Cummins M11 Service Manual Diesel Engine Repair

Foreword This manual contains complete rebuild specifications and information for the M11 model engines, and all asso- ciated components manufactured by Cummins Engine Company, Inc. A listing of accessory and component suppliers’ addresses and telephone numbers is located in Section C. Suppliers can be contacted directly for any information not covered in this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in this section. The repair procedures in this manual are based on the engine being installed on an approved engine stand. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (Troubleshooting and Repair, Specifications, Alternative Repair, and so on.) are available and can be ordered by filling out and mailing the Literature Order Form located in the Service Literature Section L. Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged. Please use the postage paid, self-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location, a Cummins Division Office, or the factory. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts. These parts can be identified by the following trademarks:

Table of Contents Section Introduction ................................................................................................................................... i Engine Identification...................................................................................................................... E Engine Disassembly and Assembly – Group 00 ........................................................................... 0 Cylinder Block – Group 01 ............................................................................................................ 1 Cylinder Head – Group 02 ............................................................................................................. 2 Rocker Levers – Group 03............................................................................................................. 3 Cam Followers – Group 04 ............................................................................................................ 4 Fuel System – Group 05 ................................................................................................................ 5 Injectors and Fuel Lines – Group 06 ............................................................................................. 6 Lubricating Oil System – Group 07 ............................................................................................... 7 Cooling System – Group 08 .......................................................................................................... 8 Drive Units – Group 09 .................................................................................................................. 9 Air Intake System – Group 10 ....................................................................................................... 10 Exhaust System – Group 11 .......................................................................................................... 11 Air Equipment – Group 12 ............................................................................................................. 12 Electrical Equipment – Group 13 .................................................................................................. 13 Engine Testing – Group 14............................................................................................................ 14 Instruments and Controls – Group 15........................................................................................... 15 Mounting Adaptations – Group 16 ................................................................................................ 16 Specifications – Group 18 ............................................................................................................. V Vehicle Braking – Group 20........................................................................................................... 20 Service Literature .......................................................................................................................... L Component Manufacturers: Names and Addresses ..................................................................... C Index ............................................................................................................................................. X

Cummins’ 22-Group System Exploded Diagram

Section i - Introduction Section Contents Page About the Manual................................................................................................................................................ i-2 Definition Of Terms ........................................................................................................................................... i-11 General Cleaning Instructions .......................................................................................................................... i-10 Glass or Plastic Bead Cleaning ...................................................................................................................... i-10 Solvent and Acid Cleaning .............................................................................................................................. i-10 Steam Cleaning .............................................................................................................................................. i-10 General Repair Instructions................................................................................................................................ i-9 Welding on a CELECT™ Controlled Vehicle ....................................................................................................... i-9 General Safety Instructions ................................................................................................................................ i-8 Important Safety Notice .................................................................................................................................... i-8 How to Use the Manual....................................................................................................................................... i-2 Illustrations ......................................................................................................................................................... i-7 Simbolos ............................................................................................................................................................ i-4 Symbole .............................................................................................................................................................. i-5 Symboles ........................................................................................................................................................... i-6 Symbols ............................................................................................................................................................. i-3 Section i - Introduction M11 Page i-1

About the Manual This M11 Shop Manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and assembly of components on M11 engines. The manual is divided into sections. Section 0 outlines the disassembly and assembly of the engine while the other sections detail specific components. How to Use the Manual This manual is divided in the same group system used for Cummins’ filmcard system. Each group is organized in a way that all mechanics, both those who are and are not familiar with the M11 engine models, can reference the manual. Refer to the Table of Contents at the front of the manual to determine the group that details the desired information. Each group contains the following in sequence: • Section contents at the beginning of each group to quickly aid in locating the information desired. • Service tools list with recommended tools needed to rebuild the components. • General information to aid in rebuilding the component, and an explanation of design change differences. • Step-by-step rebuild instructions for disassemby, cleaning, inspection and assembly of the component. • Symbols which represent the action outlined in the instructions. The definitions of the symbols, listed in four languages (English, Spanish, French and German), appear on pages i-3 through i-6. Topics will be listed alphabetically on the ‘‘Section Contents’’ page. All procedures are described using the ‘‘text symbol picture’’ (TSP) format. In general, each component rebuild will be described through a 3-step sequence of: (1) cleaning and inspection for reuse; (2) rebuild; and (3) replacement. Reference numbers (procedure numbers) are assigned to each process. Reference numbers are constructed with a section number and a two-digit sequenced number. Both metric and U.S. customary values are used in this manual. The metric value is listed first, followed by the U.S. customary in brackets. An example is 60°C [140°]. About the Manual Section i - Introduction M11 Page i-2

