Cummins M11 Series Engine Operation and Maintenance Manual – PDF DOWNLOAD

Cummins M11 Series Engine Operation and Maintenance Manual – PDF DOWNLOAD

FILE DETAILS:

Cummins M11 Series Engine Operation and Maintenance Manual – PDF DOWNLOAD

Language : English
Pages :401
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Cummins M11 Series Engine Operation and Maintenance Manual – PDF DOWNLOAD

Cummins M11 – Operation and Maintenance Manual 1
Foreword 2
Table of contents 3
Important reference numbers 4
Section i – Introduction 5
Section contents 5
To the owner and operator 7
About the manual 7
How to use the manual 7
Symbols 8
Illustrations 12
General safety instructions 13
Acronysms and abbreviations 14
Section E – Engine identification 15
Section Contents 15
Engine identification 17
Engine dataplate 17
Fuel pump dataplate 17
Cummins engine nomenclature 17
Specifications 18
General specifications 18
Fuel system 18
Lubricating oil system 18
Cooling system 18
Air intake system 19
Exhaust system 19
Electrical system 19
Batteries (specific gravity) 19
Engine diagrams 20
Section 1 – Operating instructions 21
Section contents 21
Operating instructions – general information 23
Normal starting procedure 24
Cold wheater starting using starting fluid 26
Operating the engine 27
Engine operating range 28
Cold weather operation 29
Thermo control settings 30
Winterfronts 31
Shutters 31
Engine shutdown 31
PTO application with variable speed 31
Section 2 – Maintenance guidelines 33
Section contents 33
Maintenance guidelines – General information 35
Tool requirements 35
Maintenance schedule 36
Page references for maintenance instructions 37
Maintenance record form 39
Section 3 – Maintenance procedures at daily interval 41
Section contents 41
Daily maintenance procedures – General information 43
Engine operation report 43
Fuel-water separator 44
Drain 44
Lubricating oil level 44
Maintenance check 44
Coolant level 44
Maintenance check 44
Fan, cooling 46
Inspect for reuse 46
Drive belts 47
Maintenance check 47
Crankcase breather tube 47
Maintenance check 47
Section 4 – Maintenance procedures at weekly interval 50
Section contents 50
Weekly maintenance procedures – General information 51
Air cleaner restriction 51
Maintenance check 51
Air cleaner element, paper type 51
Maintenance check 51
Air cleaner element, single heavy duty dry type 52
Maintenance check 52
Air cleaner element, dual heavy duty dry type 53
Maintenance check 53
Air cleaner element, cartdrige type 54
Maintenance check 54
Air leaks, air intake system 55
Maintenance check 55
Air tanks and reservoirs 57
Drain 57
Section 5 – Maintenance procedures at 250 hours or 6 months 59
Section contents 59
Maintenance procedures – General information 61
Fuel filter (Spin-on type) 61
Remove 61
Install 61
Fuel water separator (Superfilter) 61
Lubrication oil and filters 62
Drain 62
Cummins/Fleetguard filter specifications 64
Lubricating oil filters 64
Fill 65
Coolant filter 67
Remove 67
Install 67
Supplemental coolant additive (SCA) 68
Maintenance check 68
Air compressor air cleaner element 69
Maintenance service 69
Section 6 – Maintenance procedures at 1500 hours 71
Section contents 71
Maintenance procedures – General information 73
Overhead set 73
Adjust 73
Water pump 79
Maintenance check 79
Radiator shutter assembly 80
Maintenance check 80
Turbocharger 80
Maintenance check 80
Engine mounting bolts 81
Maintenance check 81
Engine steam cleaning 81
Clean 81
Section 7 – Maintenance procedures at 6000 hours or 2 years 83
Section contents 83
Maintenance procedures – General information 85
Cooling system 85
Clean 85
Maintenance check 87
Antifreeze 87
Section 8 – Maintenance procedures at 6000 hours 89
Section contents 89
Maintenance procedures – General information 91
Vibration damper, single 91
Maintenance check 91
Injector 91
Remove 91
STC 91
Install 93
STC 93
Fuel pump 95
Remove 95
STC 95
Install 97
STC 97
Fan hub, belt driven 98
Maintenance check 98
Turbocharger 98
Maintenance check 98
Radial bearing clearance – Checking 98
Axial clearance – Checking 99
Air compressor maintenance100
Maintenance check100
Air compressor discharge – Inspect100
Air compressor intaje – Inspect102
Section A – djustment, repair and replacement104
Section contents104
Drive belt, cooling fan106
Adjust106
Remove106
Install107
Drive belt, alternator107
Adjust107
Remove108
Install109
Water pump109
Remove109
Install112
Coolant thermostat115
Remove115
Install116
Fan drive idler pulley assembly117
Remove117
Install118
Fan hub, belt driven119
Remove119
Install120
Turbocharger121
Remove121
Install122
Air starting motor124
Engine storage – Long term124
Section D – System diagrams126
Section contents126
System diagrams – General information128
Flow diagram, fuel system129
Flow diagram129
Flow diagram, lubricating oil system130
Flow diagram130
Flow diagram, cooling system131
Flow diagram131
Flow diagram, air intake system132
Flow diagram132
Flow diagram, exhaust system133
Flow diagram133
Flow diagram, compressed air system134
Flow diagram134
Section L – Service literature136
Section contents136
Additional service literature138
Service literature ording location139
Literature order form140
Section M – Component manufacturers142
Section contents142
Component manufacturers’ adresses144
Air compressors144
Air cylinders144
Air heaters144
Air starting motors144
Alternators144
Auxiliary brakes144
Belts144
Catalytic convertors144
Coolant level switches144
Clutches144
Coolant heaters145
Drive plates145
Electric starting motors145
Electronic switches145
Engine protection controls145
Fan clutches145
Fans145
Fault lamps145
Filters145
Flexplates145
Fuel coolers145
Fuel warmers145
Gauges145
Governors146
Heat sleeves146
Hydraulic and power steering pumps146
