Foreword This manual contains complete rebuild specifications and information for the M11 model engines, and all associated 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.
Table of Contents Section Introduction ................................................................................................................................... i Engine Identification...................................................................................................................... E Engine Disassembly and Assembly – Group 00 ........................................................................... 0 Cylinder Block – Group 01 ............................................
Cummins’ 22-Group System Exploded Diagram
Section i - Introduction M11 Page i-1 Section i - Introduction Section Contents Page About the Manual................................................................................................................................................ i-2 Definition Of Terms ........................................................................................................................................... i-11 General Cleaning Instructions .................................................................
About the Manual Page i-2 Section i - Introduction M11 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.
Section i - Introduction M11 Symbols Page i-3 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: WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed. CAUTION - Minor personal injury can result, or a part, an assembly, or the engine can be damaged if the caution instructions are not followed.
Simbolos Page i-4 Section i - Introduction M11 Simbolos Los sı́mbolos siguientes son usados en este manual para clarificar el proceso de las instrucciones. Cuando aparece uno de estos sı́mbolos, su significado se especifica en la parte inferior. ADVERTENCIA - Serios daños personales o daño a la propiedad puede resultar si las instrucciones de Advertencia no se consideran.
Section i - Introduction M11 Symbole Page i-5 Symbole In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole haben folgende Bedeutung: WARNUNG - Wird die Warnung nicht beachtet, dann besteht erhöhte Unfall- und Beschädigungsgefahr. VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und Beschädigungsgefahr. AUSBAU bzw. ZERLEGEN. EINBAU bzw. ZUSAMMENBAU. INSPEKTION erforderlich. Teil oder Baugruppe REINIGEN.
Symboles Page i-6 Section i - Introduction M11 Symboles Les symboles suivants sont utilisés dans ce manuel pour aider à communiquer le but des instructions. Quand l’un de ces symboles apparaı̂t, il évoque le sens défini ci-dessous: AVERTISSEMENT - De graves lésions corporelles ou des dommages matériels considérables peuvent survenir si les instructions données sous les rubriques ″Avertissement″ ne sont pas suivies.
Section i - Introduction M11 Illustrations The illustrations used in the ″Repair Sections″ of this manual are intended to give an example of a problem, and to show what to look for and where the problem can be found. Some of the illustrations are ‘‘generic’’ and might 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.
General Safety Instructions Page i-8 Section i - Introduction M11 General Safety Instructions Important Safety Notice WARNING Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation or other bodily injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply.
Section i - Introduction M11 General Repair Instructions Page i-9 General Repair Instructions This engine incorporates the latest diesel technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. • Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to engines or components except for those detailed in Cummins Service Information.
General Cleaning Instructions Page i-10 Section i - Introduction M11 General Cleaning Instructions Solvent and Acid Cleaning Several solvent and acid-type cleaners can be used to clean the engine parts. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer’s instructions. Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit].
Section i - Introduction M11 Definition Of Terms Page i-11 Definition Of Terms A.C.: Alternating Current ACT Harness: The wiring harness used to connect the actuators to the ECM AFC: Air Fuel Control; a device in the fuel pump that limits the fuel delivery until there is sufficient intake manifold pressure to allow for complete combustion.
Definition Of Terms Page i-12 Section i - Introduction M11 Deutsch Connector: An electrical connector Dye Penetrant Method: A method used to check for cracks in a part by using a dye penetrant and a developer. Use Part No. 3375432 Crack Detection Kit, or equivalent. End Clearance: The clearance in an assembly determined by pushing the shaft in an axial direction one way, and then pushing the shaft the other way. ECM: Electronic Control Module. E.C.S.
Section i - Introduction M11 Definition Of Terms Page i-13 mm: Millimeter MPa: Megapascal MPH: Miles Per Hour MPQ: Miles Per Quart N•m: Newton-meter No.: Number OD: Outside Diameter OEM: Original Equipment Manufacturer OEM Harness: The wiring harness used to connect the ECM to the vehicle OS: Oversize PCU: PACER Control Unit ppm: Parts Per Million Protrusion: The difference in the height between two parts in the assembled state.
Definition Of Terms Page i-14 Section i - Introduction M11 NOTES
Section E - Engine Identification M11 Page E-1 Section E - Engine Identification Section Contents Page Engine Diagrams ............................................................................................................................................... E-6 Engine Identification ......................................................................................................................................... E-2 Electronic Control Module (ECM) Dataplate .....................................
Engine Identification Page E-2 Section E - Engine Identification M11 Engine Identification The model name provides the following data: M 11 - 330 E = Electronic Fuel System = Brake Horsepower = Displacement (Liters) = Engine Model Designation Engine Dataplate The engine dataplate is located on the fuel pump side of the rocker housing. The engine dataplate provides model identification as well as other important information about the engine.
Section E - Engine Identification M11 Engine Specifications Page E-3 Engine Specifications Metric [U.S. Customary] General Engine Data Horsepower (Refer to the engine dataplate) Engine speed @ Maximum Output: • Governed Speed (RPM) - Automotive ................................................................................................ 1800 • Governed Speed (RPM) - Vocational ................................................................................................. 2000 • Advertised HP (RPM) ..
Engine Specifications Page E-4 Section E - Engine Identification M11 Engine Specifications (Continued) Metric [U.S. Customary] Air Intake System Maximum Allowable Intake Restriction with Clean Air Filter Element: • Heavy Duty Dry Type Cleaner ....................................................................... Maximum Allowable Intake Restriction with Dirty Air Filter Element ...................... 254 mm H20 [10 in. H20] 635 mm H20 [25 in.
Section E - Engine Identification M11 Engine Specifications Page E-5 Metric [U.S. Customary] 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: ........................................................................................................... 650 to 800 RPM Maximum Allowable Fuel Inlet Restriction: • With Clean Filter .......................................................................
Engine Diagrams Page E-6 Section E - Engine Identification M11 Engine Diagrams The following illustrations contain information about engine components, filter locations, drain points and provisions for instrumentation and engine controls. The information and configuration of components shown in these drawings are of a general nature. Some component locations will vary depending on applications and installations.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Page 0-1 Section 0 - Engine Disassembly and Assembly - Group 00 Section Contents Page Engine Assembly ............................................................................................................................................. 0-50 Accessory Drive Assembly - Installation ......................................................................................................... 0-86 Accessory Drive Oil Seal - Installation ...........
Page 0-2 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Page JacobsW Engine Brake - Installation............................................................................................................. 0-116 Lubricating Oil Cooler - Installation .............................................................................................................. 0-137 Lubricating Oil Filter - Installation .............................................................................................
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Page 0-3 Page Engine - Preparation for Cleaning.................................................................................................................. Engine Barring Tool - Installation ................................................................................................................... Exhaust Manifold - Removal ...............................................................................................................
Service Tools - Disassembly and Assembly Page 0-4 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Service Tools - Disassembly and Assembly The following special tools are recommended to perform procedures in Group 00. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Standard Puller ST-647 Remove alternator drive pulley. Use with two (5/16 x 18 x 2 1/2) capscrews.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tool No. Service Tools - Disassembly and Assembly Page 0-5 Tool Description Oil Filter Wrench Used to remove and install lubricating oil filter. 3375049 Pipe Sealant Used to prevent leaks when installing pipe plugs or fittings. 3375066 Dial Bore Gauge Kit Used to measure inside diameters. 3375072 Engine Rebuild Stand 3375194 Support cylinder block during engine rebuild. Used with adapter plate, Part No. 3376432.
Service Tools - Disassembly and Assembly Page 0-6 Tool No. Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tool Description Connecting Rod Guide Pins 3376038 Guide connecting rods over crankshaft during removal or installation of connecting rods. Dial Indicator and Sleeve Assembly 3376050 Use with dial gauge attachment, Part No. ST-1325 to measure flywheel and flywheel housing runout. Use with magnetic base, Part No. 3377399, and extension, Part No.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tool No. Service Tools - Disassembly and Assembly Page 0-7 Tool Description Inch Pound Torque Wrench 3376592 Required to make consistent settings of the injector. Screwdriver socket, Part No. ST-669-13, must be used with this tool. Flywheel Housing Alignment Plate Align flywheel housing with cylinder block. 3376606 Guide Pin Kit 3376695 Aid during installation of flywheel, flywheel housing, vibration damper, and air manifold.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tool No. Service Tools - Disassembly and Assembly Page 0-9 Tool Description Engine Barring Tool 3824270 Used to bar the engine by hand. Also used with a slide hammer to remove the hydraulic drive adapter. Cylinder Liner Clamping Tool 3824272 Used to seat the liner in the cylinder block while measuring cylinder liner protrusion. Cam Follower Assembly Removal and Installation Tool Used to remove and install the cam follower assemblies.
General Information Page 0-10 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine Disassembly and Assembly - General Information These procedures apply to M11 engines. The differences between engine models, due to the application and optional equipment on an engine, is included in the instructions. Omit the steps that do not apply to the engine being rebuilt. 1. A Warning statement is included for any component or assembly that weighs more than 23 Kg [50 lb].
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine Lifting Brackets Warning: The engine lifting equipment must be designed to safely lift the engine as an assembly. Use a properly rated hoist and engine lifting fixture, Part No. 3822512, attached to the engine mounted lifting brackets to lift the engine. Refer to Section E for the weight of the engine you are working on. Install the engine on two engine support stands, Part No. 3376057.
Engine Disassembly (0-01) Page 0-12 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine Disassembly (0-01) Engine - Preparation for Cleaning Install caps or tape on all engine openings to prevent moisture and dirt from entering the engine: Protect all electrical components and wiring from the full force of the cleaner spray nozzle. Engine - Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Coolant Filter - Removal Turn the coolant valve to the ‘‘OFF’’ position before the filter is removed. Use fuel and water filter wrench, Part No. 3376807, to remove the coolant filter. Lubricating Oil Filters - Removal Use oil filter wrench, Part No. 3375049, to remove the oil filter. Fuel Filter - Removal Use fuel and water filter wrench, Part No. 3376807, to remove the fuel filter. Fan Drive Belt - Removal Loosen the idler pulley shaft locknut.
Engine Disassembly (0-01) Page 0-14 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fan and Fan Hub - Removal If an electric fan clutch is used, disconnect the fan clutch connector from the base wiring harness. Remove the six capscrews and the fan. NOTE: The six capscrews also hold the fan drive pulley in position. Do not allow the pulley to fall. Remove the fan drive pulley. Remove the four capscrews and the fan hub.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Alternator Belt (Bus Applications) - Removal Insert a 3/8 inch breaker bar into the space provided on the tensioner. Rotate the tensioner away from the belt until it stops. Remove the alternator belt while holding the tensioner back. Alternator Adjusting Link (Non Bus Applications) - Removal Remove the capscrew (1) from the alternator. Remove the capscrew (2) from the thermostat housing and the adjusting link.
Engine Disassembly (0-01) Page 0-16 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Alternator and Brackets (Bus Applications) Loosen the alternator pivot mounting capscrew. Remove the alternator brace link. Remove the alternator pivot capscrew and the alternator. Remove the mounting nut from the rear of the gear housing and the four cylinder block mounting capscrews from the lower alternator mounting bracket. Remove the lower alternator mounting bracket.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the v-band clamp, discharge elbow and o-ring from the turbocharger compressor discharge outlet. Remove the four turbocharger mounting nuts. Remove the turbocharger and gasket. Plug the supply and drain holes in the turbocharger. Exhaust Manifold - Removal Caution: The exhaust manifold assembly has three sections which can separate and fall causing personal injury during removal. Hold the assembly on each end to remove it.
Engine Disassembly (0-01) Page 0-18 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Thermostat Housing - Removal Loosen the bottom coolant bypass hose clamp. NOTE: If the housing is stuck, hit the housing with a mallet to loosen it. Remove the four capscrews, the housing, and the thermostat. Torque Converter Cooler Disc - Removal The torque converter cooler disc (2) restricts the water flow through the thermostat housing (1) to water pump bypass hose (2).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the nine capscrews, oil filter head and gasket. Remove the turbocharger oil drain line from the cylinder block drain connection. Alternator Drive Pulley - Removal Remove the pulley retainer capscrew. Use standard puller, Part No. ST-647, and two capscrews, (5/16-18 x 2 1/2), to remove the pulley. Alternator Drive Oil Seal - Removal Remove the five capscrews, clamping ring, oil seal and gasket.
Engine Disassembly (0-01) Page 0-20 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Water Pump - Removal Remove the two water transfer connection capscrews. Remove the three water pump mounting capscrews. Rotate the water pump outward so the water transfer connection can be removed from the water pump. Remove the water transfer connection from the water pump.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Water Filter Head - Removal Remove the three capscrews, filter head and the two o-rings. Water Header Plate - Removal Remove capscrews (1) and (2), and install two guide pins, Part No. 3376488. Remove the remaining capscrews beginning at the ends and moving toward the center of the plate. Caution: Care must be taken to ensure no surface scratches occur on the water header plate or cylinder block mounting surfaces.
Engine Disassembly (0-01) Page 0-22 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine - Installation On Rebuild Stand Use the engine rebuild stand, Part No. 3375194, and adapter plate, Part No. 3376432. Use five capscrews (5/8—11 X 2 inch) grade 5 capscrews to install the adapter plate to the rebuild stand. Torque Value: 180 N•m [135 ft-lb] Install two guide pins, Part No. 3376488, in the water header plate mounting capscrew holes at points (1) and (2) (No.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fan Hub Support - Removal Remove the three mounting capscrews and the support. Fuel Supply Hose and Filter Head - Removal Remove the fuel supply hoses at points (1) and (2). Remove the fuel filter head. Electronic Control Module - Removal Remove the ambient air pressure sensor wire connector and the ambient air pressure sensor (1), if equipped, from the front electronic control module (ECM) mounting bracket.
Engine Disassembly (0-01) Page 0-24 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the six ECM mounting capscrews, star washers and the ECM. Electronic Control Cooling Plate - Removal Remove the four mounting capscrews, the electronic control cooling plate and the mounting brackets. Starting Motor - Removal The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fuel Lines - Removal Remove the fuel supply tube (1) and the fuel drain tube (2) from the cylinder head. Remove the fuel pump gear pump cooling tube (3). Fuel Pump - Removal Remove the actuator harness wire from the fuel shutoff valve. Tag the wire for future identification. Remove the two support bracket capscrews. Remove the four fuel pump mounting capscrews, fuel pump and gasket. Remove the coupling spider.
Engine Disassembly (0-01) Page 0-26 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Air Compressor Coolant Tubes - Removal Remove the inlet tube (1) and fitting (2). Remove the outlet tube clamp capscrew (3) and the tube. Hand Hole Cover (Fuel Pump Side) - Removal Remove the four capscrews, the cover and gasket. Hydraulic Pump or Cover - Removal Remove the two capscrews, the pump and gasket. Hydraulic Pump Drive - Removal Remove the three pump drive adapter mounting capscrews.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: Do not allow the hydraulic drive gear to slide out of the adapter or the gear housing during removal. Damage to the gear will result. Remove the hydraulic drive adapter, o-ring, and hydraulic drive gear. Sensor Harness and Sensors - Removal Tag all connections as they are removed for future identification. Disconnect the connector (1) that connects the sensor and actuator harnesses.
Engine Disassembly (0-01) Page 0-28 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rocker Lever Housing Spacer - Removal If the engine is equipped with a JacobsW Engine Brake, disconnect the two electrical connections from the terminals on the inside and outside of the spacer. Disconnect the oil supply hose connection. Remove the oil supply hose. Remove the 16 capscrews and spacer.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Internal Actuator Harness - Removal Use a Torx screwdriver (T25) to loosen the screw which secures the two sections of the actuator harness together at the rear of the rocker lever housing. The screw head is accessible from inside the rocker lever housing. Disconnect the two sections of the actuator harness. Disconnect the ground wire connection of the actuator harness (1) from the engine. Tag the end for future identification.
Engine Disassembly (0-01) Page 0-30 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the internal section of the actuator wiring harness. Push Rods - Removal Mark the location of the valve push tubes and injector push rods as they are removed. The push tubes and push rods must be installed in the same location when the engine is assembled. Loosen the adjusting screws and remove the valve push tubes and injector push rods.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Crossheads - Removal Remove the crossheads. Number each crosshead with the cylinder number and position as it is removed. NOTE: Each crosshead must be installed in the same position as it was removed from when the engine is assembled. Injectors - Removal Remove the injector hold down capscrews and hold down clamps. Use injector puller, Part No. 3823579, to remove the injectors from the engine.
Engine Disassembly (0-01) Page 0-32 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the remaining 32 capscrews starting from the ends and moving toward the center. NOTE: The illustration shown is for torquing the cylinder head during installation. Reverse the order for removal. Install cylinder head lifting bracket, Part No. 3822479, on the center of the cylinder head. NOTE: If the capscrews are not available from the kit, install two rocker lever support capscrews (M14—2.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Lift the cam follower assemblies to remove them from the engine. Remove the tool from the cam follower assemblies. Lubricating Oil Pan - Removal Rotate the engine on the rebuild stand to position the engine on its side. Remove two capscrews at points (1) and (2) and install two guide pins, Part No. 3376488. Remove the remaining 32 capscrews and oil pan. Use a mallet to loosen the oil pan if it is stuck. Remove the guide pins.
Engine Disassembly (0-01) Page 0-34 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Flywheel - Removal Install two capscrews (M10-1.50 x 40) at points (1) and (2). Remove two mounting capscrews (3) and install two guide pins, Part No. 3376696. NOTE: On engines equipped with a rear engine power takeoff (REPTO), two guide pins, Part No. 3376696, are required to support the crankshaft gear until the rear crankshaft oil seal is removed. The clutch pressure plate capscrew holes are U.S.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Crankshaft Rear Oil Seal - Removal Remove the 12 capscrews and clamping ring (1), Use a heal bar to remove the oil seal (3) and dust seal (2) together. Remove the gasket (4). Flywheel Housing - Removal Remove the capscrews and both rear engine mounts. Remove capscrews (1) and (2) and install two flywheel housing guide pins, Part No. 3376697. The component weighs 23 kg [50 lb] or more.
Engine Disassembly (0-01) Page 0-36 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the crankshaft drive gear. Remove the two guide pins from the crankshaft. Remove the idler shaft retaining capscrew. Use idler shaft puller, Part No. 3823709, to remove the idler shaft. Manufacture a sleeve from 38.1 mm O.D. [1.50 inch O.D.] (D) PVC, aluminum, or equivalent, to the following dimensions: Length (L): Slot (W): 25.4 mm [1.00 in] 6.3 mm [0.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: Do not attempt to back out or rotate the plugs out of the housing. The cup plug bore will be damaged and oil leakage will occur. To gain access to the housing capscrews, use a drift to drive the cup plugs straight through into the housing. Retrieve the plugs from inside of the housing. NOTE: Do not reuse the cup plugs that are removed. The cup plugs must be replaced with new ones.
Engine Disassembly (0-01) Page 0-38 Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: Some pulleys have an oil seal dust seal installed on the pulley hub. If a dust seal is installed, remove the dust seal from the pulley. The dust seal can be slipped off the hub by hand. Accessory Drive Oil Seal - Removal Remove the five capscrews, clamping ring (1), seal (2), and gasket (3). Accessory Drive Assembly - Removal Remove the six mounting capscrews, accessory drive assembly, and gasket.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Crankshaft Front Oil Seal - Removal Remove the six capscrews, the clamping ring (1), the oil seal (3) and dust seal (2) together, and the gasket (4). Front Engine Support Bracket - Removal Remove the six capscrews and bracket. Gear Cover - Removal Six of the gear cover capscrews were removed with the front support bracket. Remove the remaining 14 capscrews and the gear cover.
Engine Disassembly (0-01) Page 0-40 Section 0 - Engine Disassembly and Assembly - Group 00 M11 To remove the camshaft and water pump idler gear assemblies, remove: • • • • • • • the three retaining capscrews, the gear retainer (4), the front thrust bearing (5), the idler gears (6), the rear thrust bearing (7), the idler gear shafts (8), the camshaft idler gear assembly includes a wear plate (9). NOTE: If SAE ‘‘B’’ hydraulic drive is used, mark the idler gear shafts for position as they are removed.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install camshaft installation pilot, Part No. 3376388. 1. Install the expander (1), Part No. 3376923, in the camshaft through the rear cover plate opening. 2. Turn the screw inside the expander clockwise to expand the swell plug. 3. Install the arbor sleeve (2) over the expander. 4. Install the locating pilot extensions (3) to the expander.
Engine Disassembly (0-01) Page 0-42 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine Barring Tool - Installation Use two flywheel mounting capscrews (M14—1.50 x 40) to install the engine barring tool, Part No. 3824270, to the flywheel end of the crankshaft. Piston Cooling Nozzles - Removal Caution: The nozzles must be removed before the piston and rod assemblies to avoid damage to the nozzles. The crankshaft must be rotated to allow access to remove all the nozzles.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Hit the heads of connecting rod capscrews with a mallet to loosen the caps from the dowel rings. Do not drop the bottom bearing shell when the cap is removed. Remove the connecting rod capscrews and caps. Caution: Do not mark on the bearing to crankshaft mating surface. Damage to the engine can occur if bearings are used again. Mark the cylinder number and the letter ‘‘L’’ in the flat surface of the bearing tangs.
Engine Disassembly (0-01) Page 0-44 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Place the rod and piston assemblies into a container to protect them from damage. A unique number, not cylinder number, is stamped on the connecting rod and matching cap. When the rods and caps are installed in the engine, the numbers on the rods and caps must match and be installed on the same side of the engine. Remove the upper rod bearing. Caution: Do not mark on the bearing to crankshaft mating surface.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: The number ‘‘4’’ main bearing cap is doweled to the block. To avoid damage to the cylinder block, do not rock the cap to remove, pull straight up. Remove the main bearing cap capscrews. Use main bearing cap puller, Part No. ST-1178, to remove the main bearing caps. The tool must be centered on the cap. Pull straight up to remove the cap. NOTE: The No. 4 main bearing cap has thrust bearings.
Engine Disassembly (0-01) Page 0-46 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Crankshaft and Upper Main Bearing Shells Removal The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Lift the crankshaft straight up to avoid damage to the crankshaft or cylinder block. Install nylon lifting sling, Part No. 3375957, around the number ‘‘3’’ and ‘‘4’’ rod bearing journals. Attach the sling to a hoist and remove the crankshaft.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 High Oil Pressure Regulator - Removal Warning: Use caution while removing the retainer plug (1). The pressure regulator spring (2) is under compression. Wear face and eye protection. Use light duty puller kit, Part No. 3375784, to remove the retainer plug (1). Remove the pressure regulator spring (2), washer (3), and valve disc (4). NOTE: The high oil pressure regulator seat will remain in the cylinder block.
Engine Disassembly (0-01) Page 0-48 Section 0 - Engine Disassembly and Assembly - Group 00 M11 When the liner is removed from the cylinder block, use DykemW or equivalent, to place a mark on the camshaft side of the liner to show liner orientation. Use DykemW or equivalent to mark the cylinder number of each liner. Pistons and Connecting Rods - Disassembly Caution: The piston pin can fall from the piston assembly when the retainer snap rings are removed. The piston and pin can be damaged.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: When the piston pin is removed from an articulated piston, the skirt will separate from the crown. Use care to prevent damage to the piston. Mark the cylinder number the piston, crown, skirt, and pin was removed from on the parts to make sure they are installed in the correct cylinder if they are used again.
Engine Assembly (0-02) Page 0-50 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine Assembly (0-02) Cylinder Block - Installation On Rebuild Stand Use adapter plate, Part No. 3376432, with the engine rebuild stand, Part No. 3375194, to assemble the engine. Use ten (5/8 - 11 x 1 3/4) grade 5 capscrews to install the adapter plate to the rebuild stand. Torque Value: 180 N•m [135 ft-lb] Install two guide pins, Part No. 3376488, into the water header plate mounting capscrew holes (1) and (2).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 • A lathe cut o-ring which has a straight outside with sharp corners and the inside which has two 45 degree chamfers, so there are no sharp corners next to the liner. This o-ring must be installed with the straight side facing the block, and the chamfered side next to the liner. If the o-ring is not installed this way, liner bore distortion can occur. Make sure the cylinder block and all parts are clean before assembly.
Engine Assembly (0-02) Page 0-52 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Put the installation tool bridge (1) across the liner and install the two cylinder head capscrews finger tight to hold the bridge down. Rotate the force plate until the areas where the protrusion measurements will be taken are exposed. Caution: Do not use an impact wrench to tighten the liner force plate screw. Excessive torque will cause damage to the liner installation tool. Tighten the forcing screw (2).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 • Inspect the liner seating edge for burrs, dirt or damage. • Replace the liner if it is damaged. • Install the liner again. • Measure the liner protrusion. If the liner protrusion still does not meet the specifications, use counterbore ledge tool, Part No. 3823558, to cut the cylinder block liner bore for shims. Refer to the Alternative Repair Manual, Bulletin No. 3810310, for the correct procedure.
Engine Assembly (0-02) Page 0-54 Section 0 - Engine Disassembly and Assembly - Group 00 M11 • Inspect the liner and cylinder block for dirt or damage. • Replace the liner if it is damaged. • Install the liner again. Measure the liner bore for out-of-roundness at points ‘‘C’’, ‘‘D’’, ‘‘E’’, ‘‘F’’ and ‘‘G’’. Measure each point in the direction ‘‘AA’’ and ‘‘BB’’. The bore must not be more than 0.10 mm [0.004 inch] out-of-round.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 • Measure the cylinder block upper liner bore (A). Cylinder Block Upper Liner Bore I.D. (A) mm in. 145.900 MIN 5.7441 146.027 MAX 5.7491 • Measure the cylinder block liner seal seat bore (B) 8.0 to 13.5 mm [0.32 to 0.53 inch] below the counterbore. Cylinder Block Liner Seal Seat Bore I.D. (B) mm in. 138.063 MIN 5.4355 138.113 MAX 5.4375 • Measure the liner outside diameter (A). Cylinder Liner Top Press Fit O.D. (A) mm in. 145.938 MIN 5.7456 145.
Engine Assembly (0-02) Page 0-56 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Replace the liner if it is damaged. Inspect the liner bore (A) and measure the protrusion (B) again. Replace the liner if it does not meet the specifications. Upper Main Bearing Shells - Installation Caution: The bearing shells are marked with the words ‘‘upper’’ and ‘‘lower’’. Each must be installed in the correct location to prevent engine damage.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use LubriplateW 105, or equivalent, to coat the bearings. Crankshaft - Installation The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Use a hoist and nylon lifting sling, Part No. 3375957. Install the sling around the numbers ‘‘3’’ and ‘‘4’’ rod bearing journals. Do not damage or move the bearing shells when the crankshaft is installed. Install the crankshaft.
Engine Assembly (0-02) Page 0-58 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Push the crankshaft toward the rear of the engine to install the rear thrust bearing, and to the front to install the front thrust bearing. The grooves in the thrust bearings must be installed toward the crankshaft to prevent damage to the crankshaft and cylinder block during engine operation. Install the upper thrust bearings into the number ‘‘4’’ main bearing saddle.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 The main bearing caps are numbered. The caps must be installed with the number on the cap matching the number on the oil pan flange of the cylinder block. The caps must be oriented so they are lock tang to lock tang. Install the main bearing caps, capscrews and washers. Caution: Do not hit the main bearing caps with a hammer. The main bearing cap and bearings can be damaged.
Engine Assembly (0-02) Page 0-60 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Complete the following steps to tighten the capscrews in the sequence shown: Torque Value: Step 1 2 3 4 5 6 7 - 68 N•m [ 50 ft-lb] 142 N•m [105 ft-lb] 210 N•m [155 ft-lb] Loosen completely 68 N•m [ 50 ft-lb] 142 N•m [105 ft-lb] 210 N•m [155 ft-lb] Use your hands to turn the crankshaft. If it does not turn freely, loosen the main bearing capscrews one at a time to locate the bearing that is too tight.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 • Inspect for burrs, dirt or damage. If nicks or burrs cannot be removed with fine crocus cloth, the cap and bearings must be replaced. Measure the thrust bearing thickness and replace the bearings if they are not within specifications. Crankshaft Thrust Bearing Thickness mm in 4.83 MIN 0.1902 4.89 MAX 0.1925 High Oil Pressure Regulator - Installation Use a spring compression tester, Part No. 3375182, to measure the relief valve spring tension.
