump gears with clean lubricating oil.
Check and fill the fuel tanks.
Check the injectors to be sure they are properly
adjusted.

CFP83 Series
Check Initial Crankcase Oil Level:
CAUTION
Never operate the engine with the oil level
below the low (“L”) mark or above the high
(“H”) mark on the dipstick
Check the oil level.
NOTE: No change in oil viscosity or type is

needed for new or newly rebuilt engines.
If below the low mark, fill the crankcase to the
low “L” (low) mark on the dipstick.
See Lubricating Oil Recommendations and
Specifications in Section 10 for oil specifications.
See the Lubricating Oil System Specification for
quantity that may be required.
Pre-Lubricate the Turbocharger:
CAUTION
New turbochargers must be pre-lubricated
before startup. Failure to pre-lube the
turbochargers will result in turbocharger
bearing failure.
Remove the turbocharger oil inlet line.
Pre-lubricate the housing by adding 50 to 60
cc (2 to 3 oz.) of clean engine lubricating oil.
Replace the line.
Pre-Lubricate the Engine

NOTE: Do not prime the engine lubricating
system from the by-pass filter.
On the top of the fuel pump, disconnect the
electric fuel solenoid. Make sure that the fuel
pump solenoid wire terminal does not touch
the engine.
Close the fuel shutoff valve from the fuel
tank to prevent the engine from starting.
Prime the engine lubricating system until a
30 psi [207 kPa] minimum pressure is
obtained.

CFP83 Series

NOTE: Use the fire pump controller or manual
setting from the gauge panel to crank the engine
through two cranking cycles.
Crank the engine at least 15 seconds, while
maintaining the external oil pressure at a
minimum of 15 psi [103kPa].
CAUTION
Never operate the engine with the oil level
below the low (“L”) mark or above the high
(“H”) mark on the dipstick
Check the oil level again.

CFP83 Series

NOTE: No change in oil viscosity or type is
needed for new or newly rebuilt engines.
If below the high mark, fill the crankcase to the
high “H” (high) mark on the dipstick.
See Lubricating Oil Recommendations and
Specifications in Section 10 for oil specifications.
See the Lubricating Oil System Specification for
quantity that may be required.
Initial Test Run

Move the throttle lever to mid-speed position.
Start the engine.

Immediately move the throttle to the low idle
position.
Allow the engine to operate at low idle speed
(700 RPM).
Check the lubricating oil pressure within 15
seconds after the engine starts.
Operate the engine at set point for 8 to 10
minutes.
Check for leaks, unusual noises, or other
indications of incorrect operation. Shut off the
engine and correct any problems found during
the inspection before proceeding.
After 8 to 10 minutes, stop the engine.
Check the engine oil and expansion tank
coolant levels. Top off if necessary.
Clean the raw water strainer.

CFP83 Series
Supplemental Test Run

Start the engine.
Bring it to the fire pump
required operating speed.
Adjust the raw water pressure
regulator to obtain the required
pressure.
Readjust the engine speed if
necessary.
Overspeed Adjustment
Procedure:
NOTE: Overspeed is already
set at factory.
Remove the calibrating screw
cover from the electronic
overspeed switch.
Turn the small screw on the
potentiometer near the word
“OVERSPEED” clockwise to
increase trip speed.
Move the throttle to the half

throttle position. Start the
engine and move the throttle
to the minimum position.

CFP83 Series

NOTE: Test button triggers overspeed at 10%
below normal.
Depress the “TEST” button push-button on the
inside of the panel.
Turn the screw to increase speed.
Verify overspeed trip/indications.
Operate the RESET switch on the front of the

engine control panel.
Repeat if necessary to further adjust the
overspeed stop setting.
Start the engine.

Check operation at rated speed.
Shut off the engine.
Press the “AUTO” button so the fire pump will
be ready to start automatically.

CFP83 Series
Completion
Support fire pump testing as per NFPA or
applicable requirements.
Contact operating personnel responsible for
fire protection system that engine is ready for
service.
Obtain authorized signature of acceptance.

CFP83 Series
Initial Start
NOTE: The object of this test is to check that the engine starts and operates normally with oil pressure being
displayed and raw water flow being established to the coolant heat exchanger. Operation at the factory-adjusted
rated speed is also checked.
NOTE: If the engine does not start, vent the fuel

system. Refer to Air in Fuel in Section 7, for FACTORY SETTING
instructions on how to vent the fuel system.
ENGINE SPEED SETTING:
NOTE: If the engine still will not start,
(@ HP SETTING)
troubleshoot as per Engine Cranks But Will Not
Start (No Exhaust Smoke) or Engine Difficult to OVERSPEED SWITCH SETTING:
Start or Will Not Start - Exhaust Smoke Present
in Section 12.
NOTE: When the engine starts, immediately
check that oil pressure is displayed. It should be
on-scale within a few seconds. Stop the engine if
oil pressure is not displayed within about 15
seconds.
NOTE: When the engine starts, immediately
check that raw water flow is established through
the coolant heat exchanger. Raw water flow
should be established immediately but some
delay may occur before the flow exits the heat
exchanger drain connection.
NOTE: Rated speed is displayed on the Factory
Setting Tag described in Section 2.
NOTE: If the engine fully loaded, it should
operate at rated speed. Unloaded, it may operate
about 10% faster. If it becomes necessary to
adjust the engine’s actual speed to match the
rated value, refer to Rated Speed Setpoint
Adjustment (CFP83-F10, F20, F30) or Rated
Speed Setpoint Adjustment (CFP83-F40) in this
section.

CFP83 Series
Initial Start (Cont)

Start the engine using either the CRANK BATT A
or the CRANK BATT B switch positions.
Check that the engine starts and operates at
about rated speed.
NOTE: If oil pressure is not present or if the Low
Oil Pressure Light does not go out, stop the
engine and troubleshoot as per Lubricating Oil
Pressure Low in Section 12.
Check that lubricating oil pressure is displayed
within 15 seconds after the engine starts.
NOTE: Raw water should be flowing through the
heat exchanger and water pressure shown on the
local pressure gauge should be no more than
414 kPa (60 psig).
Check that raw water is flowing through the heat
exchanger.
Check that raw water supply pressure is correctly
adjusted.
Operate the engine for 8 to 10 minutes.
Check for leaks, unusual noises, or other

indications of incorrect operation.
Shut off the engine by pressing the AUTO
position on the AUTO/MANUAL rocker switch
and by momentarily pressing the RESET switch.
Check that raw water flow stops automatically
shortly after the engine stops.
Correct any problems found during the inspection
before proceeding.
Check the engine lubricating oil level. Refer to
Check Lubricating Oil Level in Section 5. Top off
if necessary.
Check the coolant heat exchanger’s coolant
level. Refer to Check Coolant Level in Section 5.
Top off if necessary.
Check the raw water strainer. Clean the strainer if
necessary.

CFP83 Series
Second Start
The object of this test is to check that the engine operates normally with coolant temperature being maintained.
Oil pressure is checked at rated speed.
NOTE: Adjust engine operating speed as per

Rated Speed Setpoint Adjustment below.
Start the engine and observe that it is operating
at rated speed.
Check that the oil pressure is as specified in
Lubricating Oil System Specifications in Section
10.
NOTE: If oil pressure is not within the rated
range, troubleshoot as per Lubricating Oil
Pressure High or Lubricating Oil Pressure Low in
Section 12.
NOTE: If temperature does not stabilize, stop the

engine and refer to Coolant Temperature Above
Normal or Coolant Temperature Below Normal
(Engine Running) in Troubleshooting Section 12.
Check that engine operating temperature
stabilizes between about 82 and 95 oC [180 and
203 oF].

Correct any problems found before proceeding.
Check the engine lubricating oil level. Refer to
Check Lubricating Oil Level in Section 5. Top off
if necessary.
Check the coolant heat exchanger’s coolant
level. Refer to Check Coolant Level in Section 5.
Top off if necessary.
Check the raw water strainer. Clean the strainer if
necessary.

CFP83 Series
Rated Speed Setpoint Adjustment (CFP83-F10, F20, F30)

NOTE: If required, use this section to adjust the normal operating speed to the nameplate value.
NOTE: Rated speed is displayed on

the Factory Setting Tag described in FACTORY SETTING
Section 2. FACTORY SETTING
(@ HP SETTING)
OVERSPEED SWITCH SETTING:
Start the engine.

Observe that the engine starts and
accelerates the currently adjusted
speed setpoint.
Adjust the speed setpoint to rated

speed.
NOTE: Rated speed is adjusted by

locating the threaded linkage rod on
the fuel pump side of the engine.

CFP83 Series
Rated Speed Setpoint Adjustment (CFP83-F10, F20, F30) (Cont)

To increase the rated speed, turn the
bolt on the right side of the throttle
bracket clockwise The adjustment of
the bolt will pivot the throttle bracket
counter-clockwise and will allow more
fuel through the pump to speed up the
engine.
Loosen the lock nut and turn bolt
clockwise to allow for more RPM
speed. When rated speed is correct, 8708-cfp83
tighten lock nut against stop. Rated speed adjustment
To decrease the speed, turn the bolt
counter-clockwise on the right side of
the throttle bracket. The adjustment of
the bolt will pivot the throttle bracket
clockwise and will allow less fuel to
flow through the pump to slow down
the engine.
When rated speed is correct, tighten
the locking nuts against the stops.
The threaded bolt on the left side of
the bracket is for maximum speed
and may also need to be adjusted if
maximum speed cannot be reached.
The same adjustment sequence can
be performed for maximum speed
adjustment.
Stop the engine.
Start the engine.

accelerates to the rated speed
setpoint.
Stop the engine. Repeat the above

adjustment until the desired speed is
attained.

CFP83 Series
Rated Speed Setpoint Adjustment (CFP83-F40 Only)

NOTE: If required, use this section to adjust the normal operating speed to the nameplate value.
NOTE: Rated speed is displayed on

the Factory Setting Tag described FACTORY SETTING
in Section 2.
(@ HP SETTING)
Start the engine.

accelerates the currently adjusted
speed setpoint.
Adjust the speed setpoint to rated

speed.

CFP83 Series
Rated Speed Setpoint Adjustment (CFP83-F40) (Cont)

To increase the rated speed, turn
the bolt clockwise on the right side
of the throttle bracket. The
adjustment of the bolt will pivot the
throttle bracket to allow more fuel
through the pump to speed up the
engine.
The nut on the right, closest to the

8708-cfp83
bracket will need to be tightened to Rated speed adjustment
lock in the adjusted speed set point.
Loosen lock nuts and turn threaded
bolt clockwise to allow for more
RPM speed. When rated speed is
correct, tighten lock nut against
stop.
To decrease the speed, turn the

threaded bolt counter-clockwise.
The adjustment of the bolt in a
counter-clockwise direction will
allow less fuel to flow through the
pump to slow down the engine.
When rated speed is correct,
tighten the locking nut against the
stops.
Stop the engine.
Start the engine.

accelerates to the rated speed
setpoint.
Stop the engine. Repeat the above

adjustment until the desired speed
is attained.

CFP83 Series
Overspeed Setpoint Adjustment and Testing

Overview
Overspeed setpoint adjustment and testing is a repetitive process. Use the Adjustment Procedure to change the
setpoint. Use the Test Procedure to check the setpoint. Repeat the adjustments and checks until the desired
setpoint is demonstrated. When the overspeed setpoint is successfully demonstrated, then check that the
engine operates normally while not being tested.
NOTE: The overspeed trip setpoint is displayed

on the Factory Setting Tag described in Section FACTORY SETTING
2.
NOTE: The overspeed setpoint must be set at
(@ HP SETTING)
between 115 and 120% of the engine’s rated
speed. OVERSPEED SWITCH SETTING:
The speed switch located on the engine’s local

control panel has a TEST button which lowers
the currently adjusted overspeed by 10%. Thus,
an overspeed setpoint of 2112 rpm would be
reduced to (2112 * 0.9 =) 1901 RPM when the
test button is pressed.
Adjust the Speed Switch:

Lower the cover on the engine’s local control
panel.
Disconnect the engine speed sensor signal from
PICK-UP terminals 1 and 2.
Connect a signal generator capable of providing
between 0.25 to 120 VAC RMS signal to the
switch. The signal must be proportional to the
engine’s rated speed.
Provide an overspeed signal at the specified
overspeed switch setting frequency.

CFP83 Series
Overspeed Setpoint Adjustment and Testing (Cont)

Remove the calibrating screw cover from the
electronic overspeed switch.
NOTE: Turn the small screw on the
potentiometer near the word “OVERSPEED”
clockwise to increase trip speed. Turn it counter-
clockwise to reduce trip speed.
If the OVERSPEED light is illuminated with the
signal present, perform the following steps:
Reduce the signal frequency.
Press the RESET button.
Turn the potentiometer clockwise to raise the
setpoint.
Increase the signal frequency to setpoint.
With the OVERSPEED light off, slowly turn the
potentiometer counter-clockwise until the light is
just illuminated.
NOTE: Repeat the adjustments as required to
make the finest adjustment practical.
When the setpoint is adjusted, perform the
following steps:
Replace the screw cover at the potentiometer.
Disconnect the signal generator.
Reset the light.
Reconnect the speed sensor input.
Perform the Test Procedure as outlined to check
the effect of the adjustment.

CFP83 Series
Test Procedure
FACTORY SETTING
NOTE: The overspeed trip setpoint is displayed FACTORY SETTING
on the Factory Setting Tag described in Section ENGINE SPEED SETTING:
2. (@ HP SETTING)
Start the engine.

Observe that the engine starts and operates at
about rated speed.
NOTE: Monitor engine speed on the tachometer.
Record the observed engine speed when it trips.
It must trip between 115 and 120% of rated
speed.
NOTE: Do not exceed 120% of rated speed. If
the engine does not trip at or below 120%, stop
the engine and Adjust the Speed Switch.
Adjust the mechanical throttle adjustment to
increase engine speed to the setpoint.
Observe that the engine stops automatically and

that the overspeed trip light is illuminated.
Verify that the engine tripped at a speed between
115 and 120% of rated speed.
Press the RESET button on the speed switch.
Press the RESET switch on the front of the
engine control panel.
Observe that the overspeed light has
extinguished.
NOTE: If required by the local authority, restart
the engine at the current mechanical throttle
setpoint to demonstrate a run-away overspeed
shutdown as specified by Underwriter’s
Laboratory UL 1247.

CFP83 Series
Set/Check Normal Operation

Start the engine.
Adjust engine speed for rated value. Refer to
Rated Speed Setpoint Adjustment (CFP83-F10,
F20, F30) or Rated Speed Setpoint Adjustment
(CFP83-F40) in this section.
Stop the engine.

CFP83 Series
Crank Terminate Adjustment and Testing

NOTE: The crank terminate signal to the remote fire pump controller informs the controller that the engine has
started. This allows the controller to terminate the selected crank signal to the engine. This crank terminate
signal is produced by the overspeed switch in the engine’s local control panel. The setpoint for the crank
terminate signal is adjusted at the factory to a value above normal idling speeds but less than the rated speed.
The setpoint should not require adjustment unless it is necessary to test the switch operation or to replace the
overspeed speed switch.
NOTE: If using this procedure for troubleshooting, perform the test portion prior to making any adjustments.
Verify automatic reset of the crank terminate signal.
Prepare
Place the fire protection system in a safe mode
for engine service.
Place the AUTO/MANUAL rocker switch in the
MANUAL position.
REMOVE BATTERY POWER BEFORE

SERVICING ENGINE OR CONTROLS
For safety reasons, both batteries must be
disconnected before performing service on the
Firepump Engine or on any of its controls.
Before disconnecting the batteries, place the
Firepump Controller in its appropriate service
position in order to avoid a “Battery Failure”
alarm.
Wear safety glasses when disconnecting
batteries!
Next, disconnect both batteries at their terminals.

CFP83 Series
Crank Terminate Adjustment and Testing (Cont)
Adjust
NOTE: Refer to Drawing 10423 Sheet 1 in
Section 13.
Open the engine’s local control panel cover.
Disconnect the GRAY/RED (MPU +) wire from
PICK-UP terminal 1 at the speed switch.
Disconnect the GRAY/BLK (MPU -) wire from
PICK-UP terminal 1 at the speed switch.
Connect a signal or pulse generator to the switch
inputs with the same signal polarity.
Adjust the pulse generator to about 1100 cycles
or pulses per second.
Remove the cover from the speed switch
CRANK/TACH CAL potentiometers.
If, with this signal, the CRANK LED is illuminated
on the speed switch, turn the CRANK
potentiometer E5 clockwise until the LED
extinguishes.
Then, turn the CRANK potentiometer E5 slowly
counterclockwise until the CRANK LED
illuminates.
Replace the cover on the speed switch.

Remove the signal generator.
Connect the GRAY/RED (MPU +) wire at PICK-
UP terminal 1 at the speed switch.
Connect the GRAY/BLK (MPU -) wire at PICK-
UP terminal 1 at the speed switch.

CFP83 Series
Crank Terminate Adjustment and Testing (Cont)

For safety reasons, both batteries must be re-
connected before putting the engine and fire
protection system controller back in service.
Wear safety glasses when reconnecting
batteries!
Reconnect the batteries at their terminals after all
service work has been completed.
Test
NOTE: Monitor fire pump controller operations
from the controller. Check for the crank terminate
signal at the input terminals and observe that the
controller removes the crank output to the
engine.
Connect a digital voltmeter at crank terminate
output of the local control panel between TB2 (+)
and TB11 (-). Refer to Drawing 10423 Sheet 1 in
Section 13.
NOTE: The engine’s rated speed is displayed on
the Factory Setting Tag described in Section 2.
AUTO position.
Start the engine from the fire pump controller.
Observe that the engine starts and accelerates to
about rated speed.
Observe that the CRANK terminal LED on the
speed switch is illuminated.
Check that the local digital voltmeter indicates the
12 VDC standard (24 VDC optional) signal output
voltage.
When testing is done, stop the engine.
Remove the digital voltmeter.
Close the cover on the engine control panel.

CFP83 Series
Isolated Acceptance Testing

Demonstrate the manual local start, operation, and shutdown of the fire pump from the engine’s local starter-
solenoid controls. Demonstrate that the engine will operate in the event of blown fuses or other faults in the local
control panel. Demonstrate manual engine speed control. Manual raw water valve operations are required.
Demonstrate the manual local start, operation, and shutdown of the fire pump from the engine’s control panel.
Demonstrate that the engine starts, operates at speed, and stops in the event that the fire pump controller is not
functioning.
Demonstrate the start of the fire pump engine using each battery set separately.
Demonstrate that the fire pump engine alternator operates while the engine is running. Demonstrate that any
customer supplied battery charging systems operate when the engine is not running.
Integrated Acceptance Testing

Demonstrate the start-up, operation, and shutdown of the fire pump engine in response to operations of the
customer-installed fire pump controller. Perform this testing with the testing of the fire pump controller.
Demonstrate that the fire pump controller provides design indications and/or alarms for simulated engine oil
pressure, water temperature, and overspeed faults.
Demonstrate the actual operation of the crank terminate output from the overspeed switch.
Participate in any flushing, pressure testing, flow testing, or capacity testing required for the fire protection
system.
Complete the Cummins Fire Power Start-Up Inspection (SUI) Checklist. This is available on the Cummins Fire
Power web site (www.cumminsfirepower.com/startup).
When these items have been demonstrated, contact operating personnel responsible for fire protection system
that engine is ready for service.

CFP83 Series
General Operating Information

Cummins fire pumps are tested before being shipped from the factory and are ready to put to work in application
regarding to fire emergencies.
Correct care of your engine will result in longer life, better performance, and more economical operation.
Follow the daily maintenance checks listed in Maintenance Guidelines, Section 4.
Check the water temperature and oil pressure indicators, warning lights, and other gauges daily to make sure
they are operational.
Normal Remote Starting Procedure

The fire pump engine starts automatically upon receipt of the start command from the customer installed fire
control panel. The remote command starts the engine when the AUTO/MANUAL rocker switch at the local;
control panel is in the AUTO position. The remote start command consists of either the Crank A or the Crank B
signal. Only one should be selected.
The engine continues to operate as long as the run signal is present. When the run signal is lost, the engine
promptly stops.
When the engine starts, the crank terminate signal is sent to the fire control panel to indicate that the engine is
running. How this is displayed depends upon the fire control panel manufacturer. This indication should be
checked in the event that an automatic start is initiated. If the signal is not present, the engine can be started
locally by using the Emergency Starting Procedure in this section.
The engine may be stopped locally by selecting the manual position on the AUTO/MANUAL rocker switch and
by pressing the local RESET switch.

CFP83 Series
Normal Local Starting Procedure

Overview
The fire pump engine is started locally for testing and maintenance. Local starts for testing will be performed at
rated speed. That is, the engine starts and promptly ramps up to operating speed. If it is necessary to operate
the engine at idle speed for maintenance or troubleshooting, the engine speed must be manually reduced. After
maintenance or troubleshooting, the speed must be manually reset to the rated value shown on the Factory
Setting Tag in see Section 2.
Local Starting Procedure for Testing
CAUTION
To prevent damage to the starter, do not engage the starting motor more than 15 seconds. Wait 15
seconds between each attempt to start (electrical starting motors only).
Start the Engine

Observe the battery voltages displayed on the
engine control panel. Use the battery with the
highest indicated voltage.
NOTE: Depress the selected switch for up to 15
seconds or until the engine starts. Repeat up to
three times if necessary.
or the CRANK BATT B rocker switch positions.
NOTE: If the engine does not start after three
attempts, check the fuel supply system. Absence
of blue or white exhaust smoke during cranking
indicates no fuel is being delivered.
Engine oil pressure must be indicated on the
gauge within 15 seconds after starting.
Stop the Engine

To stop the engine, select the AUTO position on
the AUTO/MANUAL rocker switch and press the
RESET switch.

CFP83 Series
Normal Local Starting Procedure (Cont)

Local Starting Procedure for Maintenance or Troubleshooting
Engines used in fire pumps or standby service are expected to transition from crank to full load within a short
period of time.
CAUTION
Do not idle the engine for excessively long periods. Long periods of idling (more than 10 minutes) can
damage an engine because combustion chamber temperatures drop so low the fuel will not burn
completely. This will cause carbon to clog the injector spray holes and piston rings, and can cause the
valves to stick. If the engine coolant temperature becomes too low (60°C [140°F]), raw fuel will wash the
lubricating oil off the cylinder walls and dilute the crankcase oil; therefore, all moving parts of the
engine will not receive the correct amount of lubrication.
Adjust the fuel pump as per instructions in

Section 7 to get idle speed.
Manually position the fuel pump at mid throttle
position.

CAUTION
To prevent damage to the starter, do not
engage the starting motor more than 15
seconds. Wait 15 seconds between each
attempt to start (electrical starting motors
only).
or the CRANK BATT B switch positions.
NOTE: If the engine does not start after three
attempts, check the fuel supply system. Absence
of blue or white exhaust smoke during cranking
indicates no fuel is being delivered.
Engine oil pressure must be indicated on the
gauge within 15 seconds after starting.

CFP83 Series
Normal Local Starting Procedure (Cont)
CAUTION
Do not operate the engine at low idle for long
periods. Long periods at low idle, more than
10 minutes, can damage an engine because
combustion chamber temperatures will
decrease and the fuel will not completely
burn. This will cause carbon to build up
around the injector spray holes and piston
rings, which can cause the valves to stick. To
avoid damage, operate the engine at higher
idle.
When the engine starts, immediately position the

throttle linkage to an idle speed setting of about
700 RPM.
To stop the engine, select the AUTO position on
the AUTO/MANUAL rocker switch and press the
RESET switch.
Adjust the engine to operate at rated speed as
per instructions in this section.

CFP83 Series
Jumpering the Batteries

NOTE: If a battery charging system is not provided, the engine can be started using known good batteries to
provide a temporary power source. Once the engine is started, disconnect the added batteries and allow the
engine’s alternator to charge the existing batteries. It may take some time to charge the batteries with this
method.
NOTE: For maintainable lead acid batteries as supplied by Cummins N Power, check the state of charge by the
measurement of battery cell specific gravity. Refer to Battery Testing in Section 7 for more information.
WARNING
Batteries can emit explosive gases. To avoid personal injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the
negative (-) battery cable last.
CAUTION
When using jumper cables to start the
engine, make sure to connect the cables in
parallel: Positive (+) to positive (+) and
ground (-) to ground (-).
The accompanying illustration shows a typical
parallel battery connection. This arrangement,
positive (+) to positive (+), doubles the
cranking amperage.
Use this type of connection to jump start the
engine.
For a 24 VDC system, two or more 12 VDC
batteries are connected in the parallel
connection as shown. If jumpering a 24 VDC
battery setup, another 24 VDC battery pair is
required as the source.
The accompanying illustration shows a typical

series battery connection.
This arrangement, positive (+) to negative (-),
doubles the voltage.
Do not use this type of connection to jump start
the engine using a second 12 VDC battery.

CFP83 Series
Operating the Engine

Monitor Operating Values Frequently
Monitor the oil pressure and coolant temperature gauges frequently. Refer to Lubricating Oil System
Specifications or Cooling System Specifications in Section 10 for recommended operating pressures and
temperatures. Shut off the engine if any pressure or temperature does not meet the specifications.
Do not exceed a maximum coolant temperature (93°C [220°F]). The pressure cap (or radiator cap) must meet
the minimum pressure of 48 kPa [7 psi].
CAUTION
Continuous operation with low coolant temperature (below 60°C [140°F]) or high coolant temperature
(above 100°C [212°F]) can damage the engine.
Verify raw water coolant pressure and flow.
Monitor Engine Condition Periodically

Most engine failures give an early warning. Look and listen for changes in performance, sound, or engine
appearance that can indicate service or engine repair is needed. Some changes to look for are as follows:
• Engine misfires
• Vibration
• Unusual engine noises
• Fuel, oil, or coolant leaks
• Sudden changes in engine operating temperature or oil pressure
• Excessive smoke
• Loss of power
• An increase in oil consumption
• An increase in fuel consumption

CFP83 Series
Emergency Manual Starting Procedures

Overview
The engine starts automatically in the event of a fire emergency. However, if it fails to start automatically, the
engine can be started locally by either of two means. The Normal Local Starting Procedure in this section can
be used to start the engine if it fails to start because of a failure in the remote fire control system. Operating the
engine with this procedure will automatically control raw water flow.
Additionally, manual means are available to start the engine in the event of some local failures. This procedure
requires the manual operation of the raw water valves and the use of the manual starting lever on either of the
two starting solenoids.
Use the following procedures as specified:

If the red low lube oil pressure light is
illuminated, attempt an Emergency Manual
Mode Electrical Start.
If the red low lube oil pressure light is not
illuminated, attempt an Emergency Manual
Mode Non-Electrical Start.
Also, if the fuel shutoff valve is known to be
faulted, attempt an Emergency Manual Mode
Non-Electrical Start.

CFP83 Series
Emergency Manual Mode Electrical Start

Starting the Engine
Open both manual valves in the raw water
bypass supply piping.

NOTE: Use the lever on either solenoid. If one

does not crank the engine, then use the other.
Depress the lever on the selected solenoid to
start the engine.
When the engine starts, release the lever.
If the engine cranks but does not start, try the
Manual Mode Non-Electrical Start procedure in
this section.

CFP83 Series
Emergency Manual Mode Electrical Start (Cont)
Stopping the Engine

When emergency operation is done, stop the
engine by pressing the AUTO position on the
AUTO/MANUAL rocker switch and then press
the RESET switch.

CFP83 Series
Emergency Manual Mode Non-Electrical Start

(CFP 83-F10, F20, F30)
Starting the Engine

Open both manual valves in the raw water
bypass supply piping.
Throttle cable assembly is provided to allow

the operator to start the unit in manual
mode.
The Throttle cable assembly is located on

the fuel pump side of the engine and has a
pull handle that is attached to the fuel pump
lever which activates the fuel solenoid shut- Throttle Cable
off (FSO).
The throttle cable assembly is factory installed
and is securely fastened to the fuel pump lever
in position shown to allow engine to run in
closed/automatic mode.
Emergency Manual Mode Non-Electrical Start (CFP 83-F10, F20, F30)

(Cont)

CFP83 Series
In the event the automatic start is not

operational, pull on the throttle handle
assembly which will move the lever to the run
position to start the engine.
Run
Turn handle assembly to lock throttle cable

assembly in position to allow the engine to run
in manual mode.
Closed
Press down on the crank solenoid lever to

engage the starter while in manual mode.
Depress until engine starts.
NOTE: If first crank solenoid lever does not

engage the starter, repeat on second crank
solenoid lever.

CFP83 Series
Emergency Manual Mode Non-Electrical Start (CFP 83-F10, F20, F30)

(Cont)
Stopping the Engine

Once engine is operational in automatic mode,
be sure to retract the throttle cable to the
closed or automatic position to allow the engine Run
to start in automatic mode.
NOTE: If throttle cable assembly does not

retract to correct closed position, manually
push the lever to the closed or automatic
position and adjust the throttle cable assembly Closed
so that when activated, it opens and closes the
FSO lever accordingly.
Periodic inspection of the throttle cable

assembly is recommended.

CFP83 Series
Emergency Starting in Automatic Mode with Failed Fuel Shut-Off Solenoid

Throttle Cable assembly will be provided to
allow the operator to start the unit in manual
mode.
The Throttle Cable assembly is located on
the fuel pump side of the engine and has a
pull handle that is attached to the fuel pump
lever which activates the fuel solenoid shut-
off (FSO).
Throttle Cable
The throttle cable assembly is factory
installed and is securely fastened to the fuel
pump lever in position shown to allow engine
to run in closed or automatic mode.
In the event the Fuel Shut-off Solenoid has

failed, pull on the throttle handle assembly
which will move the lever to the run position Run
to start the engine.
Turn handle assembly to lock cable

assembly in position to allow the engine to
run.
Closed

CFP83 Series
Emergency Starting in Automatic Mode with Failed Fuel Shut-Off Solenoid

(Cont)
Stopping the Engine

Retract the throttle cable to the closed or
automatic position to allow the engine to
stop.
Once engine is operational and fuel solenoid

has been replaced, the cable assembly to be
restored in the closed or automatic mode.
The engine is now ready to run in automatic
mode.
NOTE: If throttle cable assembly does not

retract to correct closed position, manually
push the lever to the closed or automatic
position and adjust the throttle cable
assembly so that when activated, it opens
and closes the FSO lever accordingly.
Periodic inspection of the throttle cable

assembly is recommended.

CFP83 Series
Emergency Manual Stopping Procedure

solenoid (Fuel Shutoff Valve (FSOV)).
Reconnect the connector after the engine as
stopped.

CFP83 Series
Starting Procedure - After Extended Shutdown or Oil Change

Complete the following steps after each oil change, or after the engine has been shut off for more than 30 days
to make sure the engine receives the correct oil flow through the lubricating oil system:
Bump the engine. Refer to Pre-Lubricate the Engine in this section.
Depending upon the nature of the shutdown, perform other installation checks in this section as appropriate.
Start the engine. Refer to Normal Local Starting Procedure in this section.
If required, vent the fuel system. Refer to Air in Fuel in Section 7.

Section 4 – Maintenance Guidelines Page 4-1
CFP83 Series
Section 4 - Maintenance Guidelines

Section Contents
Page
Overview ..............................................................................................................................................................4-3
Tool Requirements .............................................................................................................................................4-4
Maintenance Schedule .......................................................................................................................................4-5
Maintenance Record Form.................................................................................................................................4-6

Page 4-2 Section 4 – Maintenance Guidelines
CFP83 Series

CFP83 Series
Overview
Cummins Inc. recommends that the engine must be maintained according to the Maintenance Schedule in this
section.
If the engine is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], perform
maintenance at shorter intervals. Shorter maintenance intervals are also required if the engine is operated in a
dusty environment or if frequent stops are made. Contact your local Cummins Authorized Repair Location for
recommended maintenance intervals.
Some of these maintenance procedures require special tools or must be completed by qualified personnel.
Contact your local Cummins Authorized Repair Location for detailed information.
If your engine is equipped with a component or accessory not manufactured by Cummins Inc., refer to the
component manufacturer's maintenance recommendations.
Use the form provided in this section as a convenient way to record maintenance performed.
NOTE: If the engine is equipped with a component or an accessory not manufactured by Cummins, refer to the
component manufacturer's maintenance recommendations.

CFP83 Series
Tool Requirements
Most of the maintenance operations described in this manual can be performed with common hand tools (metric
and S.A.E. wrenches, sockets, and screwdrivers).
The following is a list of special service tools required for some maintenance operations:
Tool Part Number Description

CC-2802 Coolant test kit
CC-2800 Refractometer
ST-1273 Pressure gauge
3375045 Torque wrench (0 to 175 ft-lb)
3375049 Oil filter wrench
3376807 Engine coolant and fuel filter wrench
3377161 Digital multimeter
3822524 Belt tension gauge, click type (v-belts and ribbed with 4 or 5 ribs)
3822525 Belt Tension Gauge, Click-type (for V-ribbed with 6 to 12 ribs)
3824556 Charge air cooler (CAC) pressure kit
3824591 Engine barring gear
3824783 Torque wrench (0 to 300 in-lb)
3824842 M10 Compuchek® fitting
3825157 Fuel Injector Connector Puller
3825156 Fuel Injector Puller
Contact your nearest Cummins Authorized Repair Location for the required service tools.
Sockets Wrenches Other

10 mm 8 mm Engine Barring Gear, Part No. 3377371
12 mm 13 mm Allen Wrench (8 mm)
13 mm 15 mm Breaker Bar (3/8-in drive)
15 mm 19 mm Flat Screwdriver
17 mm 22 mm Ratchet (3/8-in drive)
18 mm 24 mm Ratchet (1/2-in drive)
19 mm 17 mm (open end) Filter Wrenches (75 to 80 mm, 90 to 95 mm, and 118 to 131 mm)
22 mm Pliers
27 mm Torque Wrench
T-Bar Puller (75 mm)

CFP83 Series
Maintenance Schedule
Activity Trimonthly
(as per engine specifications) Daily Weekly 1 2 3 4 5 6 7 8 9 10 11 12 Procedure Page
# #
Check Air Intake Filter and Piping. x x x x x x x x x x x x x x 1 5-4
Check Coolant Level x x x x x x x x x x x x x x 2 5-4
Check Crankcase Breather Tube x x x x x x x x x x x x x x 3 5-5
Check Lubricating Oil Level x x x x x x x x x x x x x x 4 5-6
Drain Fuel-Water Separator x x x x x x x x x x x x x x 5 5-6
Inspect After Cooler / Charge Air x x x x x x x x x x x x x x 6 5-7
Cooler Piping
Inspect Charge Air Cooler Piping x x x x x x x x x x x x x x 6 5-8
Check Coolant Heat Exchanger Piping x x x x x x x x x x x x x x 7 5-9
Check Coolant Heater Piping x x x x x x x x x x x x x x 8 5-10
Bleed Fuel Tanks x x x x x x x x x x x x x 9 5-11
Clean Raw Water Strainers x x x x x x x x x x x x x 10 5-11
Check Battery Condition x x x x x x x x x x x x x 11 5-11
Test Run Engine x x x x x x x x x x x x x 12 5-12
Check Hose Condition x x x x x x x x x x x x 13 5-14
Check Engine Coolant Heater x x x x x x x x x x x x 14 5-14
Inspect Heat Exchanger Zinc Plug x x x x x x x x x x x x 15 5-14
Inspect Electrical Components x x x x x x x x x x x x 16 5-15
Check Turbochargers Mounting Nuts x x x x x x x x x x x x 17 5-15
Check Engine Mounting Bolts x x x x x x x x x x x x 18 5-15
Check Cooling System Condition x x x x x x x x x x x x 19 5-15
Check Air Cleaner Service Indicator x x x x x x x x x x x x 20 5-16
Inspect Air Intake System Piping x x x x x x x x x x x x 21 5-17
Check Fuel Pump x x x x x x x x x x x x 22 5-17
Change Lubricating Oil and Filters x x x x x x x x x x x x 23 5-18
Change Fuel Filter (Spin-on Type) x x x x x x x x x x x x 24 5-23
Clean Charge Air Cooler x x x x x x x x x x x x 25 5-25
Lubrication of Output Shafts x x x x x x x x x x x x 26 5-26
Drain and Flush Cooling System x x x x x x 27 5-27
Change Coolant Filter x x x x x x 28 5-31
Vent Fuel Supply Lines x x x x x x 29 5-34
Vent Injection Pump x x x x x x 30 5-35
Check Overspeed Switch Operation x x x 31 5-36
Check Drive Belt, Tensioner Bearing x x x 32 5-36
and Belt Tension
Adjust Valve Lash Clearance x x x 33 5-42
Inspect Turbocharger x 34 5-46
Inspect Viscous Damper x 35 5-47
Inspect Water Pump x 36 5-47
Engine Steam Cleaning x 37 5-48
Inspect Overhead Set x 38 5-49
Refer to Maintenance Procedures in Section 5 for instructions.

CFP83 Series
Maintenance Record Form

Engine Serial No. Engine Model
Owner's Name Equipment Name/Number
Date Hours or Time Actual Hours Check Performed By Comments
Interval Performed

Section 5 – Maintenance Procedures Page 5-1
CFP83 Series
Section 5 - Maintenance Procedures

Section Contents
Page
Daily ...................................................................................................................................................................................... 5-3
Weekly ................................................................................................................................................................................ 5-11
Every Three Months or 250 Hours.................................................................................................................................... 5-14
Every Six Months or 500 Hours ........................................................................................................................................ 5-27
Every Year or 1000 Hours.................................................................................................................................................. 5-36
Every Two Years or 2000 Hours ....................................................................................................................................... 5-47
Every Four Years or 5000 Hours……………………………………………………………………………………………………5-49

Page 5-2 Section 5 – Maintenance Procedures
CFP83 Series

CFP83 Series
DAILY
General Information
Preventative maintenance begins with day-to-day awareness of the engine and its system.
On a daily basis, inspect the engine for the following issues:
• Leaks
• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance
• Odor of fuel
• Correct any problems as per the instructions in this manual.
• Perform the specific checks in this section only after the engine has been stopped. Do not perform this section if the fire
pump is in operation.
Engine Operation Report

The engine must be maintained in top mechanical condition if the operator is to get optimum satisfaction from its use. The
maintenance department needs daily running reports from the operator to make necessary adjustments in the time allocated.
The daily running report also helps to make provisions for more extensive maintenance work as the reports indicate the
necessity.
Comparison and intelligent interpretation of the daily report, along with a practical follow-up action, will eliminate most
failures and emergency repairs.
Report to the maintenance department any of the following conditions:
• Low lubricating oil pressure
• Low power
• Power increases or engine surge
• Erratic or no accelerator control or response
• Any warning lights flashing or staying on
• Abnormal water or oil temperature
• Unusual engine noise
• Excessive smoke
• Excessive use of coolant, fuel, or lubricating oil
• Any fuel, coolant, or lubricating oil leaks
• Loose or damaged parts
• Worn or damaged belts

CFP83 Series
Unusual Engine Noise

During daily maintenance checks, listen for any
unusual engine noise that can indicate that service
is required.
Procedure 1 Check Air Intake Filter and Piping

Visually inspect the air intake filter and piping daily for
wear points and damage to piping, loose clamps, or
punctures.
Replace damaged air filter or pipes, and tighten loose
clamps, as necessary, to prevent the air system from
leaking. Refer to Adjustment, Repair and
Replacement in Section 7 for replacement
procedures.
Check for corrosion under the clamps and hoses of
the intake system piping. Corrosion can allow
corrosive products and dirt to enter the intake system.
Disassemble and clean, as required. Refer to
Adjustment, Repair and Replacement in Section 7 for
replacement procedures.
Torque loosened clamps.