In-line connectors146
Oil heaters146
Prelubrication systems146
Radiators146
Throttle assemblies146
Torque converters146
Section S – Service assistance148
Section contents148
Service assistance150
Routine service and parts150
Emergency and technical service150
Problem solving151
Division and regional offices152
Distributors and branches – United States153
Distributors and branches – Canada160
Distributors and branches – Australia162
Distributors and branches – New Zealand163
Regional offices – International164
Distributors – International167
Section TS – Troubleshooting symptoms176
Section contents176
Procedures and techniques178
Troubleshooting symptoms charts178
Air compressor air pressure rises slowly179
Air compressor noise excessive180
Air compressor pumping excess lubricating oil into air system181
Air compressor will not maintain adeguate air pressure (not pumping continuously)182
Air compressor will not stop pumping183
Alternator not charging or insufficient charging184
Coolant loss – Extenal185
Coolant temperature above normal – Gradual overheat186
Coolant temperature above normal – Sudden overheat188
Coolant remperature below normal189
Crankcase gases (blowby) – Excessive190
Engine acceleration and response poor191
Engine cranks but will not start (no smoke from exhaust)192
Engine decelerates slowly193
Engine difficult to start or will not start – Exhaust smoke present194
Engine noise excessive195
Engine noise excessive – Combustion knocks196
Engine power output low197
Engine runs rough at idle199
Engine runs rough or misfires200
Enhine shuts off unexpectedly or dies during deceleration201
Engine speed surges at low idle202
Engine speed surges (other than low idle)203
Engine starts but will not keep running204
Engine vibration excessive205
Engine will not crank or cranks slowly (air starting motor)206
Engine will not crank or cranks slowly (electric starting motor)207
Engine will not reach rated speed when loaded208
Engine will not shut off209
Fuel consumption – Excessive210
Fuel in coolant211
Fuel in the lubricating oil212
Lubricating oil consumption excessive213
Lubricating oil contaminated214
Lubricating oil pressure high215
Lubricating oil pressure low216
Lubricating oil sludge in the engine crankcase excessive217
Smoke, black – Excessive219
Smoke, white – Excessive220
Turbocharger pressure low221
Turbocharger leaks – Engine oil or fuel222
Section V – Maintenance specifications224
Section contents224
Specifications226
General specifications226
Fuel system226
Lubricating oil system226
Cooling system226
Air intake system227
Exhaust system227
Compressed air system227
Holset SS338/QE338 A/S models227
Holset SS296/SS296/QE296 A/C models228
Holset ST676 A/C model228
Electrical system229
Batteries (specific gravity)229
Cummins / Fleetguard filter specifications230
Lubricating oil filters230
Fuel recommendations and specifications231
Lubricating oil recommendations and specifications232
New engine break-in oils232
Artic operation engine oil232
Genral information233
Oil drain intervals234
Coolant recommendations and specifications235
Fully formulated coolant / antifreeze235
Cooling system sealing additives237
Cooling system soluble oils237
Fleetguard DCa4 service filters and liquid precharge238
Supplemental coolant additive (SCA)239
Testing SCA concentration level CC-2602 test kit240
Precautions and instructions for proper kit use240
Test intevals241
Coolant replacement requirements242
Drive belt tension243
Engine component torque values244
Artic operation245
Capscrew markings and torque values246
Capscrew markings and torque values – Metric247
Capscrew markings and torque values – US Customary248
Section W – Warranty251
Section contents251
Cummins warranty – International industrial252
Cummins warranty – United States and Canada industrial254
California emission control system warranty statement257
Index260
Cummins M11 – Parts catalog263
Product identification information265
Customer service information266
Table of contents267
Air cleaner mounting268
Accessory drive pulley269
Dataplate270
Cylinder block272
Cylinder liner274
Crankshaft275
Main bearings276
Idle gears278
Gear housing280
Cam follower282
Cylinder block plumbing284
Breather plumbing285
Air compressor plumbing286
Vibration damper287
Front gear train accessory drive288
Fuel pump drive290
Engine brake control292
Thermostat293
Alternator mounting294
Front engine support296
Fan drive298
Air fuel control plumbing300
Fuel filter301
Flywheel housing302
Fuel pump mounting304
Fuel pump305
Fuel pump housing306
Fuel pump front cover308
Fuel pump damper310
Fuel pump gear311
AFC Assembly312
Governor spring pack314
Fuel pump mounting316
Fuel system accessories317
Fuel plumbing318
Fuel valve320
Flywheel and ring gear321
Front gear cover322
Liftingg bracket324
Lubricating oil cooler326
Lubricating oil filter328
Lubricating oil pump329
Lubricating oil pump plumbing330
Cylinder block covers332
Oil pan334
Piston cooling nozzle336
Connecting rod337
Engine piston kit338
Camshaft340
Cylinder head342
Injectors344
Oil manifold346
Oil control valve348
Oil control valve plumbing350
Piston cooling nozzle352
Connecting rod353
Engine piston kit354
Camshaft356
Cylinder head358
Injectors360
Oil manifold362
Oil control valve364
Oil control valve plumbing366
Turbocharger368
Turbocharger370
Accessory drive pulley372
Rocker lever & housing374
Aftercooler376
Thermostat housing378
Throttle lever380
Valve cover381
Aftercooler water plumbing382
Corrosion resistor384
Oil cooler water plumbing386
Water pump388
Upper engine gasket set390
Lower engine gasket set391
Repair kits and sets392
Repair kits and sets393
Option index395

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