Engine Assembly (0-02) Page 0-62 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Viscosity Sensor - Installation Install the viscosity sensor in the cylinder block. Torque Value: 24 N•m [18 ft-lb] Main Oil Pressure Regulator - Installation Measure the free length of the regulator spring. Regulator Spring Free Length mm in 84.1 3.31 Use a spring compression tester to determine if the spring is defective. Replace the spring with a new spring if it is defective.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Measure the retainer plug to determine if it is defective. Main Oil Pressure Regulator Retainer Plug mm in 11.1 MIN 0.44 13.4 MAX 0.53 Warning: The regulator spring must be compressed to install the retainer plug (1). Wear face and eye protection. NOTE: A counterbore plunger and orifice is unique to engines with a viscosity sensor. Low oil pressure will result if a solid plunger is used with a viscosity sensor.
Engine Assembly (0-02) Page 0-64 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the engine on the rebuild stand to position the cylinder head mounting surface facing up. Install two guide pins, Part No. 3376697, into the flywheel housing mounting holes of the cylinder block. Apply a 2 mm [1/16 inch] bead of silicone sealant, Part No. 3823494, on the mounting surface of the housing and around each of the mounting capscrew holes. Install the flywheel housing over the guide pins.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the engine on the rebuild stand to position the cylinder head mounting surface facing up. Install two guide pins, Part No. 3376697, into the flywheel housing mounting holes of the cylinder block. Apply a 2 mm [1/16 inch] bead of sealant, Part No. 3823494, on the mounting surface of the housing and around each of the mounting capscrew holes. This component weighs 23 kg [50 lb] or more.
Engine Assembly (0-02) Page 0-66 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Remove the four alignment plate capscrews and the alignment plate. Flywheel Housing Bore Alignment - Measurement NOTE: On REPTO flywheel housings, dial gauge attachment, Part No. ST-1325, must be spaced out from the flywheel and longer mounting capscrews used. An alternative method is to use a magnetic base with the dial indicator gauge. Use dial indicator gauge, Part No.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Repeat the above steps until the maximum bore TIR is within specifications for the determined housing size. NOTE: If the bore alignment is not within specifications and the bore is not round, the housing must be replaced. Flywheel Housing Face Alignment - Measurement Caution: If the tip of the gauge enters the capscrew holes, the gauge will be damaged. Position the contact tip of the gauge against the flywheel housing face.
Engine Assembly (0-02) Page 0-68 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use the gauge block, Part No. 3823495, to measure the alignment of the oil pan mounting flange of the housing with the oil pan mounting flange of the cylinder block. The housing flange must be even with the cylinder block flange within ±0.15 mm [0.006 inch]. If it does not meet these specifications, the bore and face must be realigned.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Manufacture a sleeve from 38.1 mm O.D. [1.50 in O.D.] (D) PVC, aluminum, or equivalent, to the following dimensions: Length (L): Slot (W): 25.4 mm [1.00 in] 6.3 mm [0.25 in] Apply LubriplateW 105, or equivalent, on the outer races and the bearings. NOTE: The outer bearing races of new replacement gears are already pressed into the gear. Install the bearing and spacer into the idler gear.
Engine Assembly (0-02) Page 0-70 Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: Check the gear for freedom of rotation while using the capscrew to install the shaft. If the gear does not turn freely, it can indicate misalignment between the bore and the shaft. Remove the idler shaft and install it again. Apply LubriplateW 105 under the head of the idler shaft capscrew. Insert the capscrew through the idler shaft. Tighten the installation capscrew to draw the shaft into the bore.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use a magnetic base and dial indicator gauge, Part No. 3376050, to measure the idler gear backlash from the output shaft. Mount the gauge so the tip of the gauge is reading at the outmost edge of the output shaft. mm 0.15 0.38 REPTO Idler Gear Backlash MIN MAX in 0.006 0.015 Rear Crankshaft Oil Seal - Installation NOTE: On REPTO units, it is necessary to remove the crankshaft gear mounting capscrews before installing the oil seal.
Engine Assembly (0-02) Page 0-72 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Flywheel - Installation Install one guide pin, Part No. 3376696, into the crankshaft flange. NOTE: On REPTO units, install the crankshaft gear on the guide pin before installing the flywheel. This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. The crankshaft flange must be clean and free of damage. Install the flywheel on the guide pin.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the crankshaft one complete revolution (360 degrees). The maximum TIR must not exceed 0.127 mm [0.0050 inch]. If the TIR exceeds the specifications: • Remove the flywheel. • Inspect the flywheel mounting surface for burrs, dirt or damage. • If burrs cannot be removed with crocus cloth, or the flywheel is damaged, it must be replaced. • Inspect the crankshaft flange for burrs, dirt or damage.
Engine Assembly (0-02) Page 0-74 Section 0 - Engine Disassembly and Assembly - Group 00 M11 If the TIR still exceeds the specification, the flywheel must be replaced. Flywheel Face Runout - Measurement Install the contact tip of the indicator against the flywheel face as close as possible to the outside diameter to measure the face (4) runout. Push the flywheel forward to remove the crankshaft end thrust.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Piston and Connecting Rod - Assembly Articulated Piston The retainer snap ring must be seated completely in the piston pin groove to prevent engine damage during engine operation. Install a new snap ring in one piston pin bore of each piston skirt. Position the skirt over the piston crown. NOTE: It is not necessary to heat the articulated pistons before assembly. The piston pin is slip fit. Caution: Do not use a hammer to install the piston pin.
Engine Assembly (0-02) Page 0-76 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use piston ring expander, Part No. ST-821, to install the rings on the piston. The top piston ring is a positive twist design that has a cutback notch on the top side of the ring. The intermediate ring is a negative twist design with a cutback notch on the bottom side and a two degree taper face. It also has a black phosphate coating which helps to readily distinguish it from the top ring.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the piston and ring assembly into a container of clean 15W-40 oil. Remove the piston and ring assembly from the container and let the excess oil drain from the piston. Rotate the rings to position the ring gaps as shown. NOTE: The ring gap of each ring must not be aligned with the piston pin or with any other ring gap. If the ring gaps are not aligned correctly, the rings will not seal properly.
Engine Assembly (0-02) Page 0-78 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: Do not use a metal object to push the piston into the liner. The piston, rings or cylinder liner can be damaged. Hold the ring compressor against the cylinder block. Push the piston through the ring compressor and into the cylinder liner. Push the piston until the top ring is completely inside the cylinder liner.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Complete the following steps to tighten the capscrews in alternating sequence: Torque Value: Step 1 2 3 4 5 - 68 N•m [ 50 ft-lb] 142 N•m [105 ft-lb] 210 N•m [155 ft-lb] Loosen completely Repeat steps 1 thru 3 Connecting Rod Side Clearance Measurement Use a feeler gauge to measure the connecting rod side clearance. mm 0.10 0.30 Connecting Rod Side Clearance MIN MAX in. 0.004 0.012 The rod must move freely from side-to-side.
Engine Assembly (0-02) Page 0-80 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Gear Housing - Installation Caution: Avoid the use of excessive amounts of sealant which could result in blocked oil passages in the engine. Install a new o-ring, Part No. 3883150, into the rear of the gear housing at the oil jumper gallery (1) for the accessory drive support. Be sure to keep sealant from the hole. NOTE: Sealant requires assembly in ten minutes or less.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Lubricating Oil Pan - Installation Rotate the engine on the rebuild stand. If a front sump aluminum oil pan is used, install the spring clip on the oil transfer tube. Install a new o-ring(s) on the oil transfer tube. Use clean 15W-40 oil to lubricate the o-rings. Install the oil transfer tube into the oil pan on rear sump oil pans. On front sump aluminum oil pans, install the straight transfer tube into the cylinder block.
Engine Assembly (0-02) Page 0-82 Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: Make sure the transfer tube is aligned with the cylinder block suction tube hole when installing the oil pan. Install and tighten the 32 capscrews (M10-1.50 x 25) in the sequence shown. Torque Value: 47 N•m [35 ft-lb] Camshaft and Gear Assembly - Installation Use LubriplateW 105, or equivalent, to coat the camshaft bushings and camshaft. Install the camshaft installation pilot, Part No. 3376388.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the camshaft slowly as it is being installed into the cylinder block. Rotate the camshaft to align the holes in the camshaft gear with the thrust plate capscrew holes in the cylinder block. Align the capscrew holes in the thrust plate with the cylinder block capscrew holes. Install the two capscrews (M10-1.50 x 25) with a nylon locking patch on the threads, or apply retaining compound, Part No. 3823682, to the threads.
Engine Assembly (0-02) Page 0-84 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Lubricating Oil Pump - Installation NOTE: Do not lubricate the two oil pump body o-rings. The o-rings will swell and the pump cannot be installed. Install two new o-rings on the oil pump body. Install the thickest o-ring into the groove nearest to the oil pump drive gear. Use clean 15W-40 oil to lubricate the oil pump gears. Apply a film of LubriplateW 105 to the oil pump bore in the cylinder block.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use a dial indicator gauge assembly, Part No. 3376050, with extension, Part No. ST-537-4 and a magnetic base, Part No. 3377399, to measure the oil pump gear end clearance. Place the contact tip of the gauge against the face of the oil pump drive gear. Lubricating Oil Pump Gear End Clearance mm in 0.064 MIN 0.0025 0.270 MAX 0.0106 Hydraulic Pump Drive - Installation Use LubriplateW 105, or equivalent, to lubricate the front and rear needle bearings.
Engine Assembly (0-02) Page 0-86 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Measure the drive shaft end clearance. Use dial indicator assembly, Part No. 3376050 with extension, Part No. ST-537-4, and a magnetic base, Part No. 3377399. Hydraulic Pump Drive Shaft End Clearance mm in 0.076 MIN 0.0030 0.635 MAX 0.0250 Use a new gasket and install the hydraulic pump, if equipped, or the cover plate. Install the two mounting capscrews (M10-1.50 x 20) and tighten.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Idler Gear Assemblies - Installation Three idler gear assemblies are used: • water pump/lube pump idler gear (1), • camshaft idler gear (2), • hydraulic pump idler gear (3). Each idler gear assembly consist of: • three retaining capscrews, • gear retainer (4), • front thrust bearing (5), • idler gear (6), • rear thrust bearing (7), • idler gear shaft (8). The camshaft idler gear assembly includes a wear plate (9).
Engine Assembly (0-02) Page 0-88 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Caution: The grooved side of the front thrust bearing must be facing toward the gear to prevent damage to the gear and engine during engine operation. Align the timing marks and install the idler gear (6), front thrust bearing (5) and gear retainer (4). Install the three retaining capscrews (M10-1.50 x 60) and tighten.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Water Pump/Lube Pump Idler - Installation Caution: The grooved side of the rear thrust bearing must be facing toward the gear to prevent damage to the gear and engine during engine operation. Use LubriplateW 105, or equivalent, to lubricate the thrust bearings and idler gear shaft. Install the rear thrust bearing. Install the idler gear without the shaft.
Engine Assembly (0-02) Page 0-90 Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: The following idler gear end clearance and backlash checks applies to all three idler gears. Use a dial indicator gauge assembly, Part No. 3376050, with extension, Part No. ST-537-4, and a magnetic base, Part No. 3377399, to measure the idler gear end clearance. Place the contact tip of the gauge against the face of the idler gear. mm 0.30 0.53 Idler Gear End Clearance MIN MAX in 0.012 0.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Supports one, four and seven are doweled. The supports must align with the dowel pins in the cylinder block. Install the cam follower assemblies on the studs. Loosen the two installation tool cam follower retaining screws and remove the service tool. Install the washers and nuts on each stud. Tighten nuts on supports (1), (4) and (7) only.
Engine Assembly (0-02) Page 0-92 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the 0.76 mm [0.030 inch] feeler gauge between the number 12 lever and the number five support. Push the number five support toward the number four support. Tighten the number five support nut. Torque Value: 47 N•m [35 ft-lb] Install the 0.76 mm [0.030 inch] feeler gauge between the number 15 lever and the number six support. Push the number six support toward the number five support.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Reuse Guidelines - Flange Head Capscrews Using flange head capscrews with the torque plus angle method of installation places the capscrew beyond the yield point and permanently stretches the capscrew. These capscrews can be reused throughout the life of the engine unless the capscrew exceeds the specified free length. The free length must be checked to avoid bottoming in the block during installation. Cylinder head capscrew length gauge, Part No.
Engine Assembly (0-02) Page 0-94 Section 0 - Engine Disassembly and Assembly - Group 00 M11 The capscrew can also be checked using a set of calipers. The maximum allowable free length is measured from the bottom of the flange to the end of the capscrew (Dimension X). Part No. 3045849 3045850 Maximum Free Length 74.5 mm [2.933 in] 139.5 mm [5.492 in] Installation A plastic insert is installed in all fuel inlet passages on new and ReConW cylinder heads.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the three capscrews (M14-1.50 x 75) in the cylinder head intake ports. Install the remaining 29 capscrews (M14-1.50 x 140). The markings on the head of the flange head capscrews serve as an aid during installation. After torquing to Step 2, mark the cylinder head adjacent to one of the two single marks on the capscrew head. After all 32 capscrews have been torqued to Step 2, they must be rotated 90 degrees.
Engine Assembly (0-02) Page 0-96 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tighten the capscrews in the sequence shown to the specified values: Torque Value: Step 1 - 136 N•m [100 ft-lb] 2 - 217 N•m [160 ft-lb] 3 - Rotate 90 Degrees NOTE: Rotate at least one flat, but not more than two. Use new copper sealing washers and install the seven capscrews (M10-1.50 x 75) on the fuel pump side of the cylinder head. Tighten the capscrews in the sequence shown.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 To verify the correct static injection timing for a particular engine, check the control parts list (CPL) number on the engine dataplate, then refer to the CPL Bulletin No. 3379133. Timing codes are listed as two letter alpha characters, for example, an ‘‘HZ’’ code indicates a nominal setting of 5.97 mm [0.235 in]. Refer to the accompanying chart.
Engine Assembly (0-02) Page 0-98 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Align the swivel bracket (2) with the injector hold down capscrew hole. Install capscrew, Part No. 3823600, through the swivel bracket. The capscrew is included in the timing tool kit. NOTE: If the capscrew (3) is tightened too tight, it will restrict the piston rod travel. Tighten the capscrew (3) enough to hold the timing fixture rigid.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the injector push rod (9) between the injector camshaft follower and the plunger rod. NOTE: The push rod must be aligned properly to attain a correct reading. Caution: Always use the accessory drive shaft to rotate (bar) the crankshaft for checking the static injection timing. Using any other method will cause an error in the static injection timing or can damage the engine.
Engine Assembly (0-02) Page 0-100 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rotate the accessory drive shaft back and forth (before and after) the ‘‘0’’ (zero) indicator reading for approximately 3 degrees to be sure the piston is at TDC. Rotate the accessory drive shaft in the direction of engine rotation clockwise to 90 degrees after top dead center (ATDC). The piston plunger will be at the ‘‘L10 90 degree’’ mark on the timing fixture.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: If the crankshaft is rotated beyond the 5.160 mm [0.2032 inch] BTDC position, the crankshaft must be rotated counterclockwise back to the 45 degrees BTDC mark. Rotate the accessory drive shaft clockwise slowly until the piston travel gauge is at 5.160 mm [0.2032 inch] BTDC. Read the push rod travel gauge counterclockwise from ‘‘0’’ (zero). This travel represents the static injection timing value. In the example shown, the value is 5.97 mm [0.
Engine Assembly (0-02) Page 0-102 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Static injection timing can be changed by removing the camshaft gear and installing an offset key. To change the static injection timing, remove the camshaft idler gear. Refer to "Idler Gears - Removal, Procedure 0-01". The camshaft gear puller kit, Part No. 3824106, must be assembled before use.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the assembled camshaft gear puller on to the camshaft gear. Insert the adapter (1) of the non-slotted hole in the puller plate (2) onto the camshaft gear first. The adapter pulling surfaces (3) must point toward the center of the camshaft gear. Slide the capscrew and adapter of the slotted end of the puller plate (4) toward the end of the puller plate and insert the adapter onto the camshaft gear.
Engine Assembly (0-02) Page 0-104 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use a leather hammer to install the camshaft gear key. NOTE: Gear housing clearance makes key installation more difficult. Use care when installing the key. Use master camshaft gear, Part No. 3824652, for checking the static injection timing again. This is a slip fit gear which can be installed without heating the gear and removed without the camshaft gear puller. Install the gear onto the camshaft.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Warning: Use insulated gloves, Part No. 3823730, and hot clamp pliers, Part No. 3823732, when handling heated parts. Hot parts can cause serious personal injury. Heat the camshaft gear in an oven for a minimum of one hour, but not longer than six hours. Temperature: 235°C [450°F] Use LubriplateW 105, or equivalent, to coat the camshaft nose before installing the camshaft gear.
Engine Assembly (0-02) Page 0-106 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use a new gasket and install the camshaft rear cover plate. Tighten the three capscrews (M10-1.50 x 22). Torque Value: 47 N•m [35 ft-lb] Use a dial indicator gauge assembly, Part No. 3376050, with an extension, Part No. ST-537-4, and a magnetic base, Part No. 3377399, to measure the camshaft end clearance. Place the contact tip of the gauge against the face of the gear. mm 0.13 0.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install a new o-ring at the front of the hydraulic drive idler retainer mounting spacer. The spacer must be in the proper position. Install the gear cover and 22 mounting capscrews (M81.25 x 20). NOTE: Do not install the front engine support capscrews at this time. NOTE: Applications equipped with an automatic belt tensioner refer to the next block of text for installation of the belt tensioner bracket before tightening the mounting capscrews.
Engine Assembly (0-02) Page 0-108 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tighten the gear cover capscrews in the sequence shown. For capscrews 1 through 22: Torque Value: 20 N•m [15 ft-lb] For capscrews 23 through 28: Torque Value: 68 N•m [50 ft-lb] Automatic Belt Tensioner - Installation Install the tensioner with a (M10-1.50 x 70) capscrew. Align the cast locator pin on the tensioner with the hole in the bracket before tightening.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Orient the four punch marks on the clamping ring at the 11:30 o’clock location. Apply a coating of sealant, Part No. 3823494, to the six mounting capscrews. Install the six seal capscrews (M8-1.25 X 20) and washers. Tighten the capscrews in a star pattern in two steps. Torque Value: Step 1 - 7 N•m [ 60 in-lb] 2 - 20 N•m [180 in-lb] Place a light film of oil or anti-freeze on the inside diameter of the dust seal.
Engine Assembly (0-02) Page 0-110 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Vibration Damper Eccentricity - Measurement Install dial indicator assembly, Part No. 3376050, with magnetic base, Part No. 3377399, in the center of the vibration damper outside diameter to measure eccentricity (out-of-round). Rotate the crankshaft with the accessory drive shaft one complete revolution (360 degrees). Maximum eccentricity must not exceed 0.28 mm [0.011 inch] TIR.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Accessory Drive Pulley - Installation NOTE: Accessory drive seal dust seals are currently only to be installed on single v-groove stamped steel accessory drive pulleys. The dust seal is not compatible with other pulleys. Place a light film of oil or anti-freeze on the inside diameter of the accessory drive oil seal dust seal.
Engine Assembly (0-02) Page 0-112 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tighten the capscrews, in the sequence shown. Torque Value: 47 N•m [35 ft-lb] Injectors - Installation Do not stretch the o-rings as they are installed. The o-rings must be correctly installed in the grooves to prevent leaks. NOTE: It is important that the three injector o-rings be installed in the correct orientation. Install the three new o-rings as follows: Part No.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Crossheads - Installation If the engine is equipped with a JacobsW Engine Brake, special guideless crossheads must be installed on the exhaust valve stems. Install the crosshead with the pin over the exhaust valve closest to the center of the cylinder head. Use clean 15W-40 oil to lubricate the end of the valve stems. If the same crossheads are used, they must be installed in the same location as from which they were removed.
Engine Assembly (0-02) Page 0-114 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rocker Lever Side Clearance - Adjustment Push the number five rocker lever support toward the front of the engine and tighten the support capscrew. Torque Value: 122 N•m [90 ft-lb] Install a 0.55 mm [0.022 inch] feeler gauge between the number five support and the intake lever for the number four cylinder. Push the number six support toward the front of the engine and tighten the support capscrew.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Push the number four support toward the rear of the engine and tighten the support capscrew. Torque Value: 122 N•m [90 ft-lb] Install a 0.55 mm [0.022 inch] feeler gauge between the number four support and the intake lever for the number three cylinder. Push the number three support toward the rear of the engine and tighten the support capscrew. Torque Value: 122 N•m [90 ft-lb] Install a 0.55 mm [0.
Engine Assembly (0-02) Page 0-116 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Push Rods and Tubes - Installation Use clean 15W-40 oil to coat the ball end of the push rods and push tubes. The injector push rods (I) are longer than the valve push tubes (V). Do not allow the push rods or push tubes to fall into the engine. They can be damaged. The crankshaft must be rotated to install all the push rods and push tubes.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use clean 15W-40 oil to lubricate the o-rings. Press the connector all the way into the front housing by hand. When installing the front housing, be sure the oil connector and o-ring are in position to be pushed into the rear housing. Install the front JacobsW Engine Brake housing on the front rocker lever supports. Center the oil connector between the front and rear housings before tightening the capscrews.
Engine Assembly (0-02) Page 0-118 Section 0 - Engine Disassembly and Assembly - Group 00 M11 The valve set marks are located on the accessory drive pulley. The marks align with a pointer on the gear cover. Use the accessory drive shaft to rotate the crankshaft. Each cylinder has three rocker levers. 1. The long rocker lever (E) is the exhaust lever. 2. The center rocker lever is the injector lever. 3. The short rocker lever (l) is the intake lever.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 When the ‘‘A’’ mark is aligned with the pointer, the intake and exhaust valves for cylinder number one must be closed. If these conditions are not correct, cylinder number six must be ready to set. Set the injector and valves on the cylinder that both the intake and exhaust valve rocker lever arms are loose and can be moved from side to side by hand. Both valves are closed when both rocker levers are loose and can be moved from side to side.
Engine Assembly (0-02) Page 0-120 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Hold the adjusting screw in this position. The adjusting screw must not turn when the locknut is tightened. Without Adapter: Torque Value: 61 N•m [45 ft-lb] With Adapter: Torque Value: 47 N•m [35 ft-lb] After tightening the locknut to the correct torque value, check to make sure the feeler gauge will slide backward and forward between the crosshead and the rocker lever with only a slight drag.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Turn the slave piston adjusting screw down until it touches the feeler gauge. Hold the adjusting screw in position and tighten the locknut. Without Adapter: Torque Value: 34 N•m [25 ft-lb] With Adapter: Torque Value: 30 N•m [22 ft-lb] Caution: After the slave piston adjusting screw locknut is tightened to the correct torque value, measure the clearance with a feeler gauge again. Do not tighten the adjusting screws too tight.
Engine Assembly (0-02) Page 0-122 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use five wire clamps and capscrews (M8-1.25 x 20) to install the inside section of the actuator harness to the inside of the rocker housing. The harness and the connectors must be clear of any moving parts, so the wires will not be damaged during engine operation. Torque Value: 20 N•m [15 ft-lb] Lubricate the connector ends with lubricant DS-ES, Part No. 3822934.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install new o-ring seals on the connector ends of the internal and external actuator harness where it passes through the rocker lever housing. Lubricate the connector with lubricant DS-ES, Part No. 3822934. Install the ends through the rear end of the rocker lever housing. Using a TorxW screwdriver (T-25), tighten the locking capscrew. The screw head is on the inside plug of the harness.
Engine Assembly (0-02) Page 0-124 Section 0 - Engine Disassembly and Assembly - Group 00 M11 NOTE: Care must be used when matching connectors with sensors. Each sensor has its own unique connection. Lubricate the sensor harness wire connectors with lithium grease. Connect the correct sensor harness wire connectors to the following sensors: • oil temperature sensor (1), • oil pressure sensor (2), • engine position sensor (3).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Rocker Lever Cover - Installation Install a new gasket on the cover. Install the cover on the rocker lever housing. Install the 16 isolators and capscrews (M8-1.25 x 40) in the cover. Tighten the capscrews in the sequence shown. Torque Value: 15 N•m [130 in-lb] Install the breather hose and retaining clip. Hand Hole Cover (Fuel Pump Side of Engine) - Installation Use a new gasket and install the hand hole cover and the four capscrews (M10-1.
Engine Assembly (0-02) Page 0-126 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install and tighten the coolant inlet tube to the fitting. Torque Value: 40 N•m [30 ft-lb] Fuel Pump Support Bracket - Installation Install the fuel pump support bracket to the cylinder block with two mounting capscrews (M10-1.50 x 40). Torque Value: 47 N•m [35 ft-lb] Air Compressor - Installation NOTE: To reduce noise and vibration, the air compressor must be timed with the accessory drive.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use a new gasket and install the air compressor using four capscrews (7/16 - 14 x 1 7/8 inch) and two nuts (7/16 x 14). Torque Value: 65 N•m [50 ft-lb] Install the coolant inlet hose on the air compressor fitting (5) and tighten. Torque Value: 40 N•m [30 ft-lb] Air Compressor Air Supply Tube - Installation Install the o-ring on the air supply tube. Use vegetable oil to lubricate the o-ring.
Engine Assembly (0-02) Page 0-128 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fuel Pump (With Air Compressor) - Installation Install the spider coupling to the end of the air compressor crankshaft. Use a new gasket to install the fuel pump. Install the two outside 12 point mounting capscrews (7/ 16-14 x 1-1/4). Install the two fuel pump support bracket capscrews (3/ 8-16 x 1) to the cylinder block bracket. Tighten the four fuel pump mounting capscrews.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Electronic Control Cooling Plate - Installation Install the electronic control cooling plate and the two mounting brackets. Use two capscrews (M10-1.50 x 100) in the bottom mounting holes and two capscrews (M101.50 x 60) in the upper mounting holes. Install the heat resistant grommets on both sides of the cooling plate. Install the two heat resistant star washer grommets at the same mounting location. Tighten the four capscrews.
Engine Assembly (0-02) Page 0-130 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Spread the lubricant across the connector nose piece so it enters every pin hole and lubricates the contacts. Lubricant must not be visible on the surface of the nose piece. Install the actuator wiring harness connector to the upper plug nearest the engine on the ECM. Install the sensor wiring harness connector to the lower plug on the ECM. Tighten the connector capscrews. Torque Value: 2.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the fuel suction line from the electronic control cooling plate (1) to the filter head (2). Starting Motor - Installation The mounting capscrews for the starting motor will be metric (M16-2.00 x 45) 12 point, or U.S. Customary (5/8-11 x 3/4) hex head, depending on the flywheel housing used. Make sure to use the correct capscrews to avoid damage to the threaded holes in the flywheel housing. Install the spacer if required.
Engine Assembly (0-02) Page 0-132 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fan Idler Pulley - Installation Install the idler pulley into the fan hub support bracket. Install the washer and locknut on the idler pulley shaft. Do not tighten the locknut until the fan drive belt has been installed and adjusted. Install the adjusting screw (M10-1.50 x 170) into the idler pulley shaft.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Engine - Removal From The Rebuild Stand Use four capscrews (M10-1.50 x 40) and temporarily install the front lifting bracket to the rocker lever housing. Use two capscrews (M12-1.75) and fasten the rear lifting bracket to the cylinder head. Torque Value: 70 N•m [55 ft-lb] Warning: To prevent personal injury, use a properly rated hoist to lift the engine. The engine weighs approximately 940 kg [2070 lb]. Use lifting fixture, Part No.
Engine Assembly (0-02) Page 0-134 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Water Header Plate - Installation Install two guide pins, Part No. 3376488, in the side of the cylinder block at locations (1) and (2). Use a new gasket and install the water header plate with 18 capscrews (M10-1.50 x 25). NOTE: The capscrews are not tightened to their final torque value at this time.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Thermostat Housing Support - Installation Use a new gasket and install the support with four capscrews (M10-1.50 x 35). NOTE: The capscrews are not tightened to their final torque value at this time. Torque Value: 20 N•m [15 ft-lb] Install the air compressor water outlet tube to the fitting on the thermostat housing support.
Engine Assembly (0-02) Page 0-136 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Alternator Drive Seal - Installation The oil seal must be installed with the lip of the seal and the shaft clean and dry. The yellow dust lip of the seal must be facing out. Use the installation sleeve provided in the seal kit to install the new seal and gasket. Apply sealant, Part No. 3375066 or equivalent, to the threads of the capscrews. Install the clamping ring with five M8-1.25 x 20) capscrews.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Lubricating Oil Cooler - Installation Install two new o-rings on the water inlet and outlet transfer tube ends of the oil cooler. Lubricate the o-rings with clean 15W-40 engine oil. While holding the retainer connection in place, install both o-ring adapters onto the oil cooler tube ends as far as possible. The straight edges of the o-ring adapters must face each other when installed. Install two new o-rings on the ends of the o-ring adapters.