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. Indicates a REMOVAL or DISASSEMBLY step. Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required. CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. 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. Section i - Introduction Symbols M11 Page i-3

Simbolos Los sı ´mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando aparece uno de estos sı ´mbolos, su significado se especifica en la parte inferior. ADVERTENCIA - Serios dan õs personales o dan õ a la propiedad puede resultar si las instrucciones de Advertencia no se consideran. PRECAUCION - Dan õs menores pueden resultar, o de piezas del conjunto o el motor puede averiarse si las instrucciones de Precaucio ń no se siguen. Indica un paso de REMOCION o DESMONTAJE. Indica un paso de INSTALACION o MONTAJE. Se requiere INSPECCION. LIMPIESE la pieza o el montaje. EJECUTESE una MEDICION meca ńica o del tiempo. LUBRIQUESE la pieza o el montaje. Indica que se dara ´ una LLAVE DE TUERCAS o el TAMAN ˜ O DE HERRAMIENTA. APRIETESE hasta un par torsor especı ´fico. EJECUTESE una MEDICION ele ´ ctrica. Para informacio ń adicional refie ´rase a otro emplazamiento de este manual o a otra publicacio ń anterior. El componente pesa 23 kg [50 lb] o mas. Para evitar dano corporal empleen una cabria u obtengan ayuda para elevar el componente. Simbolos Section i - Introduction M11 Page i-4

Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole haben folgende Bedeutung: WARNUNG - Wird die Warnung nicht beachtet, dann besteht erho ¨ hte Unfall- und Bescha ¨digungsgefahr. VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und Bescha ¨digungsgefahr. AUSBAU bzw. ZERLEGEN. EINBAU bzw. ZUSAMMENBAU. INSPEKTION erforderlich. Teil oder Baugruppe REINIGEN. DIMENSION - oder ZEITMESSUNG. Teil oder Baugruppe O ¨ LEN. WERKZEUGGRO ¨ SSE wird angegeben. ANZUG auf vorgeschriebenes Drehmoment erforderlich. Elektrische MESSUNG DURCHFU ¨ HREN. Weitere Informationen an anderer Stelle bzw. in anderen Handbu ¨ chern. Das teil weigt 23 kg [50 lb] oder mehr. Zur vermeidung von koerperverletzung winde benutzen oder hilfe beim heben des teils in anspruch nehmen. Section i - Introduction Symbole M11 Page i-5

Symboles Les symboles suivants sont utilise ´ s dans ce manuel pour aider a ` communiquer le but des instructions. Quand l’un de ces symboles apparaı ˆt, il e ´voque le sens de ´ fini ci-dessous: AVERTISSEMENT - De graves le ´sions corporelles ou des dommages mate ´ riels conside ´ rables peuvent survenir si les instructions donne ´ es sous les rubriques ″Avertissement″ ne sont pas suivies. ATTENTION - De petites le ´sions corporelles peuvent survenir, ou bien une pie `ce, un ensemble ou le moteur peuvent e ˆtre endommage ´ s si les instructions donne ´ es sous les rubriques ″Attention″ ne sont pas suivies. Indique une ope ´ration de DEPOSE. Indique une ope ´ration de MONTAGE. L’INSPECTION est ne ćessaire. NETTOYER la pie `ce ou l’ensemble. EFFECTUER une MESURE me ćanique ou de temps. GRAISSER la pie `ce ou l’ensemble. Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donne ´ e. SERRER a ` un couple spe ćifique. EFFECTUER une MESURE e ´lectrique. Se reporter a ` un autre endroit dans ce manuel ou a ` une autre publication pour obtenir des informations plus comple `tes. Le composant pese 23 kg [50 lb] ou davantage. Pour eviter toute blessure, employer un appariel de levage ou demander de l’aide pour le soulever. Symboles Section i - Introduction M11 Page i-6

Cummins M11 Service Manual Diesel Engine Repair

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