Cummins M11 Series Engines Troubleshooting and Repair Manual

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This complete service repair workshop manual PDF download for the Cummins M11 Series Engines (STC, CELECT™, CELECT™ Plus Models) has easy-to-read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes.

This manual provides instructions for troubleshooting and repairing this engine in the chassis.


TABLE OF CONTENTS :

Introduction
Engine Identification
Troubleshooting Symptoms
Complete Engine — Group 00
Cylinder Block — Group 01
Cylinder Head — Group 02
Rocker Levers — Group 03
Cam Followers/Tappets — Group 04
Fuel System — Group 05
Injectors and Fuel Lines — Group 06
Lubricating Oil System — Group 07
Cooling System — Group 08
Drive Units — Group 09
Air Intake System — Group 10
Exhaust System — Group 11
Compressed Air System — Group 12
Electrical Equipment — Group 13
Engine Testing — Group 14
Mounting Adaptations — Group 16
Miscellaneous Hardware — Group 17
Vehicle Braking — Group 20
Service Literature
Component Manufacturers
Specifications
Index

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bulletin No. : 3666139–00
Total Pages : 926


This (OEM) manual pdf download has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAIN MENU
COVER PAGE
TABLE OF CONTENTS
INTRODUCTION
ABOUT THIS MANUAL
ACRONYMS AND ABBREVIATIONS
GENERAL CLEANING INSTRUCTIONS
GLASS OR PLASTIC BEAD CLEANING
SOLVENT AND ACID CLEANING
STEAM CLEANING
GENERAL REPAIR INSTRUCTIONS
WELDING ON A VEHICLE WITH AND ELECTRONIC CONTROLLED FUEL SYSTEM
GENERAL SAFETY INSTRUCTIONS
IMPORTANT SAFETY NOTICE
HOW TO USE THE MANUAL
ILLUSTRATIONS
SYMBOLS
ENGINE IDENTIFICATION
ENGINE DIAGRAMS
ENGINE IDENTIFICATION
CUMMINS ENGINE NOMENCLATURE
ECM DATAPLATE
ENGINE DATAPLATE
FUEL PUMP DATAPLATE
SPECIFICATIONS
AIR INTAKE SYSTEM
BATTERIES (SPECIFIC GRAVITY)
COOLING SYSTEM
ELECTRICAL SYSTEM
EXHAUST SYSTEM
FUEL SYSTEM
GENERAL SPECIFICATIONS
LUBRICATING OIL SYSTEM
TROUBLESHOOTING SYMPTOMS
PROCEDURES AND TECHNIQUES
TROUBLESHOOTING SYMPTOMS CHARTS
AIR COMPRESSOR AIR PRESSURE RISES SLOWLY
AIR COMPRESSOR CYCLES FREQUENTLY
AIR COMPRESSOR NOISE IS EXCESSIVE
AIR COMPRESSOR PUMPING EXCESS LUBRICATING OIL INTO THE AIR SYSTEM
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)
AIR COMPRESSOR WILL NOT PUMP AIR
AIR COMPRESSOR WILL NOT STOP PUMPING
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING
ALTERNATOR OVERCHARGING
COMMUNICATION ERROR - ELECTRONIC SERVICE TOOL OR CONTROL DEVICE
CONNECTING ROD BEARING NOISE
COOLANT IN THE LUBRICATING OIL
COOLANT LOSS (EXTERNAL)
COOLANT LOSS - INTERNAL
COOLANT TEMPERATURE ABOVE NORMAL - GRADUAL OVERHEAT