Engine Assembly (0-02) Page 0-138 Section 0 - Engine Disassembly and Assembly - Group 00 M11 JacobsW Brake Oil Supply Hose - Installation Install and tighten the oil hose on the oil filter head and JacobsW Brake connections. Hand Hole Cover (Exhaust Side of Engine) Installation Use a new gasket and install the cover with four capscrews (M10-1.50 x 20). Torque Value: 47 N•m [35 ft-lb] Dipstick Tube Bracket - Installation Use a new gasket and install the tube bracket with four capscrews (M10-1.50 x 20).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Use high temperature anti-seize compound, Part No. 3823097 or equivalent, to coat the capscrew threads, this will aid future capscrew removal. Install the exhaust manifold with twelve capscrews (M101.50 x 100) and tubular spacers. Tighten the capscrews in the sequence shown. Torque Value: Step 1 - 27 N•m [20 ft-lb] 2 - 47 N•m [35 ft-lb] Air Intake Manifold - Installation Install two guide pins, Part No. 3376696, into the rocker lever housing.
Engine Assembly (0-02) Page 0-140 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install a new sealing ring and the boost pressure sensor and the intake manifold temperature sensor. Torque Value: 27 N•m [20 ft-lb] Install the correct sensor harness wire connectors to the sensors. Use a new gasket and install the air connection to the intake manifold. Use four capscrews (M10-1.50 x 22).
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Install the discharge elbow, v-band clamp, and new o-ring seal on the turbocharger compressor discharge outlet. Tighten the clamp. Torque Value: 8 N•m [75 in-lb] Install and tighten the oil drain line. Torque Value: 27 N•m [20 ft-lb] Pour 50 to 60 cc [2.0 to 3.0 ounces] of clean engine oil in the oil supply hole of the turbocharger. Install the oil supply line to the turbocharger with two capscrews (M8-1.25 x 20).
Engine Assembly (0-02) Page 0-142 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Thermostat Housing - Installation Install the thermostat into the housing. Install a new seal in the groove on the thermostat housing mounting surface. Install the thermostat housing with four capscrews (M101.50 x 145). Torque Value: 54 N•m [40 ft-lb] Evenly space the bypass hose on the water pump and thermostat housing connections. Tighten the hose clamps.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Alternator Drive Belt (Bus Applications) Installation Install a new belt over the pulleys while holding the tensioner back. Be careful not to damage the belt while working it over the flanged pulleys. Release the tensioner and remove the breaker bar. Belt drive systems equipped with an automatic belt tensioner cannot be adjusted. A belt tension gauge will not give an accurate measure of the belt tension.
Engine Assembly (0-02) Page 0-146 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fuel Filter - Installation Use a clean, ‘‘lint-free’’ towel to clean the filter head gasket surface. Install a new o-ring on the filter head fitting. Use clean 15W-40 oil to lubricate the filter gasket surface. Use clean No. 2 diesel fuel to fill the filter. Install the filter by hand. Tighten the filter until the gasket contacts the filter head surface.
Section 0 - Engine Disassembly and Assembly - Group 00 M11 Fill the filter with clean 15W-40 oil. Install the filter on the filter head. Caution: To prevent damage to the filter threads or filter head, do not over-tighten the filter. Tighten the filters until the gasket contacts the filter head surface. Use oil filter wrench, Part No. 3375049, to tighten the filter an additional three-fourths to one (3/4 to 1) turn or follow the instructions supplied with the filter.
Engine Assembly (0-02) Page 0-148 Section 0 - Engine Disassembly and Assembly - Group 00 M11 Tighten the drain plug in the oil pan. Torque Value: 90 N•m [65 ft-lb] NOTE: Refer to ‘‘Engine Test‘‘ or ‘‘Engine Storage’’, Section 14, after the engine is assembled.
Section 1 - Cylinder Block - Group 01 M11 Page 1-1 Section 1 - Cylinder Block - Group 01 Section Contents Page Camshaft - Cleaning and Inspection for Reuse .............................................................................................. 1-48 Cleaning........................................................................................................................................................ 1-48 Inspection..............................................................................
Page 1-2 Section 1 - Cylinder Block - Group 01 M11 Page Cylinder Block - Inspection for Reuse ............................................................................................................ Camshaft Bushing Inside Diameter - ............................................................................................................. Cylinder Liner Bores - Inspection...................................................................................................................
Section 1 - Cylinder Block - Group 01 M11 Service Tools - Cylinder Block Page 1-3 Service Tools - Cylinder Block The following special tools are recommended to perform procedures in Group 01. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Connecting Rod Checking Fixture Measure connecting rod bend and twist. ST-561 Piston Ring Expander Replace piston rings on pistons.
Service Tools - Cylinder Block Page 1-4 Tool No. Section 1 - Cylinder Block - Group 01 M11 Tool Description Gear Puller 3375840 Remove the crankshaft gear. Requires jaw, Part No. 3375839, to be used. Lifting Strap Lift the cylinder block or crankshaft. 3375957 Guide 3376069 Replace cylinder block camshaft bushings. Used with camshaft bushing driver set, Part No. 3376637. Driver 3376070 Replace cylinder block camshaft bushings. Used with camshaft bushing driver set, Part No. 3376637.
Section 1 - Cylinder Block - Group 01 M11 Tool No. Service Tools - Cylinder Block Page 1-5 Tool Description Centering Rings 3376781 Used to check cylinder block main bearing bore alignment. Used with checking bare, Part No. ST-1177-16. Checking Ring 3376811 Used to check cylinder block main bearing bore alignment. Used with checking bar, Part No. ST-1177-16. Expansion Plug Driver Used with handle, Part No. 3376795, to install expansion plugs.
Cylinder Block - Exploded View Page 1-6 Section 1 - Cylinder Block - Group 01 M11 Cylinder Block - Exploded View Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Description Pin, Piston Ring, Retaining Piston Ring, Oil Ring, Compression Ring, Compression Rod, Connecting Bearing, Connecting Rod Capscrew, 12 point [14-1.5x91.25] Liner, Cylinder O-ring, Liner Housing, Dipstick Capscrew [10-1.50x20] Gasket, Dipstick Housing Cylinder Block Dowel, Pin [7/16x1 inch] Dowel, Pin [6.000x12.
Section 1 - Cylinder Block - Group 01 M11 Cylinder Block - General Information Page 1-7 Cylinder Block - General Information These procedures apply to M11 engines. The differences between engine models, due to the application and the optional equipment, is included in the instructions. Omit the steps that do not apply to the engine being rebuilt. 1. A Warning statement is included for any component or assembly that weighs more than 23 kg [50 lb].
Cylinder Block (1-01) Page 1-8 Section 1 - Cylinder Block - Group 01 M11 Pipe Plugs - Removal Use the appropriate size hex key wrench to remove all of the pipe plugs. Viscosity Sensor - Removal If the viscosity sensor was not removed during engine disassembly, use a 7/16 inch socket with a ratchet and extension and remove the viscosity sensor. Dowel Pins - Removal Use dowel pin extractor, Part No.
Section 1 - Cylinder Block - Group 01 M11 • Lubricating oil pump alignment dowel pin Cam Follower Studs - Removal Use a 11 to 13 mm [7/16 to 1/2 inch] stud extractor to remove the seven cam follower studs. Idler Shaft Ring Dowels - Removal Use puller kit, Part No. 3375784, to remove the three idler gear ring dowels. Cleaning Caution: Do not damage the machined surfaces when using a wire brush or gasket scraper.
Cylinder Block (1-01) Page 1-10 Section 1 - Cylinder Block - Group 01 M11 • Cylinder liner counter bore • Cylinder head deck surface • Cup plug bores • Main bearing saddles and caps Cylinder Block - Removal from the Rollover Stand The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Install the numbers ‘‘3’’ and ‘‘5’’ main bearing caps and tighten the capscrews. Use the lifting strap, Part No.
Section 1 - Cylinder Block - Group 01 M11 Use a gasket scraper to remove all gasket material and heavy dirt from the cylinder block. Place the cylinder block into a cleaning or soak tank. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Steam clean the cylinder block and dry with compressed air. Make sure to blow out all oil drillings, pipe plug bores, and capscrew threads.
Cylinder Block (1-01) Page 1-12 Section 1 - Cylinder Block - Group 01 M11 Dowel Pins - Installation Use a hard plastic hammer to install the following dowel pins: • Two cylinder head dowel pins • Three cam follower support dowel pins • Idler gear ring dowels (1), (2), and (3) • Lubricating oil pump dowel pin (4) Cam Follower Studs - Installation Install the seven cam follower studs with two nuts (M10x1.5) tightened together.
Section 1 - Cylinder Block - Group 01 M11 Viscosity Sensor - Installation Use a 7/16 inch socket, extension and ratchet to install the viscosity sensor. Torque Value: 24 N•m [18 ft-lb] Cylinder Block - Inspection for Reuse (1-02) NOTE: All measurements of the cylinder block must be made when the block is positioned on a flat surface. If the block is mounted on the engine stand, the measurements can be wrong because of distortion. Inspect all gasket surfaces. Visually inspect for burrs or damage.
Cylinder Block - Inspection for Reuse (1-02) Page 1-14 Section 1 - Cylinder Block - Group 01 M11 Measure the upper liner bore inside diameter. Cylinder Block Upper Liner Bore I.D. mm in 145.900 MIN 5.7441 146.027 MAX 5.7491 Measure the liner seal bore Inside diameter 8.0 to 13.5 mm [0.32 to 0.53 inch] below the counterbore. Cylinder Block Liner Seal Bore I.D. mm in 138.063 MIN 5.4355 138.113 MAX 5.
Section 1 - Cylinder Block - Group 01 M11 Use clean 15W-40 oil to lubricate the checking ring, Part No. 3376811, and the checking bar, Part No. ST-1177-16. Slide the checking bar through one of the centering rings. Install the checking ring, Part No. 3376811, on the checking bar. Slide the checking bar through the other centering ring. Inspect the checking bar for freedom of rotation. Use clean 15W-40 oil to lubricate the outside diameter of the checking ring.
Cylinder Block - Inspection for Reuse (1-02) Page 1-16 Section 1 - Cylinder Block - Group 01 M11 If the checking ring will not go through the bore, visually inspect the bore for burrs and other obstructions. After removing any burrs, if the checking ring still will not go through the bore, mark the bore for repair. If the checking ring will pass through the bore without any resistance, center the checking ring in the bore. Use a feeler gauge 0.08 mm [0.003 inch] that is not more than 12.
Section 1 - Cylinder Block - Group 01 M11 Evaluate the main bearing bore alignment inspection as follows: • If the feeler gauge will not go in the bore at any point and the checking bar rotates freely, the main bearing bore is acceptable. • If the feeler gauge will enter the bore at one point on one side of the checking ring, but will not enter the bore 180 degrees from that point on the same side and the checking bar rotates freely, there is a slight misalignment but the main bearing bore is acceptable.
Cylinder Block - Inspection for Reuse (1-02) Page 1-18 Section 1 - Cylinder Block - Group 01 M11 Remove the checking ring. NOTE: Leave the centering rings and checking bar in place if any bores are to be repaired. Refer to the Alternative Repair Manual, Bulletin No. 3810310, for salvage procedures. Main Bearing Bore Inside Diameter - Measurement Use master ring gauge, Part No. 3376576, to set up the dial bore gauge. Measure the inside diameter of all seven bores at three points. mm 121.990 122.
Section 1 - Cylinder Block - Group 01 M11 High Oil Pressure Regulator Seat Depth Measurement Measure the relief valve seat depth in the cylinder block. High Oil Pressure Relief Valve Seat Depth mm in 62.62 MIN 2.465 63.62 MAX 2.505 NOTE: If the relief valve seat is not at the specified depth, or is loose or not level in the cylinder block, the seat must be removed and inspected. Use puller kit, Part No. 3375784, to remove the seat. If the seating surfaces are free of indentations, the seat can be reused.
Camshaft Bushing - Replacement (1-03) Page 1-20 Section 1 - Cylinder Block - Group 01 M11 Camshaft Bushing Inside Diameter Measurement Measure the inside diameter of the camshaft bushings when installed. Camshaft Bushing I.D. Installed mm in 72.078 MIN 2.8377 72.142 MAX 2.8402 NOTE: If one of the bushings exceeds the maximum specifications, all bushings must be replaced. Camshaft Bushing - Replacement (1-03) Removal Use the camshaft bushing driver, Part No. 3376070, bushing driver assembly, Part No.
Section 1 - Cylinder Block - Group 01 M11 Inspection Measure the cylinder block camshaft bore inside diameter. Cylinder Block Camshaft Bore I. D. mm in 76.987 MIN 3.0310 77.040 MAX 3.0331 Installation Caution: Remove any metal chips from the camshaft bushing oil groove to prevent the lubricating system from being contaminated and causing engine damage. Use camshaft bushing driver, Part No. 3376070, and the bushing driver assembly, Part No. 3376637, to install the camshaft bushings.
Cylinder Liner - Cleaning and Inspection for Reuse (1-04) Page 1-22 Section 1 - Cylinder Block - Group 01 M11 Use the same procedure to install the numbers ‘‘6’’, ‘‘5’’, ‘‘4’’, ‘‘3’’, and ‘‘2’’ bushings. Install the guide (2) into the correct position. Install the bushing on the driver with the oil hole at the 3 O’clock position viewed from the front of the engine. Drive the bushing in the bore.
Section 1 - Cylinder Block - Group 01 M11 Cylinder Liner - Cleaning and Inspection for Reuse (1-04) Page 1-23 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam clean the liner and dry with compressed air. Use clean 15W-40 oil to lubricate the inside diameter of the liner. Allow the oil to soak in the liner for five to ten minutes.
Cylinder Liner - Cleaning and Inspection for Reuse (1-04) Page 1-24 Section 1 - Cylinder Block - Group 01 M11 Visually inspect the outside diameter of the liner for excessive corrosion or pitting. Liners with pitting generally cannot be reused. However, if the pitting is light and can be removed with fine emery cloth, the liner can be reused. Visually inspect the liner inside diameter for vertical scratches deep enough to be felt with a fingernail.
Section 1 - Cylinder Block - Group 01 M11 Idler Gear Assembly - Cleaning and Inspection for Reuse (1-05) Page 1-25 Use a dial bore gauge to measure the liner inside diameter 90 degrees apart at the top, middle, and bottom of the piston travel area. Cylinder Liner Inside Diameter mm in 125.000 MIN 4.9213 125.095 MAX 4.9250 Measure the liner top press fit area outside diameter. Cylinder Liner Top Press Fit O. D. mm in 145.938 MIN 5.7456 145.976 MAX 5.
Idler Gear Assembly - Cleaning and Inspection for Reuse (1-05) Page 1-26 Section 1 - Cylinder Block - Group 01 M11 Use a soft bristle brush to clean the oil drilling in the idler gear shaft. Use compressed air to blow out the oil drilling. Inspection Visually inspect the gear for chipped or broken teeth, and cracks. Visually inspect the shaft for damage. Use crocus cloth to remove any burrs. Measure the idler gear bushing bore inside diameter. mm 60.045 60.100 Idler Gear Bushing Bore I. D.
Section 1 - Cylinder Block - Group 01 M11 Idler Gear Assembly - Cleaning and Inspection for Reuse (1-05) Page 1-27 Measure the idler gear shaft outside diameter. mm 59.975 60.008 Idler Gear Shaft O. D. MIN MAX in 2.3612 2.3625 Measure the idler gear shaft ring dowel bore inside diameter. Idler Gear Shaft Ring Dowel Bore I.D. mm in 19.245 MIN 0.7577 19.265 MAX 0.7585 Measure the idler gear ring dowel outside diameter. mm 19.217 19.243 Idler Gear Ring Dowel O. D. MIN MAX in 0.7566 0.
Crankshaft - Cleaning and Inspection For Reuse (1-06) Page 1-28 Section 1 - Cylinder Block - Group 01 M11 Crankshaft - Cleaning and Inspection For Reuse (1-06) Cleaning Use crocus cloth to polish the machined surfaces. Use a bristle brush to clean the oil drillings. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Steam clean the crankshaft and dry with compressed air.
Section 1 - Cylinder Block - Group 01 M11 Measure the front and rear oil seal wear grooves. Crankshaft Rear Oil Seal Wear Groove mm in 0.25 MAX 0.0098 Measure the connecting rod journals outside diameter. Crankshaft Connecting Rod Journal O.D. mm in 78.950 MIN 3.1083 79.013 MAX 3.1107 Measure the main bearing journals outside diameter. Crankshaft Main Bearing Journal O.D. mm in 114.015 MIN 4.4888 114.055 MAX 4.4903 Measure the thrust face width. Crankshaft Thrust Face Width mm in 49.975 MIN 1.9675 50.
Crankshaft Magnetic Crack Inspection (1-07) Page 1-30 Section 1 - Cylinder Block - Group 01 M11 Measure the rear oil seal flange outside diameter. Crankshaft Rear Oil Seal Flange O.D. mm in 164.965 MIN 6.4947 165.035 MAX 6.4974 Measure the damper pilot outside diameter. mm 32.01 32.04 Crankshaft Damper Pilot O.D. MIN MAX in 1.2602 1.2614 Use clean 15W-40 oil to coat the entire crankshaft to prevent rust.
Section 1 - Cylinder Block - Group 01 M11 A minimum of three successive head shots are required for each section of the crankshaft. Flow the bath solution over the first one-third length of the crankshaft and apply three head shots of magnetizing current. NOTE: Turn off the flow of bath solution before the third head shot of current is completed to prevent washing the metal particles from the crankshaft. Inspect the first one-third section of the crankshaft.
Crankshaft Magnetic Crack Inspection (1-07) Page 1-32 Section 1 - Cylinder Block - Group 01 M11 A minimum of three coil shots are required for each 18 inch length to correctly magnetize the crankshaft. Flow the magnetic bath solution over the crankshaft in one third sections. Apply three coil shots after each wetting with the coil placed at quarter-length points along the crankshaft.
Section 1 - Cylinder Block - Group 01 M11 Open indications on the crankpin or main bearing journal surfaces that extend closer than 3 mm [1/8 inch] to the fillet but do not enter the fillet are acceptable. Open indications in the longitudinal direction up to 12 1/2 mm [1/2 inch] long, but not closer than 3 mm [1/8 inch] to the oil hole chamfer are acceptable. Open indications that enter the oil hole chamfer or intersect the oil hole at 45 degrees (plus or minus 10 degrees) are not acceptable.
Crankshaft Magnetic Crack Inspection (1-07) Page 1-34 Section 1 - Cylinder Block - Group 01 M11 Open indications on the gear step diameter that enter the crankshaft keyway are not acceptable. Open indications that extend over the face of the crankshaft or extend into the damper mounting capscrew holes are not acceptable. Subsurface indications cannot be seen with the naked eye after the magnetic particles have been removed. These are indications of open areas or foreign objects below the surface.
Section 1 - Cylinder Block - Group 01 M11 Main Bearings - Cleaning and Inspection for Reuse (1-08) Page 1-35 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use steam to clean the crankshaft and oil drillings. Dry with compressed air. Use a light preservative oil to lubricate the crankshaft to prevent rust.
Connecting Rod Bearings - Cleaning and Inspection for Reuse (1-09) Page 1-36 Section 1 - Cylinder Block - Group 01 M11 Measure the bearing shell thickness with a ball micrometer. Main Bearing Shell Thickness (Standard) mm in 3.895 MIN 0.1533 3.944 MAX 0.1553 Measure the thrust bearing thickness in three locations. mm 4.75 4.89 Thrust Bearing Thickness MIN MAX in 0.1870 0.
Section 1 - Cylinder Block - Group 01 Vibration Damper (Viscous) - Cleaning and Inspection for Reuse (1-10) M11 Page 1-37 Normal bearing wear produces a smooth finish which will wear into the copper lining. Exposed copper does not always indicate worn bearings. Measure the bearing thickness using a ball micrometer. Measure the thickness at three locations on each edge of the bearing. Connecting Rod Bearing Thickness (Standard) mm in 2.430 MIN 0.0957 2.473 MAX 0.
Vibration Damper (Viscous) - Cleaning and Inspection for Reuse (1-10) Section 1 - Cylinder Block - Group 01 Page 1-38 M11 Remove the paint on both sides of the damper in four locations spaced 90 degrees apart. Measure and record the thickness at two points on each of the four locations as follows: • Measure the thickness at 3.18 mm [0.125 inch] from the outer lip. • Measure the thickness at 25.4 mm [1.0 inch] from the outer lip. NOTE: This step will result in a total of eight measurements.
Section 1 - Cylinder Block - Group 01 M11 Crankshaft Gear - Replacement (1-11) Removal Use gear puller, Part No. 3375840, with jaws, Part No. 3375839, to remove the crankshaft gear. Use a flat chisel and a hammer to remove the key. Inspection Visually inspect the crankshaft gear for cracks and broken or chipped teeth. The gear must be replaced if it is damaged. Visually inspect the gear and keyway for nicks or burrs. Use crocus cloth to remove nicks and burrs.
Crankshaft Gear - Replacement (1-11) Page 1-40 Section 1 - Cylinder Block - Group 01 M11 Visually inspect the crankshaft gear journal for burrs or damage. Use crocus cloth to remove burrs. Measure the crankshaft gear inside diameter. Crankshaft Gear Bore I.D. mm 85.910 85.935 MIN MAX in 3.3823 3.3833 Measure the crankshaft gear journal outside diameter. mm 85.975 86.000 Crankshaft Gear Journal O.D. MIN MAX in 3.3848 3.3858 Installation Use a soft hammer to install the key in the crankshaft keyway.
Section 1 - Cylinder Block - Group 01 M11 Crankshaft Pulley - Cleaning and Inspection for Reuse (1-12) Page 1-41 Caution: Do not exceed the specified heating time or temperature when heating the crankshaft gear. The crankshaft gear and teeth can be damaged. Heat the gear in an oven heated to 177°C [350°F] for a minimum of 1 1/2 hours, but not more than 6 hours. Use LubriplateW No. 105, or equivalent, to lubricate the outside diameter of the crankshaft gear journal.
Connecting Rod - Cleaning and Inspection for Reuse (1-13) Page 1-42 Section 1 - Cylinder Block - Group 01 M11 Inspection Visually inspect the pulley for broken pieces, cracks, or excessive wear in the belt grooves. Replace the pulley if any of these conditions exist. Measure the pulley crankshaft pilot bore inside diameter. Crankshaft Pulley Crankshaft Pilot Bore I. D. mm in 32.05 MIN 1.2618 32.10 MAX 1.
Section 1 - Cylinder Block - Group 01 M11 Connecting Rod - Cleaning and Inspection for Reuse (1-13) Page 1-43 Inspection Visually inspect the rod and cap for damage. Replace the rod if the ‘‘I-Beam’’ is nicked or damaged. Visually inspect the connecting rod capscrew threads for damage. Visually inspect under the capscrew heads for cracks. Measure the capscrew outside diameters. Connecting Rod Capscrew O. D. mm in 12.600 MIN 0.4961 12.800 MAX 0.5039 Visually inspect the piston pin bore for damage.
Connecting Rod - Cleaning and Inspection for Reuse (1-13) Page 1-44 Section 1 - Cylinder Block - Group 01 M11 Visually inspect the bearing seating surface for nicks or burrs. If burrs cannot be removed with crocus cloth, the rod must be replaced. Measure the connecting rod piston pin bushing installed inside diameter. Connecting Rod Piston Pin Bushing I. D. (Installed) mm in 54.054 MIN 2.1281 54.099 MAX 2.1299 Caution: Use a vise with brass jaws to hold the rod.
Section 1 - Cylinder Block - Group 01 M11 Measure the connecting rod bearing bore inside diameter at 45 degrees and at 90 degrees from the parting line. Connecting Rod Bearing Bore I. D. mm in 83.975 MIN 3.3061 84.025 MAX 3.3080 If any of the three measurements are not within the specifications, the rod must be repaired or replaced. Always tag a new connecting rod with the cylinder number of the rod being replaced.
Connecting Rod - Bend and Twist Inspection (1-15) Page 1-46 Section 1 - Cylinder Block - Group 01 M11 Connecting Rod - Limits of Acceptance An indication is open if it can be seen with the naked eye in a well lighted area. Many times an open indication can be felt with a fingernail. The connecting rod must be replaced if any indications are visible in the critical areas shown. NOTE: The connecting rod must have all magnetism removed completely and cleaned thoroughly.
Section 1 - Cylinder Block - Group 01 M11 Install the piston pin mandrel, Part No. 3376693, from the mandrel set, Part No. 3376690, into the piston pin bore. Install the mandrel, Part No. 3376691, in the piston crankshaft bore and expand the mandrel. Make sure the pin on the mandrel is down and locked in position in the center of the connecting rod. Install the connecting rod into the fixture. Move the dial holder to position the contact points of the indicators on the mandrel in the piston pin bore.
Camshaft - Cleaning and Inspection for Reuse (1-16) Page 1-48 Section 1 - Cylinder Block - Group 01 M11 Alignment Inspection Install the mandrel and arbor into the connecting rod to be inspected. Install the connecting rod into the fixture. Measure the rod length and bend (alignment). mm 217.975 218.025 Connecting Rod Length MIN MAX Connecting Rod Alignment mm Bushing Installed 0.10 MAX in 8.5817 8.5836 in 0.
Section 1 - Cylinder Block - Group 01 M11 After the camshaft has been steam cleaned, do not touch the machined surfaces with bare hands. This will cause rust to form. Use clean 15W-40 oil to lubricate the camshaft. Inspection Visually inspect the valve and injector lobes for damage. NOTE: Cummins Engine Co., Inc., does not recommend repairing camshafts by grinding the valve or injector lobes. If the camshaft is damaged, it must be replaced.
Camshaft Gear - Replacement (1-17) Page 1-50 Section 1 - Cylinder Block - Group 01 M11 Measure the seven camshaft bushing journals. Camshaft Bushing Journal O. D. mm in 71.987 MIN 2.8341 72.013 MAX 2.8352 If the bushing journal outside diameters are not within specifications, the camshaft must be replaced. Camshaft Gear - Replacement (1-17) Removal Use camshaft gear puller kit, Part No. 3824106, to remove the camshaft gear from the camshaft. Install camshaft gear puller, Part No.
Section 1 - Cylinder Block - Group 01 M11 Record the size (amount of offset) and part number of the key. Record the direction the arrow on the key is pointed (toward or away from the camshaft) for future reference. Use a flat chisel and hammer to remove the camshaft key. Remove the thrust plate. Cleaning Use solvent to clean the parts and dry with compressed air. Inspection Visually inspect the camshaft nose for fretting or burrs.
Camshaft Gear - Replacement (1-17) Page 1-52 Section 1 - Cylinder Block - Group 01 M11 Measure the camshaft thrust bearing journal outside diameter. Camshaft Thrust Bearing Journal O.D. mm in 54.800 MIN 2.1575 55.200 MAX 2.1732 Measure the camshaft thrust plate inside diameter. mm 55.60 56.61 Camshaft Thrust Plate I.D. MIN MAX in 2.1890 2.2287 Measure the camshaft thrust plate thickness. Camshaft Thrust Plate Thickness mm in 8.960 MIN 0.3528 9.040 MAX 0.
Section 1 - Cylinder Block - Group 01 M11 Camshaft Gear - Replacement (1-17) Page 1-53 Measure the camshaft gear bore inside diameter. mm 46.912 46.938 Camshaft Gear bore I.D. MIN MAX in 1.8469 1.8479 Installation If the same camshaft and gear are used again, install a key with the same part number as the one that was removed. Make sure the arrow on the key is pointing in the same direction as it was when it was removed.
Camshaft - Magnetic Crack Inspection (1-18) Page 1-54 Section 1 - Cylinder Block - Group 01 M11 Caution: Do not exceed the temperature or time limits with the gear in the oven. The gear will be damaged. Put the camshaft gear into an oven heated to 235°C [450°F] for a minimum of one hour but not longer than six hours. Caution: Wear insulated gloves, Part No. 3823730, when handling heated parts. Hot parts can cause serious personal injury.
Section 1 - Cylinder Block - Group 01 M11 Use a magnetic particle testing machine to check the camshaft for cracks. Use the head shot method. Adjust the machine to 2000 ampere D.C. or rectified A.C.. Use the continuous method. Do not wet more than one-third of the camshaft at a time. Visually inspect the camshaft for cracks. Use the coil shot continuous method that is a minimum of 305 mm [12 inch]. Apply the coil shot. Amperage (Ampere Turn) MIN MAX 3600 D.C. or rectified A.C. 4000 D.C. or rectified A.C.