Torque Value: 8 N●m [72 in-lb]
Procedure 2 Check Coolant Level
WARNING
Do not remove a pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before
removing the pressure cap, (Cummins Fire Power Part No. 11407). Heated coolant spray or steam can cause
personal injury.
CAUTION
Never use a sealing additive to stop leaks in the cooling system. This can result in cooling system plugging and
inadequate coolant flow, causing the engine to overheat.
CAUTION
Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50°C
[120°F] before adding coolant.

CFP83 Series
Press down, unscrew and remove the pressure cap

(Cummins Fire Power Part No. 11407).
NOTE: Coolant level should be at the bottom of the
fill neck. It must be above the raw water tubes.
Check coolant level.
NOTE: Make up coolant added to the engine must

be mixed with the correct proportions of antifreeze,
supplemental coolant additive and water to avoid
engine damage.
Coolant specifications can be found in Coolant
Recommendations and Specifications in Section 7.
If required, prepare a coolant solution.
Fill the cooling system with coolant to the bottom of

the fill neck in the coolant heat exchanger.
When done, press down and screw in the pressure
cap (Cummins Fire Power Part No. 11407).
Procedure 3 Check Crankcase Breather Tube

Inspect the breather tube for sludge, debris, or ice in
the tube.
If the breather tube is obstructed or blocked, clean it.
Inspect the tube more frequently in icy conditions.

CFP83 Series
Procedure 4 Check Lubricating Oil Level
CAUTION
Never operate the engine with oil level below the L (low) mark or above the H (high) mark. Poor engine performance
or engine damage can occur.
NOTE: Wait at least 15 minutes after shutting off the

engine to check the oil level. This allows time for the
oil to drain into the oil pan.
The engine must be level when checking the oil level
to make sure the measurement is correct.
Check the oil level on the dipstick.
NOTE: If the lube oil is excessively high, troubleshoot
as per Oil Level Rises in Section 7.
If the lube oil level is greater than the high mark, drain
the excessive oil. Refer to Drain Oil in Change
Lubricating Oil and Filters in Section 7.
If the lube oil level is below the low mark, add oil.
Refer to Fill Oil in Change Lubricating Oil and Filters
later in this Section.
NOTE: If the lube oil is excessively low, troubleshoot
as per Lubricating Oil Consumption Excessive in
Section 12.
Oil Capacity (Low to High Mark Oil): 3.8 liters [4
U.S. qt]
For additional lubricating oil recommendations and oil
pan capacity information, refer to Lubricating Oil
Recommendations and Specifications and Lubricating
Oil System Specifications in Section 7.
Procedure 5 Drain Fuel-Water Separator

Cummins Inc. requires a fuel-water separator or fuel filter be installed in the fuel supply system. Drain the water and
sediment from the separator daily.
WARNING
Drain the water-fuel separator into a container and dispose of in accordance with local environmental regulations.

CFP83 Series
Spin-on Type
Procedure 6a Inspect Aftercooler Piping (CFP83-F10, F20, F30)

Inspect the charge air piping and hoses daily for holes,
cracks, or loose connections.
Tighten the hose clamps, if necessary.
Refer to the manufacturer's specifications for the
correct torque value.
Inspect the charge air cooler for dirt and debris

blocking the fins.
Check for cracks, holes, or other damage.
If damage is found, refer to the Charge Air Cooler
Removal/Installation in Section 7.
Inspect the intake piping daily for wear points and

damage to piping, loose clamps, or punctures that
can damage the engine.
Replace damaged pipes and tighten loose clamps
as necessary to prevent the air system from leaking.
Check for corrosion under the clamps and hoses of
the intake system piping. Corrosion can allow
corrosive products and dirt to enter the intake
system. Disassemble and clean as required.

CFP83 Series
NOTE: If more than 59 ml (2 oz) is drained, refilling of

the filter is required to prevent hard starting.
Use your hand to open the drain valve. Turn the valve
counterclockwise approximately 3½ turns until the
valve drops down 25.4 mm [1 in] and draining occurs.
Drain the filter sump until clear fuel is visible.
CAUTION
When closing the drain valve, do not over-tighten
the valve. Over-tightening can damage the
threads.
Close the valve by lifting the valve and turning it
clockwise until it is hand-tight.
If required, refill the filter. Refer to Change Fuel Filter
later in this Section for removal and installation
instructions.
Canister Type
Pull up on the drain valve lever until fluid drains out of

the drain tube. Drain the filter sump until clear fuel is
visible.
Push up on the drain valve until fluid drains out of the

drain tube.
Procedure 6b Inspect Charge Air Cooler Piping (CFP83-F40)
Inspect the charge air cooler piping and hoses daily for
holes, cracks, or loose connections.
Tighten the hose clamps, if necessary.

CFP83 Series
Inspect the charge air cooler for dirt and debris

blocking the fins.
Check for cracks, holes, or other damage.
If damage is found, refer to Charge Air Cooler (CAC)
Removal and Installation instructions in Section 7.
Inspect the intake piping daily for wear points and

damage to piping, loose clamps, or punctures that can
damage the engine.
Replace damaged pipes and tighten loose clamps as
necessary to prevent the air system from leaking.
Check for corrosion under the clamps and hoses of the
intake system piping. Corrosion can allow corrosive
products and dirt to enter the intake system.
Disassemble and clean as required.
Procedure 7 Check Coolant Heat Exchanger Piping
Visually inspect the coolant heat exchanger and

piping daily for wear points and damage to piping,
loose clamps, or punctures.
Replace damaged tubes, clamps, or pipes, and
tighten loose clamps, as necessary, to prevent the
coolant system from leaking. Refer to Adjustment,
Repair and Replacement in Section 7 for replacement
procedures.

CFP83 Series
Procedure 8 Check Coolant Heater Piping

Visually inspect the engine coolant heater hoses and
piping daily for wear points and damage to piping,
loose clamps, or punctures.
Replace damaged tubes, clamps, or pipes, and
tighten loose clamps, as necessary, to prevent the
coolant system from leaking. Refer to Adjustment,
Repair and Replacement in Section 7 for

CFP83 Series
WEEKLY
General Information
With the engine not running, perform the daily maintenance checks plus the following:
Procedure 9 Bleed Fuel Tanks
Loosen the fuel tank drain plug or open the drain

valve.
Drain approximately 1 cup of fuel to remove water
and sediment.
Close the drain valve or tighten the drain plug.
Dispose of the waste fuel in accordance with
applicable requirements.
Procedure 10 Clean Raw Water Strainers

For each raw water strainer, remove the plug.
Inspect and remove any debris.
Install the strainer plugs.
Unless otherwise directed, ensure that the bypass
line valves are closed and the normal line valves are
open.
Procedure 11 Check Battery Condition
Inspect the condition of the batteries.

Refer to Section 7 for inspection and maintenance
procedures.

CFP83 Series
Procedure 12 Test Run Engine
Start Test Run

Select the MANUAL position on the AUTO/MANUAL
Switch.
Press the CRANK A or CRANK B switch.
Check Unusual Engine Noise

Run the engine no less than 30 minutes to attain
normal running temperature.
During the weekly maintenance check, listen for any
unusual engine noise which can indicate that service
is required.
Check running indications.
Observe that the engine is operating at test speed as

follows:
Check that oil pressure is greater than 10 PSI.
Check that coolant temperature is between 140°F

and 212°F.

CFP83 Series
Check that both battery voltmeters indicate 12 VDC

standard (24 VDC optional) depending upon the
application.
Check that the inlet air restriction indicator has not

popped-up. Red plunger would be popped as shown.
Check that the Fuel Injection Failure (F.I.F.) light is

not turned on.
End Test Run

Select the AUTO position on the AUTO/MANUAL
Switch.

CFP83 Series
Every Three Months or 250 Hours

General Information
All checks or inspections listed under daily or previous maintenance intervals must also be performed at this time, in addition
to those listed under this maintenance interval.
Procedure 13 Check Hose Condition
Inspect the lubricating, fuel, and cooling system

hoses and hose connection for leaks or deterioration.
Particles of deteriorated hose can be carried through
the cooling system and slow or partially stop
circulation.
Procedure 14 Check Engine Coolant Heater

NOTE: Do not perform this inspection procedure until
24 hours after shutting off the engine.
The engine coolant heater must maintain an engine
coolant temperature of 49 °C (120 °F) or above. The
engine block must be warm to the touch in the water
jacket areas.
If the heater does not appear to be working correctly,
contact a Cummins Authorized Repair Location.
Procedure 15 Inspect Heat Exchanger Zinc Plug

Remove the zinc plug.
Inspect the plug. If it has eroded over 50 percent,
replace the plug (Cummins Fire Power Part No.
9750), and brass fitting (Cummins Fire Power Part
No. 9751).

CFP83 Series
Procedure 16 Inspect Electrical Components

Clean and tighten any loose electrical connections.
Follow the manufacturer’s recommended procedures
for servicing the electrical components and batteries.
Procedure 17 Check Turbocharger Mounting Nuts

Check the turbocharger mounting nuts. Tighten the
mounting nuts.
Torque Value: 65 N•m (50 ft-lb)
Procedure 18 Check Engine Mounting Bolts
CAUTION
Damaged engine mounts and brackets can cause
engine misalignment. Driveline component
damage can result in vibration complaints.
Inspect all rubber-cushioned mounts for cracks or
damage.
Inspect all mounting brackets for cracks or damaged
bolt holes.
Check the torque on the engine mounting nuts and
bolts. Tighten any that are loose.
Procedure 19 Check Cooling System Condition
WARNING
Check the coolant level only when the engine is stopped. Wait until the coolant temperature is below 50 °C (120 °F)
before removing the pressure cap, (Cummins Fire Power Part No. 11407). Failure to do so can cause personal injury
from heated coolant spray.

CFP83 Series
Supplemental Coolant Additive(SCA)

Check the SCA concentration level:
~At least twice a year

~At every subsequent oil drain interval if the
concentration is above 3 units
~Whenever coolant is added to the cooling system
between filter changes.
Use Fleetguard® coolant test kit, Part No. CC2602, to
check the SCA concentration level. Instructions are
included with the test kit. Refer to Coolant
Recommendations and Specifications in Maintenance
Specifications (Section V) for the correct SCA and
antifreeze level.
Antifreeze
CAUTION
Over concentration of antifreeze or use of high-
silicate antifreeze can damage the engine.
Check the antifreeze concentration.
Use a mixture of 50-percent water and 50-percent
ethylene glycol-base antifreeze to protect the engine
to -37°C [-34°F] year-around.
Antifreeze is essential in any climate. It broadens the
operating temperature range by lowering the coolant
freezing point and raising its boiling point.
The corrosion inhibitors also protect the cooling
system components from corrosion and provide
longer component life.
Procedure 20 Check Air Cleaner Service Indicator
CAUTION
Never operate the engine without an air cleaner. Unfiltered foreign objects could cause engine damage.
Maximum intake air restriction is 762 mm H2O [30.0 in H2O] for turbocharged engines.
Turbocharged engines must be operated at rated RPM and full load to check maximum intake air restriction. Replace the air
cleaner element when the restriction reaches the maximum allowable limit, or clean according to the manufacturer's
recommendations.

CFP83 Series
NOTE: Follow the manufacturer's instructions when

cleaning or replacing the air cleaner element.
NOTE: Do not remove the felt washer from the

indicator. The felt washer absorbs moisture.
Check the air cleaner service indicator, if equipped.
A mechanical restriction indicator is available to

indicate excessive air restriction through a dry-type
air cleaner. This instrument can be mounted in the air
cleaner outlet or on the instrument panel.
Change the filter element when the red indicator flag

(2) is at the raised position in the window (1).
After the air cleaner has been serviced, push the
button (3) to reset the service indicator.
NOTE: Never operate the engine without an air
cleaner. Intake air must be filtered to prevent dirt and
debris from entering the engine and causing
premature wear.
Procedure 21 Inspect Air Intake System Piping
Inspect the intake piping for cracked hoses, loose

clamps, or punctures that can allow dirt and debris to
enter the engine.
Tighten or replace parts as necessary to make sure
the air intake system does not leak.
Check for corrosion of the intake system piping under
the clamps and hoses. Corrosion can allow corrosive
Disassemble and clean as required.
Procedure 22 Check Fuel Pump
Inspect the fuel injection pump mounting nuts,

including the support bracket, for loose or damaged
hardware.

CFP83 Series
Procedure 23 Change Lubricating Oil and Filters
WARNING
To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of
in accordance with local environmental regulations.
WARNING
If no oil pressure is noted within 15 seconds after the engine is started, shut down the engine to reduce the
possibility of internal damage.
CAUTION
For composite oil pans, always use a new sealing washer on the oil drain plug. Hold the external locking nut in
place while tightening the oil drain plug.
Lubricating Oil and Filter Change Interval

Engine oil becomes contaminated and essential oil
additives are depleted with use. The amount of
contamination is related to the total amount of fuel and
oil consumed.
The oil change interval for turbocharged engines is
every 3 months or 250 hours. Change the oil and the
filters to remove the contaminants suspended in the
oil.
NOTE: If the lubricating oil is drained from the oil pan
to make an engine repair, new oil must be used. Do
not use oil after it has been drained from the oil pan.
Laboratory and field tests have determined that, when
using the recommended quality oils and filters, a
turbocharged engine in good condition and equipped
with a by-pass oil filter can consume 255 U.S. gallons
of fuel for each U.S. gallon of oil in the oil system
before the maximum level of oil contamination is
reached.
NOTE: Cummins Engine Co. Inc, does not recommend
exceeding 25,000 miles and/or 600 hours on oil
change intervals.

CFP83 Series
Drain
CAUTION
Avoid prolonged and repeated skin contact with
used engine oils. Such prolonged and repeated
contact can cause skin disorders or other bodily
injury. Wash thoroughly after contact. Keep out of
reach of children.
NOTE: If the engine is in service, the oil drain interval
of 250 hours or 3 months must be observed.
PROTECT THE ENVIRONMENT: Handling and
disposal of used engine oil is subject to federal, state,
and local laws and regulations. Use authorized waste
disposal facilities, including civic amenity sites and
garages providing authorized facilities for receipt of
used oil. If in doubt, contact state and local
environmental authorities or the Environmental
Protection Agency for guidance as to proper handling
and disposal of used engine oil.
Change the oil and filters to remove the contaminants

suspended in the oil.
NOTE: Drain the oil only when it is hot and the
contaminants are in suspension.
CAUTION
Hot oil can cause personal injury.
Operate the engine until the water temperature

reaches 60°C [140°F].
Shut the engine off.
NOTE: Use a container that can hold at least 20 liters
[21.1 qt] of oil.
NOTE: For composite oil pans, hold the external

locking nut in position with a separate wrench while
removing the drain plug. This will prevent the
bulkhead from loosening during drain plug removal.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil
and suspended contaminates are removed from
the engine.

CFP83 Series
Remove
Clean the area around the lubricating oil filter head. Using an oil
filter wrench, remove the filter. Clean the gasket surface of the
filter head with a clean lint-free cloth.
NOTE: The o-ring can stick on the filter head. Make sure it is
removed before installing the new filter.
Install
CAUTION
The lubricating oil filter should be full of oil at
start-up to prevent engine damage.
Apply a light film of lubricating oil to the gasket
sealing surface before installing the filters.
Use clean 15W-40 oil to coat the gasket surface of
the filter.
Fill the filter with clean 15W-40 oil.
CAUTION
Mechanical over tightening can distort the
threads or damage the filter element seal.
Install the filter on the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
Install the filter as specified by the filter manufacturer.

CFP83 Series
Check and clean the oil drain plug threads and

sealing surface.
Install the oil drain plug.
NOTE: Use a high-quality 15W-40 multiviscosity

lubricating oil, such as Cummins Premium Blue®, or
its equivalent, in Cummins engines. Choose the
correct lubricating oil for your operating climate as
outlined in Section 5.
Fill the engine with clean oil to the proper level.

NOTE: Capacities assume standard pan. Total
system assumes standard pan plus filter.
NOTE: When filling the oil pan, use the fill tube on the
side of the engine rather than on top of the rocker
lever cover.
WARNING
If no oil pressure is noted within 15 seconds after
the engine is started, shut down the engine to
reduce the possibility of internal damage.
Operate the engine at idle to inspect for leaks at the
filters and the drain plug.

CFP83 Series
Stop the engine.

Wait approximately 15 minutes to let the oil drain from
the upper parts of the engine.
Check the oil level again.
Add oil as necessary to bring the oil level to the H
(high) mark on the dipstick.

CFP83 Series
Procedure 24 Change Fuel Filter (Spin-on Type)
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel
system.
CAUTION
Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not
spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters
must be discarded in accordance with local environmental regulations.
CAUTION
Mechanical overtightening can distort the threads as well as damage the filter element seal or filter canister.
Remove
NOTE: Close any OEM fuel valves (if equipped) to
prevent fuel from draining or siphoning.
Clean the area around the fuel filter head. Remove
the filters. Clean the gasket surface of the filter head.
Replace the o-ring.
Install
Fill the new filter(s) with clean fuel, and lubricate the
o-ring seal with clean lubricating oil.
Fuel-water separator - used in single-filter
applications.

CFP83 Series
It will be necessary to fill the 10-micron water

stripping (suction side) fuel filter with fuel.
Do not fill the 10-micron (pressure side) fuel filter with
fuel before installation; instead, prime the fuel system
using the fuel lift pump.
Be sure the center seal ring is installed onto the filter
spud.
CAUTION
Mechanical over-tightening will distort the
threads, filter element seal or filter can.
Install the filter as specified by the filter manufacturer.
Prime
WARNING
Do not open the high-pressure fuel system with
the engine running. Engine operation causes high
fuel pressure. High-pressure fuel spray can cause
serious injury or death.
Open the fuel supply and return valves, if equipped.
Finishing Steps
Once the engine is started, slowly increase the
engine speed while air is purged from the fuel
plumbing.

CFP83 Series
Procedure 25 Clean Charge Air Cooler

If the engine experiences a turbocharger failure or
any other occasion where oil or debris is put into the
charge air cooler, the charge air cooler must be
cleaned.
Remove charge air cooler from the engine. Refer to
Section 4.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use.
Wear goggles and protective clothing to avoid personal injury.
CAUTION
Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.
Flush the charge air cooler internally with solvent in

the opposite direction of normal airflow.
Shake the charge air cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped debris.
Continue flushing until all debris or oil is removed.

CFP83 Series
WARNING
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
After the charge air cooler has been thoroughly
cleaned of all oil and debris with solvent, wash the
charge air cooler internally with hot, soapy water to
remove the remaining solvent.
Rinse thoroughly with clean water.
Blow compressed air into the charge air cooler in the
opposite direction of normal airflow until the charge
air cooler is dry internally.
Refer to Section 4 for installation procedures.
Procedure 26 Lubrication of Output Shafts
It is recommended that proper lubrication to drive

shafts and output shafts is to be completed on a
regular schedule.
Grease zerk fittings as shown.
See Section 10 for grease specifications and

lubricating oil recommendations.

CFP83 Series
Every Six Months or 500 Hours

General Information
Procedure 27 Drain and Flush Cooling System

The cooling system must be clean to work correctly.
Drain the system and flush with clean water.
If the system shows mineral buildup, scale, rust or oil, clean with a heavy duty engine coolant cleaner and follow the
manufacturer’s directions.
Drain
CAUTION
Avoid prolonged and repeated skin contact with
used antifreeze. Such prolonged, repeated
contact can cause skin disorders or other bodily
injury.
CAUTION
Wait until the temperature is below 50°C [120°F]
before removing the coolant system pressure
cap (Cummins Fire Power Part No. 11407).
Failure to do so can cause personal injury from
heated coolant spray.
Avoid excessive contact - wash thoroughly after
contact.
Keep out of reach of children.
Protect the environment: Handling and disposing
of used antifreeze can be subject to federal, state,
and local laws and regulations. Use authorized
waste disposal facilities, including civic amenity sites
and garages providing authorized facilities for the
receipt of used antifreeze. If in doubt, contact local
authorities or the EPA for guidance as to proper
handling of used antifreeze.

CFP83 Series
Drain the cooling system by opening the drain valve

on the heat exchanger and removing the plug in the
bottom of the water inlet.
A drain pan with a capacity of 20 liters [5 gal] will be
adequate in most applications.
Check for damaged hoses and loose or damaged

hose clamps.
Replace as required.
Check the heat exchanger for leaks, damage, and
buildup of dirt.
Clean and repair as required.
Flush
CAUTION
During filling, air must be vented from the engine
coolant passages. The air vents through the
“jiggle pin” openings to the top heat exchanger
hose and out the fill opening. Additional venting
is provided for engines equipped with an after
cooler. Open the petcock during filling.
NOTE: Adequate venting is provided for a fill rate of
10 liters/minute [2.6 gal/min].

CFP83 Series
NOTE: Do not install the heat exchanger cap. The

engine is to be operated without the cap for this
process.
Fill the system with a mixture of sodium carbonate
and water (or a commercially available equivalent).
NOTE: Use 0.5 kg [1.0 lb] of sodium carbonate for
every 23 liters [6 gal] of water.
Operate the engine for 5 minutes with the coolant

temperature above 82°C [180°F]. AUTO
Shut the engine off, and drain the cooling system.
MANUAL
Fill the cooling system with clean water.

NOTE: Be sure to vent the engine and aftercooler for
complete filling.
NOTE: Do not install the radiator cap or the new
coolant filter.

CFP83 Series
Operate the engine for 5 minutes with the coolant

temperature above 82°C [180°F].
Shut the engine off.
Drain the cooling system.
NOTE: If the water being drained is still dirty, the
system must be flushed again until the water is
clean.
Fill
CAUTION
The system must be filled properly to prevent air
locks. During filling, air must be vented from the
engine coolant passages.
The system has a design fill rate of 10 liters/minute
[2.8 gal/min].
CAUTION
Never use water alone for coolant. Damage from
corrosion can be the result of using water alone
for coolant.
Use a mixture of 50-percent water and 50-percent
ethylene glycol antifreeze to fill the cooling system.
Coolant Capacity (Engine Only): 4.50 liters [1.19
US Gal]

CFP83 Series
WARNING
Before removing the pressure cap, wait until the
coolant temperature is below 50°C [120°F].
Failure to do so can cause personal injury from
heated coolant spray.
Install the pressure cap (Cummins Fire Power Part
No 11407.).
Operate the engine until it reaches a temperature of
82°C [180°F], and check for coolant leaks.
Check the coolant level again to make sure the
system is full of coolant, or that the coolant level has
risen to the hot level in the recovery bottle on the
system, if so equipped.
Procedure 28 Change Coolant Filter
Remove
WARNING
Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap
(Cummins Fire Power Part No. 11407). Remove
the coolant system pressure cap and close the
shutoff valve before removing the coolant filter.
Failure to do so can result in personal injury
from heated coolant spray.
Remove the coolant system pressure cap (Cummins
Fire Power Part No. 11407).
Turn the shutoff valve to the OFF position by rotating
the knob from vertical to horizontal in the direction
shown.

CFP83 Series
WARNING
A small amount of coolant can leak when
servicing the coolant filter with the shutoff valve
in the OFF position. To reduce the possibility of
personal injury, avoid contact with hot coolant.
WARNING
Coolant is toxic. Keep away from children and
pets. If not reused, dispose of in accordance with
local environmental regulations.
CAUTION
Use caution when draining coolant that coolant
is not spilled or drained into the bilge area. Do
not pump the coolant overboard. If the coolant is
not reused, it must be discarded in accordance
with local environmental regulations.
Remove and discard the coolant filter.
Clean
Clean the gasket surface.

CFP83 Series
Install
CAUTION
Do not allow oil to get into the filter. Oil will
damage the DCA.
CAUTION
Mechanical over-tightening can distort the
threads or damage the filter head.
Apply a thin film of lubricating oil to the gasket
sealing surface before installing the new coolant
filter.
Install the coolant filter on the filter head. Tighten the
filter until the gasket contacts the filter head surface.
Tighten the coolant filter an additional 1/2 to 3/4 of a
turn, or as specified by the filter manufacturer.
CAUTION
The valve must be in the ON position to prevent
engine damage.
Turn the shutoff to the ON position by rotating the
knob from horizontal to vertical in the direction
shown.
Test Run
Install the coolant system pressure cap, (Cummins
Fire Power Part No. 11407).
Operate the engine.
Check for coolant leaks.
After the air has been purged from the system,
check the coolant level again.

CFP83 Series
Procedure 29 Vent Fuel Supply Lines
General Information
Controlled venting is provided at the injection pump through the fuel drain manifold. Small amounts of air introduced by
changing the filters or injection pump supply line will be vented automatically if the fuel filter is changed in accordance with
the instructions. No manual bleeding of fuel lines is required.
NOTE: Manual bleeding is required if any of the following is true:
• The fuel filter is not filled prior to installation.
• The injection pump is replaced.
• High-pressure fuel line connections are loosened or lines replaced.
• Engine is initially started or started after an extended period of no engine operation.
Low Pressure Fuel Line(s)

Open the vent screw.
Allow fuel to drain until the fuel flowing from the
fitting is free of air.
Tighten the vent screw.
Torque value: 8 N•m (6ft-lb)
The low pressure fuel lines are bled by pumping the
hand lever on the filter head.
High Pressure Fuel Line(s)
WARNING
The pressure of the fuel in the line is sufficient to
penetrate the skin and cause serious bodily
harm.
Venting is accomplished by loosening one or more
fittings at the injectors and cranking the engine to
allow entrapped air to bleed from the lines.

CFP83 Series
WARNING
Do not bleed a hot engine as this could cause
fuel to spill onto a hot exhaust manifold creating
a danger of fire.
With the engine at idle, vent one line at the time until
the engine runs smoothly.
Retighten Line Fittings

Tighten the line fittings and check for leaks.
Procedure 30 Vent Injection Pump
WARNING
The pressure of the fuel in the line is sufficient to
penetrate the skin and cause serious personal
injury. Wear gloves and protective clothing.
Loosen the fittings at the injectors, and crank the
engine to allow entrapped air to bleed from the lines.
Tighten the fittings.
WARNING
It is necessary to put the engine in the run
position. Because the engine could start, be sure
to follow all the safety precautions. Use the
normal engine starting procedure.
Start the engine and vent one line at a time until the
engine runs smoothly.
NOTE: Do not engage the starter for more than 30
seconds each time when it is used to vent the
system: Wait 2 minutes between engagements.

CFP83 Series
Every Year or 1000 Hours

General Information
to those listed under this maintenance interval, except for valve lash adjustment.
Procedure 31 Check Overspeed Switch Operation
Check the overspeed switch for operation.

Refer to Operating Instructions in Section 3 of the
Operational Manual for settings.
Procedure 32 Check Drive Belt, Tensioner Bearing and Belt Tension
Inspect
Remove heat exchanger, piping and hoses.
Remove the belt guard.

CFP83 Series
Remove the drive belt.
Poly-Vee Belt
Visually inspect the belt.
Check the belt for intersecting cracks. Transverse
(across the belt width) cracks are acceptable.
Longitudinal (direction of belt length) cracks that
intersect with transverse cracks are not acceptable.
Replace the belt if it is frayed or has pieces of
material missing.
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts

CFP83 Series
Cogged Belt
Inspect the belts daily. Replace the belts if they are
cracked, frayed, or have chunks of material missing.
Small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface,
which indicates belt slippage. Correctly installed and
tensioned belts will show even pulley and belt wear.
Refer to Section A for belt adjustment and
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
• Incorrect installation
• Severe operating environment
• Oil or grease on the belts
Measure the belt tension in the center span of the

pulleys.
Refer to the Belt Tension Chart in Section V for the

correct gauge and tension value for the belt width
used.
An alternate method (deflection method) can be used

to check belt tension by applying 110 N [25 lbf] force
between the pulleys on v-belts. If the deflection is
more than one belt thickness per foot of pulley center
distance, the belt tension must be adjusted.
Refer to Section A for adjustment.
For cogged belts, make sure that the belt tension

gauge is positioned so that the center tensioning leg
is placed directly over the high point (hump) of a cog.
Other positioning will result in incorrect
measurement.

CFP83 Series
Check the tensioner bearing.

The tensioner pulley should spin freely with no rough
spots detected under hand pressure.
Replace tensioner or bearing if defective.

Install the drive belt.
Torque Value: Tension Limit: 360 to 490 N•m [266

to 361 ft-lb]
Check the location of the drive belt on the belt

tensioner pulley. The belt should be centered on, or
centered close to the middle of, the pulley. Unaligned
belts, either too far forward or backward, can cause
belt wear, belt roll-off failures, or increase uneven
tensioner bushing wear.

CFP83 Series
Use the Cummins belt tensioner gauge, Part No.

3822524, to measure the tension in the drive belt.
This needs to be in the range of 360 to 490 N•m [266
to 361 ft-lb].
Check the tensioner arm, pulley, and stops for

cracks. If any cracks are noticed, the tensioner must
be replaced.
With the belt on, verify that neither tensioner arm

stops are in contact with the spring casing stop. If
either stop is touching, the drive belt must be
replaced. After replacing the belt, if the tensioner arm
stops are still in contact with the spring casing stop,
replace the tensioner.
Remove the drive belt, and check the torque of the

tensioner capscrew. After checking the torque, use a
breaker bar with a 3/8-inch ratchet to rotate the
tensioner slowly away from the area of belt contact. If
the arm rotates with any roughness or hesitancy,
replace the tensioner.

CFP83 Series
Check the belt for damage. Transverse (across the

belt width) cracks are acceptable. Longitudinal
(direction of the belt length) cracks that intersect with
transverse cracks are not acceptable.
If the belt is frayed or has any piece of material
missing, the belt is unacceptable and needs to be
replaced.
With the belt removed, verify that the tensioner arm

stop is in contact with the spring case stop.
If these two are not touching, the tensioner must be
replaced.
With the belt removed, check to be sure that the

tensioner pulley rotates freely.
Measure the clearance between the tensioner spring
case and the tensioner arm to verify tensioner wear-
out and uneven bearing wear.
If the clearance exceeds 3 mm [0.12 in] at any point,
the tensioner failed and must be replaced as a
complete assembly.
Experience has revealed that tensioners generally
will show a larger clearance gap near the lower
portion of the spring case, resulting in the upper
portion rubbing against the tensioner arm.
Always replace the belt when a tensioner is replaced.

CFP83 Series
Tensioner cap
Tensioner arm
Spring case
Tensioner pulley
Clearance gap
Inspect the tensioner for evidence of the tensioner

arm contacting the tensioner cap.
If there is evidence of the two areas making contact,
the pivot tube bushing has failed and the tensioner
must be replaced.
Procedure 33 Adjust Valve Lash Clearance
Adjust
Remove the air crossover tube from the engine if
equipped.
Disconnect the support clamps, hose clamp, and

wastegate sensing line.
Remove the crankcase vent tube and any other parts
that would prevent removal of the valve cover.

CFP83 Series
Remove valve cover.
Locate top dead center for cylinder No. 1 by rotating

the crankshaft slowly while pressing on the engine
timing pin.
The barring gear inserts into the flywheel housing
and engages the flywheel ring gear. The engine can
then be rotated by hand using a 1/2-inch ratchet or
breaker bar.
When the engine timing pin engages the hole in the

camshaft gear, cylinder No. 1 is at top dead center on
the compression stroke.
CAUTION
Be sure to disengage the engine timing pin after
locating top dead center to prevent damage to the
engine timing pin.

CFP83 Series
Intake clearance: 0.30 mm [0.012 in]

Exhaust clearance: 0.61 mm [0.024 in]
Check/set valves with engine cold - below 60°C
[140°F].
NOTE: The clearance is correct when some
resistance is “felt” when the feeler gauge is slipped
between the valve stem and the rocker lever.
Locate top dead center for cylinder No. 1.

Check/adjust the valves indicated for STEP A (I =
intake; E = exhaust).
After tightening the rocker lever locknut, check the
valve clearance to make sure the valve clearance
has not changed.
CAUTION
Be sure the engine timing pin is disengaged to
prevent damage to the engine timing pin.
Mark vibration damper and rotate the crankshaft 360
degrees.
Set the valves indicated for STEP B.

After tightening the rocker lever locknut, check the
valve clearance to make sure the valve clearance
has not changed.

CFP83 Series
NOTE: If the seal is not damaged, it can be used

again.
If the seal is damaged, install a new seal.
Install the rubber seal into the groove in the valve
cover.
Start the installation at the overlap area shown in the
illustration.
Do not stretch the rubber seal.
If the seal has more overlap than shown in the
illustration, trim the length to provide the correct
overlap.
Install new sealing o-rings on the capscrews.

Install the valve cover and wastegate sensing tube.
Install the crankcase vent tube, and secure with the

support clamps and hose clamp.
Torque Values:
A = 24 N•m [212 in-lb]
B = 43 N•m [32 in-lb]
Install the air crossover tube and any other parts

previously removed to gain access to the valve cover.

CFP83 Series
Procedure 34 Inspect Turbocharger

Remove the air intake and the exhaust piping.
Look for damaged or cracked compressor or turbine
blades.
Check to see that the turbocharger shaft spins freely.
If the compressor impeller is damaged, inspect the

intake piping and filter element for damage.
Repair any damage before operating the engine.
Remove the exhaust pipe from the turbocharger.
Inspect the turbine wheel for damage.
Replace the turbocharger if damage is found. Contact

a Cummins Authorized Repair Location for
replacement.
NOTE: If visual inspections or dimensional checks

indicate a problem, contact a Cummins Authorized
Location for Assistance.
The turbocharger must be removed for replacement
or rebuild if the clearances are beyond the limits.
Install the air intake and the exhaust piping and
tighten the clamps.

CFP83 Series
Every Two Years or 2000 Hours
General Information
Procedure 35 Inspect Viscous Damper
CAUTION
The silicone fluid in the vibration damper will
become solid after extended service and will
make the damper inoperative. An inoperative
vibration damper can cause major engine or
drivetrain failures.
Check the damper for evidence of fluid loss, dents,
and wobble.
Visually inspect the vibration damper thickness for
any deformation or raising of the damper front cover
plate.
If any variations or deformations are detected, refer to
the Troubleshooting and Repair Manual for detailed
inspection procedures.
Viscous dampers have a limited lift. The maximum
damper life specifications are located in Maintenance
Specifications.
Procedure 36 Inspect Water Pump

Inspect the water pump for drive pulley wobble and
grease or water leakage around the water pump
shaft.
Replace with a new or rebuilt, pre-lubricated unit as
necessary.
Refer to the Troubleshooting and Repair Manual for
more information.

CFP83 Series
Procedure 37 Engine Steam Cleaning
WARNING
When using a steam cleaner, wear safety glasses
or a face shield, as well as protective clothing.
Hot steam can cause serious personal injury.
Steam is the best method of cleaning a dirty engine

or a piece of equipment. If steam is not available, use
a solvent to wash the engine.
Protect all electrical components, openings, and

wiring from the full force of the cleaner spray nozzle.

CFP83 Series
Every Four Years or 5000 Hours

General Information
All maintenance checks and inspections listed in previous maintenance intervals must also be performed at this time, in
addition to those listed under this maintenance interval.
Procedure 38 Inspect Overhead Set
Preparatory Steps
Remove the crankcase breather tube, rocker lever
cover mounted breather only.
Remove the variable geometry turbocharger actuator

air supply line, if equipped.
Remove the capscrews.
Remove the rocker lever cover and gasket.
NOTE: Rocker lever cover configurations will be

different based upon if the cover is center bolted or
perimeter bolted.
Remove the plastic fuel pump drive cover located on

the front of the engine.

CFP83 Series
Adjust
CAUTION
Engine coolant temperature should be less than
60°C [140°F].
Use the barring tool, Part Number 3824591, or

equivalent, and rotate the crankshaft to align the top
dead center marks on the gear cover and the fuel
pump gear.
With the engine in this position, lash can be checked

on the following rocker arms: 1l, 1E, 2l, 3E, 4l, and
5E.
Lash Check Limits
mm in
Intake 0.152 MIN 0.006
0.559 MAX 0.022
Exhaust 0.381 MIN 0.015
0.813 MAX 0.032
NOTE: Lash checks are performed as part of a

troubleshooting procedure, and resetting is not
required during checks as long as the lash
measurements are within the above limits.

CFP83 Series
Measure lash by inserting a feeler gauge between the

crosshead and the rocker lever ball insert and socket
while lifting up on the end of the rocker arm. If the
lash measurement is out of specification, loosen the
locknut and adjust the lash to the nominal
specification.
Lash Reset Specifications
mm in
Intake 0.305 NOM 0.012
Exhaust 0.559 NOM 0.022
NOTE: Lash resets are only required at the interval

specified in the Maintenance Schedule, when lash is
measured and found out of specification, or when
engine repairs cause removal of the rocker arms
and/or loosening of the adjusting screws.
Tighten the locknut and measure again.
Use the barring tool, Part Number 3824591, or

equivalent, and rotate the crankshaft 360 degrees
and measure lash for rocker arms 2E, 3l, 4E, 5l, 6l,
and 6E. Reset the lash, if out of specification.

CFP83 Series
Finishing Steps
Center Bolted Rocket Lever Cover

Place the gasket on the cylinder head. Be sure the
gasket is properly aligned around the cylinder head
capscrews.
Install the rocker lever cover and capscrews.
Tighten the capscrews.
Perimeter Bolted Rocker Lever Cover

NOTE: If the gasket has been removed from the
rocker lever cover, a new gasket must be used.
The following installation procedure must be used

when installing the press-in gasket:
1. Press the molded gasket into the corners of the

rocker lever cover.
2. Press the gasket around the capscrew mounting
holes.
3. Press the remaining gasket into the rocker lever
cover.

CFP83 Series
Install the rocker lever cover and capscrews.
Install the crankcase breather tube, rocker lever

cover mounted breather only.
Install the variable geometry turbocharger actuator air

supply line, if equipped.

CFP83 Series

Section 6 – System Diagrams Page 6-1
CFP83 Series
Section 6 - System Diagrams

Section Contents
Page
Overview ..............................................................................................................................................................6-3
Flow Diagram, Fuel System ...............................................................................................................................6-4
Flow Diagrams, Lubricating Oil System...........................................................................................................6-5
Flow Diagrams, Cooling System.......................................................................................................................6-8
Flow Diagram, Air Intake System....................................................................................................................6-11
Flow Diagram, Exhaust System ......................................................................................................................6-12
Assembly Diagram, Raw Water Piping...........................................................................................................6-13

Page 6-2 Section 6 – System Diagrams
CFP83 Series

CFP83 Series
Overview
General Information
The following drawings show the flow through the engine systems. Although the parts can be different for
various applications and installations, the flow remains the same. The systems shown are as follows:
• Fuel System
• Lubricating Oil System
• Coolant System
• Intake Air System
• Exhaust System
• Raw Water Piping
Knowledge of the engine systems can help in troubleshooting, servicing, and general maintenance of the
engine.