COOLANT TEMPERATURE IS ABOVE NORMAL - SUDDEN OVERHEAT
COOLANT TEMPERATURE IS BELOW NORMAL
CRANKCASE GASES (BLOWBY) EXCESSIVE
CRANKING FUEL PRESSURE IS LOW
DRIVEABLITY - GENERAL INFORMATION
DRIVEABLITY /LOW POWER - CUSTOMER COMPLAINT FORM
DRIVEABILITY/LOW POWER/EXCESSIVE FUEL CONSUMPTION - CHECKLIST
ENGINE ACCELERATION OR RESPONSE POOR
ENGINE BRAKE DOES NOT OPERATE (CELECT OR CELECT PLUS)
ENGINE BRAKE - LOW RETARDING POWER OR SLOW TO ACTIVATE (CELECT OR CELECT PLUS)
ENGINE BRAKE - ONE OR MORE CYLINDERS BRAKING WITH POWER SWITCH OFF (CELECT OR CELECT PLUS)
ENGINE DECELERATES SLOWLY (CELECT AND CELECT PLUS)
ENGINE DECELERATES SLOWLY (PT)
ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE)
ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE)
ENGINE NOISE DIAGNOSTIC PROCEDURES - GENERAL INFORMATION
ENGINE NOISE EXCESSIVE
ENGINE NOISE EXCESSIVE - COMBUSTION KNOCKS
ENGINE NOISE EXCESSIVE - CONNECTING ROD
ENGINE NOISE EXCESSIVE - MAIN BEARING
ENGINE NOISE EXCESSIVE - PISTON
ENGINE NOISE EXCESSIVE - TURBOCHARGER
ENGINE POWER OUTPUT LOW (CELECT OR CELECT PLUS)
ENGINE POWER OUTPUT LOW (PT)
ENGINE RUNS ROUGH AT IDLE
ENGINE RUNS ROUGH OR MISFIRES
ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION
ENGINE SPEED SURGES AT LOW OR HIGH IDLE
ENGINE SPEED SURGES UNDER LOAD OR IN OPERATING RANGE
ENGINE STARTS BUT WILL NOT KEEP RUNNING
ENGINE VIBRATION EXCESSIVE
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)
ENGINE WILL NOT SHUT OFF
FUEL CONSUMPTION EXCESSIVE (CELECT AND CELECT PLUS)
FUEL CONSUMPTION EXCESSIVE (PT)
FUEL CONSUMPTION - CUSTOMER COMPLAINT FORM
FUEL CONSUMPTION - GENERAL INFORMATION
FUEL IN THE COOLANT
FUEL IN THE LUBRICATING OIL
INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION
INTAKE MANIFOLD PRESSURE (BOOST) IS BELOW NORMAL
LOW IDLE ADJUST SWITCH DOES NOT WORK
LUBRICATING OIL CONSUMPTION EXCESSIVE
LUBRICATING OIL CONTAMINATED
LUBRICATING OIL IN THE FUEL
LUBRICATING OIL PRESSURE HIGH
LUBRICATING OIL PRESSURE LOW
LUBRICATING OIL SLUDGE IN THE CRANKCASE EXCESSIVE
LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION
LUBRICATING OR TRANSMISSION OIL IN THE COOLANT
MAIN BEARING NOISE
OIL CONSUMPTION
OPERATING FUEL PRESSURE IS LOW
PISTON NOISE
RESPONSE TEST - CELECT AND CELECT PLUS
SMOKE, BLACK - EXCESSIVE (CELECT AND CELECT PLUS)
SMOKE, BLACK - EXCESSIVE (PT)
SMOKE, WHITE - EXCESSIVE (CELECT AND CELECT PLUS)
SMOKE, WHITE - EXCESSIVE (PT)
STEP TIMING CONTROL (STC) VALVE IS NOT SHIFTING CORRECTLY
TURBOCHARGER LEAKS ENGINE OIL OR FUELBVARIABLE SPEED (VS) GOVERNOR - FUEL LEAK AT THE THROTTLE SHAFT
VARIABLE SPEED (VS) GOVERNOR - FUEL LEAK AT THE THROTTLE SHAFT
VARIABLE SPEED (VS) GOVERNOR - SPEED IS NOT SET CORRECTLY
