Section 10 – Maintenance Specifications

Section 10 – Maintenance Specifications
CFP83 Series
Page 10-1
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
Drawing No. 9777, Section 10, Rev. 02-07
Page 10-2
Section 10 – Maintenance Specifications
CFP83 Series
THIS PAGE INTENTIONALLY LEFT BLANK
Drawing No. 9777, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP83 Series
Page 10-3
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
CFP83-F10
CFP83-F20
CFP83-F30
CFP83-F40
Cummins Engine Co. Base Engine
6CTA8.3G2
6CTA8.3G2
6CTA8.3G2
6CTAA8.3G3
Cummins Base Engine Fuel Rating
FR90242 / FR90243
FR90242 / FR90243
FR90242 / FR90243
FR90940
Model
CFP83-F10
CFP83-F20
CFP83-F30
CFP83-F40
Installation Drawing
8708 (see Section 13)
8708 (see Section 13)
8708 (see Section 13)
8710 (see Section 13)
Configuration Number
D413034GX02
D413034GX02
D413034GX02
D413035GX02
Model
CFP83-F10
CFP83-F20
CFP83-F30
CFP83-F40
Fuel System
Bosch - P3000 Direct Injection
Bosch - P3000 Direct Injection
Bosch - P3000 Direct Injection
Bosch - P7100 Inline
Aspiration
Turbocharged, Jacket Water Aftercooled (JWAC)
Turbocharged, Jacket Water Aftercooled (JWAC)
Turbocharged, Jacket Water Aftercooled (JWAC)
Turbocharged, Charge Air Cooled
Type
Firing Order
Rotation, Viewed from the Front of the Engine
Compression Ratio:
Valves per cylinder: Inlet/Exhaust
4 Cycle; In-Line; 6 Cylinder
1-5-3-6-2-4
Clockwise
16.8:1
1/1
Bore
Stroke
Displacement
Intake Valve Clearance
Exhaust Valve Clearance
Dry Weight
Wet Weight
Metric
114 mm
135 mm
8.3 liters
0.30 mm
0.61 mm
790 kg
823 kg
Drawing No. 9777, Section 10, Rev. 02-07
US
4.49 in
5.32 in
505 in.3
0.012 in
0.024 in
1742 lb
1815 lb
Page 10-4
Section 10 – Maintenance Specifications
CFP83 Series
Fuel System Specifications
Fuel
Recommended primary fuel filter
Type Number 2 Diesel Only
Fleetguard FS1251
Minimum supply line size
Minimum drain line size
Maximum fuel line length between supply tank & fuel pump
Maximum fuel height above C/L crankshaft
Maximum restriction @ lift pump-inlet - with clean filter
Maximum restriction @ lift pump-inlet - with dirty filter
Maximum return line restriction - without check valves
Minimum fuel tank vent capability
Maximum fuel temperature @ lift pump inlet
Metric
9.5 mm D.
6.4 mm D.
12 m
2030 mm
102 mm Hg
203 mm Hg
254 mm Hg
0.342 m3/hr
71 oC
US
0.375 in. D.
0.25 in. D.
40 ft.
80 in.
4.0 in. Hg
8.0 in. Hg
10.0 in. Hg
12 ft3/hr
160 oF
Lubricating Oil System Specifications
Recommended lube oil filter
Fleetguard LF9009
Oil pressure range at rated
Oil capacity of pan (high - low)
Total system capacity
Metric
276-414 kPa
18.9-15.1 litre
23.8 litre
US
40-60 PSI
20-16 U.S. quarts
6.3 U.S. Gal.
Cooling System Specifications
Recommended coolant filter
Fleetguard WF2072
Maximum raw water working pressure range at heat
exchanger
Recommended minimum water supply pipe size to heat
exchanger
Recommended minimum water discharge pipe size from
heat exchanger
Coolant water capacity (engine side)
Modulating thermostat range
Minimum raw water flow with water temperatures to 90 oF
(32 oC)
414 kPa
60 PSI
25.4 mm D.
1.0 in. D.
31.7 mm D.
1.25 in. D.
22.2 Litre
82-95 oC
1.9 litre/s
5.9 U.S. gal.
180-203 oF
30 U.S. GPM
Metric
US
Drawing No. 9777, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP83 Series
Page 10-5
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
Maximum temperature rise between ambient air and engine
air inlet
Maximum inlet restriction with dirty filter
15 oC
Metric
635 mm H2O
30 oF
US
25 in. H2O
Exhaust System Specifications
Maximum exhaust back pressure imposed by complete
exhaust system
Exhaust pipe size normally acceptable
Metric
10.2 kPa
US
40.8 in. H2O
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)
Reference wiring diagram
B.C.I. Group Size
Minimum recommended battery cold cranking amperes
(CCA)(1)
Minimum recommended battery reserve capacity
Maximum resistance of starting circuit
Typical cranking speed
Alternator (standard), internally regulated
Battery Cable Size (Metric) (For less than 1.5 meters long)
Battery Cable Size (US) (For less than 5 feet long)
(1) Cold soak at -18 oC (0 oF) or above
Drawing No. 9777, Section 10, Rev. 02-07
Standard
10423 (see Section 13)
8D
12V
1250 Amps
24V
625 Amps
400 Minutes
0.002 Ohms
120 RPM
95 Amps
10.6 mm D.
00 AWG
800 Minutes
0.004 Ohms
120 RPM
45 Amps
10.6 mm D.