Camshaft - Magnetic Crack Inspection (1-18) Page 1-56 Section 1 - Cylinder Block - Group 01 M11 Subsurface indications - An indication is subsurface if, when wiped clean of magnetic particle bath, it cannot be seen with the naked eye in a well lighted area. Subsurface indications are often ‘‘voids’’ or ‘‘non-metallic inclusions’’ which are present in the raw material.
Section 1 - Cylinder Block - Group 01 M11 Camshaft or Idler Gear - Magnetic Crack Inspection (1-19) Page 1-57 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: The camshaft must have all magnetism removed completely and cleaned thoroughly. Small metal particles will cause engine damage. Remove all magnetism from the camshaft. Use solvent or steam clean the camshaft and dry with compressed air.
Camshaft or Idler Gear - Magnetic Crack Inspection (1-19) Page 1-58 Section 1 - Cylinder Block - Group 01 M11 Adjust the amperage to the specified value. Gear O.D. Ampere Turns Less than 101 mm [4 inch] 101 to 203 mm [4 to 8 inch] Greater than 203 mm [8 inch] 4000 6000 8000 NOTE: Ampere turn is an electrical current of one ampere flowing through the coil, multiplied by the number of turns in the coil. Visually inspect the gear for cracks.
Section 1 - Cylinder Block - Group 01 M11 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: The gear must have all magnetism removed completely and cleaned thoroughly. The small metal particles will cause engine damage. Remove all magnetism from the gear. Use solvent or steam to clean the gear and dry with compressed air.
Piston - Cleaning and Inspection for Reuse (1-20) Page 1-60 Section 1 - Cylinder Block - Group 01 M11 Caution: Do not use a metal brush to clean the piston. The ring grooves will be damaged. Do not use glass beads to clean the grooves. Walnut shell or plastic bead, Part No. 3822735, blasting can be used on ring grooves on the dome and crown of the piston. Use the minimum effective pressure, and do not concentrate the spray in one area for an extended period of time.
Section 1 - Cylinder Block - Group 01 M11 Piston - Cleaning and Inspection for Reuse (1-20) Page 1-61 Visually inspect the piston skirt pin bore (1) and sides (2) for cracks or damage. Do not use pistons with cracks. If the skirt is cracked, it must be replaced. Measure the piston skirt outside diameter at room temperature 21°C [70°F]. (A) Piston Skirt O.D. mm 124.939 MIN 124.983 MAX in 4.9189 4.9206 The ring groove can be inspected with a new ring and a feeler gauge.
Gear Housing - Cleaning and Inspection for Reuse (1-21) Page 1-62 Section 1 - Cylinder Block - Group 01 M11 Measure the piston pin outside diameter and length. mm 53.997 54.003 mm 101.70 102.00 Piston Pin O.D. MIN MAX Piston Pin Length MIN MAX in 2.1259 2.1261 in 4.0039 4.0157 To check the ring gap, install the piston rings in the wear area of the cylinder liner in which they will be used. Use a feeler gauge to measure the ring gap. Replace the ring if it does not meet the following specifications.
Section 1 - Cylinder Block - Group 01 M11 Gear Housing - Cleaning and Inspection for Reuse (1-21) Page 1-63 Inspection Visually inspect the gear housing for cracks or damage. Inspect the seal grooves on both sides of the housing for debris or damage. Inspect the o-ring groove at the accessory drive oil jumper gallery for cracks or damage. Use compressed air to make sure the oil jumper gallery to the accessory drive is free of any obstructions.
Gear Cover - Cleaning and Inspection for Reuse (1-22) Page 1-64 Section 1 - Cylinder Block - Group 01 M11 Gear Cover - Cleaning and Inspection for Reuse (1-22) Cleaning Use a gasket scraper to remove all gasket material. Use crocus cloth to remove burrs from the capscrew holes and gasket surface. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Steam clean the gear cover and dry with compressed air.
Section 1 - Cylinder Block - Group 01 M11 Hand Hole Cover - Cleaning and Inspection for Reuse (1-23) Page 1-65 Hand Hole Cover - Cleaning and Inspection for Reuse (1-23) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam can cause serious personal injury. Use a gasket scraper to remove all gasket material. Steam clean the covers and dry with compressed air. Inspection Visually inspect the cover for cracks or damage.
Dipstick Tube Bracket - Cleaning and Inspection for Reuse (1-24) Page 1-66 Section 1 - Cylinder Block - Group 01 M11 Inspection Visually inspect the bracket for cracks or damage. Visually inspect the bracket for flatness.
Section 2 - Cylinder Head - Group 02 M11 Page 2-1 Section 2 - Cylinder Head - Group 02 Section Contents Page Cylinder Head - Cleaning and Inspection for Reuse ........................................................................................ 2-7 Cleaning.......................................................................................................................................................... 2-7 Inspection ................................................................................
Service Tools - Cylinder Head Page 2-2 Section 2 - Cylinder Head - Group 02 M11 Service Tools - Cylinder Head The following special tools are recommended to perform procedures in Group 02. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Valve Seat Insert Tool ST-257 Cut valve seat counterbores for oversize valve seat inserts. Used with valve guide set, Part No.
Section 2 - Cylinder Head - Group 02 M11 Tool No. Service Tools - Cylinder Head Page 2-3 Tool Description Injector Sleeve Expander ST-880 Roll and seal the upper portion of the injector sleeve in the cylinder head. Injector Seat Cutter ST-884-1 Used with pilot, Part No. ST-379-2, and cutter, ST-884-3, to machine the injector sleeve seat to the proper depth to allow the specified injector protrusion through the cylinder head. Dowel Pin Extractor Remove the dowel pins from the cylinder head.
Section 2 - Cylinder Head - Group 02 M11 Tool No. Service Tools - Cylinder Head Page 2-5 Tool Description Injector Sleeve Puller 3377079 Remove the injector sleeves from the cylinder head. This tool is designed for use with an air impact wrench. Expansion Plug Driver 3376816 Install the 1.010 inch diameter expansion plugs in the cylinder head. Use with handle, Part No. 3376795. Valve Seal Driver Used to install valve seals onto the valve guides.
Cylinder Head - Exploded View Page 2-6 Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - Exploded View Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Cylinder Head Plug, Expansion Plug, Expansion Plug, Expansion Seal, O-ring Sleeve, Injector Insert, Exhaust Valve Insert, Intake Valve Guide, Valve Stem Cup Plugs Spring, Valve Valve, Intake Collet, Valve Qty. 1 2 2 8 6 6 12 12 24 2 24 12 24 Ref. No.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - General Information Page 2-7 Cylinder Head - General Information The Cylinder Head Group consists of the cylinder head, valves, valve guides, valve springs, valve seat inserts, crossheads, and the injector sleeves. The exhaust valves are manufactured from a material that is capable of operating at a higher temperature than the intake valves. The exhaust valves can be installed in the intake valve location.
Cylinder Head - Rebuild (2-02) Page 2-8 Section 2 - Cylinder Head - Group 02 M11 Inspection Visually inspect the fuel drillings and water passages for restrictions or foreign material. Remove any obstructions. Visually inspect the valves and valve springs for cracks, bent or broken valve stems, broken valve spring collets or other damage. Visually inspect the valves for indications of leakage or burning.
Section 2 - Cylinder Head - Group 02 M11 Install a wood block between the valves and head holding fixture to support the valves. Use the valve spring compressor, Part No. ST-448, the compressor threaded adapter, Part No. 3376850, and the compressor adapter, Part No. 3376851, to compress the valve springs. Use a pencil magnet to remove the valve collets. Discard the valve collets. Slowly release the pressure on the valve spring. Remove the valve spring retainer. Remove the valve spring.
Cylinder Head - Rebuild (2-02) Page 2-10 Section 2 - Cylinder Head - Group 02 M11 Remove the valve seals from the valve guides. Inspection Use clean 15W-40 oil to lubricate the injector o-rings. Install a set of injectors with new o-rings in the cylinder head. Refer to Section 0 for proper o-ring orientation. Install the injector holddown clamps and mounting capscrews. Torque Value: 75 N•m [55 ft-lb] Install a 0-160 psi pressure gauge, Part No. 3375275, to the fuel outlet fitting.
Section 2 - Cylinder Head - Group 02 M11 Remove the injectors from the cylinder head. Remove the pipe plugs, fuel passage plugs and fuel fittings from the cylinder head. Use a dent puller to remove the expansion plugs Install the cylinder head and parts in a tank of cleaning solution. NOTE: Be sure to follow the cleaning solution manufacturer’s instructions when cleaning the parts. Remove the cylinder head and parts from the cleaning tank. Use fuel passage cleaning brush, Part No.
Cylinder Head - Rebuild (2-02) Page 2-12 Section 2 - Cylinder Head - Group 02 M11 Use magnetic crack detector, Part No. ST-1166, to find cracks in the combustion face, in areas around the valve ports and the injector bores. Place the magnetizing head on the combustion face as shown, to check for cracks that run across the cylinder head. Fill the powder spray bulb one-third (1/3) full with metal powder. Spray the powder lightly onto the combustion face. Use compressed air to remove the excess metal powder.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - Rebuild (2-02) Page 2-13 Place the magnetizing head on the combustion face as shown to check for cracks that run lengthwise of the cylinder head. Repeat the procedure as outlined above. Remove all magnetism and use solvent to clean the cylinder head. Dry with compressed air. NOTE: The cylinder head must be thoroughly cleaned after using the magnetic crack detector to remove all of the iron fragments.
Cylinder Head - Rebuild (2-02) Page 2-14 Section 2 - Cylinder Head - Group 02 M11 Measure the thickness of the cylinder head. mm 99.24 100.25 Cylinder Head Thickness MIN MAX in 3.907 3.947 Measure the valve spring free height. mm 103.30 Valve Spring Free Height (A) Nominal in 4.0669 Use valve spring tester, Part No. 3375182, to measure the valve spring load at the valve spring working height. Valve Spring Load at 71.48 mm [2.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - Rebuild (2-02) Page 2-15 Visually inspect the valves for damage and the collet grooves for wear. Measure the outside diameter of the valve stem. mm 9.580 9.633 Valve Stem O.D. MIN MAX in 0.3772 0.3793 If the valves are damaged or the stems are worn smaller than the minimum specified, the valves must be replaced. Place the valve on a flat surface and measure the head thickness (1) at the outside diameter. mm 3.15 3.
Cylinder Head - Rebuild (2-02) Page 2-16 Section 2 - Cylinder Head - Group 02 M11 Measure the width of the valve seat area (1) of the valve seat inserts. mm 1.63 2.69 Valve Seat Area (Width) MIN MAX in 0.064 0.106 If the valve seat area is worn wider than the maximum specified, refer to Grind the Valve Seats following in this procedure, or Cylinder Head Valve Seat Insert - Replacement (2-04). Caution: Support the cylinder head in the Part No.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - Rebuild (2-02) Page 2-17 Valve Seats - Grinding Use valve seat grinding machine, Part No. ST-685, and valve guide arbor set, Part No. ST-804, when grinding the valve seat inserts. Install the valve guide arbor (1) in the valve guide with the arbor puller (2). Rotate the arbor to be sure that it is installed correctly. Install the valve seat grinding stone (3), Part No. 3376077, on the driver. Install the grinder unit on the arbor.
Cylinder Head - Rebuild (2-02) Page 2-18 Section 2 - Cylinder Head - Group 02 M11 After grinding the valve seats, use a 13 mm [0.50 inch] bristle brush to clean the inside diameter of the valve guides. Use solvent to clean the cylinder head. Dry with compressed air. Install a new or reconditioned valve in the valve guide. Hold the valve firmly against the valve seat insert. Use depth gauge, Part No. 3823495, to measure the valve recess in the cylinder head. mm 0.76 1.17 Valve Recess MIN MAX in 0.030 0.
Section 2 - Cylinder Head - Group 02 M11 Caution: Do not use excessive force or the seal will be damaged. Use valve seal driver, Part No. 3823946, to install the valve seals on the valve guides. Position the seal on the tool arbor. Insert the arbor into the top of the guide and tap the tool with a plastic mallet to seat the bottom of the seal against the machined step on the valve guide. Use clean 80W, or higher, gear lube with EP additives to lubricate the valve stems.
Cylinder Head Valve Guide - Replacement (2-03) Page 2-20 Section 2 - Cylinder Head - Group 02 M11 Use vacuum tester, Part No. ST-1257, with vacuum cup, Part No. 3376100, to vacuum test the valve seating. Refer to Cylinder Head - Vacuum Test Valve Seating (2-10). Cylinder Head Valve Guide - Replacement (2-03) Disassembly Use valve guide driver, Part No. 3376398, to remove the old valve guides. Use a flexible brush and solvent to clean the valve guide bores in the cylinder head. Dry with compressed air.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head Valve Guide - Replacement (2-03) Page 2-21 Measure the outside diameter of the base of the valve guide. mm 16.513 16.526 Valve Guide O.D. of Base MIN MAX in 0.6501 0.6506 Measure the outside diameter of the seal area of the valve guide. mm 14.25 14.37 Valve Guide O.D. of Seal Area MIN MAX in 0.561 0.566 Assembly Use valve guide driver (1), Part No. 3823947, to install the new valve guides.
Cylinder Head Valve Seat Insert - Replacement (2-04) Page 2-22 Section 2 - Cylinder Head - Group 02 M11 Measure the valve guide inside diameter. New Valve Guide I.D. (Installed) mm in 9.670 MIN 0.3807 9.695 MAX 0.3817 If the valve guide is not within the specifications given, the valve guide must be replaced. Cylinder Head Valve Seat Insert Replacement (2-04) Disassembly Use slide hammer assembly, Part No. 3376617, and valve seat extractor, Part No.
Section 2 - Cylinder Head - Group 02 M11 Measure the valve seat insert bore depth in the cylinder head. Insert Bore Depth (Standard Insert) mm in 9.40 MIN 0.370 9.50 MAX 0.374 If the valve seat insert bore depth does not meet the specifications given, refer to Cylinder Head Oversize Valve Seat Insert - Installation (2-05). Measure the inside diameter of the valve seat insert bore in the cylinder head. Insert Bore I.D. (Standard Insert) mm in 45.920 MIN 1.8073 45.935 MAX 1.
Cylinder Head Oversize Valve Seat Insert - Installation (2-05) Page 2-24 Section 2 - Cylinder Head - Group 02 M11 Cylinder Head Oversize Valve Seat Insert - Installation (2-05) Valve seat inserts that are oversize on both the outside diameter and thickness are available to repair cylinder heads that are worn or damaged in the valve seat insert counterbore. The insert bore depth and inside diameter of the standard and oversize valve seat inserts are listed below.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head - Valve Grinding (2-06) Page 2-25 Cylinder Head - Valve Grinding (2-06) Use Scotch-BriteW 7448, Part No. 3823258 or equivalent, to clean the valve stems. Clean the carbon deposits from the valve face and head. NOTE: The valves must be clean and free of carbon deposits before they are ground. Valves can be cleaned by the bead blasting method in the head area only. Use valve facing machine, Part No. 3376256, to grind the face of the valve.
Cylinder Head Injector Sleeve - Replacement (2-07) Page 2-26 Section 2 - Cylinder Head - Group 02 M11 Use a lead pencil to mark across the valve face, as shown. Install the valve into the valve guide. Hold the valve against the valve seat and rotate the valve at least 10 degrees. Correct contact against the valve seat will break the marks on the valve face. Install the valves in the cylinder head. Refer to Cylinder Head - Rebuild - Assembly (2-02). Use valve vacuum tester, Part No.
Section 2 - Cylinder Head - Group 02 M11 Assembly Use vegetable oil to lubricate the injector sleeve o-rings. Install the o-ring (1) in the groove of the injector sleeve bore. Use injector sleeve driver, Part No. ST-1227, to install the injector sleeve into the cylinder head. Remove the sleeve driver. Install injector sleeve holding tool, Part No. ST-1179, in the injector sleeve. Torque Value: 50 N•m [38 ft-lb] Install the injector sleeve driver.
Cylinder Head Injector Sleeve - Replacement (2-07) Page 2-28 Section 2 - Cylinder Head - Group 02 M11 Install the expander into the injector sleeve and turn the mandrel with a 1/2 inch socket and an inch pound torque wrench. Torque Value: 9 N•m [75 in-lb] Remove the expander and holding tool from the injector sleeve. Use pilot, Part No. ST-379-2, holder, Part No. ST-884-1, and injector seat cutter, ST-844-3, to cut the injector seat.
Section 2 - Cylinder Head - Group 02 M11 Remove the injectors and apply a bluing compound to the outside diameter of the injector at the injector seat area. Install the injectors into the cylinder head without the o-rings. Torque Value: 75 N•m [55 ft-lb] Remove the injectors from the cylinder head. The bluing pattern of the injector seating area (1) must be approximately 13mm [0.50 inch] from the cylinder head surface. The injector bore seating width (2) must be a minimum of 1.52mm [0.060 inch].
Cylinder Head - Pressure Test for Reuse (2-08) Page 2-30 Section 2 - Cylinder Head - Group 02 M11 Use six of the injector sleeve holding tools, Part No. ST1179. Install the capscrew (1), flat washer (2), anvil (3), Part No. ST-179-4, and mandrel (4), Part No. ST-1179-2, in each injector bore as shown. Tighten the six injector sleeve holding tool capscrews. Torque Value: 75 N•m [55 ft-lb] Connect a regulated air supply hose to test fixture plate.
Section 2 - Cylinder Head - Group 02 M11 Remove the test equipment. Use compressed air to dry the cylinder head. Assemble the cylinder head. Refer to Cylinder Head Rebuild - Assembly (2-02) Cylinder Head - Vacuum Test Valve Seating (2-09) Use valve vacuum tester, Part No. ST-1257, to inspect the seal between the valve and the valve seat. NOTE: The valve vacuum tester is not recommended for use on used heads. Refer to Procedure 7-07 in the M11 Troubleshooting and Repair Manual, Bulletin No.
Cylinder Head - Vacuum Test Valve Seating (2-09) Page 2-32 Section 2 - Cylinder Head - Group 02 M11 Move the toggle switch (1) to the ‘‘ON’’ position. Turn the vacuum control valve (2) to the ‘‘OPEN’’ position. NOTE: The vacuum control valve is in the ‘‘OPEN’’ position if the vacuum gauge needle moves clockwise. Operate the vacuum pump until the gauge indicates the specified vacuum. mm-Hg 508 685 Valve to Valve Seat Vacuum MIN MAX in-Hg 20 25 Turn the toggle switch (1) to the ‘‘OFF’’ position.
Section 2 - Cylinder Head - Group 02 M11 Cylinder Head Valves - Magnetic Crack Inspection (2-10) Page 2-33 Cylinder Head Valves - Magnetic Crack Inspection (2-10) Use the magnetic particle residual method to inspect the valves for cracks. The exhaust valves contain two types of metal, and must be inspected by the coil shot method. There will be a magnetic leakage apparent at the point where the two metals are welded together. The leakage will appear as a wide pattern of magnetic particles.
Valve Crosshead - Cleaning and Inspection for Reuse (2-11) Page 2-34 Section 2 - Cylinder Head - Group 02 M11 Valve Crosshead - Cleaning and Inspection for Reuse (2-11) Cleaning Use solvent to clean the parts. Dry with compressed air. Inspection Visually inspect the rocker lever contact pad for wear, cracks or damage. Wear in the pad contact area must not exceed 7mm [0.250 inch] in width. Measure the valve stem pocket depth from the valve stem pocket to the rocker pad face (1). mm 12.05 12.
Section 2 - Cylinder Head - Group 02 M11 Magnetize the crosshead and inspect it with residual magnaglo. Cracks will be indicated by a bright line. The primary location for cracks will be the valve stem pocket area. If cracks are found, the crosshead must be replaced. Remove all magnetism. Use solvent to clean the crossheads. Dry with compressed air.
Valve Crosshead - Magnetic Crack Inspection (2-12) Page 2-36 NOTES Section 2 - Cylinder Head - Group 02 M11
Section 3 - Rocker Levers - Group 03 M11 Page 3-1 Section 3 - Rocker Levers - Group 03 Section Contents Page Crankcase Breather (Internal) - Cleaning and Inspection............................................................................... 3-16 Rocker Housing and Cover (Automotive) - Exploded View .............................................................................. 3-4 Rocker Lever - Magnetic Crack Inspection....................................................................................
Service Tools - Rocker Levers Page 3-2 Section 3 - Rocker Levers - Group 03 M11 Service Tools - Rocker Levers The following special tools are recommended to perform procedures in Group 03. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Rocker Lever Bushing Mandrel Install and remove the rocker lever bushings in the rocker levers.
Section 3 - Rocker Levers - Group 03 M11 Rocker Levers - Exploded View Page 3-3 Rocker Levers - Exploded View Ref. No. 1 2 3 4 5 6 7 8 9 10 Description Support, Rocker Lever Clamp, Retaining Capscrew Plug, Drive Shaft, Rocker Lever Rivet Rocker Levers, Exhaust Screw, Slotted Set Nut, Adjusting Rocker Lever, Injector Qty. 2 4 8 4 2 36 3 18 18 6 Ref. No.
Exploded View Page 3-4 Section 3 - Rocker Levers - Group 03 M11 Rocker Housing and Cover (Automotive) - Exploded View Ref. No. 1 2 3 4 5 6 Description Capscrew Isolator, Noise Cover, Rocker Housing Gasket, Rocker Cover Breather Tube Seal, Grommet Qty. 16 16 1 1 1 1 Ref. No. 7 8 9 10 11 Description Capscrew Washer, Plain Capscrew Gasket, Rocker Lever Housing Housing, Rocker Lever Qty.
Section 3 - Rocker Levers - Group 03 M11 Rocker Levers - General Information Page 3-5 Rocker Levers - General Information The rocker lever group consists of the rocker lever assembly, rocker lever housing, rocker housing cover, and the crankcase breather. The rocker levers contain replaceable bushings. Both the intake and exhaust rocker levers contain blind rivets to plug the oil drilling holes in the levers.
Rocker Lever Assembly - Cleaning and Inspection for Reuse (3-01) Page 3-6 Section 3 - Rocker Levers - Group 03 M11 Use solvent to clean the parts. Dry with compressed air. Use compressed air to make sure the oil passages are not blocked. Inspection Visually inspect the rocker levers for cracks, excessive pitting or unusual wear. Refer to the Overhead Reuse Guidelines, Bulletin No. 3810388, to identify wear patterns and excessive wear.
Section 3 - Rocker Levers - Group 03 M11 Rocker Lever Assembly - Cleaning and Inspection for Reuse (3-01) Page 3-7 Visually inspect the rocker lever shafts for pitting, scoring or other damage. Measure the outside diameter of the rocker lever shafts. mm 34.837 34.864 Rocker Lever Shaft O.D. MIN MAX in 1.3715 1.3726 Refer to Overhead Reuse Guidelines, Bulletin No. 3810388, to identify wear patterns and excessive wear.
Rocker Lever Assembly - Cleaning and Inspection for Reuse (3-01) Page 3-8 Section 3 - Rocker Levers - Group 03 M11 Use clean 15W-40 oil to lubricate the threads of the adjusting screws. Install the adjusting screws into the rocker levers. Install the locknuts on the adjusting screws. NOTE: If the engine is equipped with JacobsW Brakes, a special hex head adjusting screw must be used. Install the locknut on the adjusting screw before installing the adjusting screw in the rocker lever.
Section 3 - Rocker Levers - Group 03 M11 Rocker Lever Assembly - Rebuild (3-02) Disassembly Label the rocker lever shaft assemblies ‘‘front’’ and ‘‘rear’’ when they are removed from the engine. Label the rocker levers and supports with their relative position to each other as they are removed from the shafts. The rocker lever assemblies must be installed in the same position they were removed from. Remove the rocker lever shaft capscrews (1) and retaining clamps (2).
Rocker Lever Assembly - Rebuild (3-02) Page 3-10 Section 3 - Rocker Levers - Group 03 M11 Use solvent to clean the parts. Dry with compressed air. Use compressed air to make sure the oil passages are not blocked. Inspection Visually inspect the adjusting screws and locknuts for damaged threads. Visually inspect the adjusting screws for wear on the ball end. Visually inspect the adjusting screw threads in the rocker levers for damaged threads. Visually inspect the rocker levers for loose rivets.
Section 3 - Rocker Levers - Group 03 M11 Rocker Lever Assembly - Rebuild (3-02) Page 3-11 Use crack detection developer, Part No. 3375434, to spray the rocker levers and shaft supports. Visually inspect the levers and supports. Cracks will appear as a solid bright line. Cavitation in the casting will appear as a small round mark. If cracks or cavitation are found, the part must be replaced. Use solvent to clean the serviceable levers and supports. Dry with compressed air.
Rocker Lever Assembly - Rebuild (3-02) Page 3-12 Section 3 - Rocker Levers - Group 03 M11 Visually inspect the sockets in the injector rocker levers for wear or damage. Visually inspect the valve rocker lever pads for wear, cracks or other damage. If wear, cracks or other damage is found the rocker lever(s) must be replaced. Assembly Apply a coat of cup plug sealant, Part No. 3375068, to the outside diameter of the drive plugs. Install the shaft in an arbor press.
Section 3 - Rocker Levers - Group 03 M11 Use clean 15W-40 oil to lubricate both rocker lever shafts. Install the front end support on each shaft. Install the retaining blocks and support mounting capscrews through the end supports. Install the rocker levers on the front rocker lever shaft in the correct sequence as shown. NOTE: The rocker levers must be installed so they will be in the same position in the engine as when they were removed. Install one of the two shaft center supports on the shaft.
Rocker Lever Bushing - Replacement (3-03) Page 3-14 Section 3 - Rocker Levers - Group 03 M11 Use Scotch-BriteW 7448, Part No. 3823258 or equivalent, to remove any rough edges or burrs from the bore of the rocker lever. Use solvent to clean the rocker levers. Dry with compressed air. Inspection If cracks in the rocker lever are suspected, refer to Rocker Lever - Magnetic Crack Inspection (3-04) Measure the inside diameter of the rocker lever bore. mm 36.474 36.499 Rocker Lever Bore I.D. MIN MAX in 1.
Section 3 - Rocker Levers - Group 03 M11 Rocker Lever - Magnetic Crack Inspection (3-04) Use coil magnetization with residual magnaglow to magnetize the rocker levers. Magnetize the rocker levers in a coil of 300 to 500 amperes. Visually inspect the levers for cracks. Cracks will appear as a solid bright line. Discard cracked levers. Use a demagnetizer to remove the magnetism. Use solvent to clean the rocker levers. Dry with compressed air.
Rocker Lever Cover - Cleaning and Inspection for Reuse (3-06) Page 3-16 Section 3 - Rocker Levers - Group 03 M11 Rocker Lever Cover - Cleaning and Inspection for Reuse (3-06) Cleaning Remove all gasket material from the gasket sealing surface. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam to clean the rocker lever cover. Dry with compressed air.
Section 4 - Cam Follower Assembly - Group 04 M11 Page 4-1 Section 4 - Cam Follower Assembly - Group 04 Section Contents Page Cam Follower Assembly - Cleaning and Inspection for Reuse......................................................................... Assembly ........................................................................................................................................................ Disassembly.................................................................................
Service Tools - Cam Follower Assembly Page 4-2 Section 4 - Cam Follower Assembly - Group 04 M11 Service Tools - Cam Follower Assembly The following special tools are recommended to perform procedures in Group 04. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Cup Plug Sealant Used to seal plugs in cam follower shafts. 3375068 Crack Detection Kit Inspect components for cracks.
Section 4 - Cam Follower Assembly - Group 04 M11 Cam Follower Assembly - Exploded View Page 4-3 Cam Follower Assembly - Exploded View Ref. No. 1 2 3 4 5 6 7 8 Description Lever, Injector Cam Follower Socket, Tappet Roller, Injector Cam Follower Pin, Injector Cam Follower Lever, Valve Cam Follower Roller, Valve Cam Follower Pin, Valve Cam Follower Support, Cam Follower Shaft Qty. 6 18 6 6 12 12 12 1 Ref. No.
Cam Follower Assembly - General Information Page 4-4 Section 4 - Cam Follower Assembly - Group 04 M11 Cam Follower Assembly - General Information The cam follower group consists of the injector and valve cam followers, cam follower shafts and supports, valve push tubes and injector push rods. Label or tag all of the cam follower parts with the engine cylinder number and their relative position to the other parts as they are removed from the engine.
Section 4 - Cam Follower Assembly - Group 04 M11 Clean the cam follower parts with solvent. Dry with compressed air. Inspection Visually inspect the cam followers for cracks, scoring or other damage. Refer to Camshaft Reuse Guidelines, Bulletin No. 3666052, for visual inspection criteria of cam follower rollers. Visually inspect the sockets for excessive wear.
