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CUMMINS M11 Series User Manual

CUMMINS M11 Series
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Troubleshooting and Repair Manual
M11 Series Engines
(STC, CELECT™, CELECT™ Plus
Models)
CopyrightR 1996
Cummins Engine Company, Inc.
All rights reserved
Bulletin No. 3666139–00
Printed 2/96

Table of Contents

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CUMMINS M11 Series Specifications

General IconGeneral
Engine TypeDiesel
Engine ModelM11 Series
ConfigurationInline 6-Cylinder
Bore125 mm (4.92 in)
Stroke147 mm (5.79 in)
AspirationTurbocharged and aftercooled

Summary

Foreword

General Safety Instructions

Crucial safety precautions and warnings for performing repairs, including general guidelines and specific considerations.

Section i - Introduction

About this Manual

Provides an overview of the manual's purpose, scope, and organization for effective use.

Symbols

Explains the meaning of various symbols used throughout the manual to convey important information.

General Safety Instructions

Details essential safety precautions for personal safety during service and repair operations.

Section E - Engine Identification

Engine Dataplate

Describes the engine dataplate, its location, and the mandatory information for service parts sourcing.

Specifications

Lists key engine specifications including horsepower, bore, stroke, displacement, and weights.

Section TS - Troubleshooting Symptoms

Troubleshooting Symptoms Charts

Guides users through diagnosing and correcting engine problems based on specific symptoms and causes.

Section 0 - Complete Engine - Group 00

Engine Removal

Step-by-step instructions for safely removing the engine from the vehicle, including disconnections and support.

Engine Installation

Step-by-step instructions for installing the engine into the vehicle, including component checks and fluid filling.

Section 1 - Cylinder Block - Group 01

Bearings, Connecting Rod

Procedures for cleaning, inspecting, installing, and removing connecting rod bearings.

Camshaft

Procedures for removing, cleaning, inspecting, and installing the camshaft.

Cylinder Liner

Procedures for removing, cleaning, inspecting, and installing cylinder liners.

Section 5 - Fuel System - Group 05

Fuel Pump

Instructions for removing, cleaning, inspecting, installing, and priming the fuel pump for CELECT™ and STC systems.

Fuel System - General Information

Overview of PT, STC, CELECT™, and CELECT™ Plus fuel systems and their components.

Fuel System - Specifications

Details specifications for engine idle speed, fuel inlet restrictions, and minimum fuel pressures.

Section 6 - Injectors and Fuel Lines - Group 06

Injectors

Procedures for removing, installing, and adjusting injectors for CELECT™/CELECT™ Plus and STC systems.

Static Injection Timing

Procedure for measuring and adjusting the static injection timing using specialized tools.

Section 7 - Lubricating Oil System - Group 07

Lubricating Oil Filters

Instructions for removing and installing spin-on and canister-type oil filters, including specifications.

Lubricating Oil Pressure Regulator (Main Rifle)

Procedures for removing, inspecting, and installing the main oil pressure regulator.

Section 8 - Cooling System - Group 08

Coolant Thermostat

Procedures for leak testing and installing the coolant thermostat and its seal.

Cooling System Diagnostics

Steps for testing fan, shutters, and thermostat operation, and checking for leaks and air.

Section 10 - Air Intake System - Group 10

Aftercooler

Procedures for removing, cleaning, inspecting, pressure testing, and installing the aftercooler.

Turbocharger

Procedures for removing, cleaning, inspecting, and installing the turbocharger.

Section 12 - Compressed Air System - Group 12

Air Compressor

Procedures for removing, cleaning, inspecting, installing, and assembling the air compressor.

Air Governor (Air Compressor Pumps Continuously)

Initial checks and procedures for diagnosing air governor malfunction when the compressor runs continuously.

Section 13 - Electrical Equipment - Group 13

Alternator

Procedures for initial checks, installation, and removal of the alternator.

Starting Motor

Procedures for removing and installing the starting motor, including electrical connections.

Section 14 - Engine Testing - Group 14

Engine Run-in (Chassis Dynamometer)

Guidelines for performing engine run-in procedures using a chassis dynamometer.

Engine Testing (Engine Dynamometer)

Procedures for setting up and conducting engine tests using an engine dynamometer.

Section 16 - Mounting Adaptations - Group 16

Flywheel

Procedures for removing, cleaning, inspecting, installing, measuring, and assembling the flywheel.

Flywheel Housing

Procedures for removing, cleaning, inspecting, installing, measuring, and assembling the flywheel housing.

Section 17 - Miscellaneous - Group 17

Cup Plug

Procedures for cleaning, inspecting, installing, and removing cup plugs.

Pipe Plug

Procedures for cleaning, inspecting, installing, and removing pipe plugs, including torque values.

Section V - Specifications

Cylinder Block - Specifications

Detailed specifications for cylinder block components, including bearings, camshafts, and liners.

Fuel System - Specifications

Details specifications for engine idle speed, fuel inlet restrictions, and minimum fuel pressures.

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