CFP83 Series
Flow Diagram, Fuel System
1. Fuel from supply tank 8. Bosch® PES.MW injection pump
2. Pre-filter or screen 9. Bosch® PES.A injection pump
3. Fuel transfer pump 10. Bosch® PES.P injection pump
4. Fuel/water separator 11. Fuel drain manifold
5. Fuel filter 12. High-pressure fuel lines
6. Low-pressure supply line 13. Hole-type injectors
7. Turbocharger boost control line 14. Fuel return to supply tank

CFP83 Series
Flow Diagrams, Lubricating Oil System
1. Gerotor lubricating oil pump 8. Filter bypass valve
2. Pressure regulating valve closed 9. Filter bypass valve closed
3. Pressure regulating valve open 10. Filter bypass valve open
4. From lubricating oil pump 11. To lubricating oil filter
5. To lubricating oil cooler 12. Full-flow lubricating oil filter
6. To lubricating oil pump oil pan 13. From lubricating oil filter
7. Lubricating oil cooler 14. Main lubricating oil rifle

CFP83 Series
Flow Diagrams, Lubricating Oil System (Cont)
1. Lubrication oil filter 3. Turbocharger lubricating oil drain
2. Turbocharger lubricating oil supply 4. To main lubricating oil rifle
1. From lubricating oil cooler 4. To piston cooling nozzle
2. Main lubricating oil rifle 5. From main lubricating oil rifle
3. To camshaft 6. To connecting rod bearing

CFP83 Series
Flow Diagrams, Lubricating Oil System (Cont)
1. From cam bushings 4. Rocker lever shaft
2. Transfer slot 5. Rocker lever bore
3. Rocker lever support 6. Rocker lever

CFP83 Series
Flow Diagrams, Cooling System

CFP83 Series
Flow Diagrams, Cooling System (Cont)
1. Cylinder Bloc 5. Coolant flow past oil cooler
2. Coolant inlet 6. Upper coolant manifold
3. Water pump impeller 7. Coolant flow to cylinder head
4. Coolant flow to oil cooler
1. Cylinder Head 4. Cylinder head gasket
2. Flow from upper coolant manifold 5. Coolant flow orifice
3. Flow to liner cavity

CFP83 Series
Flow Diagrams, Cooling System (Cont)
1. Flow past cylinder liners 2. Lower coolant manifold
1. Thermostat 6. Partial coolant flow to radiator
2. Thermostats 7. Restricted flow to bypass
3. Flow to water pump inlet 8. Flow to radiator
4. Bypass passage open 9. Bypass closed
5. Flow from lower coolant manifold

CFP83 Series
Flow Diagram, Air Intake System
1. Intake air inlet to turbocharger 4. Intake manifold - integral part of cylinder head
2. Turbocharger air to charge air cooler 5. Intake valve
3. Charge air cooler

CFP83 Series
Flow Diagram, Exhaust System
1. Exhaust valve 3. Dual entry to turbocharger
2. Exhaust manifold - pulse-type 4. Turbocharger exhaust outlet

CFP83 Series
Assembly Diagram, Raw Water Piping

Raw water is used to cool the engine coolant and is supplied from the fire pump prior to the pump discharge
flange. It is forced through a cooling loop by fire pump pressure to the engine heat exchanger. Then it is
discharged to an open waste cone.
The following raw water manifold is available as an option (Cummins NPower Part No. 9659). If supplied by the
customer, National Fire Protection Association (NFPA) Pamphlet No. 20 lists the components that are required.
Refer to the Cooling System Specifications in Section 10 for process requirements. Refer to Raw Water Piping,
Lineup, and Configuration in Section 3.
12
5
11 7
6
10
9
8
1. Supply Pressure Gauge 7. Bypass Inlet Valve
2. Supply Pressure Gauge Isolation Valve 8. Normal Inlet Valve
3. 1” supply to the heat exchanger 9. Normal Strainer
4. Bypass Outlet Valve 10. Normal Pressure Regulator
5. Bypass Pressure Regulator 11. Solenoid Operated Valve
6. Bypass Strainer 12. Normal Outlet Valve

CFP83 Series

Section 7 – Adjustment, Repair, and Replacement Page 7-1
CFP83 Series
Section 7 – Adjustment, Repair and Replacement

Section Contents
Page
Overview ..............................................................................................................................................................7-5
Belts
Belt Guard Removal/Installation .......................................................................................................................7-7
Belt Removal/Installation .................................................................................................................................7-12
Automatic Belt Tensioner Removal/Installation ............................................................................................7-13
Coolant
Coolant Heat Exchanger Removal/Installation ..............................................................................................7-15
Coolant Heater Removal/Installation ..............................................................................................................7-25
Coolant Hose Removal/Installation ................................................................................................................7-30
Raw Water Pressure Regulator Removal/Installation...................................................................................7-38
Raw Water Solenoid Valve Removal/Installation...........................................................................................7-42
Water Temperature Gauge Removal/Installation ..........................................................................................7-45
Coolant Temperature Sender Removal/Installation ......................................................................................7-47
Coolant Temperature Switch Removal/Installation.......................................................................................7-49
Coolant Thermostat Removal/Installation......................................................................................................7-51
Coolant Thermostat Tests ...............................................................................................................................7-57
Coolant Water Pump Removal/Installation ....................................................................................................7-59
Coolant Filter Assembly Removal/Installation ..............................................................................................7-64
Electrical
Alternator Checks and Testing .......................................................................................................................7-67
Alternator Removal/Installation ......................................................................................................................7-70
Battery Isolator Removal/Installation .............................................................................................................7-72
Engine Harness Removal/Installation ............................................................................................................7-75
Voltmeter Removal/Installation .......................................................................................................................7-77
Battery Testing..................................................................................................................................................7-79
Battery Removal/Installation ...........................................................................................................................7-84
Check Battery Cables and Connections ........................................................................................................7-88
Starter Motor Assembly Removal/Installation ...............................................................................................7-89
Crank Solenoid Assembly Removal/Installation ...........................................................................................7-91
Control Panel Fuse Replacement ...................................................................................................................7-94

Page 7-2 Section 7 – Adjustment, Repair, and Replacement
CFP83 Series
Section Contents (Cont)

Page
Exhaust
Exhaust Manifold Removal/Installation ......................................................................................................... 7-97
Exhaust Restriction Measurement................................................................................................................. 7-99
Exhaust Shield Removal/Installation ........................................................................................................... 7-100
Fuel
Inline Fuel Injection Pump Removal/Installation ........................................................................................ 7-103
Fuel Injection Pump, In-Line, Spill Port Timing .......................................................................................... 7-111
Fuel Pump Idle Speed Adjustment............................................................................................................... 7-119
Fuel Shutoff Valve Removal/Installation ..................................................................................................... 7-120
Fuel Lift Pump Removal/Installation............................................................................................................ 7-123
Air in Fuel........................................................................................................................................................ 7-125
Measure Fuel Drain Line Restriction ........................................................................................................... 7-130
Fuel Drain Lines Removal/Installation......................................................................................................... 7-131
Fuel Filter Adapter Removal/Installation ..................................................................................................... 7-134
Measure Fuel Inlet Restriction...................................................................................................................... 7-135
Fuel Drain Manifold Removal/Installation ................................................................................................... 7-137
Low Pressure Fuel Supply Lines Removal/Installation ............................................................................. 7-139
Fuel Injectors Removal/Installation ............................................................................................................. 7-141
Fuel Return Overflow Valve Removal/Installation ...................................................................................... 7-143
High Pressure Injector Supply Lines Removal/Installation....................................................................... 7-146

CFP83 Series

Page
Intake Air
Air Leaks, Air Intake and Exhaust Systems Checks...................................................................................7-149
Air Intake Restriction Indicator Removal/Installation .................................................................................7-153
Intake Air Cleaner Element Removal/Installation ........................................................................................7-154
Air Crossover Pipe Removal/Installation .....................................................................................................7-156
Air Intake Manifold Removal/Installation .....................................................................................................7-157
Aftercooler Removal/Installation (CFP83-F10, F20, F30 Only)...................................................................7-161
Charge-Air Cooler Removal/Installation (CFP83-F40 Only) .......................................................................7-165
Turbocharger Removal/Installation ..............................................................................................................7-166
Turbocharger Axial Clearance Check...........................................................................................................7-173
Turbocharger Oil Drain Line Removal/Installation......................................................................................7-174
Turbocharger Oil Supply Line Removal/Installation...................................................................................7-176
Turbocharger Radial Bearing Clearance......................................................................................................7-177
Turbocharger Wastegate Actuator Removal/Installation ...........................................................................7-179
Oil
Lubricating Oil Cooler Removal/Installation................................................................................................7-185
Lubricating Oil and Filter Analysis ...............................................................................................................7-189
Lubricating Oil Pan Removal/Installation.....................................................................................................7-191
Lubricating Oil Pressure Regulator Removal/Installation..........................................................................7-192
Lubricating Oil Pump Removal/Installation .................................................................................................7-194
Oil Pressure Sender Removal/Installation ...................................................................................................7-204
Oil Pressure Gauge Removal/Installation ....................................................................................................7-205
Oil Pressure Switch Removal/Installation....................................................................................................7-207

CFP83 Series

Page
Speed
Speed Sensor Removal/Installation............................................................................................................. 7-209
Tachometer Removal/Installation ................................................................................................................ 7-211
Overspeed Switch Removal/Installation...................................................................................................... 7-213
Tachometer Calibration................................................................................................................................. 7-215

CFP83 Series
Overview
Coverage
This section of this manual addresses the Adjustment, Repair, and Replacement of Cummins NPower Fire
Pump Engine components. Work this manual with the associated base engine troubleshooting and repair
manual.
Base engine components are addressed in Cummins Manual No. 3666003, C Series Troubleshooting and
Repair Manual.
Refer to Service Literature in Section 8 for additional information about this manual.
Requirements
Satisfy all code requirements or local regulations necessary to remove the fire pump from service. This may
require contacting the local fire department or other authority.
Obtain the required tools and supplies for the intended service. If fluids are to be drained, get appropriate
containers. Dispose of any waste fluids or removed components in accordance with applicable environmental
requirements.
Ensure that the area is prepared for the intended service.
When work is completed, ensure that the fire pump is operational and correctly aligned for service. As required,
notify the local fire department or other authority.
Maintenance must be performed by trained, experienced technicians. Refer to Service Assistance in Section 9
for qualified service assistance.

CFP83 Series
This Page Intentionally Left Blank

CFP83 Series
Belt Guard Removal/Installation

Prepare
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C
[122°F] before removing the pressure cap (Cummins Fire Power Part No.11407). Heated coolant spray or
steam can cause personal injury.

for engine service.
MANUAL position.
Disconnect or isolate the coolant heater power

supply.

alarm.
batteries!

CFP83 Series
Belt Guard Removal/Installation (Cont)

All
Ensure that the engine and engine coolant is cool
in order to avoid burns.
Remove the engine coolant pressure cap,
(Cummins Fire Power Part No.11407).

All
Drain the engine coolant system. Refer to Drain
and Flush Coolant System in Section 5.
Remove the Upper Engine Coolant Hose from

the heat exchanger.
Remove the Lower Engine Coolant and Fill Hose
from the heat exchanger.
Remove the Coolant Vent Hose from the heat
exchanger.

CFP83 Series
Remove
Drain the coolant from the coolant heat
exchanger. Refer to Drain and Flush Cooling
System in Section 5.
Remove the Coolant Heat Exchanger’s Coolant
Outlet Hose and Vent Hose. Refer to Coolant
Hose Removal / Installation in this section.
Remove the three bolts and the belt guard.
Install
NOTE: Install only Cummins approved
replacement belt guard (Cummins Fire Power
Part No. 9625 [CFP83- F10, F20, F30] or Part
No. 9627 [CFP83- F40]).
When other work is completed, install the belt
guard using the three bolts.
Torque as per Capscrew Markings and Torque
Values in Section 10.
Install the Coolant Heat Exchanger’s Coolant
Outlet Hose and Vent Hose. Refer to Coolant
Hose Removal / Installation in this section.
Refill the coolant. Refer to Drain and Flush
Cooling System in Section 5.
Follow-Up
Install the Upper Engine Coolant Hose at the
heat exchanger.
Install the Lower Engine Coolant and Fill Hose at
the heat exchanger.
Install the Coolant Vent Hose at the heat
exchanger.

CFP83 Series

Close the aftercooler coolant vent.
All
Close the coolant drain valve.
Refill engine coolant as required Refer to Drain

Install the coolant system pressure cap
(Cummins Fire Power Part No.11407).
Reconnect the coolant heater power supply.

batteries!

CFP83 Series

NOTE: Start the engine and do a quick check for
leaks. If any coolant leaks are observed, stop the
engine, repair the leak, check coolant level, then
restart the engine.
Start the engine. Refer to Normal Local Starting
Procedure in Section 3.
Check for and repair any coolant leaks.
Ensure that repairs are completed satisfactorily.
Stop the engine.

AUTO position.
Return the fire protection system to operating
status.

CFP83 Series
Belt Removal/Installation
Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard Removal /
Installation in this section.
Remove
NOTE: The belt tensioner is spring-loaded and
must be pivoted away from the drive belt.
Pivoting in the wrong direction can result in
damage to the belt tensioner.
Lift belt tensioner to relieve tension in the belt,
and remove the belt.
Install
Service Tip: If difficulty is experienced installing
the drive belt; for example, the belt seems too
short; position the belt over the grooved pulleys
first; then, while holding the tensioner up, slide
the belt over the water pump pulley.
NOTE: The belt tensioner is spring-loaded and
must be pivoted away from the drive belt.
Pivoting in the wrong direction can result in
damage to the belt tensioner.
replacement v-ribbed belts (Cummins Part No.
3288812) or equivalent.
Lift belt tensioner to relieve tension in the belt,
and install the belt.
Allow the belt tensioner to relax.
Ensure that the belt tensioner supplies tension
to the belt without being at a mechanical limit
stop.
Follow-Up
When work is completed, install the Belt Guard
and do the listed follow up steps. Refer to Belt
Guard Removal/Installation in this section.
Check that the drive belt operates without
unusual noises.

CFP83 Series
Automatic Belt Tensioner Removal/Installation

Prepare
Do the preparatory steps and remove the Belt
Guard. Refer to Belt Guard Removal/Installation
in this section.
Remove the Drive Belt. Refer to Belt Removal/
Installation in this section.
Remove
Remove the capscrew and belt tensioner.
Install
Install the belt tensioner and tighten the
capscrew.
Follow-Up
When work is completed, install the Drive Belt.
Refer to Belt Removal/Installation in this
section.
When work is completed, install the Belt Guard
and do the listed follow up steps. Refer to Belt
Guard Removal/Installation in this section.
Check that the drive belt operates without
unusual noises.

CFP83 Series

CFP83 Series
Coolant Heat Exchanger Removal/Installation

Prepare
WARNING
WARNING
[122°F] before removing the pressure cap (Cummins Fire Power Part No. 11407). Heated coolant spray
or steam can cause personal injury.

for engine service.
MANUAL position.

supply.

alarm.
batteries!

CFP83 Series
Coolant Heat Exchanger Removal/Installation (Cont)

All
Remove the engine coolant pressure cap

All

CFP83 Series

Remove the Upper Engine Coolant Hose from
the heat exchanger.
Remove the Lower Engine Coolant and Fill Hose
from the heat exchanger.
Remove the Coolant Vent Hose from the heat
exchanger.
Close the Raw Water Manifold Bypass Line

Outlet Isolation Valve.
Close the Raw Water Manifold Normal Line
CFP83-F10, F20, or F30 Only

NOTE: If using piping supplied by Cummins Fire
Power, refer to Drawing 9637 in Section 13 for
raw water supply piping details.
Remove the 1” NPT raw water inlet piping from
the valve manifold to the heat exchanger.
Also, remove any customer-supplied raw water
outlet fittings. Save these components for reuse.

CFP83 Series

CFP83-F40 Only
Remove the raw water inlet piping from the
charge air cooler to the heat exchanger. (Refer to
Drawing 10712 in Section 13 for raw water
supply piping details.)
Also, remove any customer-supplied raw water
Pressure Test
NOTE: This test is required if internal leakage in
the heat exchanger is suspected. It may be
performed prior to the removal from the engine.
NOTE: Use teflon tape or other pipe sealant
when installing the test setup in order to prevent
leaks.
Install a 1-1/4” NPT pipe plug at the raw water
outlet of the heat exchanger.
Install a pressure test setup with 700 kPa [100
psi] pressure gauge at the 1” NPT raw water inlet
to the heat exchanger.
NOTE: There should be no detectable decrease
in the pressure reading for the duration of the
test.
Apply air pressure at 621 kPa [90 psig].
Isolate the pressure source and monitor the
pressure gauge for 5 minutes.
After testing, release the pressure.
Remove the pipe plug and the test setup.
If leakage is detected, the heat exchanger must
be replaced.

CFP83 Series
Remove
Provide temporary support for the coolant heat
exchanger in order to avoid dropping it.
Remove the four back sets of nuts, washers, and
bolts at the heat exchanger mounting clamps.
Remove the heat exchanger and clamps from the
engine.
Disassemble
If required for replacement, remove the two front
sets of nuts and bolts at the coolant heat
exchanger clamps.
If required for replacement, remove the zinc plug
and other pipe fittings from the heat exchanger.
Assemble
NOTE: Use teflon or other pipe sealant when
installing threaded pipe fittings.
If missing, install the zinc plug (Cummins Fire
Power Part No. 9750) and brass fitting (Cummins
Fire Power Part No. 9751) in the bottom of the
heat exchanger.
Torque Values: As per capscrew markings
and torque values in Section 10
If missing, install the pipe fittings removed from

the original heat exchanger. Refer to Drawing
8919 in Section 13 for component information.
If removed, position the two clamps on the heat
exchanger and install the two front sets of nuts
and bolts at the coolant heat exchanger clamps.
Do not tighten at this time. Refer to Drawing 8919
in Section 13 for component information.

CFP83 Series
Install
Provide support for the coolant heat exchanger in
order to avoid dropping it.
Position the heat exchanger and clamps on the
engine’s mounting bracket and start the four
bolts.
Start the nut and washers on the four bolts.
Align the heat exchanger with the required hose
connections and tighten the four back sets of
clamp fasteners.
Tighten the two front sets of clamp fasteners.
Torque Value: As per capscrew markings and
torque values in Section 10
Follow-Up
Install the Upper Engine Coolant Hose at the
heat exchanger.
Install the Lower Engine Coolant and Fill Hose at
the heat exchanger.
Install the Coolant Vent Hose at the heat
exchanger.
CFP83-F10, F20, or F30 Only

NOTE: If using piping supplied by Cummins Fire
Power, refer to Drawing 9637 in Section 13 for
raw water supply piping details.
Install the 1” NPT raw water inlet piping from the
valve manifold to the heat exchanger.
Also, install any customer-supplied raw water
outlet fittings.

CFP83 Series

CFP83-F40 Only
Install the raw water inlet piping from the charge
air cooler to the heat exchanger. (Refer to
Drawing 10712 in Section 13 for raw water
supply piping details.)
Also, install any customer-supplied raw water

All

CFP83 Series


batteries!

restart the engine. If no leaks are present,
promptly establish raw water flow through the
heat exchanger.

CFP83 Series
CAUTION
When establishing raw water flow, ensure that
the raw water pressure does not exceed 414
kPa (60 psig) at the heat exchanger. Adjust
the pressure regulators as required.
Slowly open the Raw Water Manifold Bypass
Line Outlet Isolation Valve.
Observe raw water flow through the heat
exchanger.
Adjust the bypass pressure regulator if required.
CAUTION
When establishing raw water flow, ensure that
the raw water pressure does not exceed 414
kPa (60 psig) at the heat exchanger. Adjust
the pressure regulators as required.
Slowly open the Raw Water Manifold Normal
Line Outlet Isolation Valve.
Observe raw water flow through the heat
exchanger.
Adjust the normal pressure regulator if required.

200 oF].
Check that no coolant hoses are collapsed.
When temperature has stabilized, stop the
engine.

CFP83 Series
WARNING
Do not remove the pressure cap from a hot
engine. Wait until the coolant temperature is
below 50°C [120°F] before removing the
pressure cap, (Cummins Fire Power Part No.
11407). Heated coolant spray or steam can
cause personal injury.
Check the coolant level. Refer to Check Coolant
Level in Section 5. Add coolant if necessary.

AUTO position.
status.

CFP83 Series
Coolant Heater Removal/Installation

Prepare
WARNING
WARNING

for engine service.
MANUAL position.

supply.

alarm.
batteries!
Next, disconnect both batteries at their
terminals.

CFP83 Series
Coolant Heater Removal/Installation (Cont)

All
NOTE: Collect the remainder of the coolant in

the heater hoses.
NOTE: Refer to Drawing 8930 in Section 13 for
detailed component information.
Remove the Upper Coolant Heater Hose.
Remove the Lower Coolant Heater Hose.
Remove
Remove the two capscrews, washers, bracket,
and coolant heater.
If required, remove the nuts, bolts, washers and
mounting bracket from the coolant heater.

CFP83 Series
Install
If missing, install the nuts, bolts, washers and
mounting bracket on the coolant heater.
Position the coolant heater and mounting
bracket and start the two bolts with washers.
Tighten the two bolts on the mounting bracket.
Follow-Up
Install the Upper Coolant Heater Hose.
Install the Lower Coolant Heater Hose.

All

CFP83 Series


batteries!
Reconnect the batteries at their terminals after
all service work has been completed.
NOTE: Start the engine and do a quick check

for leaks. If any coolant leaks are observed,
stop the engine, repair the leak, check coolant
level, then restart the engine.
Stop the engine.
WARNING
pressure cap (Cummins Fire Power Part No.

Observe that the coolant temperature cools
down but stabilizes.
Check that the engine block remains warm to
the touch.

CFP83 Series

AUTO position.
status.

CFP83 Series
Coolant Hose Removal/Installation

NOTE: This section addresses all coolant tubes and hoses. Only remove those coolant hoses that are
necessary. It is not required to remove both ends of the hose for the replacement of other components.
Prepare
WARNING
WARNING

for engine service.
MANUAL position.

supply.

alarm.
batteries!

CFP83 Series
Coolant Hose Removal/Installation (Cont)

All
Remove the engine coolant pressure cap

All
NOTE: When draining coolant, drain only the
amount needed for the required repair.
Remove the Upper Engine Coolant Hose

NOTE: Refer to Assembly Drawing 8919 in
Section 13 for detailed construction.
Loosen the hose clamp at the heat exchanger.
Loosen the hose clamp at the engine.
Pull the hose from the heat exchanger and
engine.

CFP83 Series
Remove the Lower Engine Coolant and Fill

Hoses
Remove the nuts and U-bolt supporting the lower
hose.
Loosen the upper fill hose clamp at the heat
exchanger.
Loosen the lower engine coolant hose clamp at
the heat exchanger.
Loosen the lower engine coolant hose clamp at
the engine.
Pull the hoses from the heat exchanger and
engine.
Remove the Upper Coolant Heater Hose

NOTE: Be prepared to collect the residual
coolant in the hose.
Loosen the hose clamp at the coolant heater.
Pull the hoses from the coolant heater and
engine.
Disassemble additional components if this is
required for inspection or repairs.
Remove the Lower Coolant Heater Hose

NOTE: Be prepared to collect the residual
coolant in the hose.
Loosen the hose clamp at the coolant heater.
Pull the hoses from the coolant heater and
engine.
Disassemble additional components if this is
required for inspection or repairs.

CFP83 Series
Remove the Coolant Vent Hose

Loosing the fitting at the heat exchanger.
Loosing the fitting at the engine.
Pull the tubing from the connections.
Inspect
NOTE: Inspect the cooling system hoses and
hose connection for leaks or deterioration.
Particles of deteriorated hose can be carried
through the cooling system and slow or partially
stop circulation.
Inspect the hoses and hose connections.
Replace any hoses or clamps that are damaged.
Clean any debris from the hose connections.
Install the Upper Engine Coolant Hose

Position the hose clamps on the hose.
Push the hose onto the heat exchanger and
engine.
Tighten the hose clamp at the heat exchanger.
Tighten the hose clamp at the engine.

CFP83 Series
Install the Lower Engine Coolant and Fill

Hoses
CAUTION
Do not re-install worn or damaged hoses or
corroded clamps.
Position the hoses at the connections on the heat
exchanger and engine.
Position and tighten the hose clamp at the
engine.
Position and tighten the lower hose clamp at the
heat exchanger.
Position and tighten the fill hose clamp at the
heat exchanger.
Install the nuts and U-bolt supporting the lower
hose. Tighten as per Capscrew Markings and
Torque Values in Section 10.
Install the Upper Coolant Heater Hose

Push the hose on the fitting at the heater and at
the engine connection.
Position and tighten the hose clamps.

CFP83 Series
Install the Lower Coolant Heater Hose

Push the hose on the fitting at the heater and at
the engine connection.
Position and tighten the hose clamps.
Install the Coolant Vent Hose

Connect the hose fitting at the heat exchanger.
Connect the hose fitting at the engine.
Follow-Up

CFP83 Series

All


batteries!

restart the engine.

CFP83 Series

200 oF].
When temperature has stabilized, stop the
engine.
WARNING
pressure cap, (Cummins Fire Power Part No.

AUTO position.
status.

CFP83 Series
Raw Water Pressure Regulator Removal/Installation

NOTE: This section applies only to pressure regulators supplied by Cummins Fire Power. These procedures
should be modified for alternative piping or components as supplied by the customer.
NOTE: This section applies to both the normal and bypass lines.
Prepare (Bypass Line)

Place the AUTO/MANUAL Switch at the local
panel in the MANUAL position.
Inlet Isolation Valve.
Prepare (Normal Line)

Inlet Isolation Valve

CFP83 Series
Raw Water Pressure Regulator Removal/Installation (Cont)
Remove (Bypass Line)

Loosen the pipe union upstream of the pressure
regulator.
Unscrew the pressure regulator from the outlet
isolation valve.
As required, remove the pipe nipples from the
pressure regulator.
Remove (Normal Line)

Loosen the pipe union downstream of the
pressure regulator.
Unscrew the pressure regulator from the
solenoid valve.
As required, remove the pipe nipples from the
pressure regulator.
Install (Bypass Line)

When the pressure regulator is repaired or
replaced, prepare it for installation.
NOTE: Use pipe dope or silicon sealant on
threaded fittings.
As required, install the pipe nipples on the
pressure regulator. Tighten with a pipe wrench
or equivalent.
Screw the pressure regulator onto the outlet
isolation valve.
Align and connect the pipe union. Tighten with a
pipe wrench or equivalent.

CFP83 Series
Install (Normal Line)

When the pressure regulator is repaired or
replaced, prepare it for installation.
NOTE: Use pipe dope or silicon sealant on
threaded fittings.
As required, install the pipe nipples on the
pressure regulator. Tighten with a pipe wrench
or equivalent.
Screw the pressure regulator onto the solenoid
valve.
Align and connect the pipe union. Tighten with a
pipe wrench or equivalent.
Follow-Up (Bypass Line)

Check the pressure regulator setpoint. (Refer to
instructions in Section 3.)
If required, open the Raw Water Manifold
Bypass Line Inlet Isolation Valve.
Bypass Line Outlet Isolation Valve.
Verify that raw water flow is established through

the heat exchanger.
When flow is verified, close the bypass line
outlet valve.
Ensure that the normal line inlet and outlet
valves are both open.
Ensure that the pressure gauge isolation valve
is open.
panel in the AUTO position.

CFP83 Series
Follow-Up (Normal Line)

Check the pressure regulator setpoint. (Refer to
instructions in Section 3.)
Normal Line Inlet Isolation Valve.
Normal Line Outlet Isolation Valve.
As required, close the bypass line outlet valve.
Ensure that the pressure gauge isolation valve
is open.
Start the engine to operate the raw water

solenoid valve. (Refer to instructions in Section
3.)
Verify that raw water flow is established through
the heat exchanger.
When flow is verified, stop the engine.
Observe that raw water flow stops.
panel in the AUTO position.

CFP83 Series
Raw Water Solenoid Valve Removal/Installation

NOTE: This section applies to solenoid valves supplied by Cummins Fire Power.
Prepare
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment before
servicing the batteries. To reduce the
possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-)
battery cable last.
Disconnect the positive battery cables from both
batteries.
Disconnect any customer supplied battery
chargers.
Inlet Isolation Valve.
Remove
NOTE: Minimize the loss of wire when cutting
the splices.
NOTE: Tag each end of the wire before making
the cut.
Cut the butt-splices at the connection between
the two solenoid valve pigtail wires and the fire
pump electrical harness.
Loosen the union fitting between the solenoid
valve and the pressure regulator.
Unscrew the solenoid valve from the outlet
isolation valve or inlet nipple.
Remove the solenoid valve.
If appropriate for replacement, remove the pipe
fittings from the solenoid valve.

CFP83 Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Install
replacement solenoid valves [Cummins Fire
Power Part No. 8210G4-12VDC (12 VDC) or
8210G4-24VDC (24 VDC)].
NOTE: Use thread sealant when making
threaded plumbing connections.
If removed, install the inlet and outlet fittings on
the solenoid valve.
Position the solenoid valve and start threading it
into the outlet valve or onto the outlet valve
nipple.
Thread the valve until it is tight and so that the
electrical housing is facing up.
Align and tighten the union connection.
NOTE: Use termination techniques that meet all
local requirements. Cummins recommends
crimped and insulated butt splices.
NOTE: The solenoid valve’s green pigtail lead is
not used. The other two leads are not polarity
dependent.
Splice the two solenoid pigtail leads to the fire
pump harness solenoid leads.

CFP83 Series
Raw Water Solenoid Valve Removal/Installation (Cont)
Follow-Up
WARNING
battery cable last.
Connect the positive battery cables at both
batteries.
Open the Raw Water Manifold Normal Line Inlet
Isolation Valve.
Open the Raw Water Manifold Normal Line
Operate the engine. Refer to Operating
Instructions in Section 3.
Check for leaks. Repair any leaks.
Check that raw water flow starts when the
engine starts.
Stop the engine.
Check that raw water flow stops shortly after the
engine stops.
If raw water flow does not start when the engine
starts, refer to Coolant Temperature Above
Normal in Troubleshooting Section 12.
If raw water flow does not stop shortly after the
engine stops, refer to Troubleshooting Section
12.

CFP83 Series
Water Temperature Gauge Removal/Installation

Prepare
WARNING
battery cable last.
Disconnect the positive battery cables from both
batteries.
Disconnect any customer supplied battery
chargers.
Remove
Use a nut driver or equivalent to remove the
control panel’s mounting bolt.
Pull the control panel out from the enclosure so
that it is supported by the piano hinge on the
bottom.
NOTE: Check and tag all wires with location
tags prior to removal.
Remove the two dark blue [METER +] wires
from the [I] terminal on the gauge.
Remove the single black ground wire from the
[G] terminal on the gauge.
Remove the single [WTG] wire from the [S]
terminal on the gauge.
NOTE: Catch the gauge as the meter bracket is
removed.
Remove the two nuts and the meter bracket
from the back of the panel.
Remove the gauge from the panel.

CFP83 Series
Water Temperature Gauge Removal/Installation (Cont)
Install
Position the gauge in the panel. Orient it for
ease of reading.
Position the meter bracket on the gauge’s
mounting studs. Start the nuts.
Tighten the nuts hand tight plus a full turn.
Connect the two dark blue [METER +] wires on
the [I] terminal on the gauge.
Connect the single black ground wire on the [G]
Connect the single [WTG] wire on the [S]
Raise the control panel and install the panel
mounting bolt.
Follow-Up
Reconnect the batteries and any battery
chargers.
Observe that the [WATER TEMP] gauge
indicates a reasonable value for cooling water
temperature.
If the gauge does not indicate correctly, refer to
Troubleshooting Section 12.
If the gauge does indicate correctly, place the
AUTO/MANUAL Switch at the local panel in the
MANUAL position.

CFP83 Series
Coolant Temperature Sender Removal/Installation

Prepare
WARNING
Coolant is toxic. Keep away from pets and
children. If not reused, dispose of in
accordance with local environmental
regulations.
WARNING
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap, (Cummins Fire Power Part No. 11407).
Heated coolant spray or steam can cause
personal injury.
Drain the coolant. Refer to Drain and Flush
Remove
Disconnect the temperature sensor wiring.
Remove the temperature sensor.
Install
NOTE: Apply liquid teflon sealant to the threads
when installing the temperature sensor.
Install the temperature sensor.
Torque Value:
• (Cast Iron) 50 N•m [37 ft-lb]
• (Aluminum) 30 N•m [22 ft-lb]
Reconnect the wiring.

CFP83 Series
Coolant Temperature Sender Removal/Installation (Cont)
Follow-Up
Fill coolant to proper level. Refer to Drain and
Flush Cooling System in Section 5.
stabilizes between 83 and 91 oC [181 and 196
o
F]. If temperature does not stabilize, stop the
engine and refer to Troubleshooting Instructions
Section 12.

CFP83 Series
Coolant Temperature Switch Removal/Installation

Prepare
WARNING
Coolant is toxic. Keep away from pets and
children. If not reused, dispose of in
regulations.
WARNING
engine. Wait until the temperature is below
50°C [122°F] before removing the pressure
cap, (Cummins Fire Power Part No. 11407).
Heated coolant spray or steam can cause
personal injury.
Remove
Disconnect the temperature switch wiring.
Remove the temperature switch.
Install
Apply liquid teflon sealant to the threads when
installing the temperature switch.
Install the temperature switch.
Torque Value:

CFP83 Series
Coolant Temperature Switch Removal/Installation (Cont)
Follow-Up
Fill coolant to proper level. Refer to Drain and
stabilizes between 82 and 94 oC [180 and 201
o
F]. If temperature does not stabilize, stop the
(Engine Running) in Troubleshooting Section
12.

CFP83 Series
Coolant Thermostat Removal/Installation

Prepare
WARNING
pets. If not reused, dispose of in accordance
WARNING
CAUTION
Always use the correct thermostat, and never
operate the engine without a thermostat
installed. The engine can overheat if operated
without a thermostat because the path of
least resistance for the coolant is through the
bypass to the pump inlet. An incorrect
thermostat can cause the engine to overheat
or run too cold.

for engine service.
MANUAL position.
Disconnect the battery cables at the battery
source.

Disconnect the upper engine coolant hose. Refer

to Coolant Hose Removal/Installation in this
section.

CFP83 Series
Coolant Thermostat Removal/Installation (Cont)

Remove the lower engine coolant hose and the
fill hose. Refer to Coolant Hose
Removal/Installation in this section.
Remove the belt guard. Refer to Belt Guard
Remove the drive belt. Refer to Belt
Remove the alternator. Refer to Alternator
Remove
For CFP83-F10, F20, or F30 models only,
remove the coolant filter vent tubing between the
coolant filter housing and the heat exchanger.
Remove the coolant vent tubing between the

coolant filter housing and the engine block

CFP83 Series

Remove the two water outlet capscrews from the
thermostat housing.
Remove the water outlet connection and gasket.
Clean the gasket surface on the engine block and
the outlet connection.
Remove the belt tensioner capscrew and the belt

tensioner.
Remove the two belt tensioner mounting bracket
capscrews from the thermostat housing.
Remove the two capscrews and the thermostat

housing.
CAUTION
Debris in the cooling system can cause
damage to the engine.
Remove the thermostat gasket and clean the
gasket surface.

CFP83 Series

NOTE: If the thermostats and shims may be
reused, separate and tag the shims along with
the associated thermostats.
Remove both thermostats and any shims.
Inspect for Reuse

Inspect the thermostats for damage.
Make sure both thermostats are clean and free
from corrosion.
Suspend the thermostats and a 100°C [212°F]

thermometer in a container of water.
NOTE: Do not allow the thermostats or
thermometer to touch the container.
Heat the water slowly so the wax element in the
thermostats has sufficient time to react to the
rising water temperature.
NOTE: The normal operating temperature is
stamped on the thermostat.
Inspect the thermostats as follows:

• Thermostat must begin to open within 1°C
[2°F] of 82°C [180°F].
• Thermostat must be fully open within 1°C
[2°F] of 95°C [203°F].
NOTE: The fully open clearance between the
thermostat flow valve and flange must be 41.5
mm [1.63 in] minimum.

CFP83 Series
Install the Thermostats

Use the appropriate section as follows:
If installing a new thermostat, use the Install New
Thermostat and Shims subsection.
If reusing existing thermostat and shims, use the
Reinstall Thermostat and Shims subsection.
Install New Thermostat and Shims
CAUTION
Do not shim the thermostats beyond the top
of the block.
Temporarily position the thermostats in the bore.
Measure the distance from the thermostat flange
to the top of the block surface of each thermostat
to determine the proper shim(s) to use.
NOTE: The service shims included are 0.25 mm
[0.010 in], 0.50 mm [0.020 in], 0.75 mm [0.030
in], and 1 mm [0.040 in].
NOTE: Any combination of shims can be used,
but stacking is limited to a maximum of two shims
per bore.
Select the appropriate combination of shims that
will bring each thermostat’s height as close to the
top of the block as possible.
Remove each thermostat.

Insert the selected shims into each bore, making
sure each shim is seated properly in the bore.
Install the thermostats on top of the service
shim(s) in the thermostat flanges.
NOTE: They can be within 0.23 mm [0.009 in] of
flush with the top of the block, without being
above the top of the block.
Check that the thermostats are correctly installed.
Continue to Install the Thermostat Housing.

CFP83 Series
Reinstall Thermostat and Shims

Reinstall the shims and thermostats in the same
order and position as found in the removal step.
Continue to Install the Thermostat Housing.
Install the Thermostat Housing

Install a new thermostat gasket.
Position the thermostat housing and belt

tensioner over the thermostats and gasket.
Make sure the gasket is aligned with the

capscrew holes.
Install the capscrews and finger-tighten.
Install the water outlet connection.

Tighten all capscrews.

CFP83 Series
Coolant Thermostat Tests

Coolant Thermostat Leak Test
CAUTION
The engine thermostat must operate
properly in order for the engine to operate in
the most efficient heat range. Overheating or
overcooling will shorten engine life.
WARNING
Allow the engine to cool well below 83 oC [181
o
F].
Loosen the hose clamp on the Upper Engine
Coolant Hose. Remove the hose from the
thermostat housing.
Install a hose of the same size on the

thermostat housing outlet long enough to reach
a remote, dry container used to collect coolant.
Install and tighten a hose clamp on the housing
outlet.
Place the other end of the hose in a dry
container.
If desired, install an accurate thermocouple or

temperature gauge in the ¾-inch pipe plug
located at the front of the cylinder block.
Otherwise, monitor the engine coolant
temperature on the local control panel.

CFP83 Series
Coolant Thermostat Tests (Cont)

Start the engine. Refer to Local Starting
Procedure for Testing in Section 3. Operate the
engine for one minute and then stop it.
Measure the amount of coolant collected in the
container.
The amount of coolant collected must not be
more than 150 cc [5 fl oz].
If more than 150 cc [5 fl oz] of coolant is

collected, the thermostat is leaking and must be
replaced. Refer to Coolant Thermostat
If leakage is not present, then continue to
perform the Coolant Thermostat Function Test
below.
Coolant Thermostat Function Test

Procedure for Testing in Section 3.
Allow the engine to approach operating
temperature.
Monitor the operation of the thermostat.
Thermostat Initial Opening Temperature
• MIN: 81 oC [178 oF]
• MAX: 83 oC [181 oF]
Stop the engine when the coolant starts to flow.
If the coolant does not start flowing into the
container during the initial opening temperature
range, the thermostat must be replaced. Refer
to Coolant Thermostat Removal/Installation in
this section.
Install the heat exchanger hose and tighten
hose clamp.
If used, remove the temperature sensor and
reinstall the pipe plug.
Return any coolant to the engine.

