Cummins Diesel Engine M11 Service Manual

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This Cummins Diesel Engine M11 Service Repair Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures. Additionally the manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and assembly of components.

Section i - Introduction
To the Owner and Operator
About the Manual
How to Use the Manual
Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Acronyms and Abbreviations

Section E - Engine Identification
Engine Identification
Engine Diagrams

Section 1 - Operating Instructions
Operating Instructions - Overview
Normal Starting Procedure
Cold Weather Starting
Starting Procedure After Extended Shutdown or Oil Change
Operating the Engine
Engine Operating Range
Engine Shutdown
Electronic Controlled Fuel System
Electromagnetic Interference (EMI)

Section 2 - Maintenance Guidelines
Maintenance Guidelines - Overview
Tool Requirements
Maintenance Schedule
Maintenance Record Form

Section 3 - Maintenance Procedures at Daily Interval
Daily Maintenance Procedures - Overview
Fuel-Water Separator
Lubricating Oil Level
Coolant Level
Fan, Cooling
Drive Belts
Crankcase Breather Tube
Air Tanks and Reservoirs
Charge Air Piping

Section 4 - Maintenance Procedures at 250 Hours or 6 Months
 Maintenance Procedures - Overview
Fuel Filter (Spin-on)
Lubricating Oil and Filters
Lubricating Oil Filter (Spin-on)
Coolant Filter
Supplemental Coolant Additive (SCA) and Antifreeze Concentration
Air Compresser Discharge Lines
Engine Wiring Harness

Section 5 - Maintenance Procedures at 1500 Hours
Maintenance Procedures - Overview
Overhead Set
Water Pump
Radiator Shutter Assembly
Turbocharger
Engine Mounts
Engine Steam Cleaning
Air Cleaner Restriction
Air Leaks, Air Intake and Exhaust Systems

Section 6 - Maintenance Procedures at 6000 Hours or 2 Years
Maintenance Procedures - Overview
Cooling System

Section 7 - Maintenance Procedures at 6000 Hours
Maintenance Procedures - Overview
Vibration Damper, Viscous
Fan Drive Idler Pulley Assembly
Turbocharger
Fan Hub, Belt Driven
Air Compressor Carbon Buildup

Section A - Adjustment, Repair, and Replacement
Fuel Shutoff Valve
Fuel Pump
Injector
Drive Belt, Cooling Fan
Drive Belt, Alternator
Belt Tensioner, Automatic (Alternator)
Water Pump
Coolant Thermostat
Fan Drive Idler Pulley Assembly
Fan Hub, Belt Driven
Turbocharger
Air Starting Motor

Section D - System Diagrams
 System Diagrams
Flow Diagram, Fuel System
Flow Diagram, Lubricating Oil System
Flow Diagram, Cooling System
Flow Diagram, Air Intake System
Flow Diagram, Exhaust System
Flow Diagram, Compressed Air System

Section L - Service Literature
Additional Service Literature
Service Literature Ordering Location
Customized Parts Catalog

Section S - Service Assistance
Routine Service and Parts
Emergency and Technical Service
Problem Solving
Division and Regional Offices
Distributors and Branches
Regional Offices - International
Distributors - International

Section ES - Engine Storage
Engine Storage - Long Term

Section TS - Troubleshooting Symptoms
Troublershooting Procedures and Techniques
Troubleshooting Symptom Charts
Air Compressor Air Pressure Rises Slowly
Air Compressor Cycles Frequently
Air Compressor Noise is Excessive
Air Compressor Pumping Excess Lubricating Oil into the Air System
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Air Compressor Will Not Stop Pumping
Alternator Not Charging or Insufficient Charging
Coolant Loss - External
Coolant Temperature Above Normal - Gradual Overheat
Coolant Temperature Above Normal- Sudden Overheat
Coolant Temperature is Below Normal
Crankcase Gases (Blowby) Excessive
Engine Acceleration or Response Poor
Engine Brake Does Not Operate
Engine Decelerates Slowly
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Engine Noise Excessive
Engine Noise Excessive - Combustion Knocks
Engine Power Output Low
Engine Runs Rough at Idle
Engine Runs Rough or Misfires
Engine Shuts Off Unexpectedly or Dies During Deceleration
Engine Speed Surges at Low or High Idle
Engine Speed Surges Under Load or in Operating Range
Engine Starts But Will Not Keep Running
Engine Vibration Excessive
Engine Will Not Crank or Cranks Slowly (Air Starter)
Engine Will Not Crank or Cranks Slowly (Electric Starter)
Engine Will Not Reach Rated Speed (RPM)
Engine Will Not Shut Off
Fuel Consumption Excessive
Fuel In Coolant
Fuel in Lubricating Oil
Intake Manifold Air Temperature Above Specification
Intake Manifold Pressure (Boost) is Below Normal
Lubricating Oil Consumption Excessive
Lubricating Oil Contaminated
Lubricating Oil Pressure High
Lubricating Oil Pressure Low
Lubricating Oil Sludge in the Crankcase Excessive
Lubricating Oil Temperature Above Specification
Lubricating or Transmission Oil in the Coolant
PTO or Cruise Control Does Not Operate
Smoke, Black - Excessive
Smoke, White - Excessive
Turbocharger Leaks Engine Oil or Fuel

Section V - Maintenance Specifications
General Engine
Fuel System
Lubricating Oil System
Cooling System
Air Intake System
Exhaust System
Electrical System
Compressed Air System
Cummins/Fleetguard® Filter Specifications
Fuel Recommendations and Specifications
Lubricating Oil Recommendations and Specifications
Coolant Recommendations and Specifications
Drive Belt Tension
Engine Component Torque Values
Capscrew Markings and Torque Values

Section W - Warranty
Compatibility:Win95/98/ME/XP/vista/7/8/Linux/MAC