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204-007   General Repair Instructions

General Information

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This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards.

 CAUTION 

 

Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listing of components classified as safety-related:
  1. Air Compressor
  2. Air Controls
  3. Air Shutoff Assemblies
  4. Balance Weights
  5. Cooling Fan
  6. Fan Hub Assembly
  7. Fan Mounting Bracket(s)
  8. Fan Mounting Capscrews
  9. Fan Hub Spindle
  10. Flywheel
  11. Flywheel Crankshaft Adapter
  12. Flywheel Mounting Capscrews
  13. Fuel Shutoff Assemblies
  14. Fuel Supply Tubes
  15. Lifting Brackets
  16. Throttle Controls
  17. Turbocharger Compressor Casing
  18. Turbocharger Oil Drain Line(s)
  19. Turbocharger Oil Supply Line(s)
  20. Turbocharger Turbine Casing
  21. Vibration Damper Mounting Capscrews
  • Follow all safety instructions noted in the procedures
  • Follow the manufacturer’s recommendations for cleaning solvents and other substances used during the repair of the engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools and equipment.
  • Provide a clean environment and follow the cleaning instructions specified in the procedures
  • The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause premature wear.
  • Perform the inspections specified in the procedures
  • Replace all components or assemblies which are damaged or worn beyond the specifications
  • Use genuine Cummins new or ReCon® service parts and assemblies
  • The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or Cummins ReCon® components. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations.
  • Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components

 

Welding on a Vehicle with an Electronic Controlled Fuel System

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 CAUTION 

 

Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground clamp of the welder to any of the sensors, wiring harness, the ECM or the engine. Direct welding of any electronic engine component or engine mounted component must not be attempted. Sensors, wiring harness, and ECM should be removed if nearby welding will expose these components to temperatures beyond normal operation. Additionally, all ECM connectors must be disconnected..

 
Last Modified:  14-Jul-2010
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Published by Jack

Hello, I'm Jack, a diesel engine fan and a blogger. I write about how to fix and improve diesel engines, from cars to trucks to generators. I also review the newest models and innovations in the diesel market. If you are interested in learning more about diesel engines, check out my blog and leave your feedback.