CFP83 Series
Coolant Water Pump Removal/Installation

Prepare
WARNING
pets. If not reused, dispose of in accordance
WARNING
below 50 oC [120 oF] before removing the

for engine service.
MANUAL position.

alarm.
batteries!

CFP83 Series
Coolant Water Pump Removal/Installation (Cont)

Drain engine coolant as required for the intended
service. Refer to Drain and Flush Coolant System
in Section 5.
Disconnect the lower engine coolant and fill

hoses. Refer to Coolant Hose
Remove the Belt Guard. Refer to Belt Guard

Remove the Drive Belt. Refer to Belt

Disconnect the upper engine coolant hose. Refer

section.
Loosen the capscrew for the alternator link at the

alternator. Refer to Alternator
Remove
Remove the two lower capscrews at the water
pump.
Slide the alternator link aside.
Remove the upper capscrew, the water pump
and the o-ring seal.

CFP83 Series
Clean
Clean the sealing surface on the cylinder block.
If reusing the water pump, clean the sealing
surface on the water pump.
Inspect for Reuse

NOTE: A minor streak or chemical buildup at the
weep hole is not justification for water pump
replacement. The water pump seal design
requires a coolant film for lubrication and cooling.
Therefore, it is normal to observe a minor
chemical buildup or streaking at the weep hole.
Inspect the water pump body for indications of
water leakage at the weep hole. If a repeating
drip of coolant is observed, replace the water
pump with a new unit.
NOTE: A plugged weep hole can cause the water

pump to fail. A small screwdriver or a small tool
can be used to remove any debris.
Inspect the weep hole to make sure it is open.
NOTE: Replace the water pump if it is damaged.

Inspect the water pump housing and impeller for
any physical damage.

CFP83 Series
Install
If reusing the original water pump, install a new
water pump seal (Cummins Part No 3902089)
onto the water pump housing.
Otherwise, install a new water pump kit
(Cummins Part No 3800974).
Position the water pump and start the upper

capscrew.
Position the alternator link and start the two lower
capscrew.
Tighten the three capscrews at the water pump.
Follow-Up
Install the alternator link at the alternator. Refer to
Alternator Removal/Installation in this section.
Install the upper engine coolant hose. Refer to

Coolant Hose Removal/Installation in this section.
Install the drive belt. Refer to Belt

Install the belt guard. Refer to Belt Guard

Reconnect the lower engine coolant hose. Refer

section.
Refill the coolant. Refer to Drain and Flush


CFP83 Series

batteries!

Observe that raw water is flowing through the
coolant heat exchanger.
NOTE: A leak at the water pump weep hole is not
justification for water pump replacement. The
water pump seal design requires a coolant film
for lubrication and cooling. Therefore, it is normal
to observe an occasional drip.
Check that the drive belt makes no unusual
noises.
Check that the alternator is charging.
200 oF].
After the thermostat operation has been checked,

stop the engine. Refer to Local Starting
Recheck the coolant level. Refer to Check
Coolant Level in Section 5.
AUTO position.
status.

CFP83 Series
Coolant Filter Assembly Removal/Installation

Prepare
WARNING
WARNING

for engine service.
MANUAL position.

alarm.
batteries!
Remove the coolant system pressure cap

Turn the shutoff valve to the OFF position by
rotating the knob from vertical to horizontal in the
direction shown.

CFP83 Series
Coolant Filter Assembly Removal/Installation (Cont)
Remove
WARNING
A small amount of coolant can leak when
servicing the coolant filter with the shutoff
valve in the OFF position. To reduce the
possibility of personal injury, avoid contact
with hot coolant.
Remove and discard the coolant filter.
Clean the filter housing with a dry clean rag.
Install
CAUTION
Do not allow oil to get into the filter.
Apply a thin film of lubricating oil to the gasket
sealing surface before installing the new coolant
filter.
CAUTION
Mechanical over-tightening can distort the
threads or damage the filter head.
Install the coolant filter on the filter head. Tighten
the filter until the gasket contacts the filter head
surface.
Tighten the coolant filter an additional 1/2 to 3/4
of a turn, or as specified by the filter
manufacturer.
CAUTION
The valve must be in the ON position to
prevent engine damage.
Turn the shutoff to the ON position by rotating the
knob from horizontal to vertical in the direction
shown.

CFP83 Series
Coolant Filter Assembly Removal/Installation (Cont)
Follow-Up
After the air has been purged from the system,
stop the engine.
WARNING

AUTO position.
status.

Section 7– Adjustment, Repair, and Replacement Page 7-67
CFP83 Series
Alternator Checks and Testing

Alternator Wiring Integrity Check
NOTE: Refer to Drawing 10423 Sheet 1,
Drawing 10423 Sheet 2, and Drawing 9767 in
Section 13 for schematic details.
WARNING
Batteries can emit explosive gases. To reduce
the possibility of personal injury, always
ventilate the battery compartment before
servicing the batteries.
WARNING
To reduce the possibility of arcing, remove the
negative (-) battery cable first and attach the
negative (-) battery cable last.
Check the battery and all wiring connections for
damage. Refer to Battery Cables and
Connections in this section.
Check all connections for tightness and
cleanliness. Include both the slip connectors at
the alternator and connections at the battery.
NOTE: Continuity should be in the single digit
Ohms or less. Resistance to ground should be
in the mega-Ohm range. Refer to any applicable
customer criteria.
Using a digital multimeter or other test
equipment, check for continuity between
terminals. Check also the insulation resistance
to ground.
Correct any electrical faults.
Alternator Mechanical Check

Visually check the drive belt and alternator
pulley to be sure the alternator is rotating.
Note any unusual noises such as from belt
whine or alternator mechanical fault.
Stop the engine.
Correct any mechanical failures.
Drawing No. 9777, Section 7, 02-07

CFP83 Series
Alternator Checks and Testing (Cont)

Alternator Voltage Output Test
CAUTION
Batteries must have been satisfactorily load
tested and must be charged with a resting
voltage of more than 12.4 Volts for this testing.
CAUTION
Batteries must have been satisfactorily load
tested and must be charged with a resting
voltage of more than 12.4 Volts for this testing.
NOTE: Conduct this testing at normal shop
temperature.
NOTE: Voltage should not exceed 15.5 V (for a
12 VDC system) or 31 V (for a 24 VDC system).
Start the engine and operate at rated speed.
Refer to Normal Local Starting Procedure in
Section 3.
Measure the alternator voltage output to the
batteries with digital multimeter, Cummins Part
Number 3377161.
Stop the engine.
Replace the alternator if the voltage exceeds
specification. Refer to Alternator

CFP83 Series
Alternator Checks and Testing (Cont)

Alternator Amperage Output Test
NOTE: Conduct this testing at normal shop
temperature.
NOTE: Refer to Electrical Specifications in
Section 10 for the minimum required alternator
output. Use the value listed for the system
voltage.
Connect a carbon pile load in parallel across the
battery terminals. Refer to Jumpering the
Batteries in Section 3 for how to make a parallel
connection.
Connect a clamp-on (induction) ammeter across
the alternator output cable.
Start the engine and operate at rated speed.
Section 3.
Adjust the carbon pile for maximum indication.
Note the amperage indicated on the ammeter.
Stop the engine.
Remove the test equipment.
Replace the alternator if the output is not 90% or
more of the specification value. Refer to
Alternator Removal/Installation in this section.

CFP83 Series
Alternator Removal/Installation
Prepare
Remove the belt guard. Refer to Belt Guard
Remove the drive belt. Refer to Belt
Section 13 for wiring harness information.
NOTE: Ensure that the connectors are clearly
tagged for the correct reconnection.
Disconnect the engine wiring harness
connectors from the alternator.
Remove
Disconnect the ground (-) cable from the battery
terminal.
Identify each electrical wire with a tag indicating
location.
Remove the capscrew from the alternator link.
Remove the alternator mounting screws.

Remove the alternator.

CFP83 Series
Alternator Removal/Installation (Cont)

Install
Position the alternator on the bracket, and
secure it with the mounting capscrews.
Do not tighten at this time.
Connect the alternator link to the alternator.
Finger-tighten the capscrews.
NOTE: Make sure the alternator link is properly
positioned for correct belt alignment.
Tighten the alternator mounting capscrews.

To install the alternator, the alternator mounting
components must be tightened in the following
sequence:
1. Alternator-to-alternator bracket capscrew
2. Lower brace-to-alternator capscrew
Follow-Up
Section 13 for wiring harness information.
Connect the engine wiring harness connectors
to the alternator.
Install the drive belt. Refer to Belt
Install the belt guard. Refer to Belt Guard

CFP83 Series
Battery Isolator Removal/Installation

Prepare
for engine service.
MANUAL position.
NOTE: Refer to Battery Removal/Installation in

this section for detailed instructions for
disconnecting the battery cable clamps.
Disconnect the negative battery cable from
Battery A.
Battery B.
Remove
NOTE: Ensure that all battery isolator wires are
clearly tagged for reconnection. Also note the
orientation of the existing isolator.

CFP83 Series
Battery Isolator Removal/Installation (Cont)

Disconnect the battery cable from terminal 1.
Disconnect the battery cable from terminal 2.
Disconnect the alternator cable from terminal A.
Disconnect the alternator excitation cable from
terminal E.
Remove the four mounting nuts and the battery
isolator.
Install
Align and position the battery isolator on the
four mounting studs.
Install the four mounting nuts.
Torque Value: As per capscrew markings
Connect the battery cable at terminal 1.

Connect the battery cable at terminal 2.
Connect the alternator cable at terminal A.
Connect the alternator excitation cable at
terminal E.
Ensure that all four rubber caps are in position.
Follow-Up
connecting the battery cable clamps.
Connect the negative battery cable at Battery A.
Connect the negative battery cable at Battery B.

CFP83 Series
Battery Isolator Removal/Installation (Cont)

NOTE: Refer to Drawing 10423 Sheet 2 for
schematic details. Measure voltages at the
most convenient location.
With the engine off, verify the following voltages
at the battery isolator terminals to ground:
Terminal 1 indicates battery voltage.
Terminal 2 indicates the other battery voltage.
Terminal E indicates no voltage.
With the engine running, verify the following
voltages at the battery isolator terminals to
ground:
Terminal 1 indicates battery voltage.
Terminal 2 indicates the other battery voltage.
Terminal E indicates battery voltage.
Terminal A indicates about 1 volt higher than
battery voltage.
Stop the engine.

AUTO position.
status.

CFP83 Series
Engine Harness Removal/Installation

Prepare
for engine service.
MANUAL position.

Battery A.
Battery B.
Remove
Section 13 for a depiction of the engine wiring
harness.
NOTE: Ensure that each terminal is properly
labeled for ease of reconnection.
Disconnect the harness connection at each
terminal.
Install
Section 13 for a depiction of the engine wiring
harness.
Connect the harness connection at each
terminal.

CFP83 Series
Engine Harness Removal/Installation (Cont)

Follow-Up
connecting the battery cable clamps.
Connect the negative battery cable at Battery A.
Connect the negative battery cable at Battery B.
NOTE: Refer to Second Start in Section 3 for

the suggested checks.
Observe that the engine starts with no unusual
noises or vibrations.
Verify that the engine reaches operating
temperature.
Stop the engine.

AUTO position.
status.

CFP83 Series
Voltmeter Removal/Installation
Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Remove
NOTE: Refer to Drawing 10423 Sheet 1 in 10
12 14
16
Section 13 for electrical schematic details. 8 18
Open the local control panel.

NOTE: Ensure that the wires are clearly tagged VOLTS
for reconnection.
Loosen the nuts on the stud and remove the
wires.
Remove the nuts on the mounting bracket and
remove the voltmeter from the panel.

CFP83 Series
Voltmeter Removal/Installation (Cont)

Install
Orient the voltmeter in the cutout in the 10
12 14
16
electrical panel. 8 18
Position the mounting bracket on the gauge.

Install the mounting nuts. VOLTS
Reconnect the electrical wires on the studs in

the same positions as they were originally
installed.
Tighten the nuts on the studs.

batteries!

AUTO position.
status.

CFP83 Series
Battery Testing
WARNING
Batteries can emit explosive gases. To avoid injury, always ventilate the compartment before servicing
the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-)
battery cable last.
WARNING
Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always
provide a strong tank of soda water as a neutralizing agent when servicing the batteries. Wear goggles
and protective clothing to avoid serious burns.
NOTE: This section is for conventional batteries only. Maintenance-free batteries may be supplied by the
customer. These are sealed and do not require the addition of water. Also, specific gravity cannot be checked. If
the batteries are not supplied by Cummins Fire Power, follow the battery manufacturer’s recommendations for
testing and servicing their batteries.
Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.

CFP83 Series
Battery Testing (Cont)

Check Electrolyte Level
Remove all cell covers for both sets of batteries.
Check the electrolyte level in each cell of each
battery.
NOTE: Cummins recommends the use of a self-
leveling filler. If a syringe type filler is used, use
care to prevent overflow or splashing of acid
from the cell.
CAUTION
Do not overfill the cell. Fill only to the level
indication.
CAUTION
If a syringe type filler is used, use care to
prevent overflow or splashing of acid from
the cell.
As required, fill each battery cell with distilled
water.
Install all cell covers for both sets of batteries.
If water was added, recharge the battery prior to
checking specific gravity.

CFP83 Series

Check Specific Gravity
NOTE: If water has been added to a dry cell,
recharge the battery to mix the added water
with the existing battery electrolyte. This will
prevent incorrect readings.
NOTE: The battery must be more than about ¼
charged before the hydrometer readings can be
accurate. Accurate readings may require
several hours of charging for a fully discharged
battery.
Use a hydrometer to measure the specific
gravity of each cell.
State of Charge and Specific Gravity*
% Charged Non-Tropical Tropical
100% 1.265 1.225
75% 1.225 1.185
50% 1.190 1.150
25% 1.155 1.115
0% 1.120 1.080
* At 26.7 oC [80 oF]
Check the battery fluid column in the
refractometer to determine the state of charge
of each battery cell.
NOTE: Evaluate the state of charge in respect
to the local requirements. A cold location will
require a greater specific gravity than a hot
climate for the necessary cranking amperes.
If charge is low, charge the batteries. Refer to
Battery and Electrical Installation in Section 3.

CFP83 Series

Check Battery Output
CAUTION
Do not connect battery charging cables to
any electronic control system part. This can
damage the electronic control system parts.
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.
NOTE: The required battery output in cold
cranking amperes is provided in Electrical
System Specifications in Section 10. Use the
listed value for the system voltage.
Test both sets of batteries.
NOTE: For customer supplied batteries, refer to
the manufacturer's literature for charging
instructions.
If the output amperage is low, charge the
battery. Refer to Battery and Electrical
Installation in Section 3.
Replace the battery if it will not charge to the
manufacturer's specifications or will not
maintain a charge.

batteries!

CFP83 Series

AUTO position.
status.

CFP83 Series
Battery Removal/Installation
WARNING
Batteries can emit explosive gases. To avoid injury, always ventilate the compartment before servicing
the batteries.
WARNING
Acid is extremely dangerous and can damage the machinery and can also cause serious burns. Always
provide a strong tank of soda water as a neutralizing agent when servicing the batteries. Wear goggles
and protective clothing to avoid serious burns.
Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Clear and ventilate the battery storage area.

Collect the necessary tools and safety
equipment.

CFP83 Series
Battery Removal/Installation (Cont)

Remove
NOTE: Use the correct battery tools. Use end
wrenches to loosen the battery clamps. Use a
battery cable puller to remove tight cable
clamps from the battery terminal. Use a battery
carrier to lift and carry the battery.
Remove any battery support hardware.
WARNING
To reduce the possibility of arcing, remove
the negative (-) battery cable first.
Loosen the battery cable clamps.
Remove the negative battery cable first.
Remove the positive battery cable first.
WARNING
Do not tip the battery and spill the acid.
Using a battery carrier, lift and remove the
battery.
If disposing of the battery, dispose of it in
accordance with all applicable environmental
regulations.
Clean
NOTE: Use the correct battery tools. Use a
terminal cleaning brush for the battery terminal.
Use a putty knife and wire brush to remove dirt
and corrosion from the battery body and any
support.
Clean the battery posts to remove all corrosion
and to expose the metal.
Remove any other corrosion or debris from the
battery body or battery support.

CFP83 Series

Install
NOTE: Use the correct battery tools. Use a
battery cable clamp spreader to install tight
cable clamps on the battery terminal. Use end
wrenches to tighten the battery clamps
WARNING
Do not tip the battery and spill the acid.
Using a battery carrier, carry and position the
battery.
WARNING
To reduce the possibility of arcing, attach
the negative (-) battery cable last.
Spread the positive cable clamp and position
the clamp on the post.
Tighten the positive cable clamp.
Spread the negative cable clamp and position
the clamp on the post.
Tighten the negative cable clamp.
torque values in Section 10.
Install any battery support hardware.
Follow-Up
If new batteries are installed, charge the
batteries. Refer to Battery and Electrical

batteries!

CFP83 Series

AUTO position.
status.

CFP83 Series
Check Battery Cables and Connections
WARNING
servicing the batteries.
WARNING
To reduce the possibility of arcing, remove
the negative (-) battery cable first and attach
the negative (-) battery cable last.
NOTE: There are two possible heavy-duty
battery connections:
Battery terminal and clamp
Threaded battery terminal and nut
Remove and inspect the battery cables and

connections for cracks or corrosion.
Replace broken terminals, connectors, or
cables.
If the connections are corroded, use a battery

brush or wire brush to clean the connections
until shiny.
Alternatively, if a brush won’t do the job, use an
acid neutralizing solution to remove the
corrosion.
Brush or wipe all residue or debris from the
terminals.
NOTE: Coat the terminals with a high

temperature grease to prevent corrosion.
Install the cables and tighten the battery
connections.

CFP83 Series
Starter Motor Assembly Removal/Installation

Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Remove
Disconnect the ground (-) cable from the
battery.
Identify each electrical wire with a tag indicating
location.
Remove the battery cable from the solenoid.

CFP83 Series
Starter Motor Assembly Removal/Installation (Cont)

Remove the starting motor.
Install
NOTE: Use only the Delco 39MT replacement
starter Cummings Part No. ST9370 / 3971603
(12 VDC) or Cummings Part No. ST9258 /
3957598 (24 VDC).
Align and install the starter motor.
Install and tighten the three mounting
capscrews.

batteries!

noises or vibrations.
Stop the engine.

AUTO position.
status.

CFP83 Series
Crank Solenoid Assembly Removal/Installation

NOTE: Use this procedure to remove and install either or both of the crank solenoid assemblies. The crank
solenoid assembly sub-components are not serviceable parts as supplied by Cummins Fire Power.
Prepare
for engine service.
MANUAL position.

Battery A.
Battery B.
Remove
Section 13 for schematic information related to
the crank solenoid assemblies.
NOTE: Ensure that the wires are clearly
identified for ease of reconnection.
NOTE: Observe the location of flat and lock
washers for ease of reconnection.
NOTE: Save the nuts, bolts, flat washers, and
lock washers for reuse.
Disconnect all electrical connectors from the
solenoid’s four terminal studs.
Loosen the four sets of mounting nuts, bolts,
and washers.
Remove the crank solenoid and fasteners from
the engine.

CFP83 Series
Crank Solenoid Assembly Removal/Installation (Cont)

Install
NOTE: Install the correct component. For 12
VDC systems, use Cummins NPower Part No
8824. For 24 VDC systems, use Cummins
NPower Part No 8846.
Position the four bolts through the mounting
holes.
Position the crank solenoid on the bolts, add the
lock washers, and start the nuts.
Tighten the four mounting nuts.

Section 13 for crank solenoid schematic
information.
Position the flat washers, cable lugs, lock
washers, and nuts on the studs in the same
order as was removed.
With power still disconnected, verify that the
lever handle on the crank solenoid operates
freely.
Follow-Up
reconnecting the battery cable clamps.
Connect the negative battery cable from Battery
A.
Connect the negative battery cable from Battery
B.

CFP83 Series
Crank Solenoid Assembly Removal/Installation (Cont)

Demonstrate Local Electrical Start
NOTE: If Crank Solenoid A was replaced, start
the engine using CRANK BATT A. Alternatively;
use B if B was replaced.
Start the engine electrically from the local
control panel. Refer to Normal Local Starting
Verify that the engine starts normally with no
unusual indications.
Stop the engine.
Demonstrate Local Manual Start

NOTE: If Crank Solenoid A was replaced, start
the engine using CRANK BATT A. Alternatively;
use B if B was replaced.
Start the engine manually from the crank
solenoid lever handle.
Section 3.
Verify that the engine starts normally with no
unusual indications.
Stop the engine.

AUTO position.
status.

CFP83 Series
Control Panel Fuse Replacement

Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Remove
Open the fire pump engine’s local control panel.
Loosen the cover screw and remove the fuse
block cover.

CFP83 Series
Control Panel Fuse Replacement (Cont)

NOTE: The fuses are ATO/ATC ¼” blade type
automotive fuses. The 20 Amp fuses (Fuse 1, 2,
and 3) are colored yellow. The five amp fuse is
colored tan.
Section 13 for schematic details.
NOTE: The fuses are ordered from top to
bottom as follows:
5 A Fuse F4 (Control Panel Indications)
20 A Fuse F1 (Battery A)
20 A Fuse F2 (Battery B)
20 A Fuse F3 (Crank Circuit)
Select the fuse for testing or replacement.
Pull the fuse from the fuse block.
Check for continuity either visually or with an
ohmmeter.
Check for short circuits to ground on any fuse
circuit that had an open circuited fuse. Correct
any faults.
If necessary, remove, test, or replace the
engine harness. Refer to Engine Harness
Install
Replace any fuse with an open circuit. Place the
new fuse into the fuse block and press it in until
the fuse is properly inserted.
Install the fuse block cover and tighten the
cover screw,
Close the control panel.

batteries!

CFP83 Series
Control Panel Fuse Replacement (Cont)

NOTE: If Fuse 1 or Fuse 2 was replaced, start
the engine using CRANK BATT A or CRANK
BATT B respectively.
indications.
Observe that engine speed is indicated.
Observe that raw water flow has started.
Stop the engine.

AUTO position.
status.

CFP83 Series
Exhaust Manifold Removal/Installation

Prepare
Remove the heat shield. Refer to instructions in
this section.
Remove the air intake piping from the
turbocharger. Refer to instructions in this
section.
Remove the air outlet piping from the
section.
Remove the exhaust outlet piping from the
section.
Remove the turbocharger. Refer to instructions
in this section.
Remove
Refer to Exhaust Manifold, Dry (41-011-007-tr)
in C Series Troubleshooting and Repair Manual,
Bulletin No. 3666003.
Clean

CFP83 Series
Exhaust Manifold Removal/ Installation (Cont)
Install
Follow-Up
Install the turbocharger. Refer to instructions in
this section.
Install the exhaust outlet piping at the
section.
Install the air outlet piping at the turbocharger.
Refer to instructions in this section.
Install the air intake piping at the turbocharger.
Refer to instructions in this section.
Install the heat shield. Refer to instructions in
this section.

CFP83 Series
Exhaust Restriction Measurement

Measure
NOTE: The maximum acceptable exhaust
restriction is listed in Exhaust System
Specifications in Section 10.
NOTE: A new pressure tap in the customer-
supplied exhaust piping may be required.
Install pressure gauge, Cummins Part Number
ST-1273, in the exhaust piping at the connection
to the fire pump.
Operate the engine at rated speed and load.
Section 3.
Observe the exhaust restriction.
Stop the engine. Refer to Normal Local Starting
Remove the pressure gauge and plug the
pressure tap.
If the backpressure exceeds specification,
modify the exhaust piping accordingly.

CFP83 Series
Exhaust Shield Removal/Installation

Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Remove
Remove the exhaust shield and fasteners. Refer
to Drawing 8913 (for CFP83-F10, F20, F30
models) or Drawing 8937 (for CFP83-F40
model) in Section 13.

CFP83 Series
Exhaust Shield Removal/Installation (Cont)
Install
Install the exhaust shield and fasteners. Refer to
Drawing 8913 (for CFP83-F10, F20, F30
models) or Drawing 8937 (for CFP83-F40
model) in Section 13.
Torque Value: As per capscrew markings

batteries!
If functional components were removed,

repaired, or replaced, perform the appropriate
installation checks and engine starts as listed in
Section 3. Verify that the components operate
properly.
If testing is completed, place the

AUTO/MANUAL rocker switch in the AUTO
position.

CFP83 Series

CFP83 Series
Inline Fuel Injection Pump Removal/Installation

Refer to Fuel Injection Pumps, In-Line (41-005-012) in C Series Troubleshooting and Repair Manual, Bulletin
No. 3666003.
Prepare
Clean debris.
Remove all fuel lines.
Remove control linkage.
Remove fuel shutoff solenoid.
Remove AFC air line.
Remove oil line(s).
Remove
CAUTION
A diesel engine can not tolerate dirt or water
in the fuel system. A tiny piece of dirt or a
few drops of water in the injection system
can stop the unit.
Clean all external surfaces of the injection
pump, including all line connections and fittings
that are to be disconnected.
Clean the area around the injection pump gear
cover to prevent dirt from entering the
crankcase.

Push the top dead center pin into the hole in the
camshaft gear while slowly barring the engine.
NOTE: Be sure to disengage the pin after
locating top dead center.
The barring gear inserts into the flywheel
housing and engages the flywheel ring gear.
The engine can then be rotated by hand using a
1/2-inch ratchet or breaker bar.

CFP83 Series
Inline Fuel Injection Pump Removal/Installation (Cont)

Remove the fuel pump mounting bracket.
Remove the gear cover access cap.

Remove the nut and washer from the fuel pump
shaft.
With fuel pump gear puller, Part Number

3824469, pull the fuel injection pump drive gear
loose from the shaft.
Engines equipped with the P7100, P3000, A,

and MW fuel injection pump are equipped with
support brackets that must be removed.

CFP83 Series

Remove the four fuel injection pump mounting
nuts.
Remove the fuel injection pump.
Install
Make sure the engine has cylinder No. 1 at top
dead center.
Injection Pump Timing

The injection pump also has a timing pin,
located in the governor housing, to position the
pump shaft to correspond with top dead center
for cylinder No. 1.

CFP83 Series

Remove the access plug.
Remove the timing pin.
If the timing tooth is not aligned with the timing

pin hole, rotate the pump shaft until the timing
tooth aligns.

CFP83 Series

Reverse the position of the pin so the slot of
the pin will fit over the timing tooth in the pump.
Install and secure the pin with the access plug.
CAUTION
The fuel pump drive inside diameter and the
shaft outside diameter must be clean and
dry before installing the shaft into the gear.
A non-petroleum-based cleaner can be used
to clean the drive gear and shaft mounting
surfaces. Failure to do so will result in gear
slippage in the retarded direction.
Clean the drive gear and shaft with a non-
petroleum-based cleaner.
NOTE: If the mounting flange o-ring has a
colored stripe, it can not be reused. Replace
with a new o-ring. Furthermore, do not lubricate
the new-type o-ring. Instead, lubricate the
seating area of the gear housing.
Lubricate the mounting flange of the fuel
injection pump with clean lubricating engine oil.
NOTE: The P7100 fuel injection pump driveshaft
has a provision for a Woodruff key; however, it
is not required for the P7100 drive gear.

CFP83 Series

Slide the pump shaft through the drive gear, and
position the pump flange onto the mounting
studs.
Push the pump forward until the mounting
flange and o-ring are properly fitted into the gear
housing bore.
If equipped, finger-tighten the capscrews for the
support bracket.
Tighten the mounting nuts.

Torque Value:
Mounting Nuts 44 N•m [32 ft-lb]
Tighten the capscrews for the rear support

bracket.
Torque Value:
Support Bracket 14 N•m [124 in-lb]
Install the fuel injection pump retaining nut and

washer.
Torque Value: 10 to 15 N•m [89 to 133 in-lb]

CFP83 Series

Disengage the engine timing pin.
Remove the fuel pump timing pin plug.

Reverse the position of the pin and install the
pin, plug, and sealing washer.
Tighten the fuel pump drive nut.

Torque Values:
• P7100 Pump 178 N•m [131 ft-lb]
• A Pump 95 N•m [70 ft-lb]
• EP9 Pump 127 N•m [94 ft-lb]
Install the gear cover access cap hand-tight.

Install the fuel pump mounting bracket
capscrews finger-tight.
Install support mounting capscrews finger-tight.
Make sure alignment is correct and tighten
capscrews.

CFP83 Series
CAUTION
If a replacement or repaired pump was
installed, be sure to fill the governor housing
with clean lubricating engine oil before
starting the engine. Failure to do so will
result in damage to the governor fly weights.
Remove the access plug, and fill the governor
housing with clean lubricating engine oil using
specifications below.
Oil Capacities:
• RQVK Governor 750 ml [0.71 qt]
• RQV Governor 750 ml [0.71 qt]
• RSV Governor 450 ml [0.48 qt] Bosch
• RSV-H Governor 500 ml [0.53 qt] Denso
Install the access plug.

Follow-Up

CFP83 Series
Fuel Injection Pump, In-Line, Spill Port Timing

Refer to Fuel Injection Pump, In-Line, Spill Port Timing (41-005-013) in C Series Troubleshooting and Repair
Manual, Bulletin No. 3666003.
Prepare
Clean debris.
Remove all fuel lines.
Remove control linkage.
Remove fuel shutoff solenoid.
Remove AFC air line.
Remove oil line(s).
Remove
CAUTION
A diesel engine can not tolerate dirt or water
in the fuel system. A tiny piece of dirt or a
few drops of water in the injection system
can stop the unit.
Clean all external surfaces of the injection
pump, including all line connections and fittings
that are to be disconnected.
Clean the area around the injection pump gear
cover to prevent dirt from entering the
crankcase.

Push the top dead center pin into the hole in the
camshaft gear while slowly barring the engine.
NOTE: Be sure to disengage the pin after
locating top dead center.

CFP83 Series
Fuel Injection Pump, In-Line, Spill Port Timing (Cont)

Remove the fuel pump mounting bracket.
Remove the gear cover access cap.

Remove the nut and washer from the fuel pump
shaft.
Pull the fuel pump drive gear loose from the

shaft.
Remove the four mounting nuts.
Remove the fuel pump.
Install
Make sure the engine has cylinder No. 1 at top
dead center.

CFP83 Series
Injection Pump Timing

The injection pump also has a timing pin,
located in the governor housing, to position the
pump shaft to correspond with top dead center
for cylinder No. 1.
Remove the access plug.
Remove the timing pin.

CFP83 Series

If the timing tooth is not aligned with the timing
pin hole, rotate the pump shaft until the timing
tooth aligns.
Reverse the position of the pin so the slot of the

pin will fit over the timing tooth in the pump.
Install and secure the pin with the access plug.

CFP83 Series
CAUTION
The fuel pump drive inside diameter and the
shaft outside diameter must be clean and
dry before installing the shaft into the gear.
A non-petroleum-based cleaner can be used
to clean the drive gear and shaft mounting
surfaces. Failure to do so will result in gear
slippage in the retarded direction.
Clean the drive gear and shaft with a non-
petroleum-based cleaner.
NOTE: If the mounting flange o-ring has a
colored stripe, it can not be reused. Replace
with a new o-ring. Furthermore, do not lubricate
the new-type o-ring. Instead, lubricate the
seating area of the gear housing.
Lubricate the mounting flange of the fuel
injection pump with clean lubricating engine oil.
NOTE: The P7100 fuel injection pump driveshaft
has a provision for a Woodruff key; however, it
is not required for the P7100 drive gear.
Slide the pump shaft through the drive gear, and

position the pump flange onto the mounting
studs.
Push the pump forward until the mounting
flange and o-ring are properly fitted into the gear
housing bore.
If equipped, finger-tighten the capscrews for the
support bracket.
Tighten the mounting nuts.

Torque Value:
Mounting Nuts 44 N•m [32 ft-lb]

CFP83 Series

Tighten the capscrews for the rear support
bracket.
Torque Value:
Support Bracket 14 N•m [124 in-lb]
Install the fuel injection pump retaining nut and

washer.
Torque Value: 10 to 15 N•m [89 to 133 in-lb]
Disengage the engine timing pin.

CFP83 Series

Remove the fuel pump timing pin plug.
Reverse the position of the pin and install the
pin, plug, and sealing washer.
Tighten the fuel pump drive nut.

Torque Values:
• P7100 Pump 178 N•m [131 ft-lb]
• A Pump 95 N•m [70 ft-lb]
• EP9 Pump 127 N•m [94 ft-lb]
Install the gear cover access cap hand-tight.

Install the fuel pump mounting bracket
capscrews finger-tight.
Install support mounting capscrews finger-tight.
Make sure alignment is correct and tighten
capscrews.

CFP83 Series
CAUTION
If a replacement or repaired pump was
installed, be sure to fill the governor housing
with clean lubricating engine oil before
starting the engine. Failure to do so will
result in damage to the governor fly weights.
Remove the access plug, and fill the governor
housing with clean lubricating engine oil using
specifications below.
Oil Capacities:
• RQVK Governor 750 ml [0.71 qt]
• RQV Governor 750 ml [0.71 qt]
• RSV Governor 450 ml [0.48 qt] Bosch
• RSV-H Governor 500 ml [0.53 qt] Denso
Install the access plug.

Follow-Up

CFP83 Series
Fuel Pump Idle Speed Adjustment

Refer to Fuel Pump Idle Speed (41-005-029) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Adjust
Idle Speed Adjustment, RQVK Governor

NOTE: Idle adjustment for the RQVK governor
requires setting of the idle adjustment screw.
Loosen the locknut.
NOTE: Turn the screw counterclockwise to raise
the rpm; clockwise to decrease idle speed.
Adjust the screw until the dataplate-specified
idle speed is attained with normal idle operation
accessory loads.
Tighten the lock screw.
RSV Governor
Idle adjustment for industrial engines requires
the setting of both the low-idle screw (1) and the
bumper spring screw (2).

CFP83 Series
Fuel Shutoff Valve Removal/Installation

Refer to Fuel Shutoff Valve (41-005-043) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Label and disconnect wiring.
Remove
Remove the electrical wiring.
Remove the fuel drain line.
Remove the throttle shutoff linkage.
Remove the fuel injection pump top cover.
Disassemble the fuel injection pump top cover.
Clean
Rotary Pumps
Clean around the valve.
Remove the valve.
NOTE: Be careful not to drop the piston and
spring when removing the valve.
Replace the valve and connect the electrical
wire.

CFP83 Series
Fuel Shutoff Valve Removal/Installation (Cont)
Install
Install new insulating tubes onto the terminals
on the terminal studs of the new solenoid.
Install the valve into the cover.
Install the cover and gasket onto the fuel

injection pump.
NOTE: Extreme care must be taken in
assembling the cover to the fuel injection pump
to make sure the shutoff arm is in proper contact
with the linkage hook tab.
Install the cover to the pump at a downward
angle from the driveshaft end of the fuel
injection pump; then slide the cover horizontally
into position.

CFP83 Series
Fuel Shutoff Valve Removal/Installation (Cont)
Inline Pumps
RQVK Governor Shutoff Solenoid

Remove the hitch pin clip, mounting capscrews,
and the fuel shutoff solenoid.
Install the new solenoid in reverse order of
removal and connect the wires. Make sure the
part number and cable tie block is facing away
from the engine.
Adjust the solenoid linkage as necessary so that
the plunger is magnetically held in with the
shutoff lever in the absolute full-run position.
Turn the large hex on the end of the plunger to
make adjustments.
Follow-Up

CFP83 Series
Fuel Lift Pump Removal/Installation

Refer to Fuel Lift Pump (41-005-045) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Preparatory
Clean debris from around the lift pump.
Disconnect the fuel supply lines.
Clean Piston Style

Clean the mounting surface on the cylinder
block.
Clean Diaphragm Style

Remove the lift pump.
Clean the mounting surface on the cylinder
block.

CFP83 Series
Fuel Lift Pump Removal/Installation (cont)
Install Diaphragm Style

Install the lift pump and a new gasket.
Connect the fuel lines.
CAUTION
Alternately tighten the mounting capscrews.
As the capscrews are tightened, the fuel
transfer pump plunger is pushed into the
pump. Failure to tighten the capscrews
evenly can result in the plunger being bent
or broken.
Install Piston Style

Install the pump.
Connect the fuel lines.
Follow-Up

CFP83 Series
Air in Fuel
Refer to Air in Fuel (41-006-003) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
General Information
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the
work area and areas sharing ventilation to reduce the possibility of severe personal injury or death
when working on the fuel system.
WARNING
Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold,
which can cause a fire.
The low-pressure fuel system for a Cummins engine consists of the fuel tank, lines between tank and engine,
transfer pump and lines, and fuel filter and lines. Air or bubbles at the injection pump can cause no or erratic
engine operation and/or subsequent malfunction of the fuel injection pump. Air can be introduced by leaks in the
fuel system prior to the transfer pump since fuel pressure is a vacuum. Bubbles can result from any number of
restrictions in the system:
Plugged fuel filter
Crimped fuel line
Stopped-up tank module
Inoperative transfer pump
If sufficient fuel reaches the injection pump from the low-pressure system, then solutions to engine operational
problems are elsewhere. The following steps will aid in evaluating low-pressure fuel system performance in
absence of fault codes.
NOTE: For cold-start/performance problems, perform the following steps:
Leave engine outside in cold environment for at least 12 hours.
Perform outlined test.
If the system fails to meet test criteria, replace the fuel lift pump.
Test
NOTE: A replacement of fuel supply lines, fuel
filters, fuel injection pump, high-pressure fuel
lines, and injectors will let air enter the fuel
system. Air in the system will make the engine
hard to start, run rough, misfire, produce low
power, and can cause excessive smoke and a
fuel knock.

CFP83 Series
Air in Fuel (Cont)

NOTE: Since the fuel lift pump provides positive
pressure through the fuel filter and supply line to
the fuel injection pump, loose connections or
defective seals can show as a fuel leak, not as
an air leak.
NOTE: If an excessive amount of air has

entered into the system, the system will need to
be vented.
Loosen the return banjo fitting on the fuel lift
pump.
Run the fuel lift pump until all the air has been
vented.
When all the air has been vented, retighten the
fitting.
NOTE: To run the fuel pump for 25 seconds,
crank the engine for a split second, and leave
the key in the ON position.
If air continues to bubble out of the system for

several minutes, then an air leak is present.
NOTE: An often overlooked source from which
air can enter the fuel system is between the inlet
of the fuel transfer pump and the suction tube in
the tank. Fuel tanks that have the outlet fitting at
the top will have a suction tube that extends to
the bottom of the tank. Cracks or pin holes in
the weld that join the tube to the fitting can let air
enter the fuel system.
Also, check to make sure all the fittings from the
fuel supply line on the tank to the inlet of the fuel
transfer pump are tight.
Use a sight glass at the fuel lift pump inlet to
check for air in the fuel supply lines.