Cam Follower Assembly (04-01) Page 4-6 Section 4 - Cam Follower Assembly - Group 04 M11 Measure the cam follower roller side clearance. mm 0.19 0.65 Roller Side Clearance MIN MAX in 0.007 0.026 If the roller side clearance is not within these specificatins, the roller must be replaced. Refer to Cam Follower Lever - Roller Replacement (4-03). Use a dial indicator to measure the cam follower roller to pin clearance. mm 0.08 0.20 Roller to Pin Clearance MIN MAX in 0.003 0.
Section 4 - Cam Follower Assembly - Group 04 M11 Visually inspect the cam follower shafts for scoring or damage. If scoring or damage is found, the cam follower shaft(s) must be replaced. Assembly Use clean 15W-40 oil to lubricate the cam follower shafts and the injector and valve cam followers. The cam follower levers, supports and shafts have established wear patterns and must be installed in the same position from which they were removed. The shaft end supports are not interchangeable.
Cam Follower Assembly - Rebuild (4-02) Page 4-8 Section 4 - Cam Follower Assembly - Group 04 M11 Cam Follower Assembly - Rebuild (4-02) The cam follower assembly consists of two shaft assemblies, (1) and (2), installed on the engine with a common center support (3). Disassembly The cam follower levers have established wear patterns and must be installed in the same position they were removed from.
Section 4 - Cam Follower Assembly - Group 04 M11 Drill a 1/8 inch hole in the plugs and use a standard dent puller to remove the plugs from the shafts. Clean the cam follower parts with solvent. Dry with compressed air. Inspection Visually inspect the cam follower shafts for scoring or damage. Measure the outside diameter of the cam follower shaft journals. mm 33.991 34.009 Shaft Journals O.D. MIN MAX in 1.3382 1.
Cam Follower Assembly - Rebuild (4-02) Page 4-10 Section 4 - Cam Follower Assembly - Group 04 M11 Visually inspect the cam follower levers for cracks or damage. Measure the inside diameter of the shaft bore in the cam follower levers. mm 34.086 34.116 Shaft Bore I.D. MIN MAX in 1.3420 1.3431 If the cam follower lever is damaged or the shaft bore is not within the maximum specification, the lever(s) must be replaced. Measure the cam follower roller side clearance. mm 0.19 0.
Section 4 - Cam Follower Assembly - Group 04 M11 Use the crack detection kit, Part No. 3375432, to inspect the cam follower levers and supports for cracks. Use the crack detection cleaner, Part No. 3375433, to clean the levers and supports. Dry with compressed air. Use the crack detection penetrant, Part No. 3375435, to spray the levers and supports. NOTE: Do not dry the penetrant with compressed air. Allow the penetrant to dry for 15 minutes. Remove the excess penetrant with a dry cloth.
Cam Follower Assembly - Rebuild (4-02) Page 4-12 Section 4 - Cam Follower Assembly - Group 04 M11 Assembly Apply a coat of cup plug sealant, Part No. 3375068, to the outside diameter of the shaft plugs. Install the shaft in an arbor press. NOTE: Make sure the end of the shaft is supported. Press the plug into the shaft until it is level with the end of the shaft. Use clean 15W-40 oil to check the oil flow through the cam followers.
Section 4 - Cam Follower Assembly - Group 04 M11 The cam follower levers, supports, and shafts have established wear patterns and must be installed in the same position from which they were removed. The shaft end supports are not interchangeable. Install the end support (1) on the shaft. Install the valve cam follower (2), injector cam follower (3), valve cam follower (4), and shaft support (5) on the shaft. Install the remaining cam followers and supports in the same sequence.
Cam Follower Lever - Roller Replacement (4-03) Page 4-14 Section 4 - Cam Follower Assembly - Group 04 M11 Inspection Use the magnetic crack inspection method to inspect the cam follower levers for cracks. Refer to Cam Follower Magnetic Crack Inspection (Roller Removed) (4-04) Measure the inside diameter of cam follower lever roller pin bore. mm 19.043 19.055 Roller Pin Bore I.D. MIN MAX in 0.7497 0.7502 Measure the inside diameter of the new cam follower lever roller bore. mm 19.151 19.
Section 4 - Cam Follower Assembly - Group 04 M11 Measure the outside diameter of the new roller pin. mm 19.065 19.073 Roller Pin O.D. MIN MAX in 0.7506 0.7509 Assembly The roller pin must be installed correctly to be sure the cam follower roller and roller pin are supplied with oil. Inspect the new roller pin as shown to determine the oil feed passage (1) and the alignment hole (2) locations. The oil feed passage is approximately three times as deep as the alignment hole.
Cam Follower Lever - Roller Replacement (4-03) Page 4-16 Section 4 - Cam Follower Assembly - Group 04 M11 Install the roller in the cam follower lever. Caution: Use the largest feeler gauge that will fit between the roller and the lever to prevent leg deflection when installing the roller pin. This will reduce shaving of the bronze roller pin and prevent leg breakage. Install a feeler gauge between the roller and the leg of the lever.
Section 4 - Cam Follower Assembly - Group 04 M11 Measure the cam follower roller side clearance. mm 0.19 0.65 Roller Side Clearance MIN MAX in 0.007 0.026 If the roller does not rotate freely or the side clearance does not meet the specifications, the cam follower lever must be rebuilt again. Use a dial indicator to measure the cam follower roller to pin clearance. mm 0.08 0.20 Roller to Pin Clearance MIN MAX in 0.003 0.
Cam Follower Lever Socket - Replacement (Roller Removed) (4-05) Section 4 - Cam Follower Assembly - Group 04 Page 4-18 M11 Cam Follower Lever Socket - Replacement (Roller Removed) (4-05) Disassembly Install the cam follower lever in an arbor press, as shown. Press the socket from the lever. NOTE: If a socket is replaced, the mating push rod must also be replaced. Use solvent to clean the cam follower lever. Dry with compressed air. Use compressed air to blow any debris from the oil passages.
Section 4 - Cam Follower Assembly - Group 04 M11 Assembly Install the cam follower lever in an arbor press, as shown. Use a used push rod to press the new socket into the lever. Visually inspect the bottom side of the socket through the oil passage hole in the lever. The socket must be completely seated. Push Rods and Tubes - Cleaning and Inspection for Reuse (4-06) Inspection Use solvent to clean the push rods and push tubes. Dry with compressed air.
Push Rods and Tubes - Cleaning and Inspection (4-06) Page 4-20 NOTES Section 4 - Cam Follower Assembly - Group 04 M11
Section 5 - Fuel System - Group 05 M11 Page 5-1 Section 5 - Fuel System - Group 05 Section Contents Page Fuel Pump - Cleaning and Inspection for Reuse .............................................................................................. 5-2 Cleaning.......................................................................................................................................................... 5-2 Inspection ..................................................................................
Fuel Pump - General Information Page 5-2 Section 5 - Fuel System - Group 05 M11 Fuel Pump - General Information NOTE: Warranty repairs are not to be made to the fuel pump unless the work is performed in a shop meeting all requirements established by Cummins Engine Company, Inc. to accurately calibrate, test and repair the fuel systems on Cummins engines.
Section 5 - Fuel System - Group 05 M11 Inspection Visually inspect the fuel pump body and front support for cracks or other damage. Visually inspect the fuel pump assembly for damaged capscrews and damaged or loose fuel fittings. Visually inspect the drive coupling lugs for excessive wear or damage. Visually inspect the drive coupling spider for cracks or other damage. Visually inspect the front support pilot to make sure the pilot is continuous without cracks or gaps.
Fuel Pump - Rebuild (5-02) Page 5-4 Section 5 - Fuel System - Group 05 M11 Visually inspect the fuel pump shutoff valve for loose or damaged electrical terminals. Torque Value: 3 N•m [25 in-lb] Fuel Pump - Rebuild (5-02) Disassembly Remove the snap ring and the drive coupling. NOTE: The coupling is a slip fit D shape coupling. Remove the fuel inlet connection and pulsation damper, or the filter head damper assembly. Discard the rubber o-rings.
Section 5 - Fuel System - Group 05 M11 Remove the shutoff valve, discard the o-ring. Remove the filter screen cap and the filter screen. Press both of the drive shaft seals out of the support. Press the seals in the direction of the drive coupling. Use seal removal tool, Part No. 3823239. Remove the four capscrews that hold the gear cover to the gear housing. Install two capscrews that are 100 mm [4 inches] long into the gear pump cover.
Fuel Pump - Rebuild (5-02) Page 5-6 Section 5 - Fuel System - Group 05 M11 Clamp the gear pump housing in a vise. Gently tap alternately on the head of the capscrews to loosen the gear pump cover. Remove the gear pump cover, drive gear and the idler gear. Discard the gasket. Remove the regulator retaining snap ring. Remove the regulator plunger and the spring from the gear pump cover. Inspection The gear pump components must be inspected for damage and wear.
Section 5 - Fuel System - Group 05 M11 Fuel Pump - Rebuild (5-02) Page 5-7 Check the gear pump shafts. Discard them if they are damaged. Replace the shaft if the bearing surface is worn smaller than 12.695 mm [0.4998 in] in diameter. Replace the drive shaft if there is measurable wear on the sealing surface. NOTE: If the shaft feels rough when a fingernail is moved across the sealing surface, replace the shaft. Visually inspect the gears for damage and replace them if needed. Check the gear width.
Fuel Pump - Rebuild (5-02) Page 5-8 Section 5 - Fuel System - Group 05 M11 Inspect the regulator spring for damage and replace if needed. The spring must meet the specifications as shown in the table. Regulator Spring Specifications Wire Free Part Dia. No. Load Length Length No. mm [inch] Coils Kg [lb] mm [inch] mm [inch] 3068424 1.52 [.060] 5.25 4.0 [8.9] 16.0 [.631] 21.16 [.8337] Check and clean all of the flow passages in the cover, housing and gears. Dry with compressed air.
Section 5 - Fuel System - Group 05 M11 Install the regulator spring on the regulator plunger. Install the regulator assembly in the gear pump cover. Install the plunger retaining ring. Make sure the retaining ring is securely located in the snap ring groove of the regulator plunger. Lubricate with clean engine oil and install the shafts and the gears into the body. Make sure the parts are clean. Position a new gasket on the dowel pins. Install the cover on the body. Align the location notches.
Fuel Pump - Rebuild (5-02) Page 5-10 Section 5 - Fuel System - Group 05 M11 Align the cover and body with the dowels. Tighten the four cover to body capscrews evenly. Check that the pump rotates freely with finger pressure. Torque Value: 18 N•m mm 0.023 0.038 [13 ft-lb] Shaft End Clearance MIN MAX in 0.0009 0.0015 NOTE: Gaskets are available in 0.51 mm [0.0020 inch] (red) and 0.038 mm [0.0015 inch] (purple).
Section 5 - Fuel System - Group 05 M11 Remove the two damper mounting capscrews. Install the damper assembly with a new o-ring on the gear pump. Tighten the capscrews. Torque Value: 18 N•m [13 ft-lb] NOTE: If a fuel filter and damper assembly are mounted on the gear pump, remove the four mounting capscrews. Install the fuel inlet connection. Be careful not to let dirt enter the pump. Check for free rotation of the gear pump. Fuel Damper - Disassembly and Inspection Remove the housing from the cover.
Fuel Pump - Rebuild (5-02) Page 5-12 Section 5 - Fuel System - Group 05 M11 Fuel Shutoff Valve - Cleaning and Inspection Clean all of the parts except the coil assembly in mineral spirits. NOTE: Do not get the coil wet with solvent. Clean the coil with a dry cloth. Polish the coil face with a 200 grit emery cloth on a flat surface. Visually check the valve disc, valve seat, and actuator disc for dirt, metal parts, bonding separation, corrosion, cracks or wear. Replace if necessary.
Section 5 - Fuel System - Group 05 M11 Fuel Pump - Rebuild (5-02) Page 5-13 Fuel Supply Pump - Test Description of Test The fuel supply pump must pass the specification tests. The self-priming capacity must be high enough to start the engine. The operating flow must be correct. The supply pressure must be regulated for fault-free fuel injector performance. The safety shutoff valve must stop the fuel flow at excessive pressures. Installation Install the supply pump assembly on the test stand, Part No.
Fuel Pump - Rebuild (5-02) Page 5-14 Section 5 - Fuel System - Group 05 M11 Disconnect the voltage from the shutoff valve. Check the outlet for leakage. No leakage must be evident. NOTE: Do not operate the pump at 0 flow for more than 1 minute.
Section 6 - Injectors and Fuel Lines - Group 06 M11 Page 6-1 Section 6 - Injectors and Fuel Lines - Group 06 Section Contents Page Fuel Tubes, Fittings and Mounting Parts - Cleaning and Inspection for Reuse............................................... 6-6 Inspection ....................................................................................................................................................... 6-6 Injector - CELECT™ - Exploded View...................................................
Injector - CELECT™ - Exploded View Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06 M11 Injector - CELECT™ - Exploded View Ref. No. 1. 2. 3. 4. 5. 6. 7. 8. Description Seal, O-ring Top (Red) Seal, Oring Middle (White) Seal, Oring Bottom (Blue) Drain, Fuel Solenoid Valve Connection, Wire Harness Coupling Retainer Link, Injector Qty. 1 1 1 1 1 1 1 1 Ref. No. 9. 10. 11. 12. 13. 14. 15.
Section 6 - Injectors and Fuel Lines - Group 06 M11 Injectors - General Information Page 6-3 Injectors - General Information The CELECT™ system allows an engine to have variable timing, depending on load, engine temperature, environmental conditions, etc. The timing and fueling rate are controlled electronically. The injectors used in CELECT™ engines are electronically controlled, closed nozzle unit injectors.
Injectors - Cleaning and Inspection for Reuse (6-01) Page 6-4 Section 6 - Injectors and Fuel Lines - Group 06 M11 Injectors - Cleaning and Inspection for Reuse (6-01) Caution: Do not remove the injector plungers or allow the plungers to fall out of the injector body. Injector plungers and barrels have a very precise fit and are damaged easily. Remove and discard the three injector o-rings. Use a clean, lint free cloth to clean the exterior of the injectors.
Section 6 - Injectors and Fuel Lines - Group 06 M11 Visually inspect the orifice screen for damage, contamination or metal particles. If damaged or contaminated parts are found, the injectors must be replaced. NOTE: Some CELECT™ injectors do not contain an orifice screen. Injectors - Rebuild (6-02) CELECT™ injectors cannot presently be rebuilt. They must be replaced with new injectors. Injectors - Calibration (6-03) NOTE: CELECT™ injectors do not require flow calibration.
Fuel Tubes, Fittings and Mounting Parts (6-04) Page 6-6 Section 6 - Injectors and Fuel Lines - Group 06 M11 Fuel Tubes, Fittings and Mounting Parts - Cleaning and Inspection for Reuse (6-04) Use solvent to clean the fuel tubes, fittings and parts. Dry with compressed air. Inspection Visually inspect the fuel tubes for cracks or locations where the tubing is crushed. Do not attempt to repair fuel tubing. Visually inspect the injector hold down clamps for cracks or other damage.
Section 7 - Lubricating Oil System - Group 07 M11 Page 7-1 Section 7 - Lubricating Oil System - Group 07 Section Contents Page Lubricating Oil Cooler - Cleaning and Inspection for Reuse .......................................................................... Cleaning........................................................................................................................................................ Inspection..............................................................................
Service Tools - Lubricating Oil System Page 7-2 Section 7 - Lubricating Oil System - Group 07 M11 Service Tools - Lubricating Oil System The following special tools are recommended to perform procedures in Group 07. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Lubricating Oil Pump Gear Puller Remove the lubricating oil pump main drive gear.
Section 7 - Lubricating Oil System - Group 07 M11 Exploded View Page 7-3 Lubricating Oil System - Exploded View Ref. No. Description Qty. Ref. No. Description Qty.
Lubricating Oil System - Exploded View Page 7-4 Ref. No. Description Section 7 - Lubricating Oil System - Group 07 M11 Qty. Ref. No. Description Qty.
Section 7 - Lubricating Oil System - Group 07 M11 Lubricating Oil Pan (07-01) Page 7-5 Lubricating Oil System - General Information The lubricating oil system group consists of the oil pan, the oil pan transfer tube, the oil dipstick and tube, the oil filter head, the oil cooler and the lubricating oil pump. Service replacement oil dipsticks do not have the high and low oil level marks indicated on the dipstick. The dipstick must be calibrated after the engine is installed in the chassis.
Lubricating Oil Pan Transfer Tube (07-02) Page 7-6 Section 7 - Lubricating Oil System - Group 07 M11 Visually inspect the threaded holes for damage. Damaged threads can be chased with the following taps. Oil Pan Threaded Holes Thread Location Tap Size Temperature Gauge 3/8 in. NPTF Oil Sump Heater 1-18 NS-3B Oil Drain 1 in. NPTF NOTE: If the oil pan is cracked or damaged, or if the threaded holes cannot be repaired with the taps listed above, the oil pan must be replaced.
Section 7 - Lubricating Oil System - Group 07 M11 Lubricating Oil Dipstick and Dipstick Tube - Cleaning and Inspection for Reuse (7-03) Cleaning Remove all gasket material from the gasket sealing surface. Use solvent to clean the dipstick and filler tube assembly. Dry with compressed air. Inspection Visually inspect the dipstick tube, filler tube and hand hole cover for cracks or damage. Visually inspect the dipstick tube angle.
Lubricating Oil Filter Head (7-05) Page 7-8 Section 7 - Lubricating Oil System - Group 07 M11 Install the dipstick in the dipstick tube. Add enough clean 15W-40 oil to fill the oil pan to the specified ‘‘High’’ oil pan capacity level. Refer to the preceding oil pan capacity table for the oil required. Remove the dipstick and scribe a line across the dipstick. Mark the ‘‘High’’ oil level with an ‘‘H’’.
Section 7 - Lubricating Oil System - Group 07 M11 Inspection Visually inspect the filter head for cracks or other damage. If cracks or damage is found, the filter head must be replaced. Lubricating Oil Filter Head - Rebuild (7-06) Disassembly Using snap ring pliers, remove the snap ring in the thermostat bore. Remove the oil thermostat. Caution: To avoid personal injury, use care while removing the bypass valve. The valve spring is under compression. Wear face and eye protection.
Lubricating Oil Filter Head - Rebuild (7-06) Page 7-10 Section 7 - Lubricating Oil System - Group 07 M11 Visually inspect the filter head for cracks or other damage. If cracks or damage is found, the filter head must be replaced. Visually inspect the thermostat and bypass valve for cracks or other damage. If the bypass valve is damaged, it must be replaced. Suspend the thermostat and a 116°C [240°F] thermometer in a container of new lubricating oil.
Section 7 - Lubricating Oil System - Group 07 M11 Use valve spring tester, Part No. 3375182, to inspect the operating condition of the bypass valve spring. Spring Specifications (Free Length) mm in 37.68 MIN 1.483 38.52 MAX 1.517 Spring Specifications at 29.65 mm [1.167 in] Load N lbf 110.1 MIN 24.751 121.7 MAX 27.359 If damaged parts are found, or the bypass spring is not within the specifications given, the parts must be replaced. Assembly Install the bypass valve into the filter head.
Lubricating Oil Cooler (7-07) Page 7-12 Section 7 - Lubricating Oil System - Group 07 M11 Using snap ring pliers, install the snap ring into the groove inside the bore. Install the following fittings: • Turbocharger oil supply fitting (1) Torque Value: 12 N•m [105 in-lb] • JacobsT brake supply fitting (2) Torque Value: 12 N•m [105 in-lb] • CompuchekT fitting (3).
Section 7 - Lubricating Oil System - Group 07 M11 Use the lubricating oil cooler pressure test kit, Part No. 3376861, to seal the oil passage. Install one of the pressure test plates on one of the oil passage openings. Use air pressure to blow the moisture from inside the oil passages. Use a cooling system cleaner attached to the coolant outlet side of the housing to flush the coolant passages. If the oil or coolant passages are contaminated by foriegn material, the oil cooler must be replaced.
Lubricating Oil Pump (7-08) Page 7-14 Section 7 - Lubricating Oil System - Group 07 M11 Remove the oil cooler from the tank of water. Remove the pressure test equipment. Use compressed air to dry the oil cooler. Cover all of the openings with tape to prevent dirt from entering the element when the oil cooler is not in use. Lubricating Oil Pump - Cleaning and Inspection for Reuse (7-08) Cleaning Remove the two sealing o-rings. Discard the o-rings. Use solvent to clean the oil pump. Dry with compressed air.
Section 7 - Lubricating Oil System - Group 07 M11 Measure the drive shaft end clearance in two locations 90 degrees apart. mm 0.064 0.269 Shaft End Clearance MIN MAX in 0.0025 0.0106 If the main drive gear does not turn freely by hand, cracked or broken gear teeth are found, or the shaft end clearance is not within the specifications given, the oil pump must be disassembled for further inspection. Disassembly Use the lubricating oil pump gear puller, Part No. 3375082, to remove the main drive gear.
Lubricating Oil Pump (7-08) Page 7-16 Section 7 - Lubricating Oil System - Group 07 M11 Use solvent to clean the oil pump parts. Dry with compressed air. Inspection Visually inspect the gear pockets in the pump body for excessive wear or scoring. If excessive wear or scoring is found, the oil pump must be replaced. Caution: To avoid oil pump failure and engine damage, do not attempt to drill and ream the oil pump body and cover plate.
Section 7 - Lubricating Oil System - Group 07 M11 Measure the outside diameter of the oil pump gear shafts. mm 18.669 18.681 Gear Shafts O.D. MIN MAX in 0.7350 0.7355 If the gear shafts are worn beyond the minimum limit specified, the shaft(s) must be replaced. Measure the inside diameter of the drive gear bore. mm 18.600 18.625 Drive Gear Bore I.D. MIN MAX in 0.7323 0.7333 If the drive gear bore is worn beyond the maximum limit, the drive gear must be replaced.
Lubricating Oil Pump (7-08) Page 7-18 Section 7 - Lubricating Oil System - Group 07 M11 Measure the drive gear to pump body clearance. mm 9.50 12.00 Gear to Body Clearance MIN MAX in 0.37 0.47 Use clean 15W-40 oil to lubricate the driven gear and shaft. Install the driven gear and shaft into the oil pump body. Align the dowel pins in the body with the locating holes in the cover. Install the rear cover plate and the four hex head capscrews. Alternately tighten the four hex head capscrews.
Section 7 - Lubricating Oil System - Group 07 M11 Lubricating Oil Pump - Rebuild (7-09) Caution: The lubricating oil pump body cannot be drilled and reamed due to the highly precise and sophisticated drilling and reaming required. Attempting to rebuild the oil pump can cause oil pump failure and future engine damage.
Lubricating Oil Pump - Rebuild (7-09) Page 7-20 Section 7 - Lubricating Oil System - Group 07 M11 NOTES
Section 8 - Cooling System - Group 08 M11 Page 8-1 Section 8 - Cooling System - Group 08 Section Contents Page Fan Hub - Cleaning and Inspection for Reuse ................................................................................................ 8-23 Cleaning........................................................................................................................................................ 8-23 Inspection.............................................................................
Service Tools - Cooling System Page 8-2 Section 8 - Cooling System - Group 08 M11 Service Tools - Cooling System The following special tools are recommended to perform procedures in Group 08. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Water Pump Bearing Mandrel Install the water pump bearing on the shaft.
Section 8 - Cooling System - Group 08 M11 Tool No. Service Tools - Cooling System Page 8-3 Tool Description Bearing Driver Install the bearing races in the fan idler pulley. 3375696 Water Pump Oil Seal Driver Install the water pump oil seal in the water pump body. 3376139 Water Pump Oil Seal Expander Install the water pump shaft assembly into the water pump body. 3376387 Water Pump Impeller Puller Kit 3376542 Remove or install the water pump impeller. The kit consists of: spacer pin, Part No.
Water Pump Assembly - Exploded View Page 8-4 Section 8 - Cooling System - Group 08 M11 Water Pump Assembly - Exploded View Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Seal, O-ring Gasket, Connection Bearing, Ball Seal, O-ring Ring, Retaining Seal, Water Pump Ring, Retaining Seal, Oil Cover, Water Pump Impeller, Water Pump Gear, Water Pump Body, Water Pump Seal, O-ring Capscrew Plug, Pipe Qty. 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 Ref. No.
Section 8 - Cooling System - Group 08 M11 Fan Hub - Exploded View Page 8-5 Fan Hub - Exploded View Ref. No. 1 2 3 4 5 6 Description Spacer, Bearing (Small) Ring, Retaining Bearing, Roller Seal, Grease Shaft, Fan Hub Flange Qty. 1 1 2 1 1 1 Ref. No. 7 8 9 10 11 Description Washer, Plain Hub, Fan Spacer, Bearing (Large) Cover, Fan Hub Screw, Hexagon Head Qty.
Fan Idler Pulley and Bracket - Exploded View Page 8-6 Section 8 - Cooling System - Group 08 M11 Fan Idler Pulley and Bracket - Exploded View Ref. No. 1 2 3 4 5 Description Plate Cover Seal, O-ring Capscrew Washer, Plain Bearing, Roller Qty. 1 1 1 1 1 Ref. No. 6 7 8 9 10 Description Pulley, Idler Seal, Oil Shaft, Idler Washer, Plain Nut Qty.
Section 8 - Cooling System - Group 08 M11 Water Pump Assembly - General Information Page 8-7 Water Pump Assembly - General Information The M11 engine water pump is a centrifugal type pump with a phenolic impeller. The water pump is gear driven from an idler gear in the front gear train. The water pump contains an oil seal and a unitized water seal. The water pump bearing, gear and shaft receive lubrication from engine oil in the front gear train. The M11 engine uses both metric and U.S.
Water Pump - Cleaning and Inspection for Reuse (8-01) Page 8-8 Section 8 - Cooling System - Group 08 M11 Water Pump - Cleaning and Inspection for Reuse (8-01) Cleaning Remove the o-ring and clean surface (1). Use Scotch-BriteT 7448, Part No. 3823258, to clean surface (2). Visually inspect the water pump weep hole for indication of leakage. NOTE: A streak or chemical buildup at the weep hole is not justification for water pump replacement.
Section 8 - Cooling System - Group 08 M11 Water Pump - Rebuild (8-02) Disassembly Install the water pump in a vise with brass jaws with the inlet cover facing up. Remove the three capscrews. Use a mallet to loosen the cover. Remove the inlet cover from the water pump body. Remove the o-ring from the cover. Discard the o-ring. Use the water pump impeller puller kit, Part No. 3376542, to remove the impeller. Install the spacer pin, Part No. 3822296, into the bore of the water pump impeller.
Water Pump - Rebuild (8-02) Page 8-10 Section 8 - Cooling System - Group 08 M11 Install the puller halves, Part No. 3376549, on the threaded sleeve assembly. Install the compression sleeve, Part No. 3376545, over the two puller halves. Hold the puller sleeve with an adjustable wrench. Turn the pressure screw clockwise to remove the impeller. Caution: The retainer ring will be bent or broken if it is removed before the bearing is removed from the shaft.
Section 8 - Cooling System - Group 08 M11 Install the water pump in an arbor press with the front mounting surface facing down. Caution: To avoid damage to the water pump shaft, do not allow the shaft assembly to fall when pushed from the water pump body. Press the shaft assembly from the water pump body. Caution: To prevent future water pump failure, do not damage the water seal bore when removing the water seal. Install the water pump body on a bench with the front mounting surface facing up.
Water Pump - Rebuild (8-02) Page 8-12 Section 8 - Cooling System - Group 08 M11 Install the water pump shaft assembly in a vise with brass jaws. Use a pair of long nose angle snap ring pliers to remove the rear bearing retainer ring from the shaft. Install a section of pipe (3-1/2 inch O.D. x 3 inch I.D. x 3-1/2 inch Length) in an arbor press to support the bearing separator.
Section 8 - Cooling System - Group 08 M11 NOTE: Be sure the gear surface and not the shoulder of the shaft is resting on the arbor press. Install the shaft and gear in an arbor press with the largest outside diameter end of the shaft up. Caution: Do not allow the shaft to fall when pressed from the gear. Damage to the shaft or personal injury can occur. Press the shaft from the gear. Cleaning Use Scotch-BriteT 7448, Part No.
Water Pump - Rebuild (8-02) Page 8-14 Section 8 - Cooling System - Group 08 M11 Inspection If the part being inspected does not meet the specifications given, or is damaged and no alternative is given, the part must be replaced. Visually inspect the water pump body for cracks, porosity or excessive corrosion. Measure the water pump body bearing bore inside diameter. Water Pump Body Bearing Bore I.D. mm in 51.996 MIN 2.0471 52.011 MAX 2.0477 Measure the water seal bore inside diameter (1).
