Cummins Diessel Engine m11 Troubleshooting and Repair Manual
Cummins Diessel Engine m11 Troubleshooting and Repair Manual
Cummins Diessel Engine m11 Troubleshooting and Repair Manual
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Foreword
This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and
assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions
on how to use this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by filling out and mailing the Literature Order Form located in Section L - Service Literature.
The repair procedures used in this manual are recommended by Cummins Engine Co., Inc. Some service procedures
require the use of special service tools. Use the correct tools as described.
Cummins Engine Company, Inc. encourages the user of this manual to report errors, omissions, and recommendations
for improvement. Please use the postage paid, pre-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
or call 1-800-DIESELS (1-800-343-7357).
The latest technology and the highest quality components are used to manufacture Cummins engines. When re-
placement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts. These parts
can be identified by the following trademarks:
g-01 (tr-frwd)
Table of Contents
Section
Introduction ........................................................................................................................................ i
Specifications ..................................................................................................................................... V
Index ................................................................................................................................................... X
THIS PAGE LEFT INTENTIONALLY BLANK.
M11 Series
Section i - Introduction Page i-a
Section i - Introduction
Section Contents
Page
About this Manual ............................................................................................................................................ i-1
Acronyms and Abbreviations .......................................................................................................................... i-10
General Cleaning Instructions.......................................................................................................................... i-9
Glass or Plastic Bead Cleaning ..................................................................................................................... i-9
Solvent and Acid Cleaning ............................................................................................................................ i-9
Steam Cleaning ............................................................................................................................................ i-9
General Repair Instructions.............................................................................................................................. i-8
Welding on a Vehicle with an Electronic Controlled Fuel System .................................................................... i-8
General Safety Instructions.............................................................................................................................. i-7
Important Safety Notice .................................................................................................................................. i-7
How to Use the Manual ................................................................................................................................... i-1
Illustrations ....................................................................................................................................................... i-6
Symbols ............................................................................................................................................................ i-2
M11 Series About this Manual
Section i - Introduction Page i-1
(Step 1) Locate the symptom on the Section Contents pages of Section TS.
Reference to the page number where the Troubleshooting Symptom Tree is found is made
to the right of the symptom tree title.
(Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a probable
cause of the problem, starting at the top with the simplest and easiest to repair, and con-
tinuing downward to the most difficult.
The right column of boxes provides a brief description of the corrective action with a refer-
ence number to the correct procedure used to make the repair.
(Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the
right column.
(Step 4) The Troubleshooting Symptom Charts are based on the following assumptions:
3. ‘‘Generic’’ solutions to cover problems with the most common applications and Origi-
nal Equipment Manufacturer (OEM).
Symbols M11 Series
Page i-2 Section i - Introduction
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When one
of the symbols appears, it conveys the meaning defined below:
g-01 (full-sym)
M11 Series Symbols
Section i - Introduction Page i-3
Symbols M11 Series
Page i-4 Section i - Introduction
M11 Series Symbols
Section i - Introduction Page i-5
Illustrations M11 Series
Page i-6 Section i - Introduction
Illustrations
Some of the illustrations throughout this manual are ge-
neric and will not look exactly like the engine or parts used
in your application. The illustrations can contain symbols
to indicate an action required and an acceptable or not
acceptable condition.
g-01 (illus)
M11 Series General Safety Instructions
Section i - Introduction Page i-7
• Make sure the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose tools, parts,
ignition sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a ‘‘Do Not Operate’’ tag
in the operator’s compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands
to support the product before performing any service work.
• Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel and liquid refrigerant
(freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly
emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmo-
sphere. Federal law requires capturing and recycling refrigerant.
• To avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity.
Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must
not be side-loaded.
• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in your
eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately
wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a
minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer’s instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
• To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes,
and compartments.
• Always use tools that are in good condition. Make sure you understand how to use them before performing any
service work. Use ONLY genuine Cummins or Cummins ReConT replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lessor quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
g-01 (safety)
General Repair Instructions M11 Series
Page i-8 Section i - Introduction
g-01 (repair-e)
M11 Series General Cleaning Instructions
Section i - Introduction Page i-9
g-01 (clean-e)
Acronyms and Abbreviations M11 Series
Page i-10 Section i - Introduction
g-01 (abbrev)
M11 Series
Section E - Engine Identification Page E-a
Engine Identification
Engine Dataplate
The engine dataplate shows specific information about
your engine. The engine serial number and control parts
list (CPL) provide information for ordering parts and service
needs. The engine dataplate must not be changed unless
approved by Cummins Engine Company, Inc.
The dataplate is located on the fuel pump side of the
engine, on the rocker housing. Have the following engine
data available when communicating with a Cummins Au-
thorized Repair Location. The information on the dataplate
is mandatory when sourcing service parts.