CFP83 Series
Air in Fuel (Cont)

NOTE: Since the fuel pump provides a positive
pressure through the fuel filter and supply line to
the fuel injection pump, loose connections or
defective seals should show as a fuel leak, not
as an air leak.
NOTE: A stuck-open injector can also blow

combustion gas back into the pump and cause
air to be present in the overflow.
If the engine seems to be misfiring or running
rough, break all the injector supply lines loose at
the pump end.
Crank the engine, and observe the lines.
If combustion gas seems to be blowing back
through the line, the injector is stuck open.
Remove the injector.
Take the engine to an Authorized Cummins
Repair Facility/Dealer Location for testing.
NOTE: Use two wrenches when loosening the
lines at the fuel pump: One to hold the delivery
valve and one to loosen the fuel line.
Disconnect the fuel line from the outlet of the

fuel filter.

CFP83 Series
Air in Fuel (Cont)

Attach a preferably clear hose to the outlet of
the fuel filter. (Do not use pressure test fitting.)
Place a pressure gauge on the inlet side of the
fuel filter and a vacuum gauge on the inlet side
to the transfer pump.
Insert a hose into an empty 3.8-liter [1-gal]

container.
Operate the fuel lift pump by bumping the

starter. (The lift pump should run for 25 to 30
seconds.)
Check for bubbles in fuel.
Record filter inlet pressure and transfer pump
inlet restriction.
If filter inlet pressure is greater than 34.8 kPa [5
psi], the filter element must be replaced. Repeat
test.
If inlet restriction is greater than 152.4 mm Hg [6
in Hg] or 155.1 mm Hg [3 psi], then excessive
restriction exists between fuel in the tank and
the transfer pump, which must be repaired (e.g.,
fuel line or tank module). Repeat test.

CFP83 Series
Air in Fuel (Cont)

If bubbles are present, check for air leaks in the
fuel supply circuit.
Measure the amount of fuel in the container. If
more than 1.33 liters [45 fl oz] are collected and
the fuel is bubble-free, then it is unlikely the low-
pressure fuel system is the cause of engine
operational problems.
Reconnect the lift pump that is retaining the fuel

filter pressure connections.
Running engine at high idle, the filter inlet
pressure should be greater than 42.3 kPa [6
psi]; otherwise, there is a fuel lift pump
malfunction.
If the fuel transfer pump does not run, check

electrical circuits, and verify voltage is present at
lift pump connector.
NOTE: When an engine is not running, with
switch on, the lift pump will run less than 2
seconds (varies with ECM calibration); with
starter bump, about 25 to 30 seconds.
If voltage is present, replace fuel transfer pump.
Resistance measurement across the transfer
pump terminals can be made for confirmation of
pump malfunction.
Resistance greater than 200 ohms or less than
0.2 ohm does confirm an electrical fault when
voltage is present but the fuel pump is not
running.

CFP83 Series
Measure Fuel Drain Line Restriction

Refer to Fuel Drain Line Restriction (41-006-012) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Measure
Remove the fuel drain line from the fitting at the
injection pump.
Install the 0 to 207 kPa [0 to 30 psi] pressure
gauge.
Operate the engine at rated speed and no load.
Observe the reading on the pressure gauge.

Maximum Fuel Drain Line Restriction: 69
kPa [10 psi]
If the drain line pressure is out of specification,
check for bends or kinks in the drain lines.

CFP83 Series
Fuel Drain Lines Removal/Installation

Refer to Fuel Drain Lines (41-006-013) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Remove
Remove, clean, and inspect the fuel drain lines
for reuse. Refer to Fuel Drain Lines (53-006-
013) in ISB and QSB5.9 Base Engine
Troubleshooting and Repair Manual, Bulletin
Number 3666193.
Remove
Remove the banjo fitting capscrews and
washers.

CFP83 Series
Fuel Drain Lines Removal/Installation (Cont)

Remove the banjo capscrew and sealing
washers at the fuel filter head.
Clean
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use.
Wear goggles and protective clothing to
avoid personal injury.
WARNING
and dirt can cause bodily injury.
Wash the low-pressure fuel lines in solvent.
Dry the fuel lines with compressed air.
Inspect for Reuse

Inspect the fuel drain lines for cracks and other
damage.
Inspect the fuel drain manifold banjo
connections.
NOTE: The banjo connection seals must be
discarded when removed.

CFP83 Series
Install
Install the banjo capscrew and sealing washers
at the fuel filter head.
Install the banjo fitting capscrews and washers.
Install
Install the fuel drain lines. Refer to Fuel Drain
Lines (53-006-013) in ISB and QSB5.9 Base
Engine Troubleshooting and Repair Manual,
Bulletin Number 3666193.
Follow-Up

CFP83 Series
Fuel Filter Adapter Removal/Installation

Refer to Fuel Filter (Spin-On Type) (41-006-015-tr) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Prepare
Clean debris
Remove fuel filters.
Remove
Remove the retaining nut, filter head adapter,
and sealing washers.
Install in reverse order of removal.
Install
Follow-Up

CFP83 Series
Measure Fuel Inlet Restriction

Prepare
Measure
Install a fitting at the transfer pump fuel inlet
Install a vacuum gauge that has a range of at
least 0 to 508 mm Hg [0 to 20 in Hg].
Start the engine, and run at low or high idle.

Maximum Allowable Inlet Restriction at
Low/High Idle: 101.6 mm-hg [4.0 in-hg]

CFP83 Series
Measure Fuel Inlet Restriction (Cont)

If the fuel inlet restriction is too high, check to
make sure that the OEM lines from the tank are
sized properly, there are no kinks or bends in
the lines, and the lines are not clogged.
Make sure that there are no clogged fuel
strainers or malfunctioning check valves.
Follow-Up

CFP83 Series
Fuel Drain Manifold Removal/Installation

Refer to Fuel Manifold (Drain) (41-006-021-tr) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Prepare
Inline Pumps
NOTE: Use new seals and sealing washers.
Assemble the drain line and drain manifold in
the reverse order of removal.
Torque Values:
• (Banjo Fitting Screw) 15 N•m [133 in-lb]
• (Banjo Fitting) 9 N•m [80 in-lb]
• (Bracket Capscrew) 24 N•m [18 ft-lb]
Remove Rotary Pumps

Remove the capscrew from the hold-down
clamp.
Remove the banjo fitting screws and washers.
Disconnect the drain line fitting from the
injection pump.
Remove Inline Pumps

Remove the drain line banjo capscrew from the
fuel filter head.
Remove the capscrew from the bracket on the
intake cover.
Remove the banjo capscrews from the injectors.

CFP83 Series
Fuel Drain Manifold Removal/Installation (Cont)
Install Rotary Pumps

Assemble the drain line and fuel drain manifold
in the reverse order of removal.
Torque Values:
• (Clamp Screw) 24 N•m [18 ft-lb]
Install Inline Pumps

Assemble the drain line and drain manifold in
the reverse order of removal.
Torque Values:
• (Clamp Screw) 24 N•m [18 ft-lb]
Follow-Up

CFP83 Series
Low Pressure Fuel Supply Lines Removal/Installation

Refer to Fuel Supply Lines (41-006-024) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Low Pressure Fuel Line

Thoroughly clean all fittings and components
before removal. Make sure that the debris,
water, steam, or cleaning solution does not
reach the inside of the fuel system.
Remove [Diaphragm Style Lift Pump]

Disconnect the fuel line from the lift pump and
filter head.
Use two wrenches to disconnect the line from
the lift pump.
Remove [Piston Style Lift Pump]

Disconnect the fuel line from the lift pump and
filter head.
Use two wrenches to disconnect the line from
the lift pump.
Install [Diaphragm Style Lift Pump]

Install the fuel line to the lift pump and filter
head. Use two wrenches to tighten the
connection to the lift pump.
NOTE: Do not over-tighten the connection. Fuel
leaks can result from over-tightening.

CFP83 Series
Low Pressure Fuel Supply Lines Removal/Installation (Cont)
Install [Piston Style Lift Pump]

Install the fuel line to the lift pump and filter
head. Use two wrenches to tighten the
connection to the lift pump.
Injection Pump Supply Line Replacement

Remove the bleed screw banjo fitting.
Remove the supply line (Bosch® injection
pump).
NOTE: Replace the seals (1) in the fittings if the
line is disassembled.
Remove the supply line (Lucas CAV injection
pump). The Lucas CAV pump has two fittings
for the supply line.
Replace fitting sealing washers (1), and ferrules
(2) each time they are removed.
NOTE: Replace the seals in the fittings if the

line is disassembled.
Engines rated at 2500 rpm and above require
additional fuel line support. Install as illustrated.
Follow-Up

CFP83 Series
Fuel Injectors Removal/Installation

Prepare
Clean around the injectors.
Disconnect the high-pressure fuel lines. Refer to
High Pressure Injector Supply Lines
Disconnect the fuel drain manifold. Refer to Fuel
Drain Manifold Removal/Installation in this
section.
Remove
CAUTION
Be careful not to damage the tip of the
injector when removing.
Remove the mounting capscrew, washer, and
injector.
NOTE: When removing the injector, clean
around the injector, and insert a blind plug to
prevent dust or dirt from entering the engine.
NOTE: Mark the injectors with tags showing the
cylinder number, and keep it in a safe place. If
there is no abnormality in the injector, install it in
the same position during assembly.
Install
NOTE: Install new injector gasket (Cummins
Part No. C6204113880) or replacement injector
kit (Cummins Option No. II3002.01).
Coat the injectors with anti-seize compound,
Part No. 3824879, before installation.

CFP83 Series
Fuel Injectors Removal/Installation (Cont)
CAUTION
Be careful not to damage the tip of the
injector when installing.
NOTE: When installing the injector, clean
around the injector, and do not allow dust or dirt
to enter the engine.
NOTE: If there is no abnormality in the injector,
install it in the same position during assembly.
Install the injector, washer, and mounting
capscrew.
Tighten the capscrew.
Follow-Up
Reconnect the high-pressure fuel lines. Refer to
High Pressure Injector Supply Lines
Reconnect the fuel drain manifold. Refer to Fuel
Drain Manifold Removal/Installation in this
section.
Operate the engine.

Check for leaks.
Check function.
Stop the engine.
RTN

CFP83 Series
Fuel Return Overflow Valve Removal/Installation

Prepare
Remove
Remove, clean, and inspect the fuel return
overflow valve for reuse. Refer to Fuel Return
Overflow Valve (53-006-044) in ISB and
QSB5.9 Base Engine Troubleshooting and
Repair Manual, Bulletin Number 3666193.
Remove
Remove the fuel return overflow valve and
rubber-coated sealing washer.

CFP83 Series
Fuel Return Overflow Valve Removal/Installation (Cont)
Clean
WARNING
Thoroughly flush the high-pressure relief valve
with cleaning solution.
Inspect for Reuse

Use a small screwdriver to verify that the check
ball is not sticking in the high-pressure relief
valve assembly and that the spring is not
broken.
Install
Install new rubber-coated sealing washers and
fuel return overflow valve.
NOTE: Use two wrenches when installing the
overflow valve.

CFP83 Series
Fuel Return Overflow Valve Removal/Installation (Cont)
Install
Install the fuel return overflow valve. Refer to
Fuel Return Overflow Valve (53-006-044) in ISB
and QSB5.9 Base Engine Troubleshooting and
Repair Manual, Bulletin Number 3666193.
Follow-Up

CFP83 Series
High Pressure Injector Supply Lines Removal/Installation

Refer to Injector Supply Lines (High Pressure) (41-006-051) in C Series Troubleshooting and Repair Manual,
Prepare
Clean all debris from around the fittings.
Remove Rotary Pumps

Disconnect the fuel line(s) from the injector.
NOTE: If individual lines are to be replaced,
remove the support clamp from the set of lines
containing the line to be replaced.
Disconnect the fuel line(s) from the fuel pump.
Install protective covers onto the injectors and
delivery valves to prevent entry of dirt into the
system.
Remove Inline Pumps

Disconnect the line(s) from the injector(s).
NOTE: If individual lines are to be replaced,
remove the support clamp from the set of lines
containing the line to be removed.
Disconnect the line(s) from the fuel pump.

CFP83 Series
High Pressure Injector Supply Lines Removal/Installation (Cont)
Install
CAUTION
Install the support clamp in the original
position and, to prevent damage from high-
frequency vibration, make sure the lines
have not been bent or do not contact each
other or another component.
CAUTION
To prevent damage to the fuel lines, they
must be connected to the injectors and fuel
injection pump in a free state without forcing
the connecting nuts. The fuel lines are
correctly sized for each application. Bending
the lines is not acceptable and can cause
fuel leaks.
Install Rotary Pumps

Install the fuel lines in reverse order of removal.
Torque Values:
• Line Fittings: 24 N•m [18 ft-lb]
• Support Clamp: 6 N•m [53 in-lb]
• Support Bracket: 24 N•m [18 ft-lb]

CFP83 Series
High Pressure Injector Supply Lines Removal/Installation (Cont)
Install Inline Pumps

Install the lines in reverse order of removal.
Torque Values:
• Line Fittings: 24 N•m [18 ft-lb]
• Support Clamp: 6 N•m [53 in-lb]
• Support Bracket: 24 N•m [18 ft-lb]
NOTE: If removed, reinstall the support clamp in
the original position, and make sure the lines do
not contact each other or another component.
Install a protective cover on the injectors and
fuel delivery valves to prevent the entry of dirt
into the system.
Follow-Up

CFP83 Series
Air Leaks, Air Intake and Exhaust Systems Checks

Prepare
Initial Check
CAUTION
Engine intake air must be filtered to prevent
dirt and debris from entering the engine. If
intake air piping is damaged or loose,
unfiltered air will enter the engine and cause
premature wear.
Inspect the intake air piping for cracked hoses,
damage, or loose clamps.
Replace damaged pipes, and tighten loose
clamps, as necessary, to make sure the air
intake system does not leak.
Check for corrosion of the intake system piping
under the clamps and hoses. Corrosion can
allow corrosive products and dirt to enter the
intake system. Disassemble and clean, as
required.
Operate the engine at high idle, and use a

solution of soapy water to spot intake air leaks.
If an air leak exists, the soap bubbles will be
drawn in with the air.

CFP83 Series
Air Leaks, Air Intake and Exhaust Systems Checks (Cont)

Operate the engine at full throttle and rated rpm
with maximum load.
Listen for a high-pitched whistling noise from
the turbocharger, nearby piping, and
connections.
The noise can be caused by an air leak from

the turbocharger-to-discharge elbow
connection.
Inspect for damage. Tighten loose clamps.
Any charge air cooler tubing or connecting

hoses.
Inspect the hose and tubing for damage.
Tighten the hose clamps.
Refer to the manufacturer's specifications for
the correct torque value.
Turbocharger-to-exhaust-manifold mounting
gasket.
Replace the gasket. Refer to Procedure 010-
033.

CFP83 Series

Operate the engine at full throttle and rated rpm
with maximum load.
Listen again for leaks.
Replace the turbocharger if the air piping is not
damaged and the noise can still be heard. Refer
to Procedure 010-033.
Loose connections or cracks in the suction side

of the intake pipe and after the air filter can
allow debris to be ingested by the engine,
causing rapid wear in the cylinders.
Leaks at the intake manifold, unsealed bolt
holes, or manifold cover gasket can also allow
dust and dirt to be ingested into naturally
aspirated engines.
Debris drawn into the air suction side can

damage the compressor blades, causing an
imbalance resulting in bearing failure.
To verify a bearing failure or damaged
compressor, remove the intake and exhaust
piping, and check for contact. The rotor
assembly must rotate freely and should not be
damaged. Measurement of axial and radial
clearance is described in this section.
Excessive smoke and low power from a

turbocharged engine can be caused by
pressurized air leaking from loose connections
or cracks in the crossover tube or intake
manifold. This can also cause a noise problem.

CFP83 Series

In addition to the inspection for cracks and
loose fittings, liquid soap can be applied to the
charge air cooler, connections, and the manifold
cover sealing surfaces to find the leaks. The
leaks will create bubbles that are easier to
detect. Measurement of manifold pressure is
described in this section.
Follow-Up

CFP83 Series
Air Intake Restriction Indicator Removal/Installation

A mechanical restriction indicator is available to
indicate excessive air restriction through a dry-
type air cleaner. This instrument is mounted on
the air cleaner outlet tube.
Refer to Air Filter Assembly Drawing in Section

13.
Change the filter element when the red indicator

flag (2) is at the raised position in the window
(1). See Air Cleaner Element
Removal/Installation this section.
NOTE: Do not remove the felt washer from the

indicator. The felt washer absorbs moisture.
After the air cleaner has been serviced, push
the button (3) to reset the service indicator. If
the indicator does not retract to the service
position with new air cleaner element installed,
the service indicator needs to be replaced.
Remove service indicator from Air Cleaner

Element piping. Apply Teflon sealant to the
threads on the indicator. Install new indicator on
Intake pipe.
Follow-Up
Run engine to determine if new indicator is
functioning.

CFP83 Series
Intake Air Cleaner Element Removal/Installation
CAUTION
Never operate the engine without an air cleaner. Unfiltered foreign objects could cause engine damage.
Check Air Restriction Indicator. Replace the air

cleaner element when the restriction reaches
the maximum allowable limit, or clean according
to the manufacturer's recommendations. See
Air Cleaner Restriction Removal/Installation this
section.
Turbocharged engines must be operated at
rated RPM and full load to check maximum
intake air restriction.
Maximum intake air restriction is 762 mm H2O
[30.0 in H2O] for turbocharged engines.
Loosen air cleaner clamp.
Remove the air cleaner element.
Clean and Inspect for Reuse

Inspect the air cleaner for cuts, cracks, holes, or
excessive debris.
Clean or replace if necessary.
See Air Intake System Specifications in Section
10 for correct Cummins Fire Power replacement
part number.
Check for corrosion of the intake system piping

under the clamp. Corrosion can allow corrosive

CFP83 Series
Intake Air Cleaner Element Removal/Installation (Cont)
Re-run engine at rated RPM at full load to

check maximum intake restriction.
Maximum intake air restriction is 762 mm H2O
[30.0 in H2O] for turbocharged engines.
Follow-Up

CFP83 Series
Air Crossover Pipe Removal/Installation

Refer to Air Crossover (100-010-019) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Remove
Loosen the hose clamps, and position the hose
so the crossover tube can be removed.
Install
Use new hose and clamps as required to install
the crossover tube.
Follow-Up

CFP83 Series
Air Intake Manifold Removal/Installation

Refer to Air Intake Manifold (41-010-023) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Remove the high-pressure fuel lines
Disconnect the cold starting aid, if used.
Remove the air crossover tube.
Remove
Remove the manifold cover and gasket.
NOTE: Plug the opening of the air intake with a
clean shop rag to prevent foreign matter from
entering combustion chamber.
Clean
Clean the sealing surface.
NOTE: Keep the gasket material and any other
material out of the air intake.

CFP83 Series
Air Intake Manifold Removal/Installation (Cont)
Install
NOTE: The holes shown in the illustration are
drilled through and must be sealed by applying
liquid Teflon™ sealant to the capscrews.
Install the cover and a new gasket.

Assemble the intake piping, and connect the

cold starting aid if used.

CFP83 Series
Pressure Test
Install the pressure gauge to the fitting in the
turbocharger outlet.
Install another pressure gauge, in the intake
manifold.
Operate the engine at rated rpm and load.
Record the readings on the two gauges.
If the differential pressure is greater than 21 kPa
[3 psi], check the charge air cooler for plugging.
Clean or replace if necessary.
Temperature Differential Test

Install a temperature gauge in the intake
manifold.
Lock the fan drive in the ON mode to prevent

erratic test results.
Operate the engine at rate rpm and load.
Record the intake manifold temperature.

CFP83 Series

Measure the ambient temperature.
The maximum temperature differential must not
be greater than 25°C [45°F].
If the temperature differential is greater than
25°C [45°F], check the charge air cooler for dirt
and debris on the fins, and clean as necessary.
If the problem still exists, check the cooler for
internal contamination or plugging.
Vent
WARNING
Do not mix gasoline, alcohol, or gasohol
with diesel fuel. This mixture can cause
explosion.
Install and bleed the high-pressure fuel lines.
Follow-Up

CFP83 Series
Aftercooler Removal/Installation
Refer to Aftercooler (40-010-001-tr) in B3.9, B4.5, and B5.9 Series Engines Troubleshooting and Repair
Prepare
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
regulations.
Disconnect the cold starting aid, if used.
Remove the high-pressure fuel lines.
Drain 2 liters [2.1 qt] of coolant.
Remove
Remove the coolant supply tube (1) and the
coolant return tube (2).

CFP83 Series
Aftercooler Removal/Installation (Cont)

Remove the high-pressure fuel lines.
Remove the aftercooler housing and gasket.

Plug the opening with a clean shop rag to
prevent foreign material from entering the air
intake.
Clean
Clean the sealing surface.
NOTE: Keep the gasket material and any other
material out of the air intake.

CFP83 Series
Install
NOTE: The holes shown in the illustration are
drilled through. Apply liquid Teflon™ sealant to
the capscrews.
Install the aftercooler housing and a new gasket.
Install the coolant supply tube (1) and coolant

return tube (2). Install the air crossover tube (3).

CFP83 Series
Fill
CAUTION
During filling, air must be vented from the
engine cooling passages. Open the engine
vent petcock. Make sure to open the petcock
on the aftercooler for aftercooled engines.
The system must be filled slowly to prevent
air locks. Wait 2 to 3 minutes to allow air to
be vented; then add coolant to bring the
level to the bottom of the radiator filler neck.
Failure to do so will cause entrapment of air
in cooling system and will cause engine to
overheat.
Fill the coolant system with a mixture of 50-
percent water and 50-percent ethylene-glycol-
type antifreeze.
Follow-Up

CFP83 Series
Charge Air Cooler (CAC) Removal and Installation (for CFP83-F40 only)
If the engine experiences a turbocharger failure
or any other occasion where oil or debris is put
into the charge air cooler, the charge air cooler
must be cleaned or replaced.
Remove charge air cooler from the engine.
Remove
Refer to Assembly Drawing 8967 and 10903 in
Section 13.
Disconnect the CAC Air Outlet Piping Assembly
from the CAC.
Disconnect the CAC Air Inlet Piping Assembly
from the CAC.
Disconnect the CAC Raw Water Coolant Inlet
Piping Assembly from the CAC.
Disconnect the CAC Raw Water Outlet Piping
Assembly from the CAC.
Remove the bolts from mounting bracket and
remove the cooler assembly.
Remove the two clamps from the cooler
assembly.
Install
Install two clamps on the cooler assembly
Install the cooler assembly and start the bolts
on the mounting bracket.
NOTE: Apply Teflon tape or pipe sealant to the
threaded fittings as the raw water piping is
reinstalled.
Re-connect the CAC Raw Water Coolant Outlet
Piping Assembly to the CAC.
Re-connect the CAC Raw Water Coolant Inlet
Piping Assembly to the CAC.
Connect the CAC Air Outlet Piping Assembly to
the CAC.
Connect the CAC Air Inlet Piping Assembly to
the CAC.

CFP83 Series
Turbocharger Removal/Installation
Refer to Turbocharger (41-010-033-tr) in C Series Troubleshooting and Repair Manual, Bulletin No. 3666003.
Prepare
Disconnect the intake and exhaust piping.
Remove
Remove the capscrews from the oil drain tube.
Remove the oil supply line.

CFP83 Series
Turbocharger Removal/Installation (Cont)

If equipped with a wastegate turbocharger,
remove the intake manifold pressure supply
line from the boost capsule.
Remove the exhaust clamp, turbocharger, and

gasket.
Plug the opening with a clean shop rag to
prevent foreign material from entering exhaust
system.
Clean
Clean the sealing surface. Inspect the sealing
surface and mounting studs for damage.

CFP83 Series
Install
NOTE: If the turbocharger is not to be
immediately replaced, cover the opening to
prevent any material from falling into the
manifold.
Install a new gasket and apply anti-seize

compound to the mounting studs.
Install the turbocharger and a new gasket.


CFP83 Series

If required, bend the lockplates back and loosen
the turbine housing capscrews.
Position the bearing housing to install the
turbocharger drain tube.
Install the hose and clamps on the turbocharger

drain tube loosely. Install the drain tube and
gasket on the turbocharger.
Position the turbocharger drain hose to connect

the drain tubes.
Tighten the clamps.

CFP83 Series

If loosened, tighten the turbine housing
capscrews. Bend the lockplates onto the flats to
prevent loosening.
If required, loosen the compressor housing, and

position the housing to align with the crossover
tube.
Tighten the band clamp.

Tap around the clamp with a plastic hammer
and tighten again.
CAUTION
To prevent bearing damage, new
turbochargers must be pre-lubricated before
start-up.
Pour 50 to 60 cc [3 to 4 oz] of clean lubricating
engine oil into the oil supply fitting.
Rotate the turbine wheel to allow the oil to enter
the bearing housing.

CFP83 Series

Install the exhaust outlet connection.
Do not tighten the two mounting capscrews until
the band clamp has been tightened.
Torque Values:
• Band Clamp 8 N•m [71 in-lb]
• Capscrews 43 N•m [32 ft-lb]
CAUTION
When installing the oil supply line, be sure
the line is not in direct contact with the
turbine housing or the line will burn during
operation.
Install the oil supply line.
If equipped with a wastegate turbocharger,

install the intake manifold pressure supply line
from the boost capsule.

CFP83 Series
Test
Install the air crossover tube.
Install the air inlet.
Install the exhaust piping.
Operate the engine and check for leaks.
Follow-Up

CFP83 Series
Turbocharger Axial Clearance Check

Prepare
Axial Clearance Check

Use dial depth gauge, Part Number ST-537.
Push the rotor assembly away from the gauge.
Set the gauge to zero.
Push the rotor assembly toward the gauge and

record the reading.
Axial Clearance
• Minimum 0.038 mm [0.0015 in]
• Maximum 0.093 mm [0.0037 in]
Replace the turbocharger if the clearance does
not meet specifications. See the Remove and
Install steps in this procedure.
Follow-Up

CFP83 Series
Turbocharger Oil Drain Line Removal/Installation

Prepare
Remove
Remove the capscrews from the turbocharger
oil drain tube.
Pull the drain line out of the drain line boss.
Clean
Clean the gasket sealing surfaces (first frame).
Clean the o-ring seating bore, and make sure it
is free of dirt and debris.
Inspect for Reuse

Inspect line for cracks, wear, and damage.
Inspect the o-ring for fretting and cracking, and
replace as necessary.
Check the rubber section of the drain line for
deterioration.

CFP83 Series
Turbocharger Oil Drain Line Removal/Installation (Cont)
Install
Apply a thin film of oil to the drain line o-rings.
Push the drain line into the drain line boss. Be
sure both o-rings are completely seated in the
bore.
Install the drain line capscrews with a new
gasket.
Torque Value: 24 N•m [18 ft-lb ]
Follow Up
Operate the engine, and check for leaks.

CFP83 Series
Turbocharger Oil Supply Line Removal/Installation

Prepare
Remove
Remove
Remove the oil supply line from the oil filter
head (1).
Remove the oil supply line from the
turbocharger bearing housing (2).
Inspect for Reuse

Inspect the line for cracks, wear, and damage.
Inspect o-rings for cracking and fretting.
Replace as necessary.
Install
Apply a thin film of oil to the o-ring seals.
Fill the turbocharger oil inlet with clean oil.
Install the oil supply line at both the filter head
and the turbo bearing housing.
Tighten the oil supply line to final torque.
Follow-Up

CFP83 Series
Turbocharger Radial Bearing Clearance

Prepare
Radial Clearance Check

Use a wire-type feeler gauge to measure the
clearance between the compressor wheel and
housing.
Gently push the compressor wheel toward the
compressor housing and gauge.
Record the clearance.
With the feeler gauge in the same location,

gently push the compressor wheel away from
the compressor housing and measure the
clearance between the compressor wheel and
housing.
Subtract the smaller clearance from the larger
clearance. This is the radial bearing clearance.
Radial Bearing Clearance
• Minimum 0.30 mm [0.012 in]
• Maximum 0.46 mm [0.018 in]
Repeat the procedure on the turbine wheel.
Replace the turbocharger if the radial bearing
clearance does not meet specifications. See the
Remove and Install steps in this procedure.
Inspect the turbocharger compressor intake and

discharge for oil.
If oil is present in the compressor intake as well
as in the discharge, check upstream in the
turbocharger for the source of oil.

CFP83 Series
Turbocharger Radial Bearing Clearance (Cont)

If oil is present only in the discharge side, install
the air intake and charge air cooler piping.
Refer to the OEM service manual.
Check for intake restriction. Refer to Procedure
010-031.
If excessive intake restriction is not found,
replace the turbocharger.
NOTE: If the engine experiences a
turbocharger failure or any other occasion
where oil is put into the charge air system, the
charge air system must be inspected and
cleaned. Refer to Procedure 010-027.
Follow-Up

CFP83 Series
Turbocharger Wastegate Actuator Removal and Installation

Initial Check
Inspect the integral wastegate actuator hose for
cracks or holes.
Replace the hose if damaged.
CAUTION
A bent wastegate mounting bracket,
actuator rod, or lever can cause improper
operation.
Inspect the wastegate mounting bracket,
actuator rod, and lever for damage.
If the wastegate mounting bracket, actuator rod,
or lever is bent, it must be replaced.
Prepare
Remove
NOTE: In some applications, the turbocharger
must be removed in order to remove the
wastegate actuator. Refer to Procedure 010-
033.

CFP83 Series
Turbocharger Wastegate Actuator Removal and Installation (Cont)

NOTE: Prior to removal, note position length of
the control rod from the boost capsule housing
and orientation of the boost capsule hose
connector in relation to the mounting bracket.
Remove the retaining clip from the control lever.

Disconnect the integral boost line from the
wastegate capsule.
CAUTION
Be careful not to bend the control lever.
Disconnect the boost capsule actuator rod end
from the turbocharger wastegate lever. This can
be accomplished by slowly applying regulated
air pressure to the boost capsule until the
control rod is activated.
Disconnect the control rod from the
turbocharger wastegate lever pin.
NOTE: If the boost capsule diaphragm material

is ruptured and will not hold air pressure,
manually pull the control rod outward in order to
overcome boost capsule spring tension for
removal of the control rod from the turbocharger
wastegate lever pin.
Loosen the boost capsule mounting capscrews,
disconnect the air supply hose, and remove
assembly from the mounting bracket.

CFP83 Series
Test
must be removed in order to test the wastegate
actuator. Refer to Procedure 010-033.
Disconnect the integral boost line from the

wastegate capsule.
Attach a dial indicator (1) as shown, so that its
shaft is in line with the wastegate actuator rod.
Set the indicator to zero.
Connect clean, regulated air pressure and a
pressure gauge to the capsule. Apply 200 kPa
[29 psi] to make sure the wastegate is
functioning properly.
The rod should move approximately 0.33 to
1.27 mm [0.013 to 0.050 in] without any sticking
or air leakage.
NOTE: No air should be heard (i.e., leaking
noise) through a functional wastegate capsule.
NOTE: A small amount of travel when air
pressure is first applied is normal; the tolerance
is being removed from the system.
Replace the actuator if no movement of the

actuator rod and lever is detected.

CFP83 Series
Install
must be removed in order to install a new
wastegate actuator. Refer to Procedure 010-
033.
Fit the end-link over the turbocharger wastegate

lever pin. With the spine of the spacer visible
and the turbocharger wastegate lever pushed
toward the rod, lay the actuator alongside the
mounting bracket.
NOTE: Do not fit the two studs into the
mounting holes at this time.
Adjust the length of the actuator assembly by

removing from the turbocharger, rotating the
end-link, and re-fitting the actuator until the
underside of the actuator will just fit over the
bracket mounting studs with less than 0.5-mm
[0.20-in] gap.
The setting is correct when the underside of the

actuator will just fit over the bracket with less
than 0.5-mm [0.20-in] gap.

CFP83 Series

Fit the actuator mounting studs into the holes in
the bracket, and fit both actuator mounting
capscrews.
Refit the end-link onto the crank-pin. Install the
control rod retaining clip.
Tighten the control rod jam nut against the end-

link. Cut the tie wrap and remove tie wrap and
spacer piece. Discard tie wrap. Continue turning
jam nut in the same direction, and tighten
against end-link.
Refit the air supply hose to the actuator using

the new hose clamp provided.
Follow-Up

CFP83 Series

CFP83 Series
Lubricating Oil Cooler Removal/Installation

Refer to Lubricating Oil Cooler (100-007-003) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Prepare
WARNING
Coolant is toxic. Keep away from children
and pets. If not reused, dispose of in
regulations.
WARNING
Some state and federal agencies have
determined that used engine oil can be
carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used
engine oil.
Drain the coolant.
Remove the oil filter.
Remove
Remove the turbocharger oil supply line from
the oil filter head.

CFP83 Series
Lubricating Oil Cooler Removal/Installation (Cont)

Remove the oil cooler cover, element, and
gaskets.
Clean the sealing surfaces.
Clean
Clean all debris from around the oil cooler.

CFP83 Series
Install
Assemble the oil cooler gasket, element, cooler
cover gasket, and cooler cover to the cylinder
block.
NOTE: Be sure to remove the shipping plugs (A)
from the new cooler element.
Connect the turbocharger oil supply line.

Install a new oil filter.

Follow the manufacturer's instructions for
tightening.

CFP83 Series
Fill
CAUTION
The system must be filled slowly to prevent
air locks. Be sure to open the aftercooler to
allow air to escape as the system is filled.
Fill the coolant system and lubricating oil
system.
Operate the engine to check for leaks.
Stop the engine and check the coolant and oil
level.
Pressure Test
Pressurize the element to 690 kPa [100 psi] to
check it for leaks.
Follow-Up

CFP83 Series
Lubricating Oil and Filter Analysis

Inspect
An analysis of used oil can help diagnose
internal engine damage and determine if it was
caused by one of the following:
• Intake air filter malfunction
• Coolant leaks
• Oil diluted with fuel
• Metal particles causing wear
For additional oil analysis information, Refer to

Cummins Engine Oil Recommendations,
Bulletin 3810340.
NOTE: Do not take apart an engine for repair
based solely on the results of an oil analysis.
Inspect the oil filters. If the oil filter shows
evidence of internal damage, find the source of
the problem, and repair the damage. Refer to
the appropriate procedure(s) based on the
following oil filter inspection.
WARNING
Restrain the full flow lubricating oil filter,
and carefully cut the filter (upper section of
combination filter) open. The filter element
spring is under compression and can cause
personal injury.

CFP83 Series
Lubricating Oil and Filter Analysis (Cont)

Use the tube cutter, Part No. 3376579, to open
the full-flow oil filter (upper section of the
bypass filter).
Inspect the filter element for evidence of
moisture or metal particles.
Metal Possible Source
Copper Bearings and Bushings
Chromium Piston Rings
Iron Cylinder Liners
Lead Bearing Overlay Material
Aluminum Piston Wear or Scuffing

CFP83 Series
Lubricating Oil Pan Removal/Installation

Refer to Lubricating Oil Pan (100-007-025) in C Series Troubleshooting and Repair Manual, Bulletin No.
3666003.
Prepare
Drain
WARNING
Some state and federal agencies in the
United States of America have determined
that used engine oil can be carcinogenic
and can cause reproductive toxicity. Avoid
inhalation of vapor, ingestion, and
prolonged contact with used engine oil.
WARNING
Hot oil can cause serious personal injury.
NOTE: Use a container that can hold at least 20
liters [15 qt] of lubricating oil.
Operate the engine until the coolant
temperature reaches 60°C [140°F]. Shut off the
engine. Remove the oil drain plug. Drain the oil
immediately to be sure all the oil and
suspended contaminants are removed from the
engine.
Remove
Remove the lubricating oil pan and gasket.
If the suction tube must be removed. Refer to
Procedure 007-035.

CFP83 Series
Lubricating Oil Pressure Regulator Removal/Installation

Refer to Lubricating Oil Pressure Regulator (Main Rifle) (100-007-029) in C Series Troubleshooting and Repair
Prepare
Clean debris.
Remove
Remove the plug and regulator valve.
Clean
Clean and inspect the regulator valve.

CFP83 Series
Lubricating Oil Pressure Regulator Removal/Installation (Cont)

Clean and inspect the regulator valve bore.
NOTE: In order to regulate the oil pressure, the
valve must move freely in the bore.
Install
Install a new sealing o-ring on the threaded plug
and lubricate with clean lubricating engine oil.
Install the pressure regulator assembly.
Follow-Up

CFP83 Series
Lubricating Oil Pump Removal/Installation

Prepare
Remove the drive belt. Refer to Procedure 008-
002.
Remove
Remove the vibration damper. Refer to
Procedure 001-051 or Procedure 001-052.
Remove the front gear cover. Refer to

Procedure 001-031.

CFP83 Series
Lubricating Oil Pump Removal/Installation (Cont)

Remove the four mounting capscrews (1, 2, 3,
and 4).
Remove the lube oil pump from the bore in the
cylinder block.
Inspect for Reuse

Inspect the lubricating oil pump gears for chips,
cracks, or excessive wear.
Remove the back plate.

CFP83 Series

Mark “TOP” on the gerotor planetary.
Remove the gerotor planetary.

Inspect for excessive wear or damage.
WARNING
WARNING
and dirt can cause bodily injury.
Clean all parts in solvent and dry with
compressed air.

CFP83 Series

Inspect the lubricating oil pump housing and
gerotor drive for damage and excessive wear.
CAUTION
Make sure the gerotor planetary is installed
in the original position. Failure to do so can
damage the oil pump.
Install the gerotor planetary.
Measure
Measure the tip clearance.
MAX Limit 0.1778 mm [0.007 in]

CFP83 Series

Measure the clearance of the gerotor
drive/gerotor planetary to port plate.
Measure the clearance of the gerotor planetary

to the body bore.
Measure the gear backlash.

Limits (Used Pump)
• MIN 0.75 mm [0.030 in]
• MAX 0.85 mm [0.033 in]

CFP83 Series
Install
Install the back plate.
CAUTION
Failure to fill the pump with oil during
installation can result in a slow prime at
initial engine start-up, resulting in severe
engine damage.
Lubricate the lubricating oil pump with clean
15W-40 engine oil.
CAUTION
Make sure the idler gear pin is installed in
the locating bore in the cylinder block.
Install the lubricating oil pump.

CFP83 Series

Tighten in the sequence shown.
NOTE: The back plate on the pump seats

against the bottom of the bore in the cylinder
block. When the lubricating oil pump is correctly
installed, the flange on the lubricating oil pump
will not touch the cylinder block.
NOTE: Be sure the gear backlash is correct if

installing a new lubricating oil pump.
Measure the gear backlash.
Backlash Limits
A
• MIN 0.75 mm [0.030 in]
• MAX 0.85 mm [0.033 in]
B
• MIN 0.75 mm [0.030 in]
• MAX 0.85 mm [0.033 in]
NOTE: If the adjoining gear moves when you
measure the backlash, the reading will be
incorrect.

CFP83 Series

Gear Cover - Installation
Lubricate the front gear train with clean 15W-40
engine oil.
CAUTION
The seal lip and the sealing surface on the
crankshaft must be free from all oil residue
to prevent seal leaks.
Thoroughly clean the front seal area of the
crankshaft.
NOTE: Always replace the front seal when
removing and installing the gear cover. Refer to
Procedure 001-023.
Apply a thin bead of Three-Bond™, or

equivalent, to the front cover side of the gasket
only.
NOTE: Do not remove the plastic seal pilot tool
from the lubricating oil seal at this time. Use the
plastic seal pilot tool to guide the seal on the
crankshaft.
Install the gasket and front cover on the engine.

