Cummins m11 manual download.Cummins M11 Series Engines (STC, CELECT, CELECT PLUS Models) Service Repair Manual

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Zur vermeidung von koerperverletzung winde benutzen oder hilfe beim heben des teils in anspruch nehmen. Le composant pese 23 kg [50 lb] ou davantage. The illustrations can contain symbols to indicate an action required, and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures.

The illustration can differ from your application, but the procedure given will be the same. 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. Be aware of hazardous conditions that can exist.

Remove all jewelry when working. Disconnect the air starting motor if equipped to prevent accidental engine starting. 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.

Always use blocks or proper stands to support the product before performing any service work. 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 protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas fluorocarbons into the atmosphere. Federal law requires capture and recycling refrigerant. 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. 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. Make sure you understand how to use them before performing any service work.

Do not use a fastener of lessor quality if replacements are necessary. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. General Repair Instructions This engine incorporates the latest diesel technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. In particular, unauthorized repair to safety-related components can cause personal injury or death.

Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, injestion and contact with such substances. Always use good safety practices with tools and equipment.

The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause premature wear. 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 ReConW components. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations. Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L, Literature, for ordering instructions.

Remove all three connectors going to the ECM. General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [ to degrees Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.

Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. Warning: Acid is extremely dangerous, and can damage the machinery. Always provide a tank of strong soda water as a neutralizing agent.

Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the capscrew holes and the oil drillings. If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound.

The rustproofing compound must be removed from the parts before installation on the engine. Steam Cleaning Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank.

It is a good way to clean the oil drillings. Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat. Do not steam clean the following parts: 1. Electrical Components 2. Wiring 3. Injectors 4. Fuel Pump 5. Belts and Hoses 6. Glass or Plastic Bead Cleaning Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time.

Caution: Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning on aluminum ring grooves. Small particles of glass or plastic will embed in the aluminum and result in premature wear. Valves, turbocharger shafts, etc. Follow the cleaning directions listed in the procedures. Do not use any bead blasting media on pin bores or aluminum skirts.

Use U. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after cleaning. Rinse with hot water. Dry with compressed air.

Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is sufficient intake manifold pressure to allow for complete combustion. After Top Dead Center; refers to the position of the piston or the crankshaft rod journal.

The piston is moving downward on the power stroke or intake stroke. Bottom Dead Center; refers to the position of the piston or the crankshaft rod journal. The piston is at its lowest position in the cylinder. Before Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The piston is moving upward on the power stroke or exhaust stroke. A fuel control system that electronically controls the fuel injection to improve fuel economy and to reduce the exhaust emissions.

The system does this by controlling the torque and horsepower curve, AFC smoke function, engine high speed, engine low idle speed and the road speed. Additional electronic features include cruise control, PTO, gear down protection, progressive shifting, automotive or VS governor and idle shutoff. A measurement of the difference between the centers of either two or more parts, or the bores in one part.

Control Parts List; this listing identifies the specific parts that must be installed on the engine to meet agency certification. This is a one part Room Temperature Vulcanizing RTV silicone rubber, adhesive and sealant material having high heat and oil resistance, and low compression set. A method used to check for cracks in a part by using a dye penetrant and a developer.

Use Part No. The clearance in an assembly determined by pushing the shaft in an axial direction one way, and then pushing the shaft the other way. A single component, anaerobic, polyester resin, liquid sealant compound that hardens between closely fitted metal surfaces producing a tough, hard bond with good characteristics. An equivalent product is Perma-Lok HL Some of the equivalent products are Loctite and Permabond HL A mineral oil base grease with calcium soap 2 percent to 6 percent , and zinc oxide 2 percent to 4 percent additives.

A method of checking for cracks in either steel or iron parts. This method requires a Magnaflux machine, or an equivalent machine that imparts a magnetic field on the part being checked. A hand tool consisting of a soft head; either wood, plastic, lead, brass, or rawhide on a handle.

Top Dead Center; refers to the position of the piston or the crankshaft rod journal. The piston is at its highest position in the cylinder. The rod journal is pointing straight up toward the piston. Total Indicator Reading; used when measuring the concentricity or the run out. The TIR refers to the total movement of the needle on a dial indicator, from the most negative reading to the most positive reading. A premium high temperature grease that will lubricate antifriction bearings continually from minus 40 C [minus 40 F] to plus C [plus F].