1. Engine Serial Number (ESN)
2. Control Parts List (CPL)
3. Model
4. Horsepower and rpm rating
ECM Dataplate
There are two dataplates on the top of the electronic control
module (ECM).
NOTE: The ECM referenced here is used with the CELECT™
and CELECT™ Plus fuel systems only.
The dataplate on the left contains the part number (P/N),
serial number (S/N) and the date code (D/C) of the ECM.
The dataplate on the right contains the engine serial num-
ber (ESN), fuel code (FC) and engine calibration
information.
Specifications
General Specifications
Horsepower (Refer to engine dataplate)
Engine speed @ Maximum Output:
Governed Speed (rpm)
Automotive (CELECT™ and CELECT™ Plus) .......................................................................................... 1800
Vocational (CELECT™ and CELECT™ Plus) ............................................................................................ 2100
Industrial (STC) ..................................................................................................................................... 2100
Bore and Stroke ....................................................................................... 125 mm [4.921 in] x 147 mm [5.787 in]
Displacement ...................................................................................................................... 10.8 liters [661 C.I.D.]
Firing Order ..................................................................................................................................... 1–5–3–6–2–4
Engine Weight (with standard accessories):
CELECT™ and CELECT™ Plus
Dry Weight .......................................................................................................................... 940 Kg [2070 lb]
Wet Weight ......................................................................................................................... 996 Kg [2193 lb]
STC
Dry Weight .......................................................................................................................... 929 Kg [2045 lb]
Wet Weight .......................................................................................................................... 981 Kg [2160 lb]
Fuel System
For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the particular model
involved.
Engine Idle Speed
CELECT™ ................................................................................................................................. 650 to 800 rpm
CELECT™ Plus .......................................................................................................................... 600 to 800 rpm
Fuel Inlet Maximum Restriction:
CELECT™ and CELECT™ Plus
Clean Fuel Filter .......................................................................................................... 152 mm Hg [6 in Hg]
Dirty Fuel Filter .......................................................................................................... 254 mm Hg [10 in Hg]
STC
Clean Fuel Filter .......................................................................................................... 102 mm Hg [4 in Hg]
Dirty Fuel Filter ............................................................................................................ 204 mm Hg [8 in Hg]
Fuel Drain Line Maximum Restriction
CELECT™ and CELECT™ Plus ........................................................................................ 89 mm Hg [3.5 in Hg]
STC
Without Check Valves ................................................................................................. 63 mm Hg [2.5 in Hg]
With Check Valves .................................................................................................... 165 mm Hg [6.5 in Hg]
Minimum Fuel Pressure:
During Cranking ...................................................................................................................... 172 kPa [25 psi]
1200 rpm ............................................................................................................................... 827 kPa [120 psi]
Fuel Inlet Maximum Temperature ..................................................................................................... 71°C [160°F]
Engine Minimum Cranking Speed ........................................................................................................... 150 rpm
Shutoff Valve Solenoid Coil Resistance
12 VDC .................................................................................................................................... 7.0 to 8.0 ohms
Lubricating Oil System
Oil Pressure:
Low Idle (Minimum Allowable) ................................................................................................... 70 kPa [10 psi]
At 1200 rpm or Torque Peak (Minimum Allowable) .................................................................. 207 kPa [30 psi]
Oil Capacity of Standard Engine:
Combination Filter ....................................................................................................... 2.6 liters [0.7 U.S. gal.]
Oil Pan (High-Low) ........................................................................................... 34 - 26.5 liters [9 - 7 U.S. gal.]
Cooling System
Coolant Capacity (Engine Only)
Charge Air Cooled Engines ......................................................................................... 9.5 liters [2.5 U.S. gal.]
Aftercooled Engines .................................................................................................... 12.9 liters [3.4 U.S. gal.]
Standard Modulating Thermostat-Range .................................................................. 82° to 93°C [180 to 200°F]
Cylinder Block Coolant Pressure (Pressure Cap Removed):
Minimum
Closed Thermostat - 1800 RPM - No Load ........................................................................ 138 kPa [20 psi]
Maximum
Closed Thermostat .............................................................................................................. 275 kPa [40 psi]
Maximum Allowable Operating Coolant Temperature ...................................................................... 100°C [212°F]
Minimum Recommended Operating Coolant Temperature ................................................................ 71°C [160°F]
Maximum Allowable Deaeration Time ................................................................................................ 35 minutes
Minimum Recommended Pressure Cap .......................................................................................... 48 kPa [7 psi]
Maximum Allowable Coolant Flow to Accessories — (Liters/Min. [GPM]) ......................... 75.7 Liters [20 U.S. gal.]
Coolant Sensing Fan Control:
On ............................................................................................................................................... 96°C [205°F]
Off ............................................................................................................................................... 91°C [195°F]
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