VARIABLE SPEED (VS) GOVERNOR - SURGE WITH ENGINE UNDER LOAD
COMPLETE ENGINE - GROUP 00
COMPLETE ENGINE - GENERAL INFORMATION
ENGINE INSTALLATION
INSTALL
ENGINE REMOVAL
REMOVE
SERVICE TOOLS
ENGINE REMOVAL AND INSTALLATION
CYLINDER BLOCK - GROUP 01
ACCESSORY DRIVE SEAL
CLEAN
INSTALL
REMOVE
ALTERNATOR DRIVE SEAL
CLEAN
INSTALL
REMOVE
BEARINGS, CONNECTING ROD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
BEARINGS, MAIN
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
BEARINGS, THRUST
INSTALL
REMOVE
CAMSHAFT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CAMSHAFT BUSHINGS
CLEAN
INSPECT FOR REUSE
INSTALL
NUMBER ONE BUSHING - INSTALLATION
NUMBER SEVEN BUSHING - INSTALLATION
NUMBER SIX THROUGH NUMBER TWO BUSHING - INSTALLATION
REMOVE
CAMSHAFT END CLEARNACE
MEASURE
CAMSHAFT GEAR (CAMSHAFT INSTALLED)
INSPECT FOR REUSE
INSTALL
REMOVE
CAMSHAFT GEAR (CAMSHAFT REMOVED)
INSTALL
REMOVE
CONNECTING ROD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT
ROTATION CHECK
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
CRANKSHAFT SEAL, FRONT
CLEAN
INSTALL
REMOVE
CRANKSHAFT SEAL, REAR
CLEAN
INSTALL
REMOVE
CYLINDER BLOCK AND LINER SEATS
LEAK TEST
CYLINDER LINER
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CYLINDER LINER PROTRUSION
MEASURE
PREPARATORY
GEAR COVER, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
GEAR HOUSING, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
IDLER GEAR, CAMSHAFT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
IDLER GEAR, HYDRAULIC PUMP
CLEAN
INSPECT
INSTALL
REMOVE
IDLER GEAR, WATER PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON
ASSEMBLE
CLEAN
DISASSEMBLE
GENERAL INFORMATION
INSPECT FOR REUSE
ARTICULATED PISTON
INSTALL
REMOVE
PISTON AND CONNECTING ROD ASSEMBLY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON COOLING NOZZLE
INSPECT FOR REUSE
INSTALL
REMOVE
PISTON RINGS
INSPECT FOR REUSE
SERVICE TOOLS
CYLINDER BLOCK
VIBRATION DAMPER
CLEAN
ECCENTRICITY CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
WOBBLE CHECK
WATER HEADER PLATE, CYLINDER BLOCK
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
CYLINDER HEAD - GROUP 02
CYLINDER HEAD
CLEAN
INSPECT FOR REUSE
INSTALL
LEAK TEST
PRESSURE TEST
REMOVE
SERVICE TOOLS
CYLINDER HEAD
ROCKER LEVERS - GROUP 03
CRANKCASE BREATHER (INTERNAL)
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
OVERHEAD SET
ADJUST
ENGINE BRAKE - ADJUST
GENERAL INFORMATION
INJECTOR ADJUSTMENT - CELECT AND CELECT PLUS ENGINES
INJECTOR ADJUSTMENT -STC ENGINES
VALVE ADJUSTMENT - CELECT AND CELECT PLUS ENGINES
VALVE ADJUSTMENT - STC ENGINES
MEASURE
GENERAL INFORMATION
VALVE AND INJECTOR LASH - CELECT AND CELECT PLUS ENGINES
VALVE LASH - STC ENGINES