Section 8 - Cooling System - Group 08 M11 Water Pump - Rebuild (8-02) Page 8-15 Measure the water pump impeller bore inside diameter. mm 15.339 15.365 Impeller Bore I.D. MIN MAX in 0.6039 0.6049 Visually inspect the water pump drive gear for broken teeth, cracks or excessive or uneven tooth wear. Measure the water pump drive gear bore inside diameter. mm 33.900 33.925 Drive Gear Bore I.D. MIN MAX in 1.3346 1.
Water Pump - Rebuild (8-02) Page 8-16 Section 8 - Cooling System - Group 08 M11 Measure the water pump shaft journal outside diameters. Point 1 2 3 4 Point 5 6 7 8 Shaft Journals O.D. mm 15.389 MIN 15.402 MAX 15.897 MIN 15.910 MAX 24.999 MIN 25.009 MAX 24.999 MIN 25.009 MAX in 0.6059 0.6064 0.6259 0.6264 0.9842 0.9846 0.9842 0.9846 Shaft Journals O.D. (Cont’d.) mm 33.951 MIN 33.976 MAX 29.987 MIN 30.000 MAX 27.975 MIN 28.025 MAX 27.887 MIN 27.900 MAX in. 1.3366 1.3376 1.1806 1.1811 1.1014 1.1033 1.
Section 8 - Cooling System - Group 08 M11 Visually inspect the bearing retainer rings for nicks or cracks. Assembly Use clean 15W-40 oil to lubricate the drive gear bore and the shaft. Caution: The chamfered side of the drive gear bore must be installed toward the large diameter end of the shaft to prevent damage to the gear when the water pump is installed on the engine. Install the gear in an arbor press with the chamfered side of the gear bore facing up.
Water Pump - Rebuild (8-02) Page 8-18 Section 8 - Cooling System - Group 08 M11 Use the water pump gear mandrel, Part No. 3823851, to press the shaft into the gear. NOTE: Press the shaft through until the tool contacts the gear surface. Caution: To prevent future water pump damage, the beveled side of the retainer ring must be installed toward the drive gear. Install the front bearing to water pump body retainer ring on the shaft. Use clean 15W-40 oil to lubricate the bearing and shaft bearing journal.
Section 8 - Cooling System - Group 08 M11 The flat side of the retainer ring must be installed toward the bearing. Use a pair of snap ring pliers to install the bearing retainer ring into the groove on the shaft. The sealing lip of the oil seal must be installed toward the seal driver. Install the oil seal on the water pump oil seal driver, Part No. 3376139. Install the water pump body in an arbor press with the oil seal bore (water pump mounting surface) facing up.
Water Pump - Rebuild (8-02) Page 8-20 Section 8 - Cooling System - Group 08 M11 Install the water pump body in an arbor press with the front mounting surface facing up. Caution: To avoid deformation of the seal lip and water pump leakage, water pump oil seal expander, Part No. 3376387, must be used when installing the shaft assembly. Press the shaft assembly and oil seal expander into the water pump body. Remove the oil seal expander.
Section 8 - Cooling System - Group 08 M11 Water Pump - Rebuild (8-02) Page 8-21 Caution: The use of any tool other than Part No. 3823815 can result in seal damage. Use the water pump seal driver, Part No. 3823815, to press the seal into the water pump body. Apply one drop of Loctite 290Y, Part No. 3823682 or equivalent, to the joint between the water pump shaft and the water pump seal. Install the water pump body in an arbor press with the impeller end of the shaft facing up.
Water Pump - Rebuild (8-02) Page 8-22 Section 8 - Cooling System - Group 08 M11 Install the new o-ring on the water inlet cover. Use clean vegetable oil to lubricate the o-ring. Install the water inlet cover on the water pump body. Install three (M10-1.50 x 25) capscrews in the water pump body. Torque Value: 47 N•m [35 ft-lb] Turn the water pump shaft by hand to inspect the bearings and impeller for freedom of rotation.
Section 8 - Cooling System - Group 08 M11 Fan Hub - Cleaning and Inspection for Reuse (8-03) Page 8-23 Fan Hub - Cleaning and Inspection for Reuse (8-03) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam to clean the fan hub exterior. Dry with compressed air. Inspection Visually inspect the fan hub for indication of oil seal leakage.
Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-24 Section 8 - Cooling System - Group 08 M11 Loosen the vise and turn the fan hub assembly over so the back side of the assembly is facing up. Insert a screwdriver blade under the cover flange and pry the cover out of the fan hub. Save the cover for reuse. Caution: The shaft will be damaged if the rear bearing inner race is not supported when removing the shaft. Use disassembly pot, Part No. 3823380, to support the bearing inner race.
Section 8 - Cooling System - Group 08 M11 Remove the front bearing. Use a punch and hammer to remove the rear bearing outer race. NOTE: Use care not to damage the inside bore of the hub as the bearing race is removed. Turn the hub over in the vise so the back side is facing up. NOTE: Use care not to damage the inside bore of the hub when removing the race. Use a hammer and punch to remove the front bearing outer race and large bearing spacer. NOTE: Inspect the bearing retaining ring.
Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-26 Section 8 - Cooling System - Group 08 M11 Inspection Visually check the shaft for grooves, scoring, cracks or any other types of damage. NOTE: When removing flaws with Scotch-BriteT or other material, the shaft O.D. specifications must be maintained, or the shaft must be replaced. Use Scotch-BriteT 7448, Part No. 3823258, or equivalent, to remove any minor flaws from the shaft. Use solvent to clean the shaft. Dry with compressed air.
Section 8 - Cooling System - Group 08 M11 Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-27 NOTE: When removing nicks or scratches from the hub, the inside diameter must be maintained, or the hub must be replaced. Use Scotch-BriteT 7448, Part No. 3823258 or equivalent, to remove any minor damage from the hub bore. Use solvent to clean the hub and dry with compressed air. Measure the inside diameter of the hub bearing bores. mm 65.038 65.076 Hub Bearing Bore I.D. MIN MAX in 2.5605 2.
Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-28 Section 8 - Cooling System - Group 08 M11 Visually check the grease seal contact area on the flange. The grease seal contact area must not be grooved more than 0.25 mm [0.010 inch] deep on the flange. If the groove is deeper than specified, the flange must be replaced. Measure the outside diameter (1) and inside diamter (2) of the flange. Point 1 2 Flange O.D. and I.D. mm 48.975 MIN 49.000 MAX 34.849 MIN 34.875 MAX in 1.9281 1.9291 1.3720 1.
Section 8 - Cooling System - Group 08 M11 With the large inside diameter of the bearing race facing up, use the small end of bearing driver, Part No. 3823379, to press a new front bearing race into the hub until it contacts the bearing spacer. Turn the fan hub over and support the front bearing race with disassembly pot, Part No. 3823380. With the large inside diameter of the bearing race facing up, use bearing driver, Part No.
Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-30 Section 8 - Cooling System - Group 08 M11 Use the small end of the bearing driver, Part No. 3823379, to press the spacer and bearing onto the shaft until it contacts the shaft shoulder. If the shaft is shorter than 95.2 mm [3.75 inch], support the shaft with spacer, Part No. 217008 or equivalent. With the tapered (fan mounting) end of the fan hub facing up, place the hub over the shaft and bearing assembly.
Section 8 - Cooling System - Group 08 M11 Use the small end of bearing driver, Part No. 3823379, to press the front bearing onto the shaft until the inner race of the bearing contacts the bearing spacer. Caution: Do not lubricate the grease seal. The seal must be installed with the lip of the seal clean and dry to provide a proper sealing surface and prevent hub damage. Make sure the seal installation tool and flange are clean and dry when the fan hub is assembled.
Fan Hub (Belt Driven) - Rebuild (8-04) Page 8-32 Section 8 - Cooling System - Group 08 M11 Measure the distance between the fan hub mounting faces. mm 73.4 74.0 Face to Face Distance MIN MAX in 2.890 2.913 Install the fan hub in a vise with the fan mounting flange facing up. Install the flat washer and the (M10-1.50 x 25) capscrew. Torque Value: 61 N•m [45 ft-lb] Install the fan hub in a vise so the shaft end clearance can be measured. mm 0.076 0.406 Shaft End Clearance MIN MAX in 0.0030 0.
Section 8 - Cooling System - Group 08 M11 Fan Idler Pulley - Cleaning and Inspection for Reuse (8-05) Page 8-33 Fan Idler Pulley - Cleaning and Inspection for Reuse (8-05) Cleaning Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use solvent or steam to clean the fan idler pulley exterior. Dry with compressed air. Inspection Visually inspect the idler assembly for cracked, chipped or broken pulley grooves.
Fan Idler Pulley - Rebuild (8-06) Page 8-34 Section 8 - Cooling System - Group 08 M11 Remove the cover plate and o-ring from the idler pulley. Discard the o-ring. Install the pulley shaft in a vise with brass jaws. Remove the capscrew (1) and washer (2) from the pulley shaft. Remove the idler pulley from the shaft. Remove the front bearing (1) from the idler pulley. Remove the bearing spacer (2) from the idler pulley.
Section 8 - Cooling System - Group 08 M11 Caution: Do not damage the pulley bore when removing the rear grease seal. The idler pulley can fail. Use a ‘‘flat tip’’ screwdriver or pry bar to remove the rear grease seal. Remove the rear bearing (1) from the idler pulley. NOTE: The bearing races do not need to be removed during the inspection and rebuild procedure if they are not damaged. See Inspection following, if damage is found: Install the idler pulley mounting flange in a vise with brass jaws.
Fan Idler Pulley - Rebuild (8-06) Page 8-36 Section 8 - Cooling System - Group 08 M11 Cleaning Use solvent to clean the idler pulley parts. Dry with compressed air. Inspection The new idler pulley roller bearing set consists of two bearings, two races, an inner spacer and an outer spacer. To prevent future idler pulley failure, the bearings must be replaced as a complete set and not individual parts. Bearings and races that are to be used again must also be kept in sets.
Section 8 - Cooling System - Group 08 M11 Measure the inside diameter of the idler pulley bearing bores. Front and Rear Bearing Bores I.D. mm in 45.199 MIN 1.7795 45.224 MAX 1.7805 Assembly Install the idler pulley in an arbor press with the mounting flange facing down. Use the bearing driver, Part No. 3375696, to press the front bearing race (1) into the pulley until it touches the spacer ring. Turn the pulley over with the mounting flange facing up in the arbor press. Use the bearing driver, Part No.
Fan Idler Pulley - Rebuild (8-06) Page 8-38 Section 8 - Cooling System - Group 08 M11 Install the rear bearing (1) into the mounting flange end of the pulley. The rear bearing must be seated in the rear bearing race. Install the idler pulley in an arbor press with the mounting flange facing up. Caution: Do not lubricate the seal. The oil seal must be installed with the lip of the seal clean and dry to provide a proper oil sealing surface and prevent future idler pulley damage.
Section 8 - Cooling System - Group 08 M11 Fan Idler Pulley - Rebuild (8-06) Page 8-39 Install the front bearing spacer (1) into the idler pulley bore. Install the front bearing (2) into the idler pulley bore. The front bearing must be seated in the front bearing race. Install the capscrew (1) and washer (2) into the idler pulley shaft. Torque Value: 47 N•m [35 ft-lb] Turn the idler pulley by hand to inspect the shaft for freedom of rotation.
Heater Housing, Thermostat Support and Water Header Cover (8-09) Page 8-40 Section 8 - Cooling System - Group 08 M11 Install a new o-ring and the cover plate. Heater Housing, Thermostat Support and Water Header Cover - Cleaning and Inspection (8-09) Cleaning Remove the gasket material from the engine heater housing surface (1). Remove the gasket material from the thermostat support surfaces (2, 3 and 4). Remove the gasket material from the water header cover surfaces (5, 6 and 7).
Section 8 - Cooling System - Group 08 M11 Heater Housing, Thermostat Support and Water Header Cover (8-09) Page 8-41 Use a wire brush to remove the rust and corrosion from the engine heater housing surface (1). Use a wire brush to remove the rust and corrosion from the thermostat support surface (2). Use a wire brush to remove the rust and corrosion from the water header cover surfaces (3 and 4). Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield.
Thermostat Housing Assembly - Rebuild (8-10) Page 8-42 Section 8 - Cooling System - Group 08 M11 Inspection Visually inspect the parts for cracks, damage or excessive corrosion. If damaged parts or excessive corrosion is found the part must be replaced. Thermostat Housing Assembly Rebuild (8-10) Disassembly Caution: To prevent future engine damage, do not damage the thermostat housing when removing the thermostat water seal. Use a punch and hammer to remove the thermostat water seal.
Section 8 - Cooling System - Group 08 M11 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use steam to clean the parts. Dry with compressed air. Inspection Visually inspect the parts for excessive corrosion, cracks or damage. Visually inspect the thermostat for cracks or other damage. If excessive corrosion, cracks or other damage is found the part must be replaced.
Thermostat - Operating Temperature Inspection (8-11) Page 8-44 Section 8 - Cooling System - Group 08 M11 Thermostat - Operating Temperature Inspection (8-11) Test Check the temperature marked on the thermostat to see when the thermostat is designed to open. Record the nominal opening temperature. NOTE: Do not allow the thermostat or thermometer to touch the side of the container. Suspend the thermostat and a thermometer in a container of water. Heat the water.
Section 8 - Cooling System - Group 08 M11 Water Filter Head Assembly - Cleaning and Inspection (8-12) Page 8-45 Water Filter Head Assembly - Cleaning and Inspection for Reuse (8-12) Cleaning Remove the o-ring seals (1) from the mounting flange. Discard the o-ring seals. Use solvent to clean the filter head assembly. Dry with compressed air. Inspection Visually inspect the filter head assembly for cracks or damage. Visually inspect the water filter element sealing surface (1) for cracks or damage.
Water Filter Head Assembly - Rebuild (8-13) Page 8-46 Section 8 - Cooling System - Group 08 M11 Remove the capscrew (1), and the washers (2 and 3) from the filter head. Use a pair of pliers to remove the shutoff valve shaft (4) from the filter head. Remove the o-ring (1) and spring washer (2) from the shutoff valve shaft. Cleaning Use solvent to clean the parts. Dry with compressed air. Inspection Visually inspect the filter head and water filter element sealing surface (1) for cracks or damage.
Section 8 - Cooling System - Group 08 M11 Visually inspect the water passages in the shutoff valve shaft (1). Visually inspect the shaft for corrosion or pitting. Use 240 grit aluminum oxide paper to remove the corrosion. If the parts are cracked or damaged, the filter head assembly must be replaced. Assembly Install the spring washer (1) on the shutoff valve shaft. Install a new o-ring (2) in the groove of the shaft. Use anti-seize to lubricate the shaft and o-ring.
Water Filter Head Assembly - Rebuild (8-13) Page 8-48 Section 8 - Cooling System - Group 08 M11 NOTES
Section 9 - Drive Units M11 Page 9-1 Section 9 - Drive Units Section Contents Page Accessory Drive Pulley - Cleaning and Inspection for Reuse ........................................................................ 9-17 Cleaning........................................................................................................................................................ 9-17 Inspection..................................................................................................................
Service Tools - Drive Units Page 9-2 Section 9 - Drive Units M11 Service Tools - Drive Units The following special tools are recommended to perform procedures in Group 09. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Coupling Puller Remove the splined coupling gear from the compressor drive.
Section 9 - Drive Units M11 Fuel Pump and Compressor Drive - Exploded View Page 9-3 Fuel Pump and Compressor Drive - Exploded View Ref. No. 1. 2. 3. 4. 5. 6. 6a. 7. 8. Description Washer, Copper Sealing Capscrew Pin, Groove Washer, Plain Capscrew Gear, Splined Coupling Coupling, Hub Plug, Straight Thread O-ring Gear, Fuel Pump and Compressor Drive Qty. 1 5 1 1 1 1 1 2 1 Ref. No. 9. 10. 11. 12. 13. 14. 15. 16.
Hydraulic Pump Drive - Exploded View Page 9-4 Section 9 - Drive Units M11 Hydraulic Pump Drive - Exploded View Ref. No. 1. 2. 3. 4. 5. Description Adapter, Hydraulic Pump Bearing, Needle Adapter, Spline Gear, Hydraulic Pump Plate, Cover Qty. 1 1 1 1 1 Ref. No. 6. 7. 8. 9. Description Gasket, Hydraulic Pump Screw, Captive Washer Cap Seal, O-ring Screw, Hex Flange Head Cap Qty.
Section 9 - Drive Units M11 Drive Units - General Information Page 9-5 Drive Units - General Information Fuel Pump and Compressor Drive The fuel pump and compressor drive housings are available in two designs, with and without hardware for mounting an air compressor. The fuel pump drive assembly has hardware for a hub or spider coupling. The compressor drive assembly has hardware for a splined sleeve coupling. The rebuild procedures are the same for both designs. The M11 Engine uses both metric and U.S.
Fuel Pump and Compressor Drive - Cleaning and Inspection for Reuse (9-01) Page 9-6 Section 9 - Drive Units M11 Fuel Pump and Compressor Drive Cleaning and Inspection for Reuse (9-01) Cleaning Remove all gasket material from surfaces (1 and 2). Clean the exterior of the drive with solvent, dry with compressed air. Inspection Measure the driveshaft end clearance. mm 0.10 0.30 Drive Shaft End Clearance MIN MAX in 0.004 0.
Section 9 - Drive Units M11 Visually inspect the rear thrust washer for cracks. Replace the washer if cracks are found. Refer to Fuel Pump and Compressor Drive - Rebuild (9-02). Fuel Pump and Compressor Drive Rebuild (9-02) Disassembly Remove the capscrew and washer. Caution: Install the retainer capscrew (1), without the washer to prevent damage to the shaft while the gear is being removed.
Fuel Pump and Compressor Drive - Rebuild (9-02) Page 9-8 Section 9 - Drive Units M11 Install the shaft and gear assembly in an arbor press with the part number side of the gear facing up. Caution: Do not let the shaft fall when removing it from the drive gear. Damage to the shaft or personal injury can occur. Press the shaft from the gear. Remove the straight thread o-ring plugs (1) from the drive housing. Cleaning Clean the parts with solvent. Clean the oil passages in the housing with solvent.
Section 9 - Drive Units M11 Fuel Pump and Compressor Drive - Rebuild (9-02) Page 9-9 Measure the inside diameter of the bearing bore in the drive housing. Drive Housing Bearing Bore I.D. mm in 47.676 MIN 1.8770 47.775 MAX 1.8809 Visually inspect the thrust washer for cracks or other damage. Replace the washer if it is cracked or damaged. Measure the thrust bearing thickness. mm 6.084 6.312 Thrust Bearing Thickness MIN MAX in 0.2395 0.2485 Visually inspect the shaft surface (2).
Fuel Pump and Compressor Drive - Rebuild (9-02) Page 9-10 Section 9 - Drive Units M11 Point (1) (2) (3) (4) Drive Shaft Journal O.D. mm 34.984 MIN 35.000 MAX 44.975 MIN 45.000 MAX 47.554 MIN 47.570 MAX 25.476 MIN 25.489 MAX in 1.3773 1.3779 1.7706 1.7716 1.8722 1.8728 1.0030 1.0035 Visually inspect the drive gear for cracked or severely worn teeth. Replace the drive gear if it is cracked or abormally worn teeth are found. Measure the inside diameter of the drive gear. mm 47.484 47.
Section 9 - Drive Units M11 Assembly Install the drive gear (1) in an arbor press. Support the gear as shown. NOTE: Make sure the part number side of the gear faces down. Install the largest diameter end of the shaft (2) through the gear bore (3). Align the keyway in the gear (4) with the dowel pin in the shaft (5). Place accessory drive assembly tool, Part No. 3823581, over the top (smaller diameter) end of the shaft.
Fuel Pump and Compressor Drive - Rebuild (9-02) Page 9-12 Section 9 - Drive Units M11 Caution: The grooved surface of the thrust bearing must be facing the thrust surface of the housing to provide proper lubrication and prevent damage to the drive assembly. Use LubriplateT No. 105, or equivalent to lubricate the grooved surface of the thrust bearing. Install the thrust bearing over the shaft. Install the Spline Coupling Gear Use clean 15W-40 oil to lubricate the bore of the splined coupling gear.
Section 9 - Drive Units M11 Hydraulic Pump Drive - Cleaning and Inspection for Reuse (9-03) Page 9-13 Rotate the drive shaft to check for correct assembly. Measure the drive shaft end clearance. mm 0.10 0.30 Drive Shaft End Clearance MIN MAX in 0.004 0.012 If the drive shaft end clearance does not meet these specifications, disassemble the drive and inspect the gear and thrust bearing positions.
Hydraulic Pump Drive - Rebuild (9-04) Page 9-14 Section 9 - Drive Units M11 Hydraulic Pump Drive - Rebuild (9-04) Disassembly Remove the shaft and gear assembly from the rear adapter. Use needle bearing kit, Part No. 3823774, to remove the needle bearing from the hydraulic pump adapter. Install the shaft and gear assembly in an arbor press with the part number side of the gear facing down. Caution: Do not allow the shaft to fall when removing it from the gear.
Section 9 - Drive Units M11 Hydraulic Pump Drive - Rebuild (9-04) Page 9-15 Inspection Visually inspect the hydraulic pump drive and rear adapter for cracks and fretting on the pump flange mounting surface. Visually inspect the gear for broken or abnormally worn teeth. Inspect the shaft inner splines for wear. Replace any parts that are damaged. If the part being inspected does not meet the specifications given, the part must be replaced.
Hydraulic Pump Drive - Rebuild (9-04) Page 9-16 Section 9 - Drive Units M11 Assembly Install the drive gear in an arbor press with the part number side of the gear facing down. Install the shaft into the gear. NOTE: The splined end of the shaft must be facing up (toward the non-part number side of the gear). Use the hydraulic drive gear driver, Part No. 3376820, to push the shaft into the gear until the gear driver touches the gear.
Section 9 - Drive Units M11 Accessory Drive Pulley - Cleaning and Inspection for Reuse (9-05) Page 9-17 The drive shaft end clearance must be checked with the hydraulic pump drive assembly installed on the engine. Measure the drive shaft end clearance. mm 0.076 0.635 Drive Shaft End Clearance MIN MAX in 0.0030 0.0250 If the drive shaft end clearance does not meet the specifications, the front and rear support thrust surfaces are worn excessively. Replace the rear supports and recheck.
Accessory Drive Pulley - Cleaning and Inspection for Reuse (9-05) Page 9-18 NOTES Section 9 - Drive Units M11
Section 10 - Air Intake System M11 Page 10-1 Section 10 - Air Intake System Section Contents Page Air Intake System - General Information ......................................................................................................... 10-4 CAC Air Intake System - Exploded View ......................................................................................................... 10-3 Intake Manifold - Cleaning and Inspection for Reuse ............................................................
Service Tools - Air Intake System Page 10-2 Section 10 - Air Intake System M11 Service Tools - Air Intake System The following special tools are recommended to perform procedures in Group 10. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Dial Depth Gauge Measure the turbocharger axial motion.
Section 10 - Air Intake System M11 CAC Air Intake System - Exploded View Page 10-3 CAC Air Intake System - Exploded View Ref. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Description Manifold, Intake Gasket, Intake Manifold Turbocharger Clamp, V-Band Connection, Turbo Discharge Air Connection, Air Intake Gasket, Connection Plug, Pipe Plug, Pipe Qty. 1 1 1 1 1 Ref. No. 10. 11. 12. 13. 14. 1 1 2 2 15. 16.
Air Intake System - General Information Page 10-4 Section 10 - Air Intake System M11 Air Intake System - General Information The Air Intake System Group consists of the intake manifold, charge air cooler and turbocharger. The charge air cooler uses ram air with the aid of the cooling fan to cool the intake air between the turbocharger and the intake manifold during engine operation. Refer to the OEM for information on the maintenance procedures for the charge air cooler.
Section 10 - Air Intake System M11 Turbocharger - Cleaning and Inspection for Reuse (10-01) Page 10-5 Turbocharger - Cleaning and Inspection for Reuse (10-01) Cleaning Remove all carbon deposits and gasket material from surfaces (1), (2) and (3). Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: Tape or plug all openings to prevent solvent or steam from damaging the oil cavities in the turbocharger.
Intake Manifold - Cleaning and Inspection for Reuse (10-02) Page 10-6 Section 10 - Air Intake System M11 With the feeler gauge in the same location, push the compressor wheel by hand away from the compressor housing. Install a wire feeler gauge, at the same point. Record this clearance. Subtract the smaller from the larger clearance. Compressor Wheel Radial Clearance mm in 0.15 MIN 0.006 0.64 MAX 0.025 If the radial clearance does not meet the above specifications, the turbocharger must be rebuilt.
Section 11 - Exhaust System M11 Page 11-1 Section 11 - Exhaust System Section Contents Page Exhaust Manifold - Cleaning and Inspection for Reuse .................................................................................. Cleaning ........................................................................................................................................................ Disassembly ............................................................................................................
Exhaust System - Exploded View Page 11-2 Section 11 - Exhaust System M11 Exhaust System - Exploded View Ref. No. 1. 2. 3. Description Manifold, Exhaust, Center Manifold, Exhaust, End Gasket, Exhaust Manifold Qty. 1 2 6 Ref. No. 4. 5. Description Capscrew Spacer, Mounting Qty.
Section 11 - Exhaust System M11 Exhaust System - General Information Page 11-3 Exhaust System - General Information The exhaust manifold group consists of the exhaust manifolds and the turbocharger mounting studs. Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Disassembly Use a mallet to remove the two end sections (1) from the center section (2). Cleaning Use Scotch-BriteT, or its equivalent, to remove the carbon from the gasket sealing surfaces (1).
Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Page 11-4 Section 11 - Exhaust System M11 Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use steam to clean the manifold sections. Dry with compressed air. Inspection Visually inspect the manifold sections for cracks or damage. Visually inspect the sealing connection surfaces for damage.
Section 11 - Exhaust System M11 Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Page 11-5 Apply a coat of anti-seize compound to the threads. NOTE: Install the shorter threaded end of the turbocharger mounting stud in the exhaust manifold flange. Install the studs in the mounting flange. Use two mounting nuts locked together to tighten the studs.
Exhaust Manifold - Cleaning and Inspection for Reuse (11-01) Page 11-6 NOTES Section 11 - Exhaust System M11
Section 12 - Air Equipment - Group 12 M11 Page 12-1 Section 12 - Air Equipment - Group 12 Section Contents Page Air Compressor - Cleaning and Inspection for Reuse .................................................................................... 12-6 Cleaning........................................................................................................................................................ 12-6 Inspection.................................................................................
Air Equipment - General Information Page 12-2 Section 12 - Air Equipment - Group 12 M11 Air Equipment - General Information The air equipment group consists of Cummins single and two cylinder air compressors, compressor check valves and air and coolant piping. It also includes air activated cranking motors. The air compressor is lubricated by engine lubricating oil which enters the compressor through a drilling in the support.
Section 12 - Air Equipment - Group 12 M11 The compressed air system normally consists of a gear driven air compressor, an air governor, air tanks and all necessary plumbing. The Holset single and two cylinder air compressors are engine-driven piston-type compressors which supply compressed air to operate air activated devices. The compressor runs continuously but has a loaded and unloaded operating mode.
Air Equipment - General Information Page 12-4 Section 12 - Air Equipment - Group 12 M11 E-Type System With Air Dryer Vehicles equipped with air dryers vented to the atmosphere during unloaded compressor operation, using the Holset E-Type air compressor, require the installation of an econ valve to prevent excessive oil consumption.
Section 12 - Air Equipment - Group 12 M11 Compressed Air System Flow Diagrams Compressed Air System Flow Diagrams Page 12-5
Air Compressor - Cleaning and Inspection for Reuse (12-01) Page 12-6 Section 12 - Air Equipment - Group 12 M11 Air Compressor - Cleaning and Inspection for Reuse (12-01) Cleaning Remove all gasket material from the sealing surfaces. Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Caution: Seal all openings with tape to prevent damage from solvent or steam entering the oil passages in the air compressor.
Section 12 - Air Equipment - Group 12 M11 Air Compressor - Cleaning and Inspection for Reuse (12-01) Page 12-7 Visually inspect the compressor drive gear and the fuel pump ‘‘hub type’’ drive coupling for wear or damage. Measure the single cylinder air compressor crankshaft end clearance. mm 0.05 0.15 Crankshaft End Clearance MIN MAX in 0.002 0.006 Measure the two cylinder air compressor crankshaft end clearance. mm 0.05 0.19 Crankshaft End Clearance MIN MAX in 0.002 0.