Some of the greases meeting this requirement are Aeroshell No. Caution: Aeroshell No. Cummins Engine Co. E-6 Engine Identification E-2 Engine Dataplate E-2 Engine Specifications Air Intake System Batteries Specific Gravity Cooling System Electrical System Exhaust System Fuel System General Engine Data Lubricating Oil System Engine Dataplate The engine dataplate is located on the fuel pump side of the rocker housing.

The engine dataplate provides model identification as well as other important information about the engine. Have the following engine data available when communicating with a Cummins Authorized Repair Location. The information on the dataplate is mandatory when sourcing service parts.

The dataplate on the right contains the engine serial number, fuel code and engine calibration information. Engine Specifications Metric [U. Crankshaft Rotation - viewed from the front of the engine Engine Specifications Continued Metric [U. Total System Capacity Including Filter Metric [U. Customary] Fuel System For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular model involved.

Engine Idle Speed:. Maximum Allowable Fuel Inlet Temperature Reserve capacity determines the length of time which sustained cranking can occur. A minimum of 6. Engine Diagrams The following illustrations contain information about engine components, filter locations, drain points and provisions for instrumentation and engine controls.

The information and configuration of components shown in these drawings are of a general nature. Some component locations will vary depending on applications and installations. JacobsW Engine Brake - Installation Accessory Drive Assembly - Removal Accessory Drive Oil Seal - Removal Accessory Drive Pulley - Removal Air Compressor - Removal Air Compressor Coolant Tubes - Removal Air Intake Manifold - Removal Alternator and Brackets Bus Applications Alternator Belt Bus Applications - Removal Alternator Drive Oil Seal - Removal Alternator Drive Pulley - Removal Cam Follower Assemblies - Removal Camshaft - Removal Coolant - Draining Coolant Filter - Removal Crankshaft Front Oil Seal - Removal Crankshaft Pulley and Vibration Damper - Removal Crankshaft Rear Oil Seal - Removal Crossheads - Removal Cylinder Head - Removal Cylinder Liners - Removal Electronic Control Cooling Plate - Removal Electronic Control Module - Removal Engine - Cleaning Engine - Installation On Rebuild Stand Engine - Preparation for Cleaning Engine Barring Tool - Installation Exhaust Manifold - Removal Fan and Fan Hub - Removal Fan Drive Belt - Removal Fan Hub Support - Removal Flywheel - Removal Flywheel Housing - Removal Front Engine Support Bracket - Removal Fuel Filter - Removal Fuel Lines - Removal Fuel Pump - Removal Gear Cover - Removal Gear Housing - Removal High Oil Pressure Regulator - Removal Hydraulic Pump Drive - Removal Hydraulic Pump or Cover - Removal Idler Gear Assemblies - Removal Injectors - Removal Internal Actuator Harness - Removal JacobsW Engine Brake - Removal Lifting Brackets - Removal Lubricating Oil - Draining Lubricating Oil Cooler - Removal Lubricating Oil Filter Head - Removal Lubricating Oil Filters - Removal Lubricating Oil Pan - Removal Lubricating Oil Pump - Removal Lubricating Oil Transfer Tube - Removal Main Oil Pressure Regulator - Removal Piston Cooling Nozzles - Removal Pistons and Connecting Rods - Disassembly Pistons and Connecting Rods - Removal Push Rods - Removal Rocker Lever Assemblies - Removal Rocker Lever Cover - Removal Rocker Lever Housing - Removal Rocker Lever Housing Spacer - Removal Sensor Harness and Sensors - Removal Starting Motor - Removal Thermostat Housing - Removal Thermostat Housing Support - Removal Torque Converter Cooler Disc - Removal Turbocharger - Removal Turbocharger Oil Drain Connection - Removal Viscosity Sensor - Removal Water Filter Head - Removal Water Header Plate - Removal Water Heater Housing - Removal Water Pump - Removal Engine Disassembly and Assembly - General Information Engine Lifting Brackets Service Tools - Disassembly and Assembly The following special tools are recommended to perform procedures in Group The use of these tools is shown in the appropriate procedure.

These tools can be purchased from your local Cummins Authorized Repair Location. Attaches to crankshaft flange to provide measuring of flywheel and flywheel housing runout with dial indicator gauge, Part No. Remove cylinder liners from cylinder block. Requires cylinder liner puller plate, Part No. Aid in removal and installation of crankshaft, flywheel and other components which weigh more than 23 kg [50 lb]. Remove cylinder liners from the cylinder block.

