3666075 M11 SERIES ENGINE

COVER PAGE

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 ReCon T exchange parts. These parts can be identified by the following trademarks:

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TABLE OF CONTENTS

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

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INTRODUCTION

Section i - Introduction M11 Page i-1 Section i - Introduction Section Contents About the Manual ................................................................................................................................................ i-2 Page 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 Simbolos ............................................................................................................................................................ i-4 Illustrations ......................................................................................................................................................... i-7 Symbole .............................................................................................................................................................. i-5 Symboles ...........................................................................................................................................................

i-6 Symbols ............................................................................................................................................................. i-3

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ABOUT THE MANUAL

About the Manual Section i - Introduction M11 Page i-2 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°].

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