00 AWG
Page 10-6
Section 10 – Maintenance Specifications
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.
Drawing No. 9777, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP83 Series
Page 10-7
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.
Drawing No. 9777, Section 10, Rev. 02-07
Page 10-8
Section 10 – Maintenance Specifications
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 50percent 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.
Drawing No. 9777, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP83 Series
Page 10-9
Engine Component Torque Values
Torque Table
Component
Aftercooler mounting
Aftercooler water hose clamp
Alternator link (Delco 10-15 SI)
Alternator link (Delco 20-27 SI)
Alternator mtg. bolt 10-15 Sl
Alternator mtg. 27 Sl
Alternator support (upper)
Belt tensioner flat bracket
Belt tensioner mounting
Crankshaft damper and pulley
Crossover clamp
Tee bolt type clamp
Exhaust outlet pipe, v-band clamp
Fuel filter
Fuel filter adapter nut
Lubricating oil filter
Lubricating oil cooler assembly
Lubricating oil pan drain plug
Lubricating oil pan heater plug
Lubricating oil pressure regulator plug
Starter mounting
Thermostat housing
Water inlet connection
Water pump mounting
Rocker lever (valve) cover
Water-in-fuel (WIF) sensor
Drawing No. 9777, Section 10, Rev. 02-07
Wrench Size
10 mm
8 mm
13 mm
3/4 in
15 mm
18 mm
10 mm
Allen 5 mm
15 mm
15 mm
5/16 in
11 mm
7/16 in
75 to 85 mm
24 mm
75 to 85 mm
10 mm
17 mm
27 mm
19 mm
10 mm
10 mm
15 mm
13 mm
15 mm
19 mm
N•m
ft-lb
in-lb
24
18
5
44
24
18
43
32
43
32
77
57
24
18
24
18
43
32
137
101
5
44
8
71
8
71
Install as specified by filter manufacturer.
32
24
3/4 of a turn after contact
24
18
80
59
80
59
80
59
43
32
24
18
43
32
24
18
12
106
Hand-tighten
Page 10-10
Section 10 – Maintenance Specifications
CFP83 Series
Sealants
General Information
Use either the sealants listed below or sealants containing equivalent properties.
Item Description
Pipe plugs
Gaskets
Cups plugs
O-rings
Rear camshaft expansion plug
Fuel pump studs
Turbocharger drain (in block)
Dipstick tube (in block)
Wet flywheel housing to block
Rear seal (in rear cover)
Timing pin housing capscrews
Side oil fill
Oil pan at gear housing joint
Sealing Method
Pre-coated Teflon™ or pipe sealer
No sealant required
Loctite 277 or Cummins sealant, Part Number 3375068
Lubriplate™ 105
Loctite 277 or Cummins sealant, Part Number 3375068
Loctite 242
Loctite 277 or Cummins sealant, Part Number 3375068
Loctite 277 or Cummins sealant, Part Number 3375068
Three-Bond™ sealant, Part Number 3823494
No sealant required
No sealant required
Loctite 277 or Cummins sealant, Part Number 3375068
Three-Bond™ sealant, Part Number 3823494
Drawing No. 9777, Section 10, Rev. 02-07
Section 10 – Maintenance Specifications
CFP83 Series
Page 10-11
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:
Value:
Meaning:
M8
Major thread diameter in
millimeters
M8-1.25 x 25
1.25
Distance between threads in
millimeters
X 25
Length in 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
Commercial
Steel Class
10.9
12.9
Capscrew
Head Markings
Metric Capscrew Torque Values
Class:
Diameter
8.8
Cast Iron
10.9
Aluminum
Cast Iron
12.9
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
7
8
10
12
14
16
18
20
9
14
23
45
80
125
195
280
400
5
9
17
33
60
90
140
200
290
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
13
18
33
65
115
180
280
390
550
10
14
25
50
85
133
200
285
400
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
14
23
40
70
125
195
290
400
—
9
18
29
50
95
145
210
290
—
7
11
18
30
55
90
140
180
—
4
7
14
25
40
65
100
135
—
Drawing No. 9777, Section 10, Rev. 02-07
Page 10-12
Section 10 – Maintenance Specifications
CFP83 Series
US Customary Capscrew Identification
Sample:
Value:
Meaning:
5/16 x 18 x 1-1/2
18
Number of threads per inch
5/16
Major thread diameter in
inches
1-1/2
Length in 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
w/ three lines
SAE Grade 8
U.S. Customary Capscrew Torque Values
Grade
Capscrew Body
Size
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-13
1/2-20
9/16-12
9/16-18
5/8-11
5/8-18
3/4-10
3/4-16
7/8-9
7/8-14
1-8
1-14
SAE Grade 5
Cast Iron
SAE Grade 8
Aluminum
Cast Iron
Aluminum
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
N•m
ft-lb
9
12
20
23
40
40
60
65
95
100
135
150
180
210
325
365
490
530
720
800
7
9
15
17
30
30
45
50
70
75
100
110
135
155
240
270
360
390
530
590
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650
6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480
15
18
30
33
55
60
90
95
130
150
190
210
255
290
460
515
745
825
1100
1200
11
13
22
24
40
45
65
70
95
110
140
155
190
215
340
380
550
610
820
890
8
9
16
19
25
35
45
55
75
80
110
115
150
160
255
285
380
420
570
650
6
7
12
14
20
25
35
40
55
60
80
85
110
120
190
210
280
310
420
480
Drawing No. 9777, Section 10, Rev. 02-07