Air Compressor - Cleaning and Inspection for Reuse (12-01) Page 12-8 NOTES Section 12 - Air Equipment - Group 12 M11
Section 13 - Electrical Equipment - Group 13 M11 Page 13-1 Section 13 - Electrical Equipment - Group 13 Section Contents Page Alternator Adjusting Link - Cleaning and Inspection for Reuse..................................................................... 13-3 Inspection...................................................................................................................................................... 13-3 Alternator Bracket - Cleaning and Inspection for Reuse ...........................
Electrical Equipment - General Information Page 13-2 Section 13 - Electrical Equipment - Group 13 M11 Electrical Equipment - General Information The electrical equipment used on the M11 engine is not manufactured by Cummins Engine Company, Inc. Complete instructions for adjusting, testing, and repairing the electrical equipment can be obtained from the equipment manufacturer. The following list contains the suppliers of the electrical equipment used on Cummins engines.
Section 13 - Electrical Equipment - Group 13 M11 Wiring Diagrams A complete collection of electrical wiring diagrams, as applied to all Cummins engines, is contained in Wiring Diagrams, Bulletin No. 3379099. Alternator Bracket - Cleaning and Inspection for Reuse (13-01) Inspection Use solvent to clean the bracket. Dry with compressed air. Visually inspect the bracket area (1) for cracks. Inspect the bracket for other damage. Discard damaged parts.
Alternator Bracket - Cleaning and Inspection for Reuse (13-04) Page 13-4 Section 13 - Electrical Equipment - Group 13 M11 Inspection Visually inspect the gear (1) for cracked or broken teeth. Visually inspect the drive bushing (2) and the gear shaft (3) for excessive wear or damage. Visually inspect the terminal posts (4) for loose or broken connections. If the starting motor parts are damaged or the posts are loose or damaged, the starting motor must be repaired or rebuilt.
Section 13 - Electrical Equipment - Group 13 M11 Inspect the lower bracket and mounting capscrews. If the bracket is cracked, it must be replaced. The front and rear faces of the lower bracket, where the lower bracket and upper bracket contact, must be flat and parallel. If these surfaces are not flat, the rear face ONLY can be re-faced by milling a maximum of 0.50 mm [0.020 inch] deep to clean up. However, the minimum dimension allowed from the front to rear contact faces of the lower bracket is 210.
Automatic Belt Tensioner Bracket (13-06) Page 13-6 Section 13 - Electrical Equipment - Group 13 M11 Inspect the tensioner for evidence of the pivoting tensioner arm contacting the stationary circular base. If there is evidence of these two areas contacting, the pivot tube bushing has failed and the tensioner must be replaced. Automatic Belt Tensioner Bracket (Bus Applications) - Cleaning and Inspection for Reuse (13-06) Cleaning Use solvent to clean the tensioner bracket. Dry with compressed air.
Section 14 - Engine Testing - Group 14 M11 Page 14-1 Section 14 - Engine Testing - Group 14 Section Contents Page Chassis Dynamometer ................................................................................................................................... General Test Procedure .............................................................................................................................. Charge Air Cooler Restriction ................................................................
Engine Testing - General Information Page 14-2 Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information This section outlines engine testing and engine run-in recommendations for M11 engines. All engines must be run-in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or cylinder kits. Incorrect or insufficient break-in of the piston rings will lead to early oil consumption or high blowby complaints.
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-3 Definition of Terms On Engine Performance Curve Cummins M11 Heavy Duty Engine Operating Curve Definitions: 1. Peak Torque (N•m [ft-lb]) - Maximum torque that the engine will produce. Also, sometimes referred to as COMMAND TORQUE. This is listed on the engine data plate. 2. Peak Torque RPM (RPM) - Engine speed at which peak torque is generated. This is listed on the engine data plate. 3.
Engine Testing - General Information Page 14-4 Section 14 - Engine Testing - Group 14 M11 General Run-In Procedures Caution: Refer to General Engine Test Specifications in this section before operating the engine to avoid internal component damage. The amount of time specified for the following engine run-in phases are minimums. The engine can be operated for longer periods of time at each operating range or phase with the exception of engine idling which must be kept to 5 minutes or less.
Section 14 - Engine Testing - Group 14 M11 Caution: Do not shut off the engine immediately after the run-in is completed. Allow the engine to cool by operating at low idle for a minimum of 3 minutes to avoid internal component damage. Fuel Flow Measurement on Engine or Chassis Dynamometer Accurate fuel flow measurement is important for evaluation of engine performance and troubleshooting on an engine or chassis dynamometer.
Engine Testing - General Information Page 14-6 Operation This is a schematic of the fuel measuring device, Part No. 3376375. The device consists of the following components: • Fuel Filter • Flowmeter • Float Tank • Fuel Rail Pressure Gauge • Fuel Cooler is not a part of fuel measuring device, Part No. 3376375; however, must be used when conducting test with the flow meter.
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-7 Note: On CELECT™ engines, the engine fuel inlet line must flow through the ECM cooling plate to provide proper cooling of the ECM during engine operation. The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity of fuel being drawn through the flowmeter is know as ‘‘make up’’ fuel or the amount of fuel being burned by the engine.
Engine Testing - General Information Page 14-8 Section 14 - Engine Testing - Group 14 M11 Intake Manifold Boost Pressure Correction Factors Boost pressure measured in the intake manifold is directly related to the ambient temperature, the temperature rise across the air cleaner and turbocharger, and the pressure drop across the charge air cooler. Typically when the ambient temperature rises, the boost pressure measured in the intake manifold decreases.
Section 14 - Engine Testing - Group 14 M11 2. Measure the intake manifold temperature at the 1/8 inch NPT tap near the air horn connection with the intake manifold. Measure this temperature as close as possible to the inlet of the intake manifold. Alternately, intake air temperature can be measured by using Compulink™ in the ‘‘monitor’’ mode.
Engine Testing - General Information Page 14-10 Section 14 - Engine Testing - Group 14 M11 TEST DATA FOR BOOST CORRECTION CHART Altitude: Engine Horsepower: Customer: Truck Unit: ESN: CPL: RPM Fuel Rate lb/hr Turbo Outlet Press (in Hg) Date: Vehicle Make/Model: Mileage: Intake Mfd Press (in Hg) Turbo Comp Inlet Temp (°F) Intake Mfd Temp (°F) Once the data has been obtained and the table filled, plot the data on the chart specific for your engine.
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-11 Next, find the curved line in the graph (B) closest to the measured intake manifold temperature recorded during the test. If the measured intake manifold temperature is for example 130°F, put a mark in the middle of the curved lines representing 49°C and 60°C [120°F and 140°F] intake manifold temperature. This mark must intersect the vertical line (A) drawn through the measured compressor inlet temperature.
Engine Testing - General Information Page 14-12 Section 14 - Engine Testing - Group 14 M11 Consider another example: The turbocharger compressor inlet temperature measured between the air cleaner and the turbocharger is 70°F and the intake manifold temperature is 49°C [120°F]. At the intersection of the 49°C [120°F] intake manifold temperature curve (B), and the vertical line (A) for 21.
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-13
Engine Testing - General Information Page 14-14 Section 14 - Engine Testing - Group 14 M11
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-15
Engine Testing - General Information Page 14-16 Section 14 - Engine Testing - Group 14 M11
Section 14 - Engine Testing - Group 14 M11 Engine Testing - General Information Page 14-17
Engine Testing - Specifications Page 14-18 Section 14 - Engine Testing - Group 14 M11 Engine Testing - Specifications Maintain the following limits during the engine test/run-in procedures: Due to variations in ratings of different engine models, refer to the specific ‘‘Engine Data Sheet’’ for the particular engine model being tested. Charge Air Cooler Restriction (Maximum) ................................................................ 152 mm Hg [6.0 in. Hg] 21 kPa [3.
Section 14 - Engine Testing - Group 14 M11 Dynamometer Worksheet Page 14-19 Dynamometer Worksheet Date Repair Order No. Operator ESN CPL Fuel Pump Code Complaint SC Code PARAMETER Fuel Pressure (psi @ RPM) Fuel Rate (lb/hr) Intake Mfd. Pressure (in.Hg) Intake Mfd. Temperature *Intake Air Restriction *Exhaust Air Restriction *Fuel Inlet Restriction *Fuel Drain Line Restriction Engine Blowby CODE SPECIFICATIONS 150 to 180 at Governed ACTUAL READING See Fuel Pump Code 25 in. H20, Maximum 3 in.
Service Tools - Engine Testing Page 14-20 Section 14 - Engine Testing - Group 14 M11 Service Tools - Engine Testing The following special tools are recommended to perform procedures in Section 8. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Vacuum Gauge Used to check fuel filter or intake air restriction. ST-434 Manometer ST-1111-3 Used with tool, Part No.
Section 14 - Engine Testing - Group 14 M11 Tool No. Service Tools - Engine Testing Page 14-21 Tool Description Fuel Measuring Device 3376375 Measure the rate of fuel consumption of a Cummins diesel engine. Digital Optical Tachometer Used to measure engine speed (RPM). 3377462 Blowby Check Tool 3822566 Used with manometer, Part No. ST-1111-3, to measure the engine crankcase pressure. Compulink™ Kit 3823548 Used to program and adjust CELECT™ system. Kit includes Compulink™ and all necessary cables.
Engine Dynamometer - Install Engine (14-01) Page 14-22 Section 14 - Engine Testing - Group 14 M11 Engine Dynamometer - Install Engine (14-01) NOTE: Be sure the dynamometer capacity is sufficient to permit testing at 100 percent of the engine rated horsepower. If the capacity is not enough, the testing procedure must be modified to the restrictions of the dynamometer. Use engine lifting fixture, Part No. 3822512, to install the engine to the test stand. Align and connect the dynamometer.
Section 14 - Engine Testing - Group 14 M11 Intake Air Temperature Control The use of a remote aftercooler is mandatory whenever a Cummins CAC engine is attached to an engine dynamometer for the purpose of engine run-in, performance testing and engine diagnostics. Do not attempt to run a Cummins CAC engine without any means of controlling the intake manifold air temperature. Service tool, Part No.
Engine Dynamometer - Install Engine (14-01) Page 14-24 Section 14 - Engine Testing - Group 14 M11 The air flow piping requires 4 inch I.D. aluminized steel piping. The flow circuit must have as few bends as possible maximizing the length of straight sections. However, when bends are required, use long elbows. Do not use mitered elbows, or anything that changes the air flow direction quickly. To reduce intake air restriction, air flow direction changes must occur gradually.
Section 14 - Engine Testing - Group 14 M11 Air Inlet Restriction Connect a water manometer to the air inlet pipe of the turbocharger to measure inlet restriction. The manometer adapter must be installed at a 90 degree angle to the air flow in a straight section of pipe, one pipe diameter before the turbocharger. NOTE: A vacuum gauge can be used to record the intake air restriction. Minimum Gauge Capacity: 760 mm H20 [30 inches H20].
Engine Dynamometer - Install Engine (14-01) Page 14-26 Section 14 - Engine Testing - Group 14 M11 Intake Manifold Pressure Remove the pipe plug in the intake manifold just below the inlet air connection and install the intake manifold pressure gauge, Part No. ST-1273. Engine Blowby Install the Part No. 3822566, Engine Blowby Tool, to the breather on the rocker lever cover to measure engine crankcase pressure. Install a water manometer, Part No. ST-1111-3, to the engine blowby tool.
Section 14 - Engine Testing - Group 14 M11 Engine Dynamometer - Install Engine (14-01) Page 14-27 Fuel Inlet Restriction Measure the fuel inlet restriction. Install a vacuum gauge, Part No. ST-434, between the fuel fitter and the gear pump inlet. NOTE: Do not measure fuel inlet restriction with the fuel measuring device installed. This will not measure the inlet restriction of the vehicle’s supply plumbing. Hold the gauge at the same level as the gear pump.
Engine Dynamometer - Install Engine (14-01) Page 14-28 Section 14 - Engine Testing - Group 14 M11 Fuel Drain Line Restriction Use pressure gauge, Part No. ST-1273, to measure fuel drain line restriction. NOTE: Do not measure fuel drain line restriction with the fuel measuring device installed. This will not measure the drain line restriction of the vehicle’s return plumbing. Hold the gauge at the same level as the connection.
Section 14 - Engine Testing - Group 14 M11 Starting Motor Inspect the voltage rating on the starting motor before installing the electrical wiring. Install the electrical wiring to the starting motor and batteries, if used. NOTE: If another method of starting the engine is used, follow the manufacturer’s instructions to make the necessary connections.
Engine Dynamometer - Install Engine (14-01) Page 14-30 Section 14 - Engine Testing - Group 14 M11 Connect the dynamometer test OEM wiring harness pin connector to the actuator harness power connector (shroud). To save, adjust, and write parameters to and from the ECM, refer to the CELECT™ Compulink™ Cartridge Manual, Bulletin No. 3810472. NOTE: Parameters must be returned to their original value when the test or run-in is completed.
Section 14 - Engine Testing - Group 14 M11 Connect the keyswitch panel datalink cable to the Compulink™. Depress the ‘‘POWER ON’’ button on the Compulink™. If the ‘‘Progressive Shift Feature’’ is turned ‘‘ON’’, it must be turned ‘‘OFF’’ during the engine test to allow the engine to accelerate through its RPM range. Select the ‘‘Adjustments’’ option from the main menu screen by depressing the number ‘‘2’’ on the Compulink™ keypad.
Engine Dynamometer - Install Engine (14-01) Page 14-32 Section 14 - Engine Testing - Group 14 M11 Depress the active key to cancel or back up to the screen showing the ‘‘Main Menu Option’’. The ECM is equipped with a tamperproof system that limits engine speed when the vehicle speed signal is lost.
Section 14 - Engine Testing - Group 14 M11 Engine Run-In Procedure - Engine Dynamometer (14-02) Page 14-33 Select ‘‘Set Up for CompuchekT’’ from the ‘‘Special Functions Menu’’. The Compulink™ must be left in this mode throughout the test. Future generations of Compulink™ cartridge software will allow Compulink™ in the monitor mode while running tests with parameters bypassed. The setup is now completed, and the auto/manual throttle control can be used to control engine speed.
Engine Run-In Procedure - Engine Dynamometer (14-02) Page 14-34 Section 14 - Engine Testing - Group 14 M11 It is a good practice to observe these measurements even if engine performance meets specifications. If engine performance does not meet specifications, these measurements can indicate possible reasons for underperformance.
Section 14 - Engine Testing - Group 14 M11 Engine Run-In Procedure - Engine Dynamometer (14-02) Page 14-35 Open the throttle to obtain speed at which maximum horsepower is developed and adjust the dynamometer load to achieve 75 percent of fuel rate. Operate the engine at this speed and load level for 3 minutes. Check all gauges and record the data. NOTE: Do not proceed to the next step until blowby is stable within specifications.
Engine Run-In Procedure - Engine Dynamometer (14-02) Page 14-36 Section 14 - Engine Testing - Group 14 M11 Caution: Shutting off the engine immediately after operating at full load will damage the turbocharger and internal components. Always allow the engine to cool before shutting it off. Remove the dynamometer load completely, and operate the engine at 700 to 900 RPM for 3 to 5 minutes. This period will allow the turbocharger and other components to cool. Shut off the engine.
Section 14 - Engine Testing - Group 14 M11 Chassis Dynamometer (14-03) Operation The performance of an engine installed in ‘‘on-highway’’ vehicles can be tested on a chassis dynamometer. NOTE: Due to driveline inefficiencies and engine-driven accessories, the rated horsepower will be reduced by approximately: • 20 percent for single axle vehicles • 25 percent for tandem axle vehicles The net horsepower available is called wheel horsepower (WHP).
Chassis Dynamometer (14-03) Page 14-38 Section 14 - Engine Testing - Group 14 M11 The following are general safety precautions to be observed while operating the chassis dynamometer. • Use tires that have more than 160 kilometers [100 miles] on them. Do not use new tires. • Do not use recapped tires or tires of different sizes or designs. • Make sure the tires are inflated to the manufacturer’s specifications.
Section 14 - Engine Testing - Group 14 M11 • Adjust the vehicle and dynamometer room exhaust system to make sure all exhaust gases are removed from the room. • Refer to the chassis dynamometer and vehicle manufacturer’s recommendations and specifications for testing procedures. General Test Procedure Check the engine coolant level to be sure it is filled to the proper level. Warning: Check the coolant level only when the engine is stopped.
Chassis Dynamometer (14-03) Page 14-40 Section 14 - Engine Testing - Group 14 M11 To properly monitor engine performance, record the following parameters. To limit dynamometer operating time, instrument the engine to make as many checks as possible. • • • • • • • Engine speed rpm with a verified tachometer Fuel pressure Fuel rate (Use Service Tool, Part No.
Section 14 - Engine Testing - Group 14 M11 Fuel Rate Use fuel measuring device, Part No. 3376375, to measure the rate of fuel consumption. For more information, refer to ‘‘Engine Testing - General Information’’. Install the fuel measuring device as follows: • The fuel return hose from the engine to the fuel measuring device (A). • The fuel inlet hose to the fuel filter inlet (B). • The return hose from the device (C) to the fuel tank. • The fuel inlet hose to the device from the fuel tank suction line (D).
Chassis Dynamometer (14-03) Page 14-42 Section 14 - Engine Testing - Group 14 M11 Operate the engine at maximum horsepower RPM and Advertised Horsepower. Observe the reading on the gauge. NOTE: The maximum fuel inlet restriction is as follows: Fuel Inlet Restriction (plus ECM Cooling Plate) mm Hg Clean Filter 152 MAX Dirty Filter 254 MAX in Hg 6 10 Correct the restriction or replace the fuel filter. Fuel Drain Line Restriction Use Pressure Gauge, Part No. ST-1273, to measure fuel drain line restriction.
Section 14 - Engine Testing - Group 14 M11 Intake Manifold Pressure Measure the intake manifold pressure (turbocharger boost). Install pressure gauge, Part No. ST-1273, in the intake manifold as shown. Observe the reading on the pressure gauge. NOTE: Intake manifold pressure (turbocharger boost) must be corrected for variances due to intake air temperature. Use the ‘Boost Pressure Correction Factor’s explained in ‘‘Engine Testing - General Information’’.
Chassis Dynamometer (14-03) Page 14-44 Section 14 - Engine Testing - Group 14 M11 Charge Air Cooler Restriction Measure the intake pressure drop across the charge air cooler. This test can be done with a mercury manometer or two separate gauges, Part No. ST-1273. If two gauges are being used, calibrate both gauges on a common pressure source to ensure consistency. Install one pressure gauge, Part No. ST-1273, in the fitting in the turbocharger compressor outlet elbow.
Section 14 - Engine Testing - Group 14 M11 Exhaust Air Restriction Measure the exhaust air restriction. Install the pressure gauge, Part No. ST-1273, or a manometer in the exhaust air piping. The gauge adapter must be installed near the turbocharger in a straight section of pipe at the turbine outlet. Operate the engine at advertised horsepower. Observe the gauge or manometer. Pressure must not exceed 75 mm Hg [3.0 inches Hg]. Engine Blowby Measure the engine crankcase pressure.
Engine Run-In Procedure - Chassis Dynamometer (14-04) Page 14-46 Section 14 - Engine Testing - Group 14 M11 Lubricating Oil Pressure Use Pressure Gauge, Part No. 3375275, to measure lubricating oil pressure. Install the pressure gauge to the main oil rifle and observe the oil pressure. Low Idle (minimum allowable) 69 kPa [10 psi] At 1200 RPM (minimum allowable) 207 kPa [30 psi] Coolant Pressure Use a vacuum gauge to measure engine coolant pressure.
Section 14 - Engine Testing - Group 14 M11 Engine Run-In Procedure - Chassis Dynamometer (14-04) Page 14-47 Refer to the Engine Dynamometer Worksheet in this section. Intake manifold pressure (turbo boost) must be corrected for variances due to intake air temperature. Use the ‘Boost Pressure Correction Factors’ explained in ‘‘Engine Testing - General Information’’. It is recommended to monitor block coolant pressure during run-in to aid in early indication of a cooling system problem.
Engine Run-In Procedure - Chassis Dynamometer (14-04) Page 14-48 Section 14 - Engine Testing - Group 14 M11 Operate the engine at advertised horsepower RPM and 75 percent fuel rate. Check the gauges, and record the readings. Do not proceed to the next step until a steady, acceptable blowby reading is obtained. Operate the engine at advertised horsepower RPM with a wide open throttle, for 5 minutes. Check the gauges, and record the readings.
Section 14 - Engine Testing - Group 14 M11 Engine Run-In Procedure - Without Dynamometer (14-05) Page 14-49 Caution: Do not shut off the engine immediately after the run-in is completed. Allow the engine to cool by operating it at 700 to 900 RPM for a minimum of 3 to 5 minutes to avoid internal component damages. This allows the turbocharger and other components to cool. Shut off the engine. Make sure all instrumentation is removed before removing the vehicle from the chassis dynamometer.
Engine Painting (14-06) Page 14-50 Section 14 - Engine Testing - Group 14 M11 Engine Painting (14-06) Remove all belts from the engine. Cover the following: • Exhaust and intake openings • Electrical components • Fuel inlet and drain connections • Any exposed fittings, threads and electrical wire terminals Warning: When using a steam cleaner, wear protective clothing and safety glasses or a face shield. Hot steam will cause serious personal injury. Use steam to clean the engine. Dry with compressed air.
Section 14 - Engine Testing - Group 14 M11 Engine Storage - Short Term (14-07) This procedure describes the proper method to prepare an engine for short term storage (one to six months). Operate the engine at ‘‘High Idle’’ speed until the coolant temperature indicator reaches: Temperature: 70°C [160°F] Shut off the engine. Remove the fuel lines to the engine fuel filter and the injector return line. Use Daubert Chemical NoxRust No. 518 Preservative Oil, or equivalent.
Engine Storage - Short Term (14-07) Page 14-52 Section 14 - Engine Testing - Group 14 M11 Remove the electrical wiring from the fuel pump solenoid. Drain the cooling system. NOTE: It is not necessary to drain the coolant if it is a permanent type antifreeze with a rust inhibitor. Do not drain the coolant if the engine is installed in a vehicle. Cover all openings with tape to prevent dirt and moisture from entering the engine. Install a warning tag on the engine.
Section 14 - Engine Testing - Group 14 M11 Remove the Engine From Short Term Storage Remove the tape from the openings. Remove the warning tag. Replace the oil, water and fuel filters. Prime the lubricating oil system. Use clean diesel fuel to flush the preservative oil from the fuel system. Fill the cooling system (if necessary). Adjust the injector and valve clearance. Refer to Engine Assembly (00-02). Adjust the belt tension. Refer to Engine Assembly (00-02).
Engine Storage - Long Term (14-08) Page 14-54 Section 14 - Engine Testing - Group 14 M11 Drain the lubricating oil pan. Install the drain plug. Torque Value: 90 N•m [65 ft-lb] Fill the oil pan to the ‘‘High’’ level mark with preservative oil. Use Shell 66202, or an equivalent preservative oil. The oil must meet Military Specification MIL-L-21260 Type R10 Grade 2 SAE 30. Remove the fuel lines to the engine fuel filter and the injector return line. Use Daubert Chemical NoxRust No.
Section 14 - Engine Testing - Group 14 M11 Remove the intake manifold. Remove the exhaust manifold. Refer to Engine Disassembly (0-01). Spray Shell 66202, or an equivalent preservative oil, into the intake and exhaust ports in the cylinder head and into the aftercooler housing and exhaust manifold. Install the intake manifold. Install the exhaust manifold. Refer to Engine Assembly (00-02). Remove the rocker housing cover. Refer to Engine Disassembly (0-01).
Engine Storage - Long Term (14-08) Page 14-56 Section 14 - Engine Testing - Group 14 M11 Cover all of the openings with heavy paper and tape to prevent dirt and moisture from entering the engine. Install a warning tag on the engine. The tag must indicate: • The date the engine was treated with preservatives. • The coolant and oil have been drained. • Do not operate the engine. Store the engine in an area that is dry and has a constant temperature.
Section 14 - Engine Testing - Group 14 M11 Use clean diesel fuel to flush the preservative oil from the fuel system. After operating the engine to flush out the preservative oil, install a new fuel filter(s). Adjust the injector and valve clearance. Refer to Engine Assembly (0-02). Adjust the belt tension. Refer to Engine Assembly (0-02). Tighten the intake manifold cover capscrews. Tighten the exhaust manifold capscrews. Refer to Engine Assembly (0-02).
Engine Storage - Long Term (14-08) Page 14-58 Section 14 - Engine Testing - Group 14 M11 NOTES
Section 15 - Instruments and Controls - Group 15 M11 Page 15-1 Section 15 - Instruments and Controls - Group 15 Section Contents Page Instruments and Controls - General Information ............................................................................................ Air Heaters .................................................................................................................................................... Coolant Heaters............................................................
Instruments and Controls - General Information Page 15-2 Section 15 - Instruments and Controls - Group 15 M11 Instruments and Controls - General Information The instruments and control group consists of the gauges, speed switch, safety controls, cold weather operating aids, etc. used on Cummins engines. Gauges that indicate the coolant temperature, oil pressure, and oil temperature will provide the operator information on the condition of the engine.
Section 15 - Instruments and Controls - Group 15 M11 Safety Controls Teddington Ind. Equip.
Instruments and Controls - General Information Page 15-4 Section 15 - Instruments and Controls - Group 15 M11 NOTES
Section 16 - Mounting Adaptations - Group 16 M11 Page 16-1 Section 16 - Mounting Adaptations - Group 16 Section Contents Page Flywheel - Cleaning and Inspection for Reuse ............................................................................................... Assembly....................................................................................................................................................... Disassembly .......................................................................
Service Tools - Mounting Adaptations Page 16-2 Section 16 - Mounting Adaptations - Group 16 M11 Service Tools - Mounting Adaptations The following special tools are recommended to perform procedures in Group 16. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No. Tool Description Pipe Sealant Use on capscrew threads and pipe plugs.
Section 16 - Mounting Adaptations - Group 16 M11 Mounting Adaptations - Exploded View Page 16-3 Mounting Adaptations - Exploded View Ref. No. 1 2 3 Description Support, Front Engine Cover, Access Hole Gasket, Cover Plate Qty. 1 1 1 Ref. No. 4 5 6 Description Housing, Flywheel Gear, Ring Flywheel Qty.
Rear Engine Power Takeoff - Exploded View Page 16-4 Section 16 - Mounting Adaptations - Group 16 M11 Rear Engine Power Takeoff - Exploded View Ref. No. Description 1 2 3 4 5 6 7 8 9 10 11 12 Housing, Flywheel Cover, Access Hole Gasket, Cover Plate Plug, Threaded Drain Shaft, Accessory Drive Output Flange, Power Takeoff Bearing, Roller (Large) Bearing, Roller (Medium) Seal, Rectangular Ring (Tetra) Plate, Cover (Ribbed) Capscrew Washer, Plain Qty. 1 1 1 1 1 1 1 1 1 1 4 4 Ref. No.
Section 16 - Mounting Adaptations - Group 16 M11 Mounting Adaptations - General Information Page 16-5 Mounting Adaptations - General Information The mounting adaptations group consists of the flywheel housing, flywheel, flywheel ring gear, pilot bearing, and the front engine support. The flywheel is available only as an assembly with the ring gear installed; however, the ring gear is available for service replacement.
Flywheel Ring Gear - Replacement (16-02) Page 16-6 Section 16 - Mounting Adaptations - Group 16 M11 Visually inspect the flywheel ring gear for chipped, cracked or broken teeth. If the ring gear teeth are damaged, the ring gear must be replaced. Refer to Flywheel Ring Gear - Replacement (16-02). Assembly Use a new pilot bearing when installing a new or rebuilt clutch. The pilot bearing must be installed flush with the pilot bore surface. Use a mandrel and hammer to install the pilot bearing.
Section 16 - Mounting Adaptations - Group 16 Flywheel Housing - Cleaning and Inspection for Reuse (16-03) M11 Page 16-7 Assembly Do not attempt to install the ring gear without using heat. Use an oven to heat the new ring gear for a minimum of one hour. Do not heat the ring gear for more than six hours. Temperature: 235°C [450°F] NOTE: Do not exceed the specified time or temperature. If an oven is not available, use a heating torch to heat the gear.
Front Engine Support - Cleaning and Inspection (16-04) Page 16-8 Section 16 - Mounting Adaptations - Group 16 M11 Inspection Visually inspect all surfaces of the flywheel housing for nicks, burrs or cracks. Use 240 grit emery cloth to remove small nicks and burrs. Visually inspect all threaded capscrew holes for damage. If cracks are found, the flywheel housing must be replaced. Damaged or distorted capscrew threads can be repaired with thread inserts.