CFP83 Series

Tighten the front cover mounting capscrews in
the indicated order.
Remove the plastic pilot tool from the

crankshaft.
Install the front breather and tube. Refer to

Procedure 003-018.

CFP83 Series

Install the vibration damper. Refer to Procedure
001-051 or Procedure 001-052.
Tighten the vibration damper. Refer to

Procedure 001-051 or Procedure 001-052.
Raise the belt tensioner to install the belt. Refer

to Procedure 008-002.
Follow-Up

CFP83 Series
Oil Pressure Sender Removal/Installation

Prepare
Remove
Disconnect the wire from the sending unit.
NOTE: The sending units illustrated can differ
from those installed by the original equipment
manufacturer (OEM).
Inspect for Reuse

Remove the OEM oil pressure sensor, and
install a pressure gauge.
Start the engine.
Measure the lubricating oil pressure.
Minimum lubricating oil pressure:
• Low Idle (675 to 725 rpm): 69 kPa
[10 psi]
• High Idle rpm: 207 kPa [30 psi]
Install
Install the sending unit.
Connect the wire to the sending unit.
Torque Values:
• Installed into Cast Iron 16 N•m [12 ft-lb]
• Installed into Aluminum 10 N•m [7 ft-lb ]
Follow-Up

CFP83 Series
Oil Pressure Gauge Removal/Installation

Prepare
for engine service.
MANUAL position.

alarm.
batteries!
terminals.
Remove
Section 13 for electrical schematic details.
Open the local control panel.
NOTE: Ensure that the wires are clearly tagged
for reconnection.
Loosen the nuts on the stud and remove the
wires.
Remove the nuts on the mounting bracket and
remove the gauge from the panel.

CFP83 Series
Oil Pressure Gauge Removal/Installation (Cont)
Install
Orient the gauge in the cutout in the electrical
panel.
Position the mounting bracket on the gauge.
Install the mounting nuts.
Reconnect the electrical wires on the studs in
the same positions as they were originally
installed.
Follow-up
batteries!

AUTO position.
status.

CFP83 Series
Oil Pressure Switch Removal/Installation

Prepare
Remove
Disconnect the oil pressure switch wiring.
Remove the oil pressure switch.
Install
NOTE: Apply liquid teflon sealant to the threads
when installing the temperature switch.
Install the temperature sensor.
Torque Value:
Follow-Up

CFP83 Series

CFP83 Series
Speed Sensor or Mag Pick-Up Sensor Removal/Installation

Prepare: Place the fire protection system in a
safe mode for engine service.
MANUAL position.

alarm.
batteries!
Remove The Mag Pick-Up (Speed Sensor)

which is mounted on the bell-housing and
located over the flywheel teeth. Both the Speed
Switch and the Tachometer (located in the
Engine control Panel) use the Mag Pick-Up as
the engine speed signal. The resistance on a
good Mag Pick-Up should be approximately 265
Ohms.
Remove the 2-wire cable that is connected to it.
(The cable wires are not polarity sensitive, so it
makes no difference how the wires are
connected to it). Remove the Mag Pick-Up by
turning it out counter-clockwise.

CFP83 Series
Speed Sensor or Mag Pick-Up Sensor Removal/Installation (Cont)

When installing a new Mag Pick-Up, first check
that the threads in the bell-housing are clean.
Any burrs may prevent proper installation.
Install the Mag Pick-Up by threading it into the

bell-housing until its tip is bottomed out against
the flywheel. Then back out the Mag Pick-Up ½
turn. Reconnect the 2-wire cable. Reconnect
the batteries.

batteries!

AUTO position on the fire pump panel.
Return the fire protection system controller back
to operating status.

CFP83 Series
Tachometer Removal/Installation
MANUAL position.

alarm.
batteries!
To remove the tachometer, open the cover of

the Engine Control Panel. Disconnect the 3-
wire connector that is plugged into the back of
the tachometer. Next, remove the tachometer’s
retaining bracket.

CFP83 Series
Tachometer Removal/Installation (Cont)

Install the new tachometer in reverse order.
Refer to instructions for Tachometer Calibration
in this section.

batteries!

AUTO position.

CFP83 Series
Overspeed Switch Removal/Installation

MANUAL position.

alarm.
batteries!
Begin removing the Speed Switch by first

documenting the wires that are connected to its
terminals. If necessary, place a piece of
masking tape on each wire, noting the terminal
number that it’s connected to.
Once all of the wires are removed, the Speed

Switch can be removed from the Engine Control
Panel by removing the four screws that are
securing it to the panel. Each screw is fastened
to the back of the Control Panel. In order to
access the four retaining nuts, the Control
Panel may have to be loosened from the engine
frame to allow clearance for a wrench.

CFP83 Series
Overspeed Switch Removal/Installation (Cont)

Once the Speed Switch is removed, install the
new one in reverse order. All Speed Switches
are factory calibrated for the specific Firepump
Engine model that it’s intended to be used with.
No adjustments will be necessary.

batteries!

AUTO position.

CFP83 Series
Tachometer Calibration
After a new tachometer has been installed, it
will be necessary to calibrate it. In order to do
this, the engine must be started and verified
that it is operating at rated speed.
15
10 20
RPM x 100
5 25
0 HOURS 30
With a small flat-blade screwdriver, turn the trim

pot, located on the back of the tachometer, until
its indicator agrees with the engine speed.

CFP83 Series

Section 8 – Service Literature Page 8-1
CFP83 Series
Section 8 – Service Literature

Section Contents
Page
Additional Service Literature.............................................................................................................................8-3
Service Literature Ordering Location ...............................................................................................................8-4

Page 8-2 Section 8 – Service Literature
CFP83 Series

Section 8 – Service Literature Page 8-3
CFP83 Series
Additional Service Literature

General Information
The following publications can be purchased at your selected Service Literature Ordering Location:
Bulletin Title of Publication
3379000 Air for Your Engines
3379001 Fuel for Cummins Engines Bulletin
3379009 Operation, Cold Weather
3666003 C Series Troubleshooting and Repair Manual
3666008 C Series Engine Shop Manual
3666021 C Series Specifications Manual
3666109 Alternative Repair Manual, B and C Series Engines
3666132 Coolant Requirements and Maintenance Bulletin
3810340 Cummins Engine Oil Recommendations Bulletin

Page 8-4 Section 8 – Service Literature
CFP83 Series
Service Literature Ordering Location

Contact Information
Region Ordering Location
United States and Canada Cummins Distributors – 1-800 DIESELS

1-800-343-7357
OR
Credit Cards at 1-800-646-5609
OR
Order online at www.powerstore.cummins.com
U.K., Europe, Mid-East, Africa, and Eastern European Cummins Engine Co., Ltd.
Countries
Royal Oak Way South
Daventry
Northants, NN11 5NU, England
South and Central America (excluding Brazil and Cummins Americas, Inc.
Mexico)
16085 N.W. 52nd Avenue
Hialeah, FL 33104
Brazil and Mexico Cummins Inc.

International Parts Order Dept., MC 40931
Box 3005
Columbus, IN 47202-3005
Far East (excluding Australia and New Zealand) Cummins Diesel Sales Corp.
Literature Center
8 Tanjong Penjuru
Jurong Industrial Estate
Singapore
Australia and New Zealand Cummins Diesel Australia

Maroondah Highway,
P.O.B. 139 Ringwood 3134
Victoria, Australia

Section 9 – Service Assistance Page 9-1
CFP83 Series
Section 9 – Service Assistance

Section Contents
Page
Routine Service and Parts ................................................................................................................................9-3
Problem Solving .................................................................................................................................................9-4

Page 9-2 Section 9 – Service Assistance
CFP83 Series

Section 9 – Service Assistance Page 9-3
CFP83 Series
Routine Service and Parts

Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your
engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been
trained to provide sound advice, expert service, and complete parts support. Check the telephone directory yellow
pages or refer to the directory in this section for the nearest Cummins Authorized Repair Location.
Emergency and Technical Service

The Cummins Customer Assistance Center provides a
24-hour, toll free telephone number to aid in technical
and emergency service when a Cummins Authorized
Repair Location can not be reached or is unable to
resolve an issue with a Cummins product.
If assistance is required, call Toll-Free:
1-800-DIESELS (1-800-343-7357)
Includes all 50 states, Bermuda, Puerto Rico, Virgin
Islands, and the Bahamas.
Outside of North America contact your Regional
Office. Telephone numbers and addresses are listed
in the International Directory.
See also www.cummins.com

Page 9-4 Section 9 – Service Assistance
CFP83 Series
Problem Solving
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cummins
Authorized Repair Location in your area. Refer to the telephone directory yellow pages for the one nearest you. If
the problem has not been handled satisfactorily, follow the steps outlined below:
If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement.
If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, most
problems are solved below the Division or Regional office level. Telephone numbers and addresses are listed in
this section.
Before calling, write down the following information:
• Engine model and serial number
• Type and make of equipment
• Total kilometers [miles] or hours of operation
• Warranty start date
• Nature of problem
• Summary of the current problem arranged in the order of occurrence
• Name and location of the Cummins Distributor or Dealer
If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office,
write to:
Cummins Customer Assistance Center - 41403,
Cummins Engine Company, Inc.,
Box 3005, Columbus, IN 47202-3005

Section 10 – Maintenance Specifications Page 10-1
CFP83 Series
Section 10 – Maintenance Specifications

Section Contents
Page
General Engine Data.........................................................................................................................................10-3
Fuel System Specifications .............................................................................................................................10-4
Lubricating Oil System Specifications ...........................................................................................................10-4
Cooling System Specifications .......................................................................................................................10-4
Air Intake System Specifications ....................................................................................................................10-5
Exhaust System Specifications ......................................................................................................................10-5
Electrical System Specifications ....................................................................................................................10-5
Cummins/Fleetguard® Filter Specifications..................................................................................................10-6
Fuel Recommendations and Specifications ..................................................................................................10-6
Lubricating Oil Recommendations and Specifications ................................................................................10-7
Coolant Recommendations and Specifications ............................................................................................10-8
Engine Component Torque Values.................................................................................................................10-9
Sealants ...........................................................................................................................................................10-10
Capscrew Markings and Torque Values.......................................................................................................10-11

Page 10-2 Section 10 – Maintenance Specifications
CFP83 Series

CFP83 Series
General Engine Data

NOTE: The following engine and system specification data is extracted from the curves and data sheets that
were current when this document was prepared. Refer to Performance Curve Drawing 9744 and Data Sheet
Drawing 9745 for the most current information. Contact Cummins Fire Power at 920-337-9750 if current
information is required.
Refer to the base engine troubleshooting and repair manual for base engine coverage (see Service Literature in
Section 8).
Model Cummins Engine Co. Base Engine Cummins Base Engine Fuel Rating
CFP83-F10 6CTA8.3G2 FR90242 / FR90243
CFP83-F20 6CTA8.3G2 FR90242 / FR90243
CFP83-F30 6CTA8.3G2 FR90242 / FR90243
CFP83-F40 6CTAA8.3G3 FR90940
Model Installation Drawing Configuration Number

CFP83-F10 8708 (see Section 13) D413034GX02
Model Fuel System Aspiration

CFP83-F10 Bosch - P3000 Direct Injection Turbocharged, Jacket Water Aftercooled (JWAC)
CFP83-F40 Bosch - P7100 Inline Turbocharged, Charge Air Cooled
Type 4 Cycle; In-Line; 6 Cylinder

Firing Order 1-5-3-6-2-4
Rotation, Viewed from the Front of the Engine Clockwise
Compression Ratio: 16.8:1
Valves per cylinder: Inlet/Exhaust 1/1
Metric US
Bore 114 mm 4.49 in
Stroke 135 mm 5.32 in
Displacement 8.3 liters 505 in.3
Intake Valve Clearance 0.30 mm 0.012 in
Exhaust Valve Clearance 0.61 mm 0.024 in
Dry Weight 790 kg 1742 lb
Wet Weight 823 kg 1815 lb

CFP83 Series
Fuel System Specifications

Fuel Type Number 2 Diesel Only
Recommended primary fuel filter Fleetguard FS1251
Metric US
Minimum supply line size 9.5 mm D. 0.375 in. D.
Minimum drain line size 6.4 mm D. 0.25 in. D.
Maximum fuel line length between supply tank & fuel pump 12 m 40 ft.
Maximum fuel height above C/L crankshaft 2030 mm 80 in.
Maximum restriction @ lift pump-inlet - with clean filter 102 mm Hg 4.0 in. Hg
Maximum restriction @ lift pump-inlet - with dirty filter 203 mm Hg 8.0 in. Hg
Maximum return line restriction - without check valves 254 mm Hg 10.0 in. Hg
Minimum fuel tank vent capability 0.342 m3/hr 12 ft3/hr
Maximum fuel temperature @ lift pump inlet 71 oC 160 oF
Lubricating Oil System Specifications

Recommended lube oil filter Fleetguard LF9009
Metric US
Oil pressure range at rated 276-414 kPa 40-60 PSI
Oil capacity of pan (high - low) 18.9-15.1 litre 20-16 U.S. quarts
Total system capacity 23.8 litre 6.3 U.S. Gal.
Cooling System Specifications

Recommended coolant filter Fleetguard WF2072
Metric US
Maximum raw water working pressure range at heat 414 kPa 60 PSI
exchanger
Recommended minimum water supply pipe size to heat 25.4 mm D. 1.0 in. D.
exchanger
Recommended minimum water discharge pipe size from 31.7 mm D. 1.25 in. D.
heat exchanger
Coolant water capacity (engine side) 22.2 Litre 5.9 U.S. gal.
Modulating thermostat range 82-95 oC 180-203 oF
Minimum raw water flow with water temperatures to 90 oF 1.9 litre/s 30 U.S. GPM
(32 oC)

CFP83 Series
Air Intake System Specifications

NOTE: Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping
is damaged or loose, unfiltered air will enter the engine and cause premature wear.
Recommended air cleaner element (Standard) K&N RU5045
(Optional) Donaldson B105006
Metric US
Maximum temperature rise between ambient air and engine 15 oC 30 oF
air inlet
Maximum inlet restriction with dirty filter 635 mm H2O 25 in. H2O
Exhaust System Specifications

Metric US
Maximum exhaust back pressure imposed by complete 10.2 kPa 40.8 in. H2O
exhaust system
Exhaust pipe size normally acceptable 102 mm D. 4 in. D.
Electrical System Specifications

Start Circuit
The start circuit consists of a single starter motor and redundant starter control relays as well as using
redundant power sources either 12 V or 24 V comprised of 12 V wet type storage batteries (optional at
shipment).
The battery, starter and starter solenoid positive terminals are booted with a non-conducting cover or otherwise
insulated from unintended grounding. Battery cable leads from the batteries to the designated connection points
in the starting circuit are minimum 6.53 mm D. (No. 2 AWG), neoprene or rubber insulated with a 1.5 mm (0.060
in.) minimum insulation thickness rated 80°C (176 oF) minimum. The starter and starter solenoid are all metal
enclosed.
Wiring for automatic starting (negative ground) Standard
Reference wiring diagram 10423 (see Section 13)
B.C.I. Group Size 8D
12V 24V
Minimum recommended battery cold cranking amperes 1250 Amps 625 Amps
(CCA)(1)
Minimum recommended battery reserve capacity 400 Minutes 800 Minutes
Maximum resistance of starting circuit 0.002 Ohms 0.004 Ohms
Typical cranking speed 120 RPM 120 RPM
Alternator (standard), internally regulated 95 Amps 45 Amps
Battery Cable Size (Metric) (For less than 1.5 meters long) 10.6 mm D. 10.6 mm D.
Battery Cable Size (US) (For less than 5 feet long) 00 AWG 00 AWG
(1) Cold soak at -18 oC (0 oF) or above

CFP83 Series
Cummins/Fleetguard® Filter Specifications

General Information
Fleetguard® is a subsidiary of Cummins Inc. Fleetguard® filters are developed through joint testing at Cummins
and Fleetguard®. Fleetguard® filters are standard on new Cummins engines. Cummins Inc. recommends their
use.
Fleetguard® products meet all Cummins Source Approval Test standards to provide the quality filtration
necessary to achieve the engine's design life. If other brands are substituted, insist on products that the supplier
has tested to meet Cummins high-quality standards.
Cummins can not be responsible for problems caused by non-genuine filters that do not meet Cummins
performance or durability requirements.
Fuel Recommendations and Specifications

Fuel Recommendations
WARNING
Do not mix gasoline, alcohol, or gasohol with diesel fuel. This mixture can cause an explosion.
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.
Use only number 2 diesel (ASTM no. 2D) fuel.
Any adjustment to compensate for reduced performance with a fuel system using alternate fuel is not
warrantable.
Additional information for fuel recommendations and specifications can be found in Fuel for Cummins Engines,
Bulletin No. 3379001. See Section 8, Service Literature, for ordering information.

CFP83 Series
Lubricating Oil Recommendations and Specifications

Oil Performance Recommendations
Using quality engine lubricating oils, along with appropriate oil drain and filter change intervals, is a critical factor
in maintaining engine performance and durability. Refer to Service Literature in Section 8 for reference to
related Cummins service bulletins.
Cummins Engine Company, Inc. recommends the use of a high-quality SAE 15W-40 heavy-duty engine oil
(such as Cummins Premium Blue®), which meets the American Petroleum Institute (API) performance
classification CH4/SG.
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent.
New Engine Break-In Oils

Do not use special “break-in” lubricating oils for new or rebuilt Cummins engines. Use the same type of oil
during the “break-in” as that which is used in normal operation.
Recommended Oil Change Intervals

The oil change interval for turbocharged engines is every 6 months or 250 hours.
Oil Viscosity Recommendations

The use of multiviscosity lubricating oil has been found to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining lubrication at high operating temperatures.
While 15W-40 oil is recommended for most climates, refer to the accompanying table for oil viscosity
recommendations for extreme climates.
NOTE: Limited use of low-viscosity oils, such as 10W-30, can be used for easier starting and providing sufficient
oil flow at ambient temperatures below -35°C [23°F]. However, continuous use of low viscosity oils can decrease
engine life because of wear. Refer to the accompanying chart.

CFP83 Series
Coolant Recommendations and Specifications

General Information
Heavy-duty diesel engines require a balanced coolant mixture of water and antifreeze. Drain and replace the
mixture every 1 year or 1500 hours of operation (whichever occurs first) to eliminate buildup of harmful
chemicals.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant
freezing point and by raising its boiling point. Do not use more than 50-percent antifreeze in the mixture unless
additional freeze protection is required. Never use more than 68-percent antifreeze under any condition.
Use soft water in the coolant mixture. Contaminants in hard water neutralize the corrosion inhibitor components.
Water must not exceed 300-ppm hardness or contain more than 100 ppm of either chloride or sulfate.
Specifications
Use low-silicate antifreeze that meets ASTM4985 test (GM6038M spec.) criteria.
Refer to Service Literature in Section 8 for reference to related Cummins service bulletins.
Concentration
Antifreeze must be used in any climate for both freeze and boiling point protection. Cummins recommends a 50-
percent concentration level (40-percent to 60-percent range) of ethylene glycol or propylene glycol in most
climates. Antifreeze at 68-percent concentration provides the maximum freeze protection and must never be
exceeded under any condition. Antifreeze protection decreases above 68 percent.
Ethylene Glycol Propylene Glycol
40% = -23°C [-10°F] 40% = -21°C [-6°F]

50% = -37°C [-34°F] 50% = -33°C [-27°F]
60% = -54°C [-65°F] 60% = -49°C [-56°F]
68% = -71°C [-90°F] 68% = -63°C [-82°F]
Concentration Testing
Antifreeze concentration must be checked using a refractometer (such as Fleetguard® Part No. CC2800).
“Floating ball” types of density testers or hydrometers are not accurate enough for use with heavy-duty diesel
cooling systems.

CFP83 Series
Engine Component Torque Values

Torque Table
Component Wrench Size N•m ft-lb in-lb
Aftercooler mounting 10 mm 24 18
Aftercooler water hose clamp 8 mm 5 44
Alternator link (Delco 10-15 SI) 13 mm 24 18
Alternator link (Delco 20-27 SI) 3/4 in 43 32
Alternator mtg. bolt 10-15 Sl 15 mm 43 32
Alternator mtg. 27 Sl 18 mm 77 57
Alternator support (upper) 10 mm 24 18
Belt tensioner flat bracket Allen 5 mm 24 18
Belt tensioner mounting 15 mm 43 32
Crankshaft damper and pulley 15 mm 137 101
Crossover clamp 5/16 in 5 44
Tee bolt type clamp 11 mm 8 71
Exhaust outlet pipe, v-band clamp 7/16 in 8 71
Fuel filter 75 to 85 mm Install as specified by filter manufacturer.
Fuel filter adapter nut 24 mm 32 24
Lubricating oil filter 75 to 85 mm 3/4 of a turn after contact
Lubricating oil cooler assembly 10 mm 24 18
Lubricating oil pan drain plug 17 mm 80 59
Lubricating oil pan heater plug 27 mm 80 59
Lubricating oil pressure regulator plug 19 mm 80 59
Starter mounting 10 mm 43 32
Thermostat housing 10 mm 24 18
Water inlet connection 15 mm 43 32
Water pump mounting 13 mm 24 18
Rocker lever (valve) cover 15 mm 12 106
Water-in-fuel (WIF) sensor 19 mm Hand-tighten

CFP83 Series
Sealants
General Information
Use either the sealants listed below or sealants containing equivalent properties.
Item Description Sealing Method
Pipe plugs Pre-coated Teflon™ or pipe sealer
Gaskets No sealant required
Cups plugs Loctite 277 or Cummins sealant, Part Number 3375068
O-rings Lubriplate™ 105
Rear camshaft expansion plug Loctite 277 or Cummins sealant, Part Number 3375068
Fuel pump studs Loctite 242
Turbocharger drain (in block) Loctite 277 or Cummins sealant, Part Number 3375068
Dipstick tube (in block) Loctite 277 or Cummins sealant, Part Number 3375068
Wet flywheel housing to block Three-Bond™ sealant, Part Number 3823494
Rear seal (in rear cover) No sealant required
Timing pin housing capscrews No sealant required
Side oil fill Loctite 277 or Cummins sealant, Part Number 3375068
Oil pan at gear housing joint Three-Bond™ sealant, Part Number 3823494

CFP83 Series
Capscrew Markings and Torque Values

General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the
capscrew being replaced. Using the wrong capscrews can result in engine damage.
Always use the torque values listed in the following tables when specific torque values are not available.
Do not use the torque values in place of those specified in other sections of this manual.
The torque values in the table are based on the use of lubricated threads.
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 Capscrew Identification

Sample: M8-1.25 x 25
Value: M8 1.25 X 25
Meaning: Major thread diameter in Distance between threads in Length in millimeters
millimeters millimeters
Metric Capscrew Head Markings

Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the
surface of the nuts.
8.8 10.9 12.9
Commercial
Steel Class
Capscrew
Head Markings
Metric Capscrew Torque Values

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 — — — — — —

CFP83 Series
US Customary Capscrew Identification

Sample: 5/16 x 18 x 1-1/2
Value: 5/16 18 1-1/2
Meaning: Major thread diameter in Number of threads per inch Length in inches
inches
U.S. Customary Capscrew Head Markings

U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
SAE Grade 5 SAE Grade 8
w/ three lines
U.S. Customary Capscrew Torque Values

Grade SAE Grade 5 SAE Grade 8
Capscrew Body Cast Iron Aluminum Cast Iron Aluminum

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

Section 11 – Warranty Information Page 11-1
CFP83 Series
Section 11 – Warranty Information

LIMITED WARRANTY
EXCLUSIVE EXPRESS LIMITED WARRANTY: Cummins NPower, LLC (“CNP”), 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 CNP, six (6) months from
CNP shipment date), the diesel fire pump drivers, manufactured and sold by CNP, 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
non-transferable 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 CNP;
• Additional components added to a diesel fire pump driver package subsequent to shipment of the
engine; or
• Starting batteries and heaters.
DISCLAIMER OF WARRANTIES: Except for the Exclusive Warranty provided above, which is in lieu of all
other express and implied warranties, CNP 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 CNP 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 CNP’s reasonable discretion, to repair,
replacement or other appropriate adjustment of a non-conforming diesel fire pump driver determined, upon
CNP’s inspection, to have been properly installed, maintained and operated in accordance with the Operations
and Maintenance manual furnished by CNP. IN ANY EVENT, CNP 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
start-up 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.

Page 11-2 Section 11 – Warranty Information
CFP83 Series

Section 12 – Troubleshooting Page 12-1
CFP83 Series
Section 12 – Troubleshooting
Section Contents
Page
Troubleshooting Procedures and Techniques ..............................................................................................12-3
Troubleshooting Symptoms Charts ...............................................................................................................12-3
Alternator Overcharging with the Engine Running.......................................................................................12-4
Neither Battery is Charging with the Engine Running..................................................................................12-5
Only One Battery is Charging with the Engine Running ..............................................................................12-7
Voltage Indications Differ ................................................................................................................................12-8
Coolant Contamination ....................................................................................................................................12-9
Excessive Coolant Loss.................................................................................................................................12-11
Coolant Temperature Above Normal ............................................................................................................12-12
Coolant Temperature Below Normal (Engine Off).......................................................................................12-16
Coolant Temperature Below Normal (Engine Running) .............................................................................12-17
Raw Water Drain Steaming ............................................................................................................................12-18
Raw Water Solenoid Valve Fails to Operate ................................................................................................12-19
Auto Start Failure - Does not Crank on A.....................................................................................................12-20
Auto Start Failure - Does not Crank on B.....................................................................................................12-21
Auto Start Failure - Does not Crank on A or B ............................................................................................12-22
Auto Start Failure – Cranks but does not Start ...........................................................................................12-23
Auto Start Failure – Engine Starts but Crank Terminate does not Occur ................................................12-25
Manual Start Failure from Solenoid Lever - Does not Crank on A ............................................................12-27
Manual Start Failure from Solenoid Lever - Does not Crank on B ............................................................12-28
Manual Start Failure from Solenoid Lever - Does not Crank on A or B ....................................................12-29
Manual Start Failure from Control Panel - Does not Crank on A...............................................................12-30
Manual Start Failure from Control Panel - Does not Crank on B...............................................................12-31
Manual Start Failure from Control Panel - Does not Crank on A or B ......................................................12-32
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) .............................................................12-33
Engine Cranks Slowly But Does Not Start ...................................................................................................12-37
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present .........................................................12-38
Engine Acceleration or Response Poor .......................................................................................................12-42
Engine Noise Excessive - Mechanical..........................................................................................................12-47
Engine Noise Excessive — Combustion Knocks........................................................................................12-50
Engine Runs Rough at Idle ............................................................................................................................12-52

Page 12-2 Section 12 – Troubleshooting
CFP83 Series

Page
Engine Runs Rough or Misfires Under Load .............................................................................................. 12-55
Engine Speed Surges at Idle......................................................................................................................... 12-58
Engine Speed Surges Under Load............................................................................................................... 12-61
Engine Vibration Excessive at Rated Speed............................................................................................... 12-63
Engine Stops During Operation ................................................................................................................... 12-65
Engine Will Not Reach Rated Speed (RPM) ................................................................................................ 12-67
Engine Will Not Shut Off Remotely .............................................................................................................. 12-71
Engine Will Not Shut Off Locally .................................................................................................................. 12-72
Excessive Black Exhaust Smoke ................................................................................................................. 12-73
Excessive White Exhaust Smoke................................................................................................................. 12-76
Fuel Consumption Is Excessive ................................................................................................................... 12-78
Fuel or Lubricating Oil Leaking From Exhaust Manifold........................................................................... 12-80
Lubricating Oil Contaminated....................................................................................................................... 12-82
Coolant in the Lubricating Oil....................................................................................................................... 12-83
Fuel in the Lubricating Oil............................................................................................................................. 12-85
Lubricating Oil Consumption Excessive..................................................................................................... 12-86
Lubricating Oil in the Coolant....................................................................................................................... 12-88
Lubricating Oil Pressure High ...................................................................................................................... 12-89
Lubricating Oil Pressure is Low ................................................................................................................... 12-91
Oil Level Rises ............................................................................................................................................... 12-94
Lubricating Oil Sludge in the Crankcase Excessive .................................................................................. 12-95
Turbocharger Leaks Engine Oil or Fuel ...................................................................................................... 12-97
Crankcase Gases (Blowby) - Excessive ...................................................................................................... 12-98
Engine Overspeed Trip.................................................................................................................................. 12-99
Tachometer Does Not Indicate Engine Speed .......................................................................................... 12-100

CFP83 Series
Troubleshooting Procedures and Techniques

General information
This guide describes some typical engine operating problems, their causes, and some acceptable corrections to
those problems.
WARNING
Performing troubleshooting procedures NOT outlined in this in Section can result in equipment damage
or personal injury or death
Troubleshooting must be performed by trained, experienced technicians.
Consult a Cummins Authorized Repair Location for diagnosis and repair beyond that which is contained in this
manual, and for symptoms not listed in this in section.
Before beginning any troubleshooting, refer to the General Safety Instructions in Section 1 of this manual.
Follow the suggestions below for troubleshooting:
Study the complaint thoroughly before acting.
Refer to the Engine Identification diagrams in Section 2, the System Diagrams in Section 6, and the Assembly
Drawings in Section 13.
Do the easiest and most logical things first.
Find and correct the cause of the complaint.
Troubleshooting Symptoms Charts
WARNING
Troubleshooting presents the risk of equipment damage, personal injury or death Troubleshooting must
be performed by trained, experienced technicians.
Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms.
Read each row of blocks from top to bottom.
Follow through the chart to identify the corrective action.

CFP83 Series
Alternator Overcharging with the Engine Running

NOTE: If the batteries are overcharged while the engine is not running, troubleshoot the customer supplied
battery charging system.
Cause Correction
Batteries have failed. Check the condition of the batteries. Refer to Battery
Testing Section 7. Replace any defective batteries.
The internal voltage regulator in the alternator is Test the alternator electrically. Refer to Alternator
malfunctioning. Checks and Testing in Section 7.
If required, replace the alternator. Refer to Alternator
Removal/Installation Section 7.
Contact an Authorized Cummins Repair Facility.

CFP83 Series
Neither Battery is Charging with the Engine Running

NOTE: If one or both batteries do not charge with the engine stopped, troubleshoot the customer supplied
NOTE: If only one battery is maintaining charge, go to Only One Battery is Charging with the Engine Running.
Cause Correction
Battery cables or connections are loose, broken, or Check the battery cables and connections. Refer to
corroded (excessive resistance). Battery Cables and Connections (013-009) in
Troubleshooting and Repair Manual C Series Engines,
Bulletin Number 3666003-02. Ensure that all
connections are free of corrosion and that no cables
are broken.
Battery condition is poor. Load-test the battery. If the battery charge is low,
charge the battery. If battery fails the second load test,
replace the battery. Refer to Batteries (013-007) in
Bulletin Number 3666003-02.
Alternator rotor is not turning. Test the alternator mechanically. Refer to Alternator
Checks and Testing in Section 7.
If the alternator shaft does not spin freely because of a
bad bearing, replace the alternator. Refer to Alternator
If the alternator does not turn because of a bad drive
belt, replace the drive belt. Refer to Belt
If the alternator does not charge because of poor drive
belt tension, replace the automatic tensioner. Refer to
Automatic Belt Tensioner Removal/Installation in
Section 7.
If the alternator pulley is loose on the shaft, tighten the
pulley. Refer to Alternator Pulley (013-006) in

CFP83 Series
Neither Battery is Charging with the Engine Running (Cont)

Cause Correction
Battery Isolator input has faulted. Test continuity from the alternator to the battery
isolator input. Refer to Drawing 10423 Sheet 2 in
Section 13. Repair any open circuit.
Test continuity through the battery isolator. If an
internal open circuit is detected, replace the battery
isolator. Refer to Battery Isolator Removal/Installation
in Section 7.
Alternator excitation is lost. Test the alternator electrically. Refer to Alternator

If required, replace the replaceable diode. Refer to
Drawing 10423 Sheet 1 in Section 13.
If required, locate and repair the open circuit or short to
ground in the alternator excitation wiring.
Alternator connection to ground is poor. Inspect the alternator mounting hardware for a proper
electrical connection to the battery. Remove any paint
and debris from the ground connection. Check
mounting bracket bolts for proper torque.
Alternator internal voltage regulator is malfunctioning. Test the alternator electrically. Refer to Alternator
If required, replace the alternator. Refer to Alternator
Battery temperature is above specification. Position the batteries away from heat sources.

CFP83 Series
Only One Battery is Charging with the Engine Running

NOTE: If one or both batteries do not charge with the engine stopped, troubleshoot the customer supplied
NOTE: If neither battery is maintaining charge, go to Neither Battery is Charging with the Engine Running.
Cause Correction
Battery has failed. Test battery condition. Refer to Battery Testing in

Section 7.
If the battery has failed, replace the failed battery
units. Refer to Battery Removal/Installation in Section
7.
Battery cables or connections are loose, broken, or Check the battery cables and connections. Ensure
corroded (excessive resistance). that all connections are free of corrosion and that no
cables are broken.
Battery isolator has failed. Remove the battery isolator. Refer to Battery Isolator
Test the internal diodes for open circuit or short to
ground. Refer to the Schematic, Electrical Wiring,
If required, obtain a replacement battery isolator.
Install the battery isolator. Refer to Battery Isolator
Voltmeter is providing false indication. Go to Voltage Indications Differ in this section.

CFP83 Series
Voltage Indications Differ

NOTE: The two voltmeters may differ slightly due to calibration differences between the meters. Normal
differences in battery condition may also cause differences in indication. These are normal differences and
require no action. A voltage difference of more than three or four volts should be investigated.
Cause Correction
One battery is discharged or failing. Check battery condition. Replace failing battery
elements.
Check wiring for corrosion. Ensure good electrical
contact.
Charge discharged batteries by running the engine or
with an external battery charger.
If the battery does not charge with the engine running,
go to Only One Battery is Charging with the Engine
Running.
Fuse 1 or Fuse 2 is open. Check for apparent wire damage or shorts to grounds.
Refer to Drawing 10423 Sheet 1 in Section 13. Correct
any electrical faults.
Replace the failed fuse.
If the fuse operates again, locate and correct the
overload or repair the short circuit.
Open circuit or short to ground in indicator wiring. Locate and repair the electrical fault. Refer to Drawing
Voltmeter has failed. Remove wiring at the voltmeter and apply test voltage.
If necessary, replace the faulted voltmeter. Refer to
Voltmeter Removal/Installation in Section 7.

CFP83 Series
Coolant Contamination
Cause Correction
Coolant is rusty and has debris. Drain and flush the cooling system. Refer to Drain and
If the drained coolant has excessive rust or debris,
change the coolant more frequently or contact a
Cummins Authorized Repair Facility.
Otherwise, refill with correct mixture of antifreeze and
water. Refer to Drain and Flush Cooling System in
Section 5.
Lubricating oil cooler is leaking oil into the coolant. Drain and flush the cooling system. Refer to Drain and
Coolant begins to have the texture and color of Flush Cooling System in Section 5.
chocolate pudding.
Check the lubricating oil cooler for coolant leaks and
cracks. Refer to Lubricating Oil Cooler
Removal/Installation in Section 7. Replace the oil
cooler gasket or other parts.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section 5.
If the problem persists, the cylinder block may be
cracked or porous. Refer to a Cummins Authorized
Repair Facility.

CFP83 Series
Coolant Contamination (Cont)

Coolant Heat Exchanger is leaking raw water into the Drain and flush the cooling system. Refer to Drain
coolant. Coolant volume increases and pressure is and Flush Cooling System in Section 5.
relieved when the unit is operating. Antifreeze
Remove Coolant Heat Exchanger. Refer to Coolant
concentration decreases.
Heat Exchanger Removal/Installation in Section 7.
Perform a pressure test of the raw water side of the
heat exchanger. Refer to Coolant Heat Exchanger
Removal/Installation in Section 7. If the heat
exchanger leaks, it should be replaced.
Install a known good Coolant Heat Exchanger. Refer
to Coolant Heat Exchanger Removal/Installation in
Section 7.
Check and adjust raw water pressure regulator
setpoints. Refer to Raw Water Piping, Lineup, and
Configuration in Section 3.
Check and, if required, replace the Zinc Plug. Refer to
Inspect Heat Exchanger Zinc Plug in Section 5.
Refill with correct mixture of antifreeze and water.
Refer to Drain and Flush Cooling System in Section
5.
Coolant is inadvertently contaminated with unknown Drain and flush the cooling system. Refill with correct
liquids. mixture of antifreeze and water. Refer to Drain and

CFP83 Series
Excessive Coolant Loss

Cause Correction
External engine leak is present at a seal, gasket, or Inspect the engine and its components for seal,
draincock. gasket, or draincock leaks. Correct any leaks.
Pressure cap is malfunctioning or has low-pressure Inspect the pressure cap (Cummins Fire Power Part
rating. No. 11407). Refer to Radiator Pressure Cap (008-
047) in Troubleshooting and Repair Manual C Series
Engines, Bulletin Number 3666003-02.
Cooling system hose is collapsed, restricted, or leaking. Inspect the hoses. Refer to Check Hose Condition in
Section 5. Replace any damaged hoses. Refer to
Coolant Hose Removal/Installation in Section 7.
Engine is overheating. Refer to the Coolant Temperature Above Normal

symptom tree.
Coolant is leaking into the lubricating oil. Check for coolant in the oil. Refer to the Coolant in the
Lubricating Oil symptom tree in this section.
Coolant is leaking into the combustion chamber. Remove the cylinder head, and inspect cylinder head,
gasket, and pistons for evidence of coolant. Refer to
Cylinder Head (002-004) in Troubleshooting and
Repair Manual C Series Engines, Bulletin Number
3666003-02.
Refer to a Cummins Authorized Repair Facility.

CFP83 Series
Coolant Temperature Above Normal

NOTE: The thermostat’s normal operating temperature range is 82-95 oC [180-203 oF]. The High Water
Temperature lamp on the local control panel (see Instrument Panel in Section 2) illuminates at 93 (92-94) oC
[200 (198-202) oF]. The lamp will only illuminate if the engine is running. If the lamp is illuminated or if
temperature is otherwise excessive, the engine should be stopped as soon as practical and the problem
corrected.
Cause Correction
Raw water flow is improperly aligned. Check that the raw water manifold is aligned for normal
flow through the solenoid valve (preferred) or bypass
flow around the solenoid valve (alternative). (Refer to
Drawing 9659 in Section 13.)
Align flow if required.
Raw water pressure regulator is improperly adjusted. NOTE: Pressure should be about 414 kPa [60 psig] or
slightly less.
Check the raw water pressure indication.
If pressure is indicated but is low, adjust the regulator
(Refer to Check Raw Water Pressure Regulator
Setpoints in Section 3.)
If pressure is not indicated or is excessively low, go to
Raw water solenoid has failed in this table.
Raw water solenoid has failed. If pressure is excessively low when aligned for normal
flow, open the bypass valves.
Then, when practical, troubleshoot the raw water
solenoid valve. Refer to Raw Water Solenoid Valve Fails
to Operate in this section.
If the solenoid valve operates, replace the pressure
regulator. (Refer to Raw Water Pressure Regulator
Removal/Installation in Section 7.)
If pressure is excessively low when aligned for bypass
flow, open the normal valves.
Then, when practical, replace the pressure regulator.
(Refer to Raw Water Pressure Regulator
Removal/Installation in Section 7.)

