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M11 Series
CUMMINS M11 Series User Manual
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T
r
ou
bleshooting
and
Repair
Manual
M1
1
Series
Engines
(ST
C,
CELEC
T™,
CELEC
T™
P
lus
Models)
Copyrigh
t
R
1996
Cummins
Engine
Company
,
Inc
.
All
right
s
reserv
ed
Bulletin
No.
3666
139–00
Printed
2/96
2
Table of Contents
Section Ts - Troubleshooting Symptoms
25
Table of Contents
25
Procedures and Techniques
27
Air Compressor Air Pressure Rises Slowly
28
Air Compressor Cycles Frequently
29
Air Compressor Noise Is Excessive
30
Air Compressor Pumping Excess Lubricating Oil into the Air System
31
Air Compressor will Not Maintain Adequate Air Pressure (Not Pumping Continuously
33
Air Compressor will Not Pump Air
34
Air Compressor will Not Stop Pumping
35
Alternator Not Charging or Insufficient Charging
36
Alternator Overcharging
38
Communication Error - Electronic Service Tool or Control Device
39
Coolant in the Lubricating Oil
42
Coolant Loss (External
43
Coolant Loss - Internal
45
Coolant Temperature above Normal - Gradual Overheat
46
Coolant Temperature Is above Normal - Sudden Overheat
49
Coolant Temperature Is below Normal
51
Crankcase Gases (Blowby) Excessive
53
Cranking Fuel Pressure Is Low
54
Section 1 - Cylinder Block - Group 01
184
Accessory Drive Seal
191
Clean
192
Install
192
Install
195
Bearings, Main
197
Remove
197
Clean
198
Inspect for Reuse
198
Install
199
Bearings, Thrust
202
Remove
202
Install
203
Camshaft
205
Remove
205
Clean
208
Inspect for Reuse
209
Install
210
Camshaft Bushings
214
Clean
214
Remove
214
Inspect for Reuse
215
Install
215
Number Six through Number Two Bushings - Installation
216
Remove
218
Inspect for Reuse
219
Install
221
Camshaft Gear (Camshaft Removed)
224
Install
224
Remove
224
Clean
227
Connecting Rod
227
Inspect for Reuse
227
Remove
227
Crankshaft
229
Crankshaft Gear, Front (Crankshaft Installed)
229
Install
229
Remove
229
Rotation Check
229
Clean
230
Inspect for Reuse
230
Install
231
Crankshaft Pulley
233
Inspect for Reuse
233
Install
233
Remove
233
Crankshaft Seal, Front
234
Remove
234
Clean
235
Install
235
Crankshaft Seal, Rear
236
Remove
236
Clean
237
Install
237
Cylinder Block and Liner Seats
238
Leak Test
238
Cylinder Liner
240
Clean
242
Inspect for Reuse
242
Install
244
Gear Cover, Front
246
Remove
246
Clean
248
Inspect for Reuse
249
Install
250
Gear Housing, Front
253
Remove
253
Clean
256
Clean
262
Idler Gear, Camshaft
262
Install
264
Remove
266
Clean
267
Inspect for Reuse
267
Install
269
Idler Gear, Water Pump
270
Remove
270
Inspect for Reuse
272
Install
274
Clean
276
Disassemble
276
General Information
276
Piston
276
Remove
276
Articulated Piston
277
Inspect for Reuse
277
Assemble
279
Install
279
Remove
279
Piston Cooling Nozzle
280
Install
283
Remove
284
Clean
285
Inspect for Reuse
285
Install
285
Install
293
Remove
293
Section 3 - Rocker Levers - Group 03
326
Clean
328
Crankcase Breather (Internal)
328
Inspect for Reuse
328
Install
329
Overhead Set
329
Adjust
334
General Information
334
Injector Adjustment - CELECT™ and CELECT™ Plus Engines
336
Valve Adjustment - CELECT™ and CELECT™ Plus Engines
337
Valve Adjustment - STC Engines
341
General Information
345
Aluminum Supports
347
Clean
347
Install
352
Clean
355
Inspect for Reuse
355
Remove
355
Rocker Lever Cover
355
Install
356
Remove
357
Rocker Lever Housing
357
Clean
359
Inspect for Reuse
360
Install
360
Section 4 - Cam Followers/Tappets - Group 04
365
Cam Follower Assembly
367
Remove
367
Clean
368
Disassemble
368
Inspect for Reuse
368
Install
371
Push Rods or Tubes
373
Remove
373
Inspect for Reuse
374
Install
375
Section 5 - Fuel System - Group 05
378
Flow Diagram, Fuel System
386
Fuel Consumption
393
Measure
393
Fuel Flow
396
Initial Check
396
Minimum Cranking Pressure
397
Minimum Operating Pressure
397
Pressure Test
397
Fuel Pump
399
Clean
400
CELECT™ or CELECT™ Plus
401
Inspect for Reuse
401
Stc
402
CELECT™ or CELECT™ Plus
403
General Information
403
Prime
403
Stc
404
Remove
406
Fuel Pump High Idle Speed (VS Governor)
407
Install
407
Adjust
408
Fuel Pump Idle Speed
408
High Speed
408
Fuel Pump Pulsation Damper
410
Inspect for Reuse
410
Adjust
411
Fuel Pump Throttle Lever
411
Adjust
412
Fuel Pump Throttle Linkage
412
Fuel Pump VS Throttle Shaft Housing
413
Section 8 - Cooling System - Group 08
539
Coolant Filter
558
Inspect for Reuse
561
Coolant Heater Housing
562
Inspect for Reuse
563
Coolant Thermostat
564
Leak Test
564
Inspect for Reuse
571
Coolant Thermostat Seal
574
Inspect for Reuse
575
Coolant Vent Lines
576
Initial Check
576
Cooling System
577
Pressure Test
582
Air in Cooling System
583
Cooling System - Air or Combustion Gas Test
583
Initial Check
583
Air Compressor
585
Combustion Gas Leak
586
Cooling System Diagnostics
589
Analyzing the Data
593
General Information
595
Table of Contents
860
Accessory Drive Seal
871
Alternator Drive Seal
871
Bearings, Main
871
Crankshaft Pulley
871
Crankshaft Seal, Front
871
Cylinder Block - Torque Values
871
Crankshaft Seal, Rear
872
Gear Cover, Front
872
Gear Housing, Front
872
Idler Gear, Camshaft
872
Idler Gear, Hydraulic Pump
872
Idler Gear, Water Pump
873
Piston and Connecting Rod Assembly
873
Piston Cooling Nozzle
873
Water Header Plate, Cylinder Block
873
Cylinder Head
874
Cylinder Head - Specifications
874
Cylinder Head
875
Cylinder Head - Torque Values
875
Accessory Drive
893
Drive Units - Specifications
893
Accessory Drive
894
Drive Units - Torque Values
894
Alternator
902
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CUMMINS M11 Series Specifications
General
Engine Type
Diesel
Engine Model
M11 Series
Configuration
Inline 6-Cylinder
Bore
125 mm (4.92 in)
Stroke
147 mm (5.79 in)
Aspiration
Turbocharged and aftercooled
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