Section 16 - Mounting Adaptations - Group 16 M11 Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-9 Use a dent puller to remove the seal. Do not damage the surface of the housing or the seal bore. NOTE: When the housing is turned over, the bearing will fall out. Do not allow the bearing to become damaged. Turn the housing over so the four cover plate capscrews are accessible. Be careful not to damage the output shaft.
Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-10 Section 16 - Mounting Adaptations - Group 16 M11 Support the housing in a press with the cylinder block mating surface down. With a long mandrel, press out the idler shaft bushing. Remove and discard the o-ring. Use a hammer and a brass drift to remove the two bearing outer races from the bore of the idler gear. Discard the outer races. Remove the large spacer ring fromt the center groove of the gear. Discard the spacer ring.
Section 16 - Mounting Adaptations - Group 16 M11 Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-11 Inspect the output flange for damage or wear grooves from the oil seal. Replace the flange if it is defective. Inspect the REPTO housing for cracks at the rear engine mounting surfaces and the flywheel bore. Replace the housing if it is cracked. Inspect the idler shaft bushing for wear. Replace the bushing if it is worn.
Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-12 Section 16 - Mounting Adaptations - Group 16 M11 Assembly Install a new o-ring on the idler shaft bushing. Use Lubriplate to lubricate the o-ring. Support the housing evenly with the engine mating surface up. Press the new bushing into the housing until it is below the surface of the cylinder block mating surface. Use LubriplateW 105 to lubricate the larger bearing race. Use the larger end of driver, Part No.
Section 16 - Mounting Adaptations - Group 16 M11 Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-13 Position the housing on the table so the cylinder block mating surface is up. Install the output shaft assembly into the housing. The correct shaft end clearance (rolling resistance) is determined by the number and thickness of shims used between the two bearings. When the shim thickness is increased, there is more shaft end clearance and less rolling resistance.
Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-14 Section 16 - Mounting Adaptations - Group 16 M11 Temporarily install the output flange before installing the oil seal. Use clean 15W-40 oil to lubricate the splines. Install the flat washer and capscrew. Use gear locking tool, Part No. 3823891, to hold the output shaft while tightening the capscrew. Torque Value: 205 N•m [150 ft-lb] Measure the shaft end play. mm 0.00 0.03 REPTO Shaft End Play MIN MAX in 0.000 0.
Section 16 - Mounting Adaptations - Group 16 M11 Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-15 If the rolling resistance is not within the specifications, remove the output flange and smaller bearing. Add or subtract shims to obtain the correct rolling resistance. NOTE: Adding more shims will decrease the resistance, and removing shims will increase resistance. Any combination of shims can be used.
Rear Engine Power Takeoff (REPTO) - Rebuilding (16-05) Page 16-16 Section 16 - Mounting Adaptations - Group 16 M11 Install the cover and four capscrews. Torque Value: 18 N•m [14 ft-lb] Insert a new spacer ring into the bore of the idler gear. Push it in until it snaps into place in the center groove. Use Lubriplate 105 to lubricate the bearing outer races. Press the two new bearing outer races into the bore of the idler gear. The larger side of the taper must face toward the outside of the gear.
Section V - Specifications - Group 18 M11 Page V-1 Section V - Specifications - Group 18 Section Contents Page Capscrew Markings and Torque Values .......................................................................................................... V-46 Capscrew Markings and Torque Values - Metric ............................................................................................ V-46 Capscrew Markings and Torque Values - U.S. Customary .......................................................
Specifications - General Information Page V-2 Section V - Specifications - Group 18 M11 Specifications - General Information The specifications in this section are organized in the same sequence used in each group of this manual. The minimum and maximum tolerance limit specifications are listed in both metric and U.S. Customary dimensions.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-3 Ref.No./Steps Metric U.S. Component Specifications and Torque Values Engine Assembly - Specifications Cylinder Liner Protrusion 0.00 mm 0.13 mm MIN MAX 0.000 in 0.005 in Cylinder Liner to Block Clearance 0.25 mm MIN 0.010 in Cylinder Liner Out of Round 0.10 mm MAX 0.004 in Crankshaft End Clearance 0.10 mm 0.56 mm MIN MAX 0.004 in 0.
Component Specifications and Torque Values Page V-4 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. SAE No. 00 0 1/2 1 2 3 787.7 648.0 584.4 511.3 447.8 409.7 mm mm mm mm mm mm MAX MAX MAX MAX MAX MAX 31.01 25.51 23.01 20.13 17.63 16.13 in in in in in in SAE No. 00 0 1/2 1 2 3 0.31 0.25 0.25 0.20 0.20 0.20 mm mm mm mm mm mm MAX MAX MAX MAX MAX MAX 0.012 0.010 0.010 0.008 0.008 0.008 in in in in in in SAE No. 00 0 1/2 1 2 3 0.31 0.25 0.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-5 Ref.No./Steps Metric U.S. Piston Ring End Gap The ring gaps must not be aligned with the piston pin bore. Rotate the rings to position the gaps as shown. Connecting Rod Side Clearance 0.10 mm 0.30 mm MIN MAX 0.004 in 0.012 in Gear Housing Protrusion (below the cylinder block oil pan rail) 0.15 mm MAX 0.006 in Camshaft End Clearance 0.13 mm 0.33 mm MIN MAX 0.
Component Specifications and Torque Values Page V-6 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. Idler Gear End Clearance 0.30 mm 0.53 mm MIN MAX 0.012 in 0.021 in Idler Gear Backlash 0.08 mm 0.41 mm MIN MAX 0.003 in 0.016 in Accessory Drive Gear Backlash 0.08 mm 0.41 mm MIN MAX 0.003 in 0.016 in 0.76 mm MIN 0.030 in 74.5 mm 139.5 mm MAX MAX 2.933 in 5.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-7 Ref.No./Steps Metric U.S. Vibration Damper Face Runout Measurement 0.28 mm MAX 0.011 in Rocker Lever Side Clearance 0.55 mm MIN 0.022 in JacobsT Brake Slave Piston Clearance 0.38 mm MIN 0.015 in 0.36 mm 0.69 mm MIN MIN 0.014 in 0.027 in Injector Adjustment 1. Bottom plunger 2. Loosen adjusting screw 2 flats and torque locknut.
Component Specifications and Torque Values Page V-8 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. Engine Assembly - Capscrew Torque Values Cylinder Liner Clamping Plate Forcing Screw Main Bearing Note: Tighten the capscrews in the sequence shown.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Crankshaft Rear Oil Seal Note: Tighten in a star pattern. Component Specifications and Torque Values Page V-9 Ref.No./Steps 1 2 Flywheel Note: Tighten the capscrews in a star pattern. Connecting Rod 1 2 3 4 5 6 7 Piston Cooling Nozzle Gear Housing Note: Tighten the capscrews in sequence shown Block Mounted Front Sump Suction Tube Retainer Lubricating Oil Pan Note: Tighten the capscrews in the sequence shown. 1 2 Metric U.
Component Specifications and Torque Values Page V-10 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-11 Ref.No./Steps Cam Follower Support Nuts Cylinder Head Note: Tighten the cylinder head capscrews in the sequence shown. Note: Rotate at least one flat, but not more than two. 1 2 3 Cylinder Head (Fuel Pump Side) Tighten the capscrews in the sequence shown. Gear Cover Capscrews 1 through 22 Capscrews 23 through 28 Metric U.S.
Component Specifications and Torque Values Page V-12 Component or Assembly (Procedure) Accessory Drive Oil Seal Accessory Drive Pulley Rocker Lever Housing Note: Tighten the capscrews in the sequence shown. Rocker Lever Assembly Section V - Specifications - Group 18 M11 Ref.No./Steps 1 2 Metric U.S.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-13 Metric U.S.
Component Specifications and Torque Values Page V-14 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Rocker Lever Cover Note: Tighten the capscrews in the sequence shown. Metric U.S.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-15 Ref.No./Steps Metric U.S.
Component Specifications and Torque Values Page V-16 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Metric U.S. Fan Hub Support 75 N•m 55 ft-lb Fan Hub 47 N•m 35 ft-lb Fan Pulley and Fan 47 N•m 35 ft-lb Water Header Plate Note: Tighten the capscrews in the sequence shown.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-17 Metric U.S. Lubricating Oil Filter Head 47 N•m 35 ft-lb Lubricating Oil Cooler Mounting 47 N•m 35 ft-lb Oil Cooler Thermostat Support Mounting Flange 47 N•m 35 ft-lb Dipstick Tube and Housing 47 N•m 35 ft-lb 27 N•m 47 N•m 20 ft-lb 35 ft-lb Air Intake Manifold Note: Tighten the capscrews in the sequence shown.
Component Specifications and Torque Values Page V-18 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-19 Ref.No./Steps Metric U.S. Cylinder Block Liner Seal Seat Bore I.D. 138.063 mm 138.113 mm MIN MAX 5.4355 in 5.4375 in Main Bearing Bore I.D. 121.990 mm 122.015 mm MIN MAX 4.8028 in 4.8037 in 39.95 mm 40.05 mm MIN MAX 1.573 in 1.577 in Main Oil Pressure Regulator Valve Bore I.D. 22.226 mm 22.301 mm MIN MAX 0.8750 in 0.
Component Specifications and Torque Values Page V-20 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. Cylinder Block Camshaft Bore I.D. 76.987 mm 77.040 mm MIN MAX 3.0310 in 3.0331 in Cylinder Liner I.D. 125.000 mm 125.095 mm MIN MAX 4.9213 in 4.9250 in Cylinder Liner Top Press Fit O.D. 145.938 mm 145.976 mm MIN Max 5.7456 in 5.7471 in 137.937 mm 138.013 mm MIN MAX 5.4306 in 5.4336 in Idler Gear Bushing Bore I.D. 60.045 mm 60.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-21 Ref.No./Steps Metric U.S. Idler Gear Ring Dowel O.D. 19.217 mm 19.243 mm MIN MAX 0.7566 in 0.7576 in Idler Gear Thrust Washer Thickness 2.400 mm 2.470 mm MIN MAX 0.0945 in 0.0972 in 0.25 mm MAX 0.0098 in Crankshaft Connecting Rod Journal O.D. 78.950 mm 79.013 mm MIN MAX 3.1083 in 3.1107 in Crankshaft Main Bearing Journal O.D. 114.015 mm 114.055 mm MIN MAX 4.
Component Specifications and Torque Values Page V-22 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. Crankshaft Damper Pilot O.D. 32.01 mm 32.04 mm MIN MAX 1.2602 in 1.2614 in Main Bearing Shell Thickness (Standard) 3.895 mm 3.944 mm MIN MAX 0.1533 in 0.1553 in Note: For visual inspection criteria, refer to the Parts Reuse Guidelines, Bulletin No. 3810303. Crankshaft Thrust Bearing Thickness Connecting Rod Bearing Thickness (Standard) 4.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Crankshaft Pulley Crankshaft Pilot Bore I.D. Component Specifications and Torque Values Page V-23 Ref.No./Steps Metric U.S. 32.05 mm 32.10 mm MIN MAX 1.2618 in 1.2638 in Connecting Rod Capscrew O.D. 12.600 mm 12.800 mm MIN MAX 0.4961 in 0.5039 in Connecting Rod Piston Pin Bushing I.D. (Installed) 54.054 mm 54.099 mm MIN MAX 2.1281 in 2.1299 in Connecting Rod Bearing Bore I.D. 83.975 mm 84.025 mm MIN MAX 3.
Component Specifications and Torque Values Page V-24 Component or Assembly (Procedure) Section V - Specifications - Group 18 M11 Ref.No./Steps Metric U.S. Camshaft Bushing Journal O.D. 71.987 mm 72.013 mm MIN MAX 2.8341 in 2.8352 in Camshaft Gear Mounting Surface O.D. 46.987 mm 47.013 mm MIN MAX 1.8499 in 1.8509 in Camshaft Thrust Bearing Journal O.D. 54.800 mm 55.200 mm MIN MAX 2.1575 in 2.1732 in Camshaft Thrust Plate I.D. 55.60 mm 56.61 mm MIN MAX 2.1890 in 2.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Component Specifications and Torque Values Page V-25 Ref.No./Steps Metric U.S. Piston Ring Groove Width Use a new ring and a 0.15 mm [0.006 inch] feeler gauge. If the feeler gauge enters the groove without resistance the piston must be replaced. Piston Pin Bore I.D. • Articulated Crown 54.040 mm 54.055 mm MIN MAX 2.1276 in 2.1281 in 54.007 mm 54.015 mm MIN MAX 2.1263 in 2.1266 in 101.700 mm 102.000 mm 53.997 mm 54.
Cylinder Block - Rebuild Page V-26 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Block - Torque Values Main Bearing Capscrews Note: Tighten the main bearing capscrews in the sequence shown.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-27 Ref.No./Steps Metric U.S. Valve Spring Free Height: A 103.300 mm Nominal 4.0669 in Valve Spring Working Height: B 71.48 mm Nominal 2.8142 in Load for Working Height at 71.48 mm [2.8142 in]: C 1252 N 1584 N MIN MAX 281 lbf 356 lbf 9.580 mm 9.633 mm MIN MAX 0.3772 in 0.3793 in 3.15 mm 3.62 mm MIN MAX 0.124 in 0.143 in 9.670 mm 9.730 mm MIN MAX 0.3807 in 0.3831 in 9.
Cylinder Block - Rebuild Page V-28 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Valve Guide O.D. (Seal Area) 14.25 mm 14.37 mm MIN MAX 0.561 in 0.566 in Valve Guide O.D. (Base) 16.513 mm 16.526 mm MIN MAX 0.6501 in 0.6506 in 1.63 mm 2.69 mm MIN MAX 0.064 in 0.106 in 0.05 mm MAX 0.002 in 0.76 mm 1.17 mm MIN MAX 0.030 in 0.046 in Valve Head Thickness (at. O.D.) 3.15 mm 3.62 mm MIN MAX 0.124 in 0.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-29 Ref.No./Steps Valve Insert Bore I.D. (Standard Insert) Metric U.S. 45.920 mm 45.935 mm MIN MAX 1.8073 in 1.8085 in 2.28 mm 2.65 mm MIN MAX 0.090 in 0.104 in 2.28 mm 2.54 mm MIN MAX 0.090 in 0.100 in 12.05 mm 12.55 mm MIN MAX 0.474 in 0.494 in Note: Refer to Cylinder Head - Oversize Valve Seat Installation (2-05) for oversize valve insert dimensions.
Cylinder Block - Rebuild Page V-30 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cam Follower Assembly - Rebuild Specifications Cam Follower Roller Side Clearance 0.19 mm 0.65 mm MIN MAX 0.007 in 0.026 in Cam Follower Roller to Pin Clearance 0.08 mm 0.20 mm MIN MAX 0.003 in 0.008 in Cam Follower Shaft Journal O.D. 33.991 mm 34.009 mm MIN MAX 1.3382 in 1.3389 in Cam Follower Lever Shaft Bore I.D. 34.086 mm 34.116 mm MIN MAX 1.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-31 Ref.No./Steps Metric U.S. Cam Follower Roller Pin (New) O.D. 19.065 mm 19.073 mm MIN MAX 0.7506 in 0.7509 in Cam Follower Lever Socket Bore I.D. 19.024 mm 19.050 mm MIN MAX 0.7490 in 0.7500 in Cam Follower Lever Socket (New) O.D. 19.062 mm 19.088 mm MIN MAX 0.7505 in 0.7515 in Gear Pump Shaft Bearing Surface O.D. 12.695 mm MIN 0.4998 in Gear Width 31.707 mm MIN 1.
Cylinder Block - Rebuild Page V-32 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Shaft End Clearance Metric 0.023 mm 0.038 mm U.S. MIN MAX 0.0009 in 0.0015 in Regulator Spring Specifications Part No. 3068424 Wire Dia. mm [inch] 1.52 [.060] No. Coils 5.25 Load Kg [lb] 4.0 [8.9] Length mm [inch] 16.0 [.631] Free Length mm [inch] 21.16 [.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-33 Ref.No./Steps Metric U.S. Injectors - Rebuild Specifications CELECT™ injectors cannot presently be rebuilt. Lubricating Oil System - Specifications Oil Pan Capacity: • Automotive Lubricating Oil Thermostat • Initial Opening Temperature • Fully Open Temperature • Maximum Opening Distance Lubricating Oil Filter Head Bypass Valve Spring: • Free Length • Load at 29.65 mm [1.
Cylinder Block - Rebuild Page V-34 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil Pump Drive Gear Bore I.D. 18.600 mm 18.625 mm MIN MAX 0.7323 in 0.7333 in Lubricating Oil Pump Gear to Body Clearance 9.50 mm 12.00 mm MIN MAX 0.37 in 0.47 in Lubricating Oil System - Torque Values Rear Cover Plate 20 N•m 18 ft-lb Cooling System - Rebuild Specifications Water Pump Body Bearing Bore I.D. 51.996 mm 52.011 mm MIN MAX 2.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-35 Ref.No./Steps Water Pump Shaft Journals O.D. Water Pump Shaft Journals O.D. (Cont’d.) 15.389 mm 15.402 mm MIN MAX 0.6059 in 0.6064 in 2 15.897 mm 15.910 mm MIN MAX 0.6259 in 0.6264 in 3 24.999 mm 25.009 mm MIN MAX 0.9842 in 0.9846 in 4 24.999 mm 25.009 mm 33.951 mm 33.976 mm MIN MAX MIN MAX 0.9842 0.9846 1.3366 1.3376 6 29.987 mm 30.000 mm MIN MAX 1.1806 in 1.1811 in 7 27.
Cylinder Block - Rebuild Page V-36 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fan Hub Face to Face Distance 73.4 mm 74.0 mm MIN MAX 2.890 in 2.913 in Fan Idler Pulley End Clearance 0.05 mm 0.25 mm MIN MAX 0.002 in 0.010 in 1 32.975 mm 33.000 mm MIN MAX 1.2982 in 1.2992 in 2 19.037 mm 19.050 mm MIN MAX 0.7495 in 0.7500 in 45.199 mm 45.224 mm MIN MAX 1.7795 in 1.7805 in 0.00 mm 0.25 mm MIN MAX 0.000 in 0.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-37 Ref.No./Steps Metric U.S. Fan Hub Retaining Capscrew 61 N•m 45 ft-lb Fan Idler Pulley Assembly Retaining Capscrew 47 N•m 35 ft-lb Drive Units - Rebuild Specifications Accessory Drive Shaft End Clearance 0.10 mm 0.30 mm MIN MAX 0.004 in 0.012 in 47.676 mm 47.775 mm MIN MAX 1.8770 in 1.8809 in 6.084 mm 6.312 mm MIN MAX 0.2395 in 0.2485 in 1 34.984 mm 35.000 mm MIN MAX 1.
Cylinder Block - Rebuild Page V-38 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Accessory Drive Splined Coupling I.D. 25.400 mm 25.425 mm MIN MAX 1.0000 in 1.0010 in Accessory Drive Hub Coupling I.D. 25.425 mm 25.438 mm MIN MAX 1.0010 in 1.0015 in Accessory Drive Pulley Bore I.D.: 35.060 mm 35.098 mm MIN MAX 1.3803 in 1.3818 in Drive Shaft Installed Height in the Drive Gear 40.91 mm 40.97 mm MIN MAX 1.611 in 1.
Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Cylinder Block - Rebuild Page V-39 Ref.No./Steps Hydraulic Pump Drive Shaft Installed Height in the Drive Gear Hydraulic Pump Drive Rear Adapter Bore Bearing Depth Metric U.S. 18.50 mm 19.50 mm MIN MAX 0.728 in 0.768 in 0.254 mm 0.762 mm MIN MAX 0.0100 in 0.0300 in Air Intake System - Inspection Specifications Turbocharger Shaft Axial Movement 0.038 mm 0.089 mm MIN MAX 0.0015 in 0.
Cylinder Block - Rebuild Page V-40 Section V - Specifications - Group 18 M11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Electrical Equipment - Inspection Specifications Alternator Bracket (Bus Applications) Lower Bracket Front to Rear Mounting Surface Automatic Tensioner Bracket Locator Hole I.D. 210.7 mm MIN 8.30 in 4.00 mm 4.50 mm MIN MAX 0.354 in 0.
Section V - Specifications - Group 18 M11 Injection Timing Codes Page V-41 Injection Timing Codes Note: Injection timing is measured at 5.161 mm [0.2032 inch] BTDC piston travel. Timing Code CELECT™ HZ Push Rod Travel Range mm in -5.92 to -6.02 -0.233 to -0.237 Read the push rod travel gauge counterclockwise from ‘‘0’’. This travel represents the injection timing value. In the example shown, the value is 1.98 mm [0.078 inch].
Drive Belt Tension Page V-42 Section V - Specifications - Group 18 M11 Drive Belt Tension SAE Belt Size Belt Tension Gauge Part No. Click-type Burroughs Belt Tension New Belt Tension Range Used* N lbf N lbf .380 in. 3822524 620 140 270 to 490 60 to 110 .440 in. 3822524 620 140 270 to 490 60 to 110 1/2 in. 3822524 ST-1138 620 140 270 to 490 60 to 110 11/16 in. 3822524 ST-1138 620 140 270 to 490 60 to 110 3/4 in. 3822524 ST-1138 620 140 270 to 490 60 to 110 7/8 in.
Section V - Specifications - Group 18 M11 FRACTION, DECIMAL, MILLIMETER CONVERSIONS Page V-43 FRACTION, DECIMAL, MILLIMETER CONVERSIONS 8 THS. 16 THS. 32 NDS. 64 THS. INCHES MM 1 0.0156 0.397 0.0313 0.794 0.0469 1.191 0.0625 1.588 0.0781 1.984 0.0938 2.381 0.1094 2.778 0.1250 3.175 0.1406 3.572 0.1563 3.969 0.1719 4.366 0.1875 4.763 0.2031 5.159 0.2188 5.556 0.2344 5.953 0.2500 6.350 0.2656 6.747 0.2813 7.144 0.2969 7.541 0.3125 7.938 0.3281 8.334 0.
Weight and Measures - Conversion Factors Page V-44 Section V - Specifications - Group 18 M11 Weight and Measures - Conversion Factors QUANTITY Area Fuel Consumption Fuel Performance Force Length Power Pressure Temperature Torque Velocity Volume: liquid displacement Weight (mass) Work U.S. CUSTOMARY METRIC Unit Name sq. inch Abbr. in2 sq. foot pounds per horsepower hour miles per gallon gallons per mile pounds force inch foot horsepower pounds force per sq.
Section V - Specifications - Group 18 M11 Newton-Meter to Foot-Pound Conversion Chart Page V-45 Newton-Meter to Foot-Pound Conversion Chart N•m ft-lb N•m ft-lb N•m ft-lb 1 8.850756 in-lb 55 41 155 114 5 44 in-lb 60 44 160 118 6 53 in-lb 65 48 165 122 7 62 in-lb 70 52 170 125 8 71 in-lb 75 55 175 129 9 80 in-lb 80 59 180 133 10 89 in-lb 85 63 185 136 0.
Capscrew Markings and Torque Values Page V-46 Section V - Specifications - Group 18 M11 Capscrew Markings and Torque Values Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S.
Section V - Specifications - Group 18 M11 Pipe Plug Torque Values Page V-47 Capscrew Markings and Torque Values - U.S.
Tap-Drill Chart - U.S. Customary & Metric Page V-48 Section V - Specifications - Group 18 M11 Tap-Drill Chart - U.S. Customary & Metric NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential holding power.
Section 20 - Vehicle Braking - Group 20 M11 Page 20-1 Section 20 - Vehicle Braking - Group 20 Section Contents Page Vehicle Braking - General Information ............................................................................................................
Vehicle Braking - General Information Page 20-2 Section 20 - Vehicle Braking - Group 20 M11 Vehicle Braking - General Information For installation and adjustment of the JacobsW Engine Brake, Model 411, refer to the installation and parts manuals. The Installation Manual, Form No. 018874, and the Parts Manual, Form No.
Section L - Service Literature M11 Page L-1 Section L - Service Literature Section Contents Page Additional Service Literature............................................................................................................................. L-2 Service Literature Ordering Location ...............................................................................................................
Additional Service Literature Page L-2 Section L - Service Literature M11 Additional Service Literature The following publications can be purchased by filling in and mailing the Literature Order Form: 1 BULLETIN NO.
Section L - Service Literature M11 Service Literature Ordering Location Page L-3 Service Literature Ordering Location Region Ordering Location United States and Canada Cummins Distributors or Contact 1-800-DIESELS (1-800-343-7357) U.K., Europe, Mid-East, Africa, and Eastern European Countries Cummins Engine Co., Ltd. Royal Oak Way South Daventry Northants, NN11 5NU, England South and Central America (excluding Brazil and Mexico) Cummins Americas, Inc. 16085 N.W.
Service Literature Ordering Location Page L-4 Section L - Service Literature M11
Literature Order Form Use this form for prompt handling of your literature order. Item Bulletin Number Title of Publication U.S. Price Each Quantity $ 1 Amount $ 2 3 4 5 6 Order Total $ Contact your Cummins distributor for prices and availability. For problems with literature orders, contact 1-800-DIESELS (1-800-343-7357) (for U.S.A. and Canada). Prices subject to change without notice.
Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor. FROM: Name: Street Address: City: State: Zip Code: Country: SHIP TO: (Name and address where literature is to be shipped) Name: Street Address: City: State: Zip Code: Country: Please cut on dotted line ---------------------------------------------------------------------------------------- Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor.
Section C - Component Manufacturers Page C-1 Section C - Component Manufacturers Section Contents Page Component Manufacturers’ Addresses ............................................................................................................ Air Compressors ............................................................................................................................................. Air Cylinders ...........................................................................................
Component Manufacturers’ Addresses Page C-2 Section C - Component Manufacturers Component Manufacturers’ Addresses NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers may be contacted directly for any specifications not covered in this manual. Air Compressors Alternators Bendix Heavy Vehicles Systems Div. of Allied Automotive 901 Cleveland Street Elyria, OH 44036 Telephone: (216) 329-9000 Holset Engineering Co., Inc.
Section C - Component Manufacturers Electric Starting Motors Butec Electrics Cleveland Road Leyland PR5 1XB England Telephone: 0744-21663 C.A.V. Electrical Equipment P.O. Box 36 Warple Way London W3 7SS England Telephone: 01-743-3111 A.C. Delco Components Group Civic Offices Central Milton Keynes MK9 3EL England Telephone: 0908-66001 Delco-Remy P.O. Box 2439 Anderson, IN 46018 Telephone: (317) 646-7838 Leece-Neville Corp. 1374 E.
Component Manufacturers’ Addresses Page C-4 United Technologies Diesel Systems 1000 Jorie Blvd. Oak Brook, IL 60521 Telephone: (312) 325-2020 Heat Sleeves Bentley Harris Manufacturing Co. 100 Bentley Harris Way Gordonville, TN 38563 Telephone: (313) 348-5779 Hydraulic and Power Steering Pumps Hobourn Eaton Ltd. Priory Road Strood Rochester Kent ME2 2BD Telephone: 0634-71773 Honeywell Control Systems Ltd.
Index Page 1 About the Manual ....................................................................... i-2 Accessory Drive Pulley - Cleaning and Inspection for Reuse. 9-17 Cleaning................................................................................. 9-17 Inspection............................................................................... 9-17 Air Compressor - Cleaning and Inspection for Reuse............ 12-6 Cleaning...........................................................................
Index Page 2 Crankshaft Gear - Replacement .............................................. 1-39 Inspection............................................................................... 1-39 Installation.............................................................................. 1-40 Removal ................................................................................. 1-39 Crankshaft Magnetic Crack Inspection ................................... 1-30 Coil Shot (Circumferental Magnetization) ............
Index Page 3 Rocker Lever Housing - Installation ....................................... 0-111 Rocker Lever Side Clearance - Adjustment ........................... 0-114 Sensor Harness - Installation ................................................ 0-123 Starting Motor - Installation ................................................... 0-131 Static Injection Timing - Checking .......................................... 0-97 Static Injection Timing - General Information ..........................
Index Page 4 Engine Testing - General Information .................................... 14-2 Chassis Dynamometer, Portable Dynamometer or Load Bank Run-In ................................................................................... 14-2 Definition of Terms On Engine Performance Curve ................. 14-3 Engine Dynamometer Run-In ................................................ 14-2 Fuel Flow Measurement on Engine or Chassis Dynamometer . 14-5 Installation ...........................................
Index Page 5 Lubricating Oil Pump - Cleaning and Inspection for Reuse... 7-14 Assembly................................................................................ 7-17 Cleaning................................................................................. 7-14 Disassembly ........................................................................... 7-15 Inspection..................................................................... 7-14 , 7-16 Lubricating Oil Pump - Rebuild..............................