CFP83 Series
Coolant Temperature Above Normal (Cont)

Cause Correction
Raw water piping or heat exchanger is plugged. Check the raw water strainer for blockage. Refer to
Drawing 9659 in Section 13. Clean the strainer if
necessary.
Check the Cummins supplied raw water piping for
blockage. Clean the piping if necessary.
Check the customer supplied raw water piping for
blockage. Remove any blockage.
Check for flow through the heat exchanger. If
necessary, replace the heat exchanger. Refer to
Coolant Heat Exchanger Removal/Installation in
Section 7.
Coolant level is below specification. Check the coolant level. Refer to Check Coolant Level in
Section 5. Add coolant as required.
If coolant level was excessively low, go to Excessive
Coolant Loss in this section.
Cooling system hose is collapsed or restricted. Inspect the hoses. Refer to Check Hose Condition in
Section 5. Replace any damaged hoses. Refer to
Coolant thermostat is malfunctioning. Remove and test the coolant thermostat. Refer to
Coolant Thermostat Removal/Installation in Section 7.
Replace the thermostat if it is defective.
Coolant water pump is malfunctioning. Remove and inspect the water pump. Refer to Coolant
Water Pump Removal/Installation in Section 7. Replace
the thermostat if it is defective.

CFP83 Series

Cause Correction
Lubricating oil is contaminated with coolant or fuel. Check the appearance of the lubricating oil. If the color
and texture is abnormal, refer to the Lubricating Oil
Contaminated symptom tree.
Cooling system hose is collapsed, restricted, or Inspect the hoses. Refer to Check Hose Condition in
leaking. Section 5. Replace any damaged hoses. Refer to
Coolant mixture of antifreeze and water is not correct. Verify the concentration of antifreeze in the coolant.
Refer to Check Cooling System Condition in Section 5.
Add antifreeze or water to correct the concentration.
Refer to Coolant Recommendations and Specifications
in Section 10.
Lubricating oil level is above or below specification. Check the oil level. Refer to Check Engine Oil Level in
Section 5. Add or drain oil, if necessary.
Coolant temperature sender is malfunctioning. Check for an open or short circuit at the temperature
sender. If required, replace the temperature sender.
Refer to Coolant Temperature Sender Removal/
Coolant temperature gauge is malfunctioning. Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section 7.

CFP83 Series

Cause Correction
Coolant temperature switch is malfunctioning. Remove the temperature switch. Refer to Coolant
Temperature Switch Removal/Installation in Section 7.
Test the temperature switch. Repair or replace the
switch, if necessary.

CFP83 Series
Coolant Temperature Below Normal (Engine Off)

Cause Correction
The 120 VAC power supply to the coolant heater is Connect the power supply. Correct any electrical faults
not connected. in the supply circuit.
The heater’s overload thermostat has operated. Ensure that there is coolant in the heater. Allow time for
the automatic overload reset to occur.
Coolant temperature sender is malfunctioning. Replace the temperature sender. Refer to Coolant
Temperature Sender Removal/Installation in Section 7.
Coolant temperature gauge is malfunctioning. Replace the temperature sender. Refer to Coolant
Coolant is not free to circulate through the heater. Ensure that the coolant hoses are clear. Refer to
The coolant heater has failed electrically. Replace the coolant heater. Refer to Coolant Heater
Contact a Cummins Authorized Repair Facility.

CFP83 Series
Coolant Temperature Below Normal (Engine Running)

Cause Correction
Coolant thermostat has failed open. Test operation of the thermostat. Refer to Coolant
Thermostat Tests in Section 7.
If necessary, replace the thermostat. Refer to Coolant
Thermostat Removal/Installation in Section 7.
Coolant temperature sender is malfunctioning. Replace the temperature sender. Refer to Coolant
Coolant temperature gauge is malfunctioning. Replace the temperature gauge. Refer to Coolant
Temperature Gauge Removal/Installation in Section 7.

CFP83 Series
Raw Water Drain Steaming

NOTE: The raw water drain from the Coolant Heat Exchanger may steam if raw water flow is inadequate when
the engine is running. It may also steam shortly after the engine is stopped. If coolant is leaking into the raw
water drain piping, the steaming may last for some time while the engine cools. Antifreeze may also be
observed in the raw water drain.
Cause Correction
Raw water flow did not start when the engine started. Check engine coolant temperature. Go to Coolant
Temperature Above Normal in this section.
Engine coolant is leaking into the raw water piping in When practical, remove the coolant heat exchanger
the coolant heat exchanger. and perform the pressure test. Refer to Coolant Heat
Exchanger Removal/Installation in Section 7. If
pressure is not maintained, replace the heat
exchanger.

CFP83 Series
Raw Water Solenoid Valve Fails to Operate

NOTE: The raw water solenoid failure may fail to open or to close. The normally closed valve may fail to open
when the engine starts. This fault will prevent raw water flow through the normal valves. Bypass flow should be
aligned in this event. The valve may also fail to close because of mechanical blockage. In this event, the raw
water flow from the heat exchanger does not stop when it should. Depending upon the fire protection system
piping, the open solenoid valve may drain all water from the fire protection system piping that is higher than the
engine’s piping.
Cause Correction
Solenoid valve fails to close when the engine stops. Replace the solenoid valve. Refer to Raw Water
Solenoid Valve Removal/Installation in Section 7.
Clean the raw water strainer more frequently.
Increase the frequency of operational testing.
Solenoid valve fails to energize. Check electrical continuity and insulation from ground
to the solenoid. Repair any open or short circuits in the
wiring.
Solenoid fails to open mechanically. NOTE: Apply the correct operating voltage, 12 VDC
standard (24 VDC optional) depending upon the
model.
Apply temporary voltage to the solenoid. If the
solenoid fails to operate, replace it. Refer to Raw
Water Solenoid Valve Removal/Installation in Section
7.

CFP83 Series
Auto Start Failure - Does not Crank on A

NOTE: The fire pump engine will not crank automatically when solenoid A is selected at the fire protection
system. However, it does start automatically when solenoid B is selected.
Cause Correction
The electrical connection from the fire protection Test continuity and insulation from ground between the
system to Terminal Board TB 9 has failed. fire protection system and the engine control panel.
Locate and repair any electrical fault in the field wiring
or in the fire protection system panel.
The electrical connection from Terminal Board TB 9 to Test continuity and insulation from ground between the
Relay K1 has failed. TB 9 and Relay K1. Locate and repair any electrical
fault. Refer to Drawing 10423 Sheet 1 in Section 13.
Relay K1 has failed. Check de-energized continuity at Relay K1 pin 87 to

30. Replace K1 if the circuit is open.

CFP83 Series
Auto Start Failure - Does not Crank on B

NOTE: The fire pump engine will not crank automatically when solenoid B is selected at the fire protection
system. However, it does start automatically when solenoid A is selected.
Cause Correction
The electrical connection from the fire protection Test continuity and insulation from ground between the
system to Terminal Board TB 10 has failed. fire protection system and the engine control panel.
Locate and repair any electrical fault in the field wiring
or in the fire protection system panel.
The electrical connection from Terminal Board TB 10 Test continuity and insulation from ground between the
to Relay K2 has failed. TB 10 and Relay K2. Locate and repair any electrical
fault. Refer to Drawing 10423 Sheet 1 in Section 13.
Relay K2 has failed. Check de-energized continuity at Relay K2 pin 87 to

30. Replace K1 if the circuit is open.

CFP83 Series
Auto Start Failure - Does not Crank on A or B

NOTE: The fire pump engine will not crank automatically when either solenoid A or solenoid B is selected at the
fire protection system. However, it does crank and start when started locally. If local starting problems are
identified, go to the applicable Manual Start Failure troubleshooting table.
Cause Correction
The Fire Protection System fails to produce either Locate and correct the common mode fault in the Fire
redundant start signal to the fire pump. Protection System.

CFP83 Series
Auto Start Failure – Cranks but does not Start

NOTE: The fire pump engine will crank automatically when either solenoid A or solenoid B is selected at the fire
protection system. However, the engine does not start. The engine will start locally. If local starting problems are
identified, go to the applicable Manual Start Failure troubleshooting table.
Cause Correction
The overspeed switch as actuated. The overspeed Press the RESET switch on the local control panel.
lamp is illuminated on the local control panel.
Control power from the Fire Protection System is not When practical, locate and correct the fault in the Fire
available at local control panel TB1. Protection System or the field wiring to the local control
panel.
Circuit Breaker CB is open in the local control panel. Check whether Circuit Breaker CB at the local control
panel is open. Refer to Drawing 10423 Sheet 1 in
Section 13.
If open, reset the circuit breaker.
Locate and correct any electrical faults in the control
panel.
Press the RESET switch on the local control panel.
The AUTO/MANUAL Rocker Switch fails to select When practical, open Circuit Breaker CB at the local
AUTO mode. control panel and test switch operation electrically.
Refer to Drawing 10423 Sheet 1 in Section 13.
If required, replace the switch or repair other electrical
faults.
When done, close Circuit Breaker CB at the local
control panel and reset rocker switch to Auto mode.

CFP83 Series
Auto Start Failure – Cranks but does not Start (Cont)

The overspeed switch has failed. Check power and grounding to the overspeed switch.
Refer to Drawing 10423 Sheet 1 in Section 13. Repair
If required, test and adjust the overspeed setting.
Refer to Overspeed Setpoint Adjustment and Testing
in Section 3.
Replace the overspeed switch. Refer to Overspeed
Switch Removal/Installation in Section 7.

CFP83 Series
Auto Start Failure – Engine Starts but Crank Terminate does not Occur
Cause Correction
The overspeed switch not correctly adjusted or has When practical, with the engine running, verify speed
failed. sensor input to the overspeed switch. Refer to Drawing
If signal is not present, go to The speed sensor has
failed. The tachometer also indicates zero speed in
this table.
Adjust the overspeed switch crank terminate setpoint.
Refer to instructions in Section 3.
If required, replace the overspeed switch. Refer to
Overspeed Switch Removal/Installation in Section 7.
Fuse 3 has opened. The raw water solenoid valve also Open the raw water bypass valves.
fails to open.
When practical, replace Fuse F3.
Locate and repair any local electrical fault. Refer to
The speed sensor has failed. The tachometer also When practical, locate and repair any electrical fault in
indicates zero speed. the speed sensor circuitry. Refer to Drawing 10423
Sheet 1 in Section 13.
If necessary, replace the speed sensor. Refer to
Speed Sensor Removal/Installation in Section 7.
An electrical fault is present in the Fire Protection When practical, test continuity and insulation from
System. ground in the fire protection system and the engine
control panel. Locate and repair any electrical fault in
the fire protection system panel.
An electrical fault is present between Control Panel TB When practical, test continuity and insulation from
2 and the Fire Protection System. ground between the fire protection system and the
engine control panel. Locate and repair any electrical
fault in the field wiring.

CFP83 Series
Auto Start Failure – Engine Starts but Crank Terminate does not Occur
(Cont)
An electrical fault is present in the control panel When practical, test continuity and insulation from
between Fuse F3 and TB 2. ground between Fuse F3 and TB 2. Locate and repair
any electrical fault. Refer to Drawing 10423 Sheet 1 in
Section 13.

CFP83 Series
Manual Start Failure from Solenoid Lever - Does not Crank on A

NOTE: The fire pump engine will not crank locally from the solenoid lever when solenoid A is actuated.
However, it does start when solenoid B is actuated.
Cause Correction
Battery A is discharged or has failed. Recharge or replace the battery.
An electrical fault is present between Battery A and the When practical, test continuity and insulation from
starter motor. ground between Battery A and the starter motor.
Locate and repair any electrical fault. Refer to Drawing
Solenoid A’s switch contact does not close. Remove and test Solenoid A lever and switch
operation. Refer to Crank Solenoid Assembly
If required, replace Solenoid A.

CFP83 Series
Manual Start Failure from Solenoid Lever - Does not Crank on B

NOTE: The fire pump engine will not crank locally from the solenoid lever when solenoid B is actuated.
However, it does start when solenoid A is actuated.
Cause Correction
Battery B is discharged or has failed. Recharge or replace the battery.
An electrical fault is present between Battery B and the When practical, test continuity and insulation from
starter motor. ground between Battery B and the starter motor.
Locate and repair any electrical fault. Refer to Drawing
Solenoid B’s switch contact does not close. Remove and test Solenoid B lever and switch
operation. Refer to Crank Solenoid Assembly
If required, replace Solenoid B.

CFP83 Series
Manual Start Failure from Solenoid Lever - Does not Crank on A or B

NOTE: The fire pump engine will not crank locally when either solenoid lever is actuated.
Cause Correction
Starter motor has failed. Replace the starter motor. Refer to Starter Motor
An electrical fault is present in the power or ground Test continuity and insulation from ground between the
circuit for the starter motor. battery splice, the ground connection, and the starter
motor. Locate and repair any electrical fault. Refer to
Engine is seized. Bar the engine over to break the seizure.

CFP83 Series
Manual Start Failure from Control Panel - Does not Crank on A

NOTE: The fire pump engine will not crank locally from the control panel when CRANK BATT A is selected.
However, it does start when CRANK BATT B is selected.
Cause Correction
The CRANK BATT A switch fails to make contact. When practical, test the electrical operation of the
CRANK BATT A switch. Refer to Drawing 10423 Sheet
1 in Section 13. Replace the switch if faulted.
Relay K1 fails in the local manual mode. When practical, test the electrical operation of the
Relay K1. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the relay if faulted.
Solenoid A fails to energize due to electrical fault in the Test continuity and insulation from ground between the
power or ground circuit. CRANK BATT A switch, Relay K1, and the starter
Solenoid. Also, check the solenoid coil connection to
ground. Locate and repair any electrical fault. Refer to
Solenoid A fails to operate. When practical, test the electrical operation of the
Solenoid A. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the solenoid if faulted.

CFP83 Series
Manual Start Failure from Control Panel - Does not Crank on B

NOTE: The fire pump engine will not crank locally from the control panel when CRANK BATT B is selected.
However, it does start when CRANK BATT A is selected.
Cause Correction
The CRANK BATT B switch fails to make contact. When practical, test the electrical operation of the
CRANK BATT B switch. Refer to Drawing 10423 Sheet
1 in Section 13. Replace the switch if faulted.
Relay K2 fails in the local manual mode. When practical, test the electrical operation of the
Relay K2. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the relay if faulted.
Solenoid B fails to energize due to electrical fault in the Test continuity and insulation from ground between the
power or ground circuit. CRANK BATT B switch, Relay K2, and the starter
Solenoid. Also, check the solenoid coil connection to
ground. Locate and repair any electrical fault. Refer to
Solenoid B fails to operate. When practical, test the electrical operation of the
Solenoid B. Refer to Drawing 10423 Sheet 1 in Section
13. Replace the solenoid if faulted.

CFP83 Series
Manual Start Failure from Control Panel - Does not Crank on A or B

NOTE: The fire pump engine will not crank locally from the control panel when either CRANK BATT A or
CRANK BATT B is selected. However, it does start when a solenoid lever is actuated.
Cause Correction
The MANUAL mode rocker switch contact fails to When practical, test the electrical operation of the
close. AUTO/MANUAL rocker switch. Refer to Drawing
10423 Sheet 1 in Section 13. Replace the solenoid if
faulted.
An electrical fault exists in the signal power circuit or Test continuity and insulation from ground between the
the ground to the Relays K1 and K2. AUTO/MANUAL rocker switch and the relays. Also,
check the relay connection to ground. Locate and
repair any electrical fault. Refer to Drawing 10423
Sheet 1 in Section 13.
Fuse F3 has opened. The raw water solenoid valve Open the raw water bypass valves.
also fails to open.
When practical, replace Fuse F3.
Locate and repair any local electrical fault. Refer to
An electrical fault exists in the signal power circuit or Test continuity and insulation from ground between
the ground to the overspeed switch’s crank circuit. Fuse F3 and the overspeed switch’s crank circuit.
Also, check the crank circuit output to the CRANK
BATT switches. Locate and repair any electrical fault.
Overspeed switch crank circuit fails to reset with If required, test and adjust the crank setting. Refer to
engine shutdown. Overspeed Setpoint Adjustment and Testing in Section
3.
If required, replace the overspeed switch. Refer to
Overspeed Switch Removal/Installation in Section 7.

CFP83 Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke)
Cause Correction
No fuel in supply tank. Check and replenish fuel supply. Check fittings and
hose connections and hose conditions.
Air is in the fuel system. Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and
fuel filters as necessary.
Vent air from the system. Refer to Air in Fuel in
Section 7.
Fuel Shutoff Valve (FSOV) fails to open. If the fuel shutoff valve is not functioning, manually
override it. Refer to Emergency Starting With Failed
Fuel Shut-Off Solenoid in Section 3.
When practical, check the wiring for electrical faults.
If the wiring is OK, replace the Fuel Shutoff Valve.
Refer to Fuel Shutoff Valve (FSOV) Removal/
Fuel grade is not correct for the application or the fuel Operate the engine from a tank of high-quality fuel.
quality is poor. Refer to Fuel Recommendations and Specifications in
Section 10.
Fuel connections on the suction side of the fuel lift Tighten all the fuel fittings and connections between
pump are loose. the fuel tanks and fuel lift pump.

CFP83 Series
Engine Cranks Normally But Will Not Start (No Exhaust Smoke) (Cont)
Cause Correction
Fuel lift pump malfunctioning. Inspect the fuel transfer pump. Replace if necessary.
Refer to Fuel Lift Pump (005-045) in Troubleshooting
and Repair Manual C Series Engines, Bulletin
Number 3666003-02.
Fuel filter is blocked. Remove and inspect the fuel filter. Replace the fuel
filter if necessary. Refer to Change Fuel Filter (Spin-
on Type) in Section 5.
Fuel suction standpipe in the fuel tank is broken. Check and repair the standpipe, if necessary.
Fuel tank air breather hole is clogged. Clean the fuel tank breather.
Fuel supply line restriction is present. Clean all pre-filters and screens. Check the fuel
suction line for restriction.
Excessive water in the fuel filter. Drain the fuel water separator and replace the fuel
filter. Refer to Change Fuel Filter (Spin-on Type) in
Section 5.
Intake and exhaust system restricted. Check the intake and exhaust systems for restrictions.
Inspect the intake air filter and replace as necessary.
Refer to Air Leaks, Air Intake and Exhaust Systems
(010-024) in Troubleshooting and Repair Manual C
Series Engines, Bulletin Number 3666003-02.

CFP83 Series
Cause Correction
Fuel injection pump not getting fuel or air in fuel. Check fuel flow or bleed fuel system. Refer to Air in
Fuel (006-003) in Troubleshooting and Repair Manual
C Series Engines, Bulletin Number 3666003-02.
Fuel return restriction excessive. Inspect the fuel return lines for restrictions. Refer to
Fuel Drain Line Restriction (006-012) in
Troubleshooting and Repair Manual C Series
Fuel pump return overflow valve is malfunctioning. Inspect the return overflow valve. Replace if
necessary. Refer to Fuel Return Overflow Valve (006-
Fuel injection pump timing is not correct. Put the engine at top dead center. Check and adjust
the fuel timing. Refer to Fuel Injection Pumps, In-Line
Injection pump driveshaft or driveshaft key is damaged. Repair or replace the injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 7.
Fuel injection pump is malfunctioning. Remove the fuel injection pump. Refer to Fuel
Injection Pump Removal/Installation in Section 7.
Check the calibration of the fuel injection pump. Refer
to Fuel Injection Pumps, In-Line (005-012) in

CFP83 Series
Cause Correction
Camshaft timing is not correct (after engine rebuild or Check the gear train timing alignment. Refer to
repair). Camshaft (001-008) in Troubleshooting and Repair
Manual C Series Engines, Bulletin Number 3666003-
02.
Fuel injectors are plugged. Replace the fuel injectors. Refer to Fuel Injectors
Throttle linkage misadjusted or damaged. Adjust or repair the linkage. Refer to instructions in
Section 7.
Starting motor rotation is not correct. Check the direction of crankshaft rotation. Refer to
instructions in Section 7.
Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 7.
Starting motor is not turning the engine. Replace the starting motor if necessary. Refer to
Starter Motor Assembly Removal/Installation in
Section 7.

CFP83 Series
Engine Cranks Slowly But Does Not Start

NOTE: Typical engine cranking speed is 120 RPM. Engine cranking speed can be checked with a hand-held
tachometer, stroboscope, or electronic service tool.
Cause Correction
The batteries are cold. Ensure that the batteries are protected from extreme
temperatures.
The battery cables or connections are loose, broken, or Check the battery cables and connections. Ensure
corroded creating excessive resistance. that connections are clean and tight.
The battery is not properly charged or has failed. Recharge the battery. If the battery does not take the
charge, replace it.
Lubricating oil level is too high. Check the oil level. Refer to Check Engine Oil Level in
Section 7. Drain any excess oil.
Lubricating oil is the wrong grade or type. Check the grade and type of oil. Refer to Lubricating
Oil Recommendations and Specifications in Section
10.
If the wrong type or grade of oil is present, drain and
replace it. Refer to Change Lubricating Oil and Filters
in Section 7.
Engine temperature is too low. Troubleshoot as per Coolant Temperature Below

Normal (Engine Off) in this section.
Starting motor is malfunctioning. Replace the starting motor. Refer to Starter Motor
Assembly Removal/Installation in Section 7.

CFP83 Series
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present

NOTE: If the engine cranks slowly, refer to Engine Cranks Slowly But Does Not Start in this section.
Cause Correction
Fuel tank level is low. Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Fuel drain line is restricted. Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as
necessary.
Fuel return line improperly plumbed. Make sure the fuel return line is plumbed to the
bottom of the fuel tank.
Fuel filter is clogged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Section 10.
Fuel shutoff valve (FSOV) is malfunctioning. Check for loose wires and verify that the fuel shutoff
valve solenoid is functioning. Check to be sure
manual shutoff lever is not binding at the injection
pump. Refer to Fuel Pump Control Lever and Spring

CFP83 Series
Engine Difficult to Start or Will Not Start - Exhaust Smoke Present (Cont)
Cause Correction
(005-012) or Fuel Injection Pump, In-Line, Spill Port
Timing (005-013) in Troubleshooting and Repair
Manual C Series Engines, Bulletin Number
3666003-02.
Fuel injection pump is malfunctioning. Replace the fuel injection pump. Refer to Fuel
Injection Pumps, In-Line (005-012) or Fuel Injection
Pump, In-Line, Spill Port Timing (005-013) in
Air is present in the fuel supply system to the engine. Check for air in the fuel system. Refer to Air in Fuel
Fuel pre-filter is clogged. Clean the customer-supplied fuel pre-filter.
Fuel suction line is restricted. Check the fuel suction line for restriction.

CFP83 Series
Cause Correction
Fuel suction standpipe in the fuel tank is broken. Check and repair the standpipe, if necessary.
Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
the pump output pressure. Replace the fuel lift pump if
necessary. Refer to Fuel Lift Pump Removal/
Section 7.
Intake air flow is restricted. Check the air intake system for restriction. Refer to
Check Air Cleaner Service Indicator in Section 5.
Replace the air filter if required.
Charge air cooler air flow is restricted (CFP83-F45 Inspect the air cooler for internal and external
Only), intake air is overheated. restrictions. Replace the restricted cooler if necessary.
Refer to Clean Charge Air Cooler (CAC) in Section 7.
Aftercooler air flow is restricted (CFP83-F10, F20, F30 Inspect the air cooler for internal and external
Only), intake air is overheated. restrictions. Replace the restricted cooler if necessary.
Refer to Aftercooler Assembly (010-002) in

CFP83 Series
Cause Correction
Exhaust air flow is restricted. Check the exhaust air piping for restriction. Remove
any restriction.
Valves are not sealing correctly. Check and adjust the valves. Refer to Valve, Cylinder
Head (002-020) in Troubleshooting and Repair
3666003-02.
Injectors worn or malfunctioning. Remove and test the injectors. Replace as necessary.
Refer to Injector (006-026) in Troubleshooting and
3666003-02.
Engine compression is low. Perform the compression check to identify the

malfunction. Correct as required. Refer to Engine
Testing (Chassis Dynamometer) (014-002) in

CFP83 Series
Engine Acceleration or Response Poor

Cause Correction
Fuel level is low in the tank. Fill the fuel tank. Fill and bleed the fuel lines to the
engine.
Fuel inlet restriction. Check for fuel inlet restriction. Refer to Fuel Inlet
Restriction (006-020) in Troubleshooting and Repair
3666003-02.
Fuel drain line is restricted. Check the fuel drain lines for restriction. Clear or
replace the fuel lines, check valves, or tank vents as
necessary.
Section 7.
Fuel leak. Check the fuel lines, fuel connections, and fuel filters
for leaks. Check the fuel lines to the supply tanks.
Air is present in the fuel supply system to the engine. Check for air in the fuel system. Refer to Air in Fuel
Section 10.

CFP83 Series
Engine Acceleration or Response Poor (Cont)

Cause Correction
Fuel supply line restriction between the fuel pump and Check the fuel supply line from the fuel pump to the
the injectors. cylinder head for sharp bends that can cause
restrictions. Refer to Fuel Supply Lines (006-024) in
Fire pump is not correctly sized for the engine. Check for correct pump sizing.
Air intake or exhaust leaks. Inspect the air intake and exhaust systems for air
leaks. Refer to Air Leaks, Air Intake and Exhaust
Systems (010-024) in Troubleshooting and Repair
3666003-02.
3666003-02.
Fuel pre-filter is clogged. Clean the customer-supplied fuel pre-filter.

CFP83 Series

Cause Correction
Fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
Turbocharger wastegate is malfunctioning (if Check the wastegate for correct operation. Refer to
equipped). Turbocharger Wastegate Actuator (010-050) in
Turbocharger wheel clearance is out of specification. Check the radial bearing clearance and axial
clearance. Inspect the turbocharger. Repair or replace
the turbocharger if necessary. Refer to Turbocharger
Axial Clearance (010-038) and Turbocharger Radial
Bearing Clearance (010-047) in Troubleshooting and
3666003-02.

CFP83 Series

Cause Correction
Turbocharger is malfunctioning. Replace the turbocharger if necessary. Refer to

Turbocharger (010-033) in Troubleshooting and
3666003-02.
3666003-02.
Exhaust system restriction is not within specification. Check the exhaust system for restrictions. Refer to
Exhaust Restriction (011-009) in Troubleshooting and
3666003-02.
Exhaust air is leaking. Check the exhaust piping for loose or damaged piping
connections and missing pipe plugs.
Check the turbocharger and exhaust manifold
mounting.
If required, replace the turbocharger. Refer to
Turbocharger Removal/Installation in Section 7.
The charge air cooler is restricted or leaking (CFP83- Inspect the charge air cooler for air restrictions or
F40 Only). leaks. If required, replace the charge air cooler. Refer
to Charge Air Cooler Removal/Installation in
Section 7.

CFP83 Series

Cause Correction
The aftercooler is restricted or leaking (CFP83-F10, Inspect the air cooler for internal and external
F20, F30 Only). restrictions. Replace the restricted cooler if necessary.
Overhead adjustments are not correct. Measure and adjust the overhead settings. Refer to
Overhead Set (003-004) in Troubleshooting and
3666003-02.

Valves are not sealing correctly. Check and adjust the valves. Refer to Valve, Cylinder
02.
Internal engine damage. Analyze the oil and inspect the filters to locate an area
of probable damage. Refer to Lubricating Oil Analysis

CFP83 Series
Engine Noise Excessive - Mechanical

Cause Correction
Lubricating oil is thin or diluted. Check the oil level. Refer to Check Lubricating Oil
Level in Section 7. If the oil level is above the high
mark, go to Oil Level Rises in this section.
Otherwise, ensure that the correct type and grade of
lubricating oil is being used. Refer to the Lubricating
Oil Recommendations and Specifications in
Section 10.
Lubricating oil pressure is below specification. NOTE: Oil pressure should range between 69 and
345 kPa [10 to 50 PSI] with the engine running.
Check the oil pressure on the local control panel.
If the pressure is low, refer to the Lubricating Oil
Pressure Low symptom tree in this section.
Vibration damper is damaged. Inspect the vibration damper. Refer to Inspect

Vibration Damper in Section 5. If the vibration damper
is damaged, refer to a Cummins Authorized Repair
Facility.
Engine mounts are worn or damaged. Inspect the engine mounts. If the engine mounts are
worn or damaged, refer to a Cummins Authorized
Repair Facility.
Coolant temperature is above specification. Check the coolant temperature indication on the local
control panel. If the high coolant temperature light is
illuminated, refer to the Coolant Temperature Above
Normal symptom tree in this section.

CFP83 Series
Engine Noise Excessive – Mechanical (Cont)

Cause Correction
Drive belt is squeaking due to insufficient tension or Check the automatic belt tensioner. If required,
high loading. replace the tensioner. Refer to Automatic Belt
Tensioner Removal/Installation in Section 7.
Exhaust air flow is restricted. Check the exhaust air piping for restriction. Remove
any restriction.
Intake air or exhaust leaks. Refer to the Excessive Black Exhaust Smoke
symptom tree in this section.
Turbocharger noise. Turbocharger fluttering noises can be heard during

deceleration or quick throttle closing. This noise is
normal.
Air leakage between the turbocharger and head. Tighten the clamp between turbocharger and head.
Repair leaks between turbocharger and head.
Valve lash excessive. Adjust valves. Make sure the push rods are not bent
or rocker levers not severely worn. Refer to Push
Rods or Tubes (004-014) and Overhead Set (003-

CFP83 Series
Engine Noise Excessive – Mechanical (Cont)

Cause Correction
Gear train backlash is excessive or the gear teeth are Check the gear backlash and the gear teeth. Refer to
damaged. Gear Housing, Front (001-033) in Troubleshooting
Number 3666003-02.
Power knock. Inspect rod bearings. Replace if necessary. Refer to

Connecting Rod (001-014) in Troubleshooting and
3666003-02.

CFP83 Series
Engine Noise Excessive — Combustion Knocks

Cause Correction
Engine is overloaded. Check for added mechanical loading from damaged or

defective pump, changes in suction head, or changes
in discharge piping restriction.
Fuel grade is not correct for the application or the fuel Operate the engine using the correct fuel. Refer to
quality is poor. Fuel Recommendations and Specifications in Section
10.
Air is present in the fuel supply to the engine. Check for air in the fuel system. Tighten or replace the
Section 7.
3666003-02.
Coolant temperature is below specification. Refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree in this section.

CFP83 Series
Engine Noise Excessive — Combustion Knocks (Cont)

Cause Correction
3666003-02.

CFP83 Series
Engine Runs Rough at Idle

NOTE: Operation at idle speed is for maintenance only.
Cause Correction
The engine is cold. Allow the engine to warm to operating temperature.

If the engine will not reach operating temperature,
refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree.
Idle speed is set too low. Check and adjust the low-idle screw. Refer to Fuel
Pump Idle Speed (005-029) in Troubleshooting and
3666003-02.
Engine mounts are worn, damaged, loose, or not Verify the condition of the mounts. Refer to Engine
correct. Mounts (016-010) in Troubleshooting and Repair
3666003-02.
Air is present in the fuel system. Bleed the fuel system and check for suction leaks.
Refer to Fuel Supply Lines (006-024) in
Fuel filter is becoming plugged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel supply to the engine is inadequate. Locate and correct the restriction in fuel flow to the
engine.

CFP83 Series
Engine Runs Rough at Idle (Cont)

Cause Correction
The fuel lift pump is malfunctioning. Inspect the fuel lift pump. Replace if necessary. Refer
to Fuel Lift Pump (005-045) in Troubleshooting and
3666003-02.
Fuel grade is not correct for the application or the fuel Operate the engine on the required fuel. Refer to Fuel
quality is poor. Recommendations and Specifications in Section 10.
Fuel pump overflow valve is malfunctioning. Inspect the return overflow valve. Replace if
Fuel injection pump timing is incorrect. Put the engine at top dead center. Check and adjust
the fuel timing. Refer to Fuel Injection Pump, In-Line,
Spill Port Timing (005-013) in Troubleshooting and
3666003-02.
Valves are not sealing correctly. Check and adjust the valves. Refer to Overhead Set


CFP83 Series
Engine Runs Rough at Idle (Cont)

Cause Correction
Injector is malfunctioning. Inspect the injectors. Replace the injectors as

necessary. Refer to Injector (006-026) in
Fuel injection pump is malfunctioning. Remove the fuel pump. Refer to Procedure Fuel
Injection Pumps, In-Line (005-012) in Troubleshooting
Number 3666003-02. Calibrate the fuel pump.

CFP83 Series
Engine Runs Rough or Misfires Under Load

Cause Correction
The engine is cold. Allow the engine to warm to operating temperature.

If the engine will not reach operating temperature,
refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree.
Air is present in the fuel system. Check for air in the fuel system. Tighten or replace the
Section 7.
The fuel filter is becoming plugged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel supply to the engine is inadequate. Locate and correct the restriction in fuel flow to the
engine.
Fuel grade is not correct for the application or the fuel Operate the engine on the required fuel. Refer to Fuel
Engine fuel leak is present. Check the fuel lines, fuel connections, fuel delivery
valve seals, and fuel filters for leaks. Check the fuel
lines from the supply tank(s). Refer to Fuel Supply
Lines (006-024) in Troubleshooting and Repair
3666003-02. Calibrate the fuel pump.

CFP83 Series
Engine Runs Rough or Misfires Under Load (Cont)

Cause Correction
Engines, Bulletin Number 3666003-02. Calibrate the
fuel pump.
The fuel lift pump is malfunctioning. Inspect the fuel lift pump. Replace if necessary. Refer
to Fuel Lift Pump (005-045) in Troubleshooting and
Calibrate the fuel pump.
Injectors are worn or malfunctioning. Check the injectors and replace any malfunctioning
injectors. Refer to Injector (006-026) in
fuel pump.

malfunction. Correct as required. Refer to Section 9.

CFP83 Series
Engine Runs Rough or Misfires Under Load (Cont)

Cause Correction
Fuel injection pump timing is incorrect. Check and adjust the injection pump timing. Refer to
Fuel Injection Pumps, In-Line (005-012) in
Fuel injection pump is malfunctioning. Replace the fuel pump. Refer to Fuel Injection Pumps,
In-Line (005-012) in Troubleshooting and Repair Manual
Camshaft timing is not correct (after engine rebuild or Check the gear train timing alignment. Refer to
repair). Camshaft (001-008) in Troubleshooting and Repair
Manual C Series Engines, Bulletin Number 3666003-02.
Camshaft, tappets, or pushrods are damaged. Inspect the camshaft and tappets. Refer to Camshaft
(001-008) or Tappet (004-015) in Troubleshooting and

CFP83 Series
Engine Speed Surges at Idle

NOTE: Operation at idle speed is for maintenance only.
Cause Correction
engine.
Idle speed is set too low. Check and adjust the low-idle screw. Refer to Fuel
Pump Idle Speed (005-029) in Troubleshooting and
3666003-02.
Air is in the fuel supply to the engine. Check for air in the fuel system. Tighten or replace the
fuel connections, fuel lines, fuel tank standpipe and fuel
filters as necessary.
Vent air from the system. Refer to Air in Fuel in Section
7.
The fuel filter is plugged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel flow to the engine is not adequate. Locate and correct the restriction in the customer-
supplied fuel lines to the engine.
Fuel grade is not correct for the application or the fuel Operate the engine with the required fuel. Refer to Fuel
A fuel supply line restriction exists between the fuel Check the fuel supply line or passage for sharp bends or
injection pump and the injectors. restriction. Remove any restrictions.

CFP83 Series
Engine Speed Surges at Idle (Cont)

Cause Correction
Moisture is present in the wiring harness connectors. Dry the connectors with Cummins electronic cleaner,
Part Number 3824510.
Engine is operating under excessive load. Check for added mechanical loading from damaged or
defective pump, changes in suction head, or changes in
discharge piping restriction.
Section 7.
Engine fuel leak is present. Check the fuel lines, fuel connections, fuel delivery valve
seals, and fuel filters for leaks. Check the fuel lines from
the supply tank(s). Refer to Fuel Supply Lines (006-024)
in Troubleshooting and Repair Manual C Series
Engines, Bulletin Number 3666003-02. Calibrate the fuel
pump.
injectors. Refer to Injector (006-026) in Troubleshooting
and Repair Manual C Series Engines, Bulletin Number

CFP83 Series
Engine Speed Surges at Idle (Cont)

Cause Correction

CFP83 Series
Engine Speed Surges Under Load

Cause Correction
Pump suction head or pump discharge head changes. Some variation in speed response to load changes is
normal. Excessive speed changes may occur upon
sudden failures in either suction or discharge piping
systems.
engine.
Air is in the fuel supply to the engine. Check for air in the fuel system. Tighten or replace the
Section 7.
The fuel filter is plugged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 7.
Fuel flow to the engine is not adequate. Locate and correct the restriction in the customer-
The fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
Fuel grade is not correct for the application or the fuel Operate the engine with the required fuel. Refer to
quality is poor. Fuel Recommendations and Specifications in
Section 10.

CFP83 Series
Engine Speed Surges Under Load (Cont)

Cause Correction
A fuel supply line restriction exists between the fuel Check the fuel supply line or passage for sharp bends
injection pump and the injectors. or restriction. Remove any restrictions.
injectors. Refer to Injector (006-026) in
fuel pump.
In-Line (005-012) in Troubleshooting and Repair
3666003-02.
Moisture is present in the wiring harness connectors. Dry the connectors with Cummins electronic cleaner,
Part Number 3824510.

CFP83 Series
Engine Vibration Excessive at Rated Speed

Cause Correction
Engine runs rough or is misfiring. Refer to the Engine Runs Rough or Misfires Under
Load symptom tree in this section.
Alternator bearing is worn or damaged. Check if the alternator is vibrating excessively.