Requires two puller arm extension feet, Part No. Use with dial gauge attachment, Part No. ST to measure flywheel and flywheel housing runout. Use with magnetic base, Part No. ST, to measure gear end clearance and backlash. Cylinder Liner Driver Install cylinder liner in cylinder block.

Install drive pulleys. Use pulley pusher adapter, Part No. Adapt M11 cylinder block to the engine rebuild stand, Part No. Requires 12 M Install the high oil pressure regulator retainer plug in the cylinder block to a specified depth.

Required to make consistent settings of the injector. Screwdriver socket, Part No. ST, must be used with this tool. Aid during installation of flywheel, flywheel housing, vibration damper, and air manifold. The kit contains two each of guide pins, Part Nos. Filter Wrench Used to remove or tighten spin on fuel filter s and coolant filter. Install expansion plug to specified depth. Use with expansion plug driver handle, Part No.

Used to bar the engine by hand. Also used with a slide hammer to remove the hydraulic drive adapter. The differences between engine models, due to the application and optional equipment on an engine, is included in the instructions. Omit the steps that do not apply to the engine being rebuilt. A Warning statement is included for any component or assembly that weighs more than 23 Kg [50 lb].

To avoid personal injury, use a hoist or get assistance from more than one person when removing or installing these parts. Most of the capscrews used on the M11 engine are metric. Some components, such as the air compressor and fuel pump, are installed using U. Customary capscrews. All fasteners have right-hand threads unless a Caution states that a fastener has left-hand threads.

Disassembly 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. The instructions in this procedure are organized in a logical sequence to disassemble the M11 engine. This is not the only sequence to disassemble a M11 engine.

Certain parts must be removed in the sequence indicated. Use this sequence until you become familiar with the engine. Discard all gaskets, seals, hoses, filters, and o-rings unless these parts are needed for a failure analysis. Label, tag, or mark the parts for location as they are removed. This will help find all of the parts that can be involved in a failure, and simplify the assembly procedure. Label, tag, mark, or photograph all special equipment prior to the removal from an engine.

This engine assembly procedure does not include the installation of special optional equipment. Force must be used to remove certain parts. A mallet can be used when force is required. All of the fasteners must be removed before using force. Avoid as much dirt as possible during disassembly. The accumulation of additional dirt will make it more difficult to clean the components.

Assembly This procedure assumes that all of the components and assemblies have been cleaned, replaced, or rebuilt and are ready to be installed on the engine. Torque values are listed in each step. If a torque value is not specified, use the chart listed in the specifications section, Group 18, to determine the correct torque value. Many of the gaskets and o-rings are manufactured from a material designed to absorb oil. These gaskets will enlarge and provide a tight seal after coming in contact with oil.

Use ONLY a recommended contact adhesive or a vegetable based oil to install these parts. Always use a capscrew of the same system, metric or U. Customary, the same dimension and the same grade as the capscrew removed.

The use of a longer capscrew than the capscrew that is listed can result in damage to the engine. Engine Lifting Brackets Warning: The engine lifting equipment must be designed to safely lift the engine as an assembly. Use a properly rated hoist and engine lifting fixture, Part No. Refer to Section E for the weight of the engine you are working on. Engine Disassembly Engine - Preparation for Cleaning Install caps or tape on all engine openings to prevent moisture and dirt from entering the engine: Protect all electrical components and wiring from the full force of the cleaner spray nozzle.

Engine - Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Steam clean and dry with compressed air. Lubricating Oil - Draining 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.

The oil pan capacity is 34 Liters [9. Remove the oil drain plug from the bottom of the oil pan. Drain the oil into a suitable container. Use fuel and water filter wrench, Part No. Fan Drive Belt - Removal Loosen the idler pulley shaft locknut. Turn the adjusting screw counterclockwise to release tension, and remove the belt.

Fan and Fan Hub - Removal If an electric fan clutch is used, disconnect the fan clutch connector from the base wiring harness. Remove the six capscrews and the fan. NOTE: The six capscrews also hold the fan drive pulley in position. Do not allow the pulley to fall. Loosen the adjusting link capscrew 2. Loosen the pivot capscrew and nut 3. Turn the adjusting screw 4 to release tension, and remove the belt. Rotate the tensioner away from the belt until it stops.

Remove the alternator belt while holding the tensioner back. Remove the capscrew 2 from the thermostat housing and the adjusting link.

Remove the pivot bolt and alternator. Alternator and Brackets Bus Applications Loosen the alternator pivot mounting capscrew. Remove the alternator brace link. Remove the alternator pivot capscrew and the alternator. Remove the mounting nut from the rear of the gear housing and the four cylinder block mounting capscrews from the lower alternator mounting bracket.

Remove the lower alternator mounting bracket. Remove the belt tensioner from the front of the engine. Remove the three mounting capscrews and the tensioner bracket from the gear cover.

Turbocharger - Removal Remove the oil supply line and gasket from the top of the turbocharger. Remove the other end of the supply line from the lubricating oil filter head. Remove the oil drain line and gasket from the bottom of the turbocharger. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the v-band clamp, discharge elbow and o-ring from the turbocharger compressor discharge outlet.

Remove the four turbocharger mounting nuts. Remove the turbocharger and gasket. Plug the supply and drain holes in the turbocharger. Exhaust Manifold - Removal Caution: The exhaust manifold assembly has three sections which can separate and fall causing personal injury during removal.

Hold the assembly on each end to remove it. Remove one capscrew from each end section of the exhaust manifold and install two guide pins, Part No. Remove the remaining capscrews. Remove the exhaust manifold, gaskets and the two guide pins.

Air Intake Manifold - Removal Remove the intake manifold pressure sensor and the intake manifold temperature sensor wire connectors from the top rear end of the intake manifold.

Tag the wires as they are removed for future identification. Remove the boost pressure sensor 1 and the intake manifold temperature sensor 2 from the manifold. Remove the wire clamps holding the harness to the manifold. Remove the air intake connection and gasket from the top of the manifold. Remove two of the mounting capscrews and install two guide pins, Part No. Remove the remaining capscrews, beginning at the ends and moving toward the center, intake manifold and gasket.

Remove the guide pins. Use four M10 x 25 capscrews and install the front lifting bracket on the rocker lever housing. Thermostat Housing - Removal Loosen the bottom coolant bypass hose clamp. NOTE: If the housing is stuck, hit the housing with a mallet to loosen it. Both metric and U. The metric value is listed first, followed by the U. 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 defined 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.

CLEAN the part or assembly. Refer to another location in this manual or another publication for additional information. The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. El componente pesa 23 kg [50 lb] o mas. Para evitar dano corporal empleen una cabria u obtengan ayuda para elevar el componente. Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben.

Weitere Informationen an anderer Stelle bzw. Das teil weigt 23 kg [50 lb] oder mehr. Zur vermeidung von koerperverletzung winde benutzen oder hilfe beim heben des teils in anspruch nehmen. Le composant pese 23 kg [50 lb] ou davantage. The illustrations can contain symbols to indicate an action required, and an acceptable or not acceptable condition.

The illustrations are intended to show repair or replacement procedures. The illustration can differ from your application, but the procedure given will be the same. 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. Be aware of hazardous conditions that can exist. Remove all jewelry when working.

Disconnect the air starting motor if equipped to prevent accidental engine starting. 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.

Always use blocks or proper stands to support the product before performing any service work. 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 protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas fluorocarbons into the atmosphere.

Federal law requires capture and recycling refrigerant. 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. 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. Make sure you understand how to use them before performing any service work. Do not use a fastener of lessor quality if replacements are necessary. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. General Repair Instructions This engine incorporates the latest diesel technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards.

In particular, unauthorized repair to safety-related components can cause personal injury or death. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, injestion and contact with such substances.

Always use good safety practices with tools and equipment. The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause premature wear. 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 ReConW components. All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations. Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location.

Refer to Section L, Literature, for ordering instructions. Remove all three connectors going to the ECM. General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [ to degrees Fahrenheit].

A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. Warning: Acid is extremely dangerous, and can damage the machinery. Always provide a tank of strong soda water as a neutralizing agent.

Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the capscrew holes and the oil drillings. If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound.

The rustproofing compound must be removed from the parts before installation on the engine. Steam Cleaning Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way to clean the oil drillings.

Warning: Wear protective clothing to prevent personal injury from the high pressure and extreme heat. Do not steam clean the following parts: 1. Additionally a few seconds after your payment you will receive an email with your instant manual download link. You have three days after payment to download and save your manual. Only logged in customers who have purchased this product may leave a review.

Click to enlarge. Add to Wishlist. Product added! Browse Wishlist. The product is already in the wishlist! Description Additional information Description Cummins m11 series engines shop manual pdf contains help for troubleshooting and will support you how to fix your problems immediately. The Content What an easy way to find your problem and repair it on the spot, no downtime on the job site, with our downloadable repair manual pdf you instantly have access to the material needed to get you running again.

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