Replace the alternator if necessary. Refer to
Alternator Removal/Installation in Section 7.
Water pump bearing is worn or damaged. Check if the water pump is vibrating excessively.
Replace the pump if necessary. Refer to Water Pump
Automatic belt tensioner bearing is worn or damaged. Check if the belt tensioner is vibrating excessively.
Replace the tensioner if necessary. Refer to
Automatic Belt Tensioner Removal/Installation in
Section 7.
Vibration damper is damaged. Inspect the vibration damper. Refer to Vibration

Damper, Viscous (001-052) in Troubleshooting and
Engine mounts are worn, damaged, loose, or not Verify the condition of the mounts. Refer to Engine
correct. Mounts (016-010) in Troubleshooting and Repair

CFP83 Series
Engine Vibration Excessive at Rated Speed (Cont)

Power components loose or broken. Inspect the crankshaft and rods for damage that
causes an unbalance. Refer to Crankshaft (001-016)
or Connecting Rod (001-014) in Troubleshooting and
Flywheel housing is not aligned correctly. Check the flywheel housing alignment. Refer to
Flywheel Housing (016-006) in Troubleshooting and
Flywheel capscrews are loose or broken. Check the flywheel and the mounting capscrews.
Refer to Flywheel (016-005) in Troubleshooting and

CFP83 Series
Engine Stops During Operation

Cause Correction
Normal automatic mode shutdown occurs when the fire No action required This is a desirable outcome.
protection systems removes the signal power feed to
the local control panel.
In the automatic mode, the signal power feed is lost Locate and correct the electrical fault in the fire
from the fire protection system to the control panel. protection system or the field wiring to the engine
control panel.
Signal power is lost by the operation of the circuit Press the circuit breaker reset button on the engine
breaker the engine control panel. control panel.
Locate and correct the electrical fault in engine
control panel. Refer to Drawing 10423 Sheet 1 in
Section 13.
An overspeed trip has occurred. The overspeed trip Go to Engine Overspeed Trip in this section.
light is illuminated on the local control panel. Remote
indications may also be present.
Alternatively, a related overspeed switch failure has
occurred. The trip indications may not be present.
The fuel shutoff valve (FSOV) has failed. Check the wiring continuity and insulation from
ground for the Fuel Shutoff Switch. Refer to Drawing
10423 Sheet 1 and Drawing 10423 Sheet 2 in Section
13. Correct any electrical faults.
If required, replace the FSOV. Refer to Fuel Shutoff
Valve (FSOV) Removal/Installation in Section 7.
Fuel tank level is low. Fill the fuel tank. Fill and bleed the fuel lines to the
engine.

CFP83 Series
Engine Stops During Operation (Cont)

Cause Correction
Clogged fuel tank air breather hole. Clean the fuel tank breather.
Customer-supplied fuel pre-filter is clogged. Clean the fuel pre-filter. Fill and bleed the fuel lines to
the engine.
Fuel piping to engine is clogged. Clean and repair the fuel piping to the engine.
The fuel filter is clogged. Replace the fuel filter. Refer to Change Fuel Filter in
Section 5.
Air is trapped in the low pressure fuel lines at the Bleed the fuel lines. Refer to Air in Fuel in Section 7.
engine.
The fuel lift pump is malfunctioning. Check the fuel lift pump for correct operation. Check
02.

CFP83 Series
Engine Will Not Reach Rated Speed (RPM)

Cause Correction
Load is excessive for engine horsepower rating. Reduce the engine load.
Throttle adjustment is not correct. Check the throttle adjustment. Refer to instructions in
Section 3.
Fuel shutoff lever (mechanical) is partially engaged. Check for correct solenoid operation. Refer to Fuel
Shutoff Valve (005-043) in Troubleshooting and Repair
3666003-02.
Engine fuel leak is present. Check the fuel lines, fuel connections, fuel delivery
valve seals, and fuel filters for leaks. Check the fuel
lines from the supply tank(s). Refer to Fuel Supply
Lines (006-024) in Troubleshooting and Repair Manual
Fuel pump return overflow valve is malfunctioning. Inspect the return overflow valve. Replace if necessary.
Refer to Fuel Return Overflow Valve (006-044) in
Bulletin Number 3666003-02. Calibrate the fuel pump.
Tachometer is not calibrated. Compare the tachometer reading with a handheld

tachometer or an electronic service tool reading.
If out of calibration, calibrate the tachometer as
necessary at the CAL adjustment on the back of the
gauge. Refer to Tachometer Calibration in Section 7.

CFP83 Series
Engine Will Not Reach Rated Speed (RPM) (Cont)

Cause Correction
Tachometer is malfunctioning. Replace the tachometer. Refer to Tachometer

Engine power output is low. Refer to the Engine Acceleration or Response Poor
symptom tree in this section.
Fuel grade is not correct for the application, or the Operate the engine with the required fuel. Refer to Fuel
fuel quality is poor. Recommendations and Specifications in Section 10.
Section 5.
Charge air cooler air flow is restricted (CFP83-F40 Inspect the charge air cooler for internal and external
Only). restrictions. Replace the restricted cooler if necessary.
Refer to Charge Air Cooler (CAC) Removal and
Aftercooler air flow is restricted (CFP83-F10, F20, Inspect the aftercooler for internal and external
F30 Only). restrictions. Replace the aftercooler if necessary. Refer
to Aftercooler Assembly (010-002) in Troubleshooting

CFP83 Series

Cause Correction
Fuel supply is not adequate. Locate and correct the restriction in the customer-
Exhaust back pressure is too high. NOTE: The maximum allowable exhaust back pressure
is specified in Exhaust System Specifications in Section
10.
Measure the exhaust back pressure. Correct the
problem if it is above specification.
The fuel lift pump is malfunctioning. Inspect the fuel lift pump. Replace if necessary. Refer to
Fuel Lift Pump (005-045) in Troubleshooting and Repair
Turbocharger wastegate is malfunctioning (CFP83- Check the wastegate for correct operation. Refer to
F40 Only). Turbocharger Wastegate Actuator (010-050) in

CFP83 Series

Cause Correction
A base engine problem is present. Check the engine for high crankcase pressure, low
compression, static injection timing, damaged pistons,
camshaft, and other parts. Refer to Engine Testing
(Chassis Dynamometer) (014-002) in Troubleshooting
3666003-02.

CFP83 Series
Engine Will Not Shut Off Remotely

NOTE: Stop the engine mechanically by moving the manual shutoff lever to the STOP position. Refer to
Emergency Manual Stopping Procedure in Section 3.
Cause Correction
Stop circuit malfunction in the fire pump controller of NOTE: In the AUTO mode, the fire pump engine stops
field wiring. upon loss of signal power from the fire pump controller.
Check the engine stop circuit in the fire pump controller.
Correct any faults.
Check for short to voltage on the signal wiring from the
fire pump controller to the engine control panel. Correct
any faults.
Check operation of the switch contacts of the
AUTO/MANUAL switch at the engine control panel.
Replace the switch if the switch contacts fail to operate
properly.
Fuel shutoff valve (FSOV) is malfunctioning. Check for correct solenoid operation. Refer to Fuel
Shutoff Valve (005-043) in Troubleshooting and Repair
Engine is running on fumes drawn into the air intake. Check the air intake ducts. Locate and isolate the
source of the fumes. Repair as necessary.

CFP83 Series
Engine Will Not Shut Off Locally

NOTE: Stop the engine mechanically by moving the manual shutoff lever to the STOP position. Refer to
Emergency Manual Stopping Procedure in Section 3.
Cause Correction
Engine is running on fumes drawn into the air intake. Check the air intake ducts. Locate and isolate the
source of the fumes. Repair as necessary.
Fuel shutoff valve (FSOV) is malfunctioning. Check for correct solenoid operation. Refer to Fuel
Shutoff Valve (005-043) in Troubleshooting and
3666003-02.
3666003-02.

CFP83 Series
Excessive Black Exhaust Smoke

Cause Correction
Engine is being lugged down. Increase pump suction head or decrease pump
discharge head.
Air filter is plugged. Check the air intake system for restriction. Refer to
AFC plunger not fully open. Inspect AFC air tube and fuel drain lines for
restriction. Inspect the AFC operation.
Aftercooler restricted (CFP83-F10, F20, F30 Only). Inspect for plugged passages in the aftercooler. Refer
to Aftercooler Assembly (010-002) in Troubleshooting
Number 3666003-02.
Exhaust system restriction. Check the exhaust system for any restrictions. Refer
to Exhaust Restriction (011-009) in Troubleshooting
Number 3666003-02.
Charge air cooler is restricted or leaking (CFP83-F40 Inspect the charge air cooler for air restrictions or
Only). leaks.

CFP83 Series
Excessive Black Exhaust Smoke (Cont)

Cause Correction
Air leak between the turbocharger and the intake Check for leaks in the air crossover tube, charge air
manifold. cooler connections, hoses, or through holes in the
manifold cover and repair or replace if necessary.
Refer to Air Leaks, Air Intake and Exhaust Systems
Exhaust leaks at the manifold or turbocharger. Check and correct any leaks in the exhaust manifold
or turbocharger gaskets. Check for a cracked exhaust
manifold. Refer to Exhaust Manifold, Dry (011-007) in
Turbocharger wastegate is malfunctioning. Check the wastegate for correct operation. Refer to
Turbocharger Wastegate Actuator (010-050) in
Turbocharger is worn or malfunctioning. Check for the specified boost pressure. Inspect the
turbocharger. Replace if necessary. Refer to
Turbocharger Axial Clearance (010-038) and
Turbocharger Radial Bearing Clearance (010-047) in
Fuel is contaminated. Operate the engine from a tank of high-quality fuel.

Refer to Fuel Recommendations and Specifications in
Section 10.
3666003-02.

CFP83 Series
Excessive Black Exhaust Smoke (Cont)
Cause Correction
Injector sealing washer not correct. Check to see if an extra sealing washer is installed
under injector. Remove any additional sealing washer.
Only one is required. Refer to Injector (006-026) in
Injector sealing washer not correct. Remove injector and install the proper sealing washer.
3666003-02.
Fuel injection pump is malfunctioning. Remove the fuel injection pump. Check the calibration
of the fuel injection pump. Refer to Fuel Injection
Pumps, In-Line (005-012) in Troubleshooting and
3666003-02.

CFP83 Series
Excessive White Exhaust Smoke

Cause Correction
Coolant temperature is below specification or the intake Refer to the Coolant Temperature Below Normal
manifold air temperature is below specification. (Engine Running) symptom tree.
Poor fuel quality or wrong fuel grade. Operate the engine from a tank of high-quality fuel.
Section 10.
3666003-02.
Refer to Injector (006-026 in Troubleshooting and
3666003-02.
3666003-02.
3666003-02.

CFP83 Series
Excessive White Exhaust Smoke (Cont).

Cause Correction
Coolant is leaking into the combustion chamber. Refer to the Excessive Coolant Loss symptom tree in
this section.
Fuel injection pump is malfunctioning. Remove the fuel injection pump. Check the calibration
of the fuel injection pump. Refer to Fuel Injection
Pumps, In-Line (005-012) in Troubleshooting and
3666003-02.

CFP83 Series
Fuel Consumption Is Excessive

Cause Correction
Air intake system restriction is above specification. Check the air intake system for restriction. Refer to
Replace the air filter as necessary.
Engine is operating under excessive load. Check for excessive loading from the water pump.
Fuel is leaking. Check the fuel lines, fuel connections, and fuel filters
for leaks. Check the fuel lines to the supply tanks.
Repair any leaks.
Poor-quality fuel is being used. Assure good-quality No. 2 diesel fuel is being used.
Section 10.
Charge air cooler air flow is restricted (CFP83-F40 Inspect the charge air cooler for internal and external
Only). restrictions. Replace it if necessary. Refer to Charge
Air Cooler (CAC) Removal and Installation in
Section 7.
Aftercooler air flow is restricted (CFP83-F10, F20, F30 Inspect the aftercooler for internal and external
Only). restrictions. Replace it if necessary. Refer to
Aftercooler Assembly (010-002) in Troubleshooting
3666003-02.
Injectors are worn or malfunctioning. Remove and test the injectors. Replace as necessary.
3666003-02.

CFP83 Series
Fuel Consumption Is Excessive (Cont)

Cause Correction
Intake and exhaust system manifold leaks are present. Check the intake and exhaust systems for leaks. Refer
to Air Leaks, Air Intake and Exhaust Systems (010-
the fuel timing. Refer to Fuel Injection Pump, In-Line,
Spill Port Timing (005-013) in Troubleshooting and
3666003-02.
3666003-02.
Hour meter is malfunctioning. Check operation of the hour meter. Replace the
tachometer if necessary. Refer to Tachometer
Lubricating oil level is above specification. Check the oil level. Refer to Check Engine Oil Level in
Section 5. Drain excess oil and correct the deficiency
in maintenance processes.

CFP83 Series
Fuel or Lubricating Oil Leaking From Exhaust Manifold

Cause Correction
Intake air restriction is high. Check the air intake system for restriction. Refer to
Engine is operating for extended periods under light or Limit operations at idle speed to maintenance
no-load conditions (slobbering). activities only.
Injector needle valve sticking. Check or replace the injector. Refer to Injector (006-
Turbocharger oil drain line is restricted. Remove the turbocharger oil drain line and check for
restriction. Clean or replace the oil drain line. Refer to
Turbocharger Oil Drain Line (010-045) in
Turbocharger oil seal is leaking. Check the turbocharger compressor and turbine
seals. Refer to Turbocharger (010-033) in
Worn piston rings. Check for excessive blowby. Refer to Crankcase

Blowby, Measure (014-010) in Troubleshooting and
3666003-02.

CFP83 Series
Fuel or Lubricating Oil Leaking From Exhaust Manifold (Cont)

Cause Correction
Valve guide seals are leaking. Inspect the valve guide seals. Replace if necessary.
Refer to Valve Guide Seal, Cylinder Head (002-016) in
Fuel injection pump timing is not correct. Put the engine at top dead center. Check and adjust the
fuel timing. Refer to Fuel Injection Pumps, In-Line (005-

CFP83 Series
Lubricating Oil Contaminated

NOTE: If excessive sludge is present in the oilpan, refer to Lubricating Oil Sludge in the Crankcase Excessive in
this section.
Cause Correction
Bulk oil supply is contaminated. Check the bulk oil supply. Replace it is necessary.
Refer to Lubricating Oil Recommendations and
Drain the oil and replace with non-contaminated oil.
Also, replace the oil filter. Refer to Change Lubricating
Oil and Filters in Section 7.
Fuel is present in the lubricating oil. Refer to the Fuel in Lubricating Oil symptom tree.
Coolant is present in the lubricating oil. Refer to the Coolant in Lubricating Oil symptom tree in
this section.
Metal is present in the lubricating oil. Contact an Authorized Cummins Repair Facility.
Identify unknown lubricating oil contamination. Analyze the oil and inspect the filters to identify the
contamination. Contact an Authorized Cummins
Repair Facility.

CFP83 Series
Coolant in the Lubricating Oil

Cause Correction
Lubricating oil cooler is leaking. Check the lubricating oil cooler for coolant leaks and
cracks. Refer to Lubricating Oil Cooler (007-003) in
Aftercooler is leaking. Inspect and pressure-test the aftercooler for leaks.

Cylinder head gasket is leaking. Check the cylinder head gasket. Refer to Cylinder
3666003-02.
Cylinder head is cracked or porous. Remove intake and exhaust manifolds. Check for
evidence of coolant leak. If necessary, operate engine
at low idle. Pressure-test the cylinder head. Refer to
3666003-02.
Cylinder head expansion plugs leaking or Inspect the cylinder head. Refer to Cylinder Block
misassembled. (001-026) in Troubleshooting and Repair Manual C
Cylinder liner is cracked or porous. Inspect the cylinder liners for cracks and pitting. Refer
to Cylinder Liner (001-028) in Troubleshooting and
3666003-02.

CFP83 Series
Coolant in the Lubricating Oil (Cont)

Cause Correction
Cylinder block is cracked or porous. Inspect the cylinder block. Refer to Cylinder Block (001-

CFP83 Series
Fuel in the Lubricating Oil

Cause Correction
Fuel transfer pump malfunctioning. Check or replace the fuel transfer pump. Refer to Fuel
Lift Pump (005-045) in Troubleshooting and Repair
3666003-02.
Injector needle valve sticking. Inspect the injectors. Replace if necessary. Refer to
Injector (006-026) in Troubleshooting and Repair
3666003-02.
Internal plunger seal leaking (inline). Remove the fuel injection pump and repair if
necessary. Refer to Fuel Injection Pumps, In-Line
Injection Pumps, In-Line (005-012) in Troubleshooting
Number 3666003-02.

CFP83 Series
Lubricating Oil Consumption Excessive

Cause Correction
Verify the oil consumption rate. Check the amount of oil added versus the hours of
operation.
An external engine leak is present. Inspect the engine and its components for seal,
gasket, tappet cover, oil cooler, or draincocks leaks.
Repair or correct any leaks.
Crankcase ventilation system is plugged. Check and clean the crankcase breather and vent
tube. Refer to Crankcase Breather Tube (003-018) in
Lubricating oil does not meet specifications for Change the oil and filters. Refer to Change
operating conditions. Lubricating Oil and Filters in Section 7.
Use the oil type recommended in Lubricating Oil
Lubricating oil cooler is leaking. Check the lubricating oil cooler for coolant leaks.
Refer to Lubricating Oil in the Coolant in this section.
Turbocharger leaking lubricating oil to the air intake or Inspect the air crossover tube for evidence of
exhaust. lubricating oil transfer. Refer to Air Crossover (010-
Lubricating oil drain interval is excessive. Verify the correct lubricating oil drain interval. Refer to
Change Lubricating Oil and Filters in Section 5.

CFP83 Series
Lubricating Oil Consumption Excessive (Cont)

Cause Correction
Piston rings not sealing (blue smoke). Check for excessive blowby. Refer to Engine Testing
(Chassis Dynamometer) (014-002) in Troubleshooting
3666003-02.
Valve seals are worn. Inspect the valve seals. Replace the valve seals, if
necessary. Refer to Valve Guide Seal, Cylinder Head
(002-016) and Valve, Cylinder Head (002-020) in

CFP83 Series
Lubricating Oil in the Coolant

Cause Correction
Bulk coolant supply is contaminated. Check the bulk coolant supply. Refer to Coolant
Drain the coolant and replace with non-contaminated
coolant. Refer to Drain and Flush Cooling System in
Section 7.
Replace the coolant filters. Refer to Change Coolant
Filter in Section 7.
Lubricating oil cooler is malfunctioning. Check the oil cooler. Refer to Lubricating Oil Cooler
Cylinder head gasket is leaking. Check the cylinder head gasket. Refer to Cylinder
3666003-02.
Cylinder head is cracked or porous. Remove intake and exhaust manifolds. Check for
evidence of coolant leak. If necessary, operate engine
at low idle. Pressure-test the cylinder head. Refer to
3666003-02.
Cylinder block is cracked or porous. Inspect the cylinder block. Refer to Cylinder Block

CFP83 Series
Lubricating Oil Pressure High

Cause Correction
The engine is cold. Allow the engine to warm to operating temperature. If

the engine will not reach operating temperature, refer
to the Coolant Temperature Below Normal (Engine
Running) symptom tree in this section.
Lubricating oil viscosity is not correct. Drain the oil and replace the oil filter. Refer to Change
Lubricating Oil and Filters in Section 7.
Use the correct oil. Refer to Lubricating Oil
Lubricating oil filter is not correct. Replace the oil filter. Refer to Change Lubricating Oil
and Filters in Section 7.
Use the correct oil filter. Refer to Lubricating Oil
The pressure regulator valve is struck open. Check and replace valve. Refer to Cylinder Head
The lubricating oil pump installation not correct. Verify that the correct lubricating oil pump and o-rings
are installed. Refer to Lubricating Oil Pump (007-031)

CFP83 Series
Lubricating Oil Pressure High (Cont)

Cause Correction
The pressure gauge is malfunctioning. Install a temporary pressure gauge at main oil rifle.
Compare the indications with the engine running.
If required, replace the pressure sender. Refer to Oil
Pressure Sender Removal/ Installation in Section 7.
If required, replace the pressure gauge. Refer to Oil
Pressure Gauge Removal/ Installation in Section 7.

CFP83 Series
Lubricating Oil Pressure is Low

NOTE: Low oil pressure is normally indicated by a low pressure reading on the pressure gauge and by the Low
Oil Pressure Light on the engine control panel. If both low pressure indications are present, check for an actual
low oil pressure. If only one indication is present, check first to see if the indication is incorrect.
Cause Correction
Lubricating oil level is low. Check and replenish lubricating oil. Refer to Check
Lubricating Oil Level in Section 7.
Cylinder head core and expansion plugs leaking or Check cylinder head. Refer to Cylinder Head (002-
misassembled. 004) in Troubleshooting and Repair Manual C Series
Lubricating oil is diluted. Refer to the Lubricating Oil Contaminated symptom

tree in this section.
Lubricating oil filter is plugged. Replace the oil and filter. Refer to Change Lubricating
Pressure gauge is malfunctioning. Check for electrical faults for the pressure gauge
wiring. Refer to Drawing 10423 Sheet 1 in Section 13.
Correct any electrical faults. Ensure that power and
grounding are connected. Ensure that the field wire to
the sender is not open or shorted to ground. Correct
If required, replace the pressure sender. Refer to Oil
Pressure Sender Removal/ Installation in Section 7.
If required, replace the pressure gauge. Refer to Oil
Pressure Gauge Removal/ Installation in Section 7.

CFP83 Series
Lubricating Oil Pressure is Low (Cont)

Cause Correction
Oil pressure switch fails to open the contacts on Check for a short circuit in the wiring to the pressure
running pressure. The Low Oil Pressure Light switch or in the wiring to the remote Fire Pump
remains illuminated yet the oil pressure gauge Controller. Refer to Drawing 10423 Sheet 1 in Section
indicates normal pressure when the engine is 13. Correct any electrical faults.
running.
If required, replace the oil pressure switch. Refer to Oil
Pressure Switch Removal/ Installation in Section 7.
Lubricating oil filter is not correct. Replace the oil filter. Refer to Change Lubricating Oil
Pressure regulator valve is struck open. Check and replace valve. Refer to Lubricating Oil
Pressure Regulator (Main Rifle) (007-029) in
Lubricating oil cooler is plugged. Check the oil cooler. Refer to Lubricating Oil Cooler
Lubricating oil cooler was replaced with shipping Check and remove shipping plugs. Refer to Lubricating
plugs left in cooler. Oil Cooler (007-003) in Troubleshooting and Repair
Lubricating oil pump is malfunctioning. Inspect the lubricating oil pump. Refer to Lubricating Oil
Pump (007-031) in Troubleshooting and Repair Manual

CFP83 Series
Lubricating Oil Pressure is Low (Cont)

Cause Correction
Lubricating oil suction or transfer tube is loose or Remove and inspect the oil pan or suction tube. Refer to
broken, or the gasket or o-rings are leaking. Lubricating Oil Pan (007-025) in Troubleshooting and
3666003-02.
Main bearing capscrews are loose, worn or not Check the torque on the main bearing capscrews.
tightened correctly. Inspect the capscrews for wear. Refer to Bearings, Main
Main bearings are damaged or worn, or the wrong Inspect the main bearings for damage, excessive wear,
bearings are installed. and the correct part number. Refer to Bearings, Main
Camshaft journals and number 1 bushing are Inspect the camshaft journals and number 1 bushing for
severely damaged. wear. Refer to Camshaft Bushings (001-010) in

CFP83 Series
Oil Level Rises

NOTE: Oil level may increase due to thermal expansion as the engine warms up and then decrease as the
engine cools down. Slight variations due to temperature changes are normal.
Cause Correction
Excessive oil has been added to the engine. Drain the excess oil. Refer to Change Lubricating Oil
Fuel is leaking into the oil system. Troubleshoot as per Lubricating Oil Contaminated in
this section.
Coolant is leaking into the oil system. Troubleshoot as per Lubricating Oil Contaminated in
this section.

CFP83 Series
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
Bulk oil supply is contaminated. Check the bulk oil supply. Replace it is necessary.
Refer to Lubricating Oil Recommendations and
Drain the oil and replace with non-contaminated oil.
Also, replace the oil filter. Refer to Change Lubricating
Coolant temperature is below specification. Refer to the Coolant Temperature Below Normal
(Engine Running) symptom tree in this section.
Crankcase ventilation system is plugged. Check and clean the crankcase breather and vent
tube. Refer to Rocker Lever (003-008) in
Section 10.
Lubricating oil does not meet specifications for Check the grade and type of oil. Refer to Lubricating
operating conditions. Oil Recommendations and Specifications in
Section 10.
If the wrong type or grade of oil is present, drain and
replace it. Refer to Change Lubricating Oil and Filters
in Section 7.
Lubricating oil drain interval is excessive. Verify the correct lubricating oil drain interval. Refer to
Change Lubricating Oil and Filters in Section 7.

CFP83 Series
Lubricating Oil Sludge in the Crankcase Excessive (Cont)

Cause Correction
Lubricating oil is contaminated with coolant or fuel. Go to the Lubricating Oil Contaminated symptom tree in
this section.
Crankcase pressure is excessive. Check for excessive blowby. Refer to the Crankcase
Gases (Blowby) Excessive symptom tree in this section.

CFP83 Series
Turbocharger Leaks Engine Oil or Fuel

Cause Correction
Engine is operating for extended periods under light or Limit engine operations at idle speed to maintenance
no-load conditions (slobbering). activities only. If required, adjust the engine’s speed as
per Rated Speed Setpoint Adjustment in Section 3.
Turbocharger drain line is restricted. Remove the turbocharger drain line and check for
restriction. Clean or replace the drain line. Refer to
Turbocharger Oil Drain Line (010-045) in
Turbocharger oil supply line loose or leaking. Check and tighten oil supply line fitting(s), if necessary.
Replace the supply line if necessary. Refer to
Turbocharger Oil Supply Line (010-046) in
Lubricating oil or fuel is entering the turbocharger. Troubleshoot the turbocharger as per Turbocharger

CFP83 Series
Crankcase Gases (Blowby) - Excessive

Cause Correction
Cylinder head valve guides are excessively worn. Check the valve guides for wear. Replace the cylinder
head if necessary. Refer to Cylinder Head (002-004)
Pistons or piston rings are worn, damaged, or not Check the pistons for correct part numbers. Refer to
correct. Control Parts List (CPL), Bulletin 3379133 or
4021327.
Check the pistons and rings for wear and damage.
Refer to Piston (001-043) and Piston Rings (001-047)
Turbocharger oil seal is leaking. Check the turbocharger compressor and turbine
seals. Refer to Turbocharger (010-033) in

CFP83 Series
Engine Overspeed Trip

NOTE: An engine overspeed trip occurs when the engine’s speed exceeds the value specified on the Factory
Setting Tag described in Section 2. The trip isolates the fuel supply to the engine and it stops immediately. The
trip is indicated on the local control panel and inside the local control panel on the speed switch. Additionally, a
trip output is supplied to the fire protection system for remote display.
Cause Correction
Engine actually operated at too great a speed due to Correct the cause of the load failure.
catastrophic load failure such as pipe break, pump
mechanical failure, or loss of suction.
Engine actually operated at too great a speed due to Check rated speed setting as specified on the Factory
configuration error. Setting Tag described in Section 2. Refer to Rated
Speed Setpoint Adjustment and Testing in Section 3.
Overspeed switch is set at too low a setpoint. Check overspeed speed setting as specified on the
Factory Setting Tag described in Section 2. Refer to
Overspeed Setpoint Adjustment and Testing in Section
3.
Speed switch wiring failure has occurred. Check continuity and insulation from ground for the
signal power wiring and ground wiring to the speed
switch. Refer to Drawing 10423 Sheet 1 in Section 13.
Replace defective components and repair electrical
faults.
Speed switch failure has occurred. If the speed switch fails to operate as per Overspeed
Setpoint Adjustment and Testing in Section 3, replace
the speed switch. Refer to Overspeed Switch

CFP83 Series
Tachometer Does Not Indicate Engine Speed

Cause Correction
Fuse F4 has opened. If required, replace Fuse F4.

Locate and correct the electrical fault that caused the
fuse to operate. Refer to Drawing 10423 Sheet 1 in
Section 13.
An electrical fault exists in the tachometer power and Check continuity and insulation from ground for the
grounding circuits. power wiring and ground wiring to the tachometer.
Replace defective components and repair electrical
faults.
An electrical fault exists in the speed sensor input Check continuity and insulation from ground for the
circuit. This fault may also cause a failure in the crank speed sensor circuit. Refer to Drawing 10423 Sheet 1
terminate signal to the fire protection system. in Section 13. Replace defective components and
repair electrical faults.
The speed sensor has failed. With the engine running, check the signal from the
speed sensor with an oscilloscope or pulse counter.
Replace the speed sensor is it has failed. Refer to
Speed Sensor Removal/Installation in Section 7.
The tachometer has failed. Check the operation of the tachometer with a pulse
generator. Replace the tachometer is it has failed.
Refer to Tachometer Removal/Installation in Section 7.

Section 13 - 9777 Assembly Drawings Page 13-1 CFP83 Series Rev 02/10
(1)
Section 13 - Assembly Drawings
Sheet Revision
Description Drawing No.
No Level
Drawing, Installation, Fire Pump, CFP83-F10/20/30 (6CTA8.3) 8708 J
Drawing, Installation, Fire Pump, CFP83-F40 (6CTAA8.3) 8710 J
Options, Engine, Fire Pump, G-Drive, CFP83-F40 (6CTAA8.3) 8728 B
Options, Engine, Fire Pump, G-Drive, CFP83-F10/20/30 (6CTA8.3) 8738 B
Assembly, Engine Mounting, CFP83 8907 B
Leg, Engine Support, Rear 8412 E
Leg, Engine Support, Front 8908 D
Assembly, Air Cleaner, CFP83-F10/20/30 8911 E
Assembly, Air Cleaner, CFP83-F40 9531 D
Assembly, Air Filter Cover Implementation Date 04-09 14798 B
Assembly, Heat Shield, Exhaust, CFP83-F10/20/30 8913 D
Assembly, Heat Shield, Exhaust, CFP83-F40 8937 B
Assembly, Charge Air Cooling, CFP83-F40 8967 A
Assembly, Plumbing, CAC Heat Exchanger, CFP83-F40 10903 B
Assembly, Hose Water 11086 C
Assembly, Heat Exchanger C8.3 8919 F
Assembly, Vent Line 9658 -
Assembly, Coolant Heater C8.3 8930 E
Assembly, Operator's Station, 6B, CFP83-F10/20/30 9560 E
Assembly, Operator's Station, 6CTAA8.3, CFP83-F40 9592 C
Assembly, Instrument Panel, 12VDC, Alternate Beginning 09/06 10452 E
Assembly, Instrument Panel, 24VDC, Alternate Beginning 09/06 10453 E
Assembly Sensor Package, C8.3, (Non-ECM) 9574 A
Assembly, Fuel Lines, C8.3 CFP83-F10 9575 B
Assembly, Fuel Lines, 6CTAA8.3, CFP83-F40 9588 B
Assembly, Pulley Guard, CFP83-F10/20/30 9625 A
Assembly, Pulley Guard, CFP83-F40 9627 B
Misc Piping, Cooling Loop, Raw Water, 6C, CFP83-F10/20/30 9637 E
Misc Piping, Cooling Loop, Raw Water, 6C, CFP83-F40 10712 C
Assembly, Raw Water Cooling Loop, 1" 9659 D
Assembly, Solenoid Override, CFP83-F10/20/30 9830 A
Assembly, Solenoid Override, CFP83-F40 10365 B
Fuel Line, 3/8"NPT Obsolete 12-09 10234 -
Fuel Line, 1/4"NPT Obsolete 12-09 10235 -
Exhaust, 4" Bellows w/Elbow 8780 D
Assembly, Drive Shaft & Guard 10165 -
Assembly, Stub-Shaft, SAE#3, 2.25" QSB, QSC, 4B, 6B, 6C 8619 B
Kit, Loose Wires, 4B, 6B, 6C, QSB, QSC 9767 D
General Layout, Fire Pump, CFP83 CFP83_GEN D
General Layout, Fire Pump, CFP83-F40 CFP83_F40GEN D
Schematic, Control Panel Alternate Beginning 09/06 10423 1-6 E
Harness, Engine 8513 1-2 L
(1) Also see Engine Identification in Sec 2 the System Diagrams in Sec 6.
The most current revisions to these drawings and releated documents
accessible at: http://www.cumminsfirepower.com/products.html.
Section 13 - 9777 Assembly Drawings Page 13-1 CFP83 Series Rev 02/10
(1)
Section 13 - Assembly Drawings

BILL OF MATERIAL
ITEM QTY DESCRIPTION PART NUMBER
1 3 CLAMP, 4" NOMINAL, AC400 8815
2 1 AIR FILTER, 4" DIA. INLET, CFP59,6E,83,9E FIREPUMP 9606
3 1 TUBE, AIR CLEANER EXTENSION, FIREPUMP 9576
4 1 COUPLING, RUBBER, 4", NELSON #89835K 89835K
5 1 RESTRICTION INDIACOR, 1/8" NPT RAX00-2352
5 2
3
REF. SCALES
This document contains confidential and trade secret information, is the

property of Cummins NPower, LLC and is given to the receiver in confidence. CUMMINS NPOWER, LLC NPOWER SYSTEMS
The receiver, by receiving and retaining of the document accepts the CORPORATE OFFICE DESIGN CENTER
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
1600 BUERKLE ROAD 875 LAWRENCE DRIVE
confidential or trade secret information therein, (2) not copy the document, WHITE BEAR LAKE, MN DEPERE, WISCONSIN
(3) not disclose to others either the document or the confidential or trade WWW.NPOWER.CUMMINS.COM
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
TITLE 1: ASSEMBLY, AIR CLEANER, CFP83
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE TITLE 2: FIRE PUMP
ANGULAR DIMENSIONS 1± IMPERIAL UNITS METRIC UNITS
DWG UNITS: DRAWN BY: S. DANFORTH DATE: 28APR2004
E OMIT PN: 9525 ENF PN: 2008-275 MAC 10-14-2008 THIRD ANGLE PROJECTION .XX IN/LB/S APPD BY: DATE:
MACHINE TOLERANCES MACHINE TOLERANCES
=± 0.010 .X = ± 0.4
.XXX = ± 0.005 .XX = ± 0.2
-
D REV PER AIR CLEANER DAVE N 13DEC06

FORM TOLERANCES FORM TOLERANCES
.XX = ± 0.030
.XXX = ± 0.015
.X = ± 0.8
.XX = ± 0.4 EST WEIGHT: SCALE: DO NOT SHEET DRAWING NO: REV:
9.400 0.300 SCALE 1OF1 8911 E
FAB TOLERANCES FAB TOLERANCES
REV DESCRIPTION OF REVISION REV BY DATE .XX = ± 0.060

.XXX = ± 0.030
.X = ± 1.5
.XX = ± 0.8
BILL OF MATERIAL
ITEM QTY DESCRIPTION PART NUMBER
1 3 CLAMP, 4" NOMINAL, AC400 8815
2 1 AIR FILTER, 4" DIA. INLET, CFP59,6E,83,9E FIREPUMP 9606
3 1 COUPLING, RUBBER, 4", NELSON #89835K 89835K

3
4 1 RESTRICTION INDIACOR, 1/8" NPT RAX00-2352
1 4
REF. SCALES
This document contains confidential and trade secret information, is the

property of Cummins NPower, LLC and is given to the receiver in confidence. CUMMINS NPOWER, LLC NPOWER SYSTEMS
The receiver, by receiving and retaining of the document accepts the CORPORATE OFFICE DESIGN CENTER
document in confidence and agrees that, except as authorized in writing by
Cummins NPower, it will (1) not use the document or any copy thereof or the
1600 BUERKLE ROAD 875 LAWRENCE DRIVE
confidential or trade secret information therein, (2) not copy the document, WHITE BEAR LAKE, MN DEPERE, WISCONSIN
(3) not disclose to others either the document or the confidential or trade WWW.NPOWER.CUMMINS.COM
secret information therein, and (4) upon completion of the need to retain
the document, or upon demand, return the document, all copies thereof, and
all material copied therefrom. COPYRIGHT Cummins NPower, LLC
TITLE 1: ASSEMBLY, AIR CLEANER, CFP83
UNLESS OTHERWISE SPECIFIED ALL DIMENSION TOLERANCES ARE TITLE 2: FIRE PUMP
ANGULAR DIMENSIONS 1± IMPERIAL UNITS METRIC UNITS
DWG UNITS: DRAWN BY: DAVE N DATE: 07JUL2004
D OMIT PN:9525 ENF PN:2008-275 MAC 10-14-2008 THIRD ANGLE PROJECTION .XX IN/LB/S APPD BY: DATE:
MACHINE TOLERANCES MACHINE TOLERANCES
=± 0.010 .X = ± 0.4
.XXX = ± 0.005 .XX = ± 0.2
-
C REV PER AIR CLEANER DAVE N 13DEC06

FORM TOLERANCES FORM TOLERANCES
.XX = ± 0.030
.XXX = ± 0.015
.X = ± 0.8
.XX = ± 0.4 EST WEIGHT: SCALE: DO NOT SHEET DRAWING NO: REV:
5.253 0.375 SCALE 1OF1 9531 D
FAB TOLERANCES FAB TOLERANCES
REV DESCRIPTION OF REVISION REV BY DATE .XX = ± 0.060

.XXX = ± 0.030
.X = ± 1.5
.XX = ± 0.8

Cfp83 Series: Fire Pump Drive Engines

Uploaded by

Copyright:

Available Formats

Cfp83 Series: Fire Pump Drive Engines

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cfp83 Series: Fire Pump Drive Engines

Uploaded by

Copyright:

Available Formats

CFP83 SERIES

Operation & Maintenance Manual

© 2005 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A.

Drawing No. 9777, Section 0, Rev. 02-07

Drawing No. 9777, Section 0, Rev. 02-07

THIS PAGE INTENTIONALLY LET BLANK

Drawing No. 9777, Section 0, Rev. 02-07

Drawing No. 9777, Section 1, Rev. 02-07

THIS PAGE INTENTIONALLY LEFT BLANK

Drawing No. 9777, Section 1, Rev. 02-07

To the Owner and Operator

About the Manual

How to Use the Manual

Drawing No. 9777, Section 1, Rev. 02-07

Refer to another location in this manual or another publication for additional

Indicates a REMOVAL or DISASSEMBLY step

LUBRICATE the part or assembly.

CLEAN the part or assembly.

TIGHTEN to a specific torque.

Indicates an INSTALLATION or an ASSEMBLY step

PERFORM a mechanical or time MEASUREMENT.

PERFORM an electrical MEASUREMENT.

Drawing No. 9777, Section 1, Rev. 02-07

The illustrations used in this manual are

The illustrations are also intended to show

Drawing No. 9777, Section 1, Rev. 02-07

General Safety Instructions

Drawing No. 9777, Section 1, Rev. 02-07

General Safety Instructions (Cont.)

Drawing No. 9777, Section 1, Rev. 02-07

General Cleaning Instructions

Drawing No. 9777, Section 1, Rev. 02-07

Drawing No. 9777, Section 1, Rev. 02-07

Using Abrasive Pads and Abrasive Paper

Drawing No. 9777, Section 1, Rev. 02-07

Cleaning Gasket Surfaces

Solvent and Acid Cleaning

Drawing No. 9777, Section 1, Rev. 02-07

Plastic Bead Cleaning

Drawing No. 9777, Section 1, Rev. 02-07

Plastic Bead Cleaning (Cont)

Drawing No. 9777, Section 1, Rev. 02-07

Acronyms and Abbreviations

Drawing No. 9777, Section 1, Rev. 02-07

Section 2 - Engine Identification

Drawing No. 9777, Section 2, Rev. 02-07

THIS PAGE INTENTIONALLY LEFT BLANK

Drawing No. 9777, Section 2, Rev. 02-07

Fire Pump Engines

Drawing No. 9777, Section 2, Rev. 02-07

External Engine Components and Views

Instrument Panel Side

Drawing No. 9777, Section 2, Rev. 02-07

Drawing No. 9777, Section 2, Rev. 02-07

Drawing No. 9777, Section 2, Rev. 02-07

Drawing No. 9777, Section 2, Rev. 02-07

Drawing No. 9777, Section 2, Rev. 02-07

1. Battery “A” Voltmeter 8. Overspeed Warning Light

Drawing No. 9777, Section 2, Rev. 02-07