ROCKER LEVER ASSEMBLY
ASSEMBLE
ALUMINUM SUPPORTS
CAST IRON SUPPORTS
CLEAN
DISASSEMBLE
GENERAL INFORMATION
INSPECT FOR REUSE
INSTALL
REMOVE
ROCKER LEVER COVER
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ROCKER LEVER HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
ROCKER LEVERS
CAM FOLLOWERS/TAPPETS - GROUP 04
CAM FOLLOWER ASSEMBLY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
PUSH RODS OR TUBES
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
CAM/FOLLOWER/TAPPETS
FUEL SYSTEM - GROUP 05
FLOW DIAGRAM, FUEL SYSTEM
FUEL CONSUMPTION
MEASURE
FUEL FLOW
INITIAL CHECK
LEAK TEST
PRESSURE TEST
MINIMUM CRANKING PRESSURE
MINIMUM OPERATING PRESSURE
FUEL PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
CELECT OR CELECT PLUS
STC
PRIME
CELECT OR CELECT PLUS
GENERAL INFORMATION
STC
REMOVE
CELECT OR CELECT PLUS
STC
ROTATION CHECK
FUEL PUMP GEAR PUMP CHECK VALVE
INSTALL
REMOVE
FUEL PUMP HIGH IDLE SPEED (VS GOVERNOR)
ADJUST
HIGH SPEED
IDLE SPEED
FUEL PUMP IDLE SPEED
ADJUSTMENT
FUEL PUMP PRESSURE REGULATOR
INITIAL CHECK
FUEL PUMP PULSATION DAMPER
INSPECTION FOR REUSE
FUEL PUMP THROTTLE LEVER
ADJUST
FUEL PUMP THROTTLE LINKAGE
ADJUST
FUEL PUMP VS THROTTLE SHAFT HOUSING
INSTALL
REMOVE
FUEL SHUTOFF VALVE (FSOV)
INSPECT FOR REUSE
FUEL SYSTEM - GENERAL INFORMATION
INSTALLATION RECOMMENDATIONS
INSTALLATION PUBLICATIONS
OVERHEAD FUEL TANK REQUIREMENTS
PROPER USE OF FUEL SYSTEM GAUGES
SERVICE TOOLS
FUEL SYSTEM
SPECIFICATIONS
FUEL RECOMMENDATIONS
FUEL OIL RECOMMENDED PROPERTIES
FUEL SYSTEM
STALL SPEED CHECK LIST
IF THE STALL SPEED IS TOO HIGH, CHECK THE FOLLOWING:
IF THE STALL SPEED IS TOO LOW, CHECK THE FOLLOWING:
STALL SPEED TEST
STALL SPEED CHECK
CONVERTER TRANSMISSIONS STALL SPEED
TIME SPEED CHECK
VS GOVERNER ADJUSTING SCREW SEALING WASHERS
INSTALL
REMOVE
VS GOVERNER IDLE SPRING
INSTALL
REMOVE
INJECTORS AND FUEL LINES - GROUP 06
AFC NO AIR CHECK
MEASURE
AIR IN FUEL
TEST
GEAR PUMP DRAIN METHOD
SIGHTGLASS METHOD
CYLINDER MISFIRES OR SMOKES
AUTOMATED CYLINDER PERFORMANCE TEST
CELECT OR CELECT PLUS
CYLINDER CUTOUT TEST
CELECT OR CELECT PLUS
STC
EXHAUST MANIFOLD TEMPERATURE TEST
EXHAUST MANIFOLD TILT-BACK METHOD
GENERAL INFORMATION
ECM COOLING PLATE
INSTALL
REMOVE
FUEL DRAIN LINE RESTRICTION
MEASURE
FUEL FILTER (SPIN-ON TYPE)
INSTALL
REMOVE
FUEL INLET RESTRICTION
MEASURE
FUEL SUPPLY LINES
INSPECT FOR REUSE
REMOVE
INJECTOR
INSTALL
CELECT OR CELECT PLUS
STC
REMOVE
CELECT OR CELECT PLUS
STC
INJECTORS AND FUEL LINES - GENERAL INFORMATION
THEORY OF OPERATION - CELECT AND CELECT PLUS FUEL SYSTEM
HYDROMECHANICAL SUBSYSTEM
INJECTION CYCLE
THEORY OF OPERATION - PT FUEL SYSTEM
THEORY OF OPERATION - STC FUEL SYSTEM
SERVICE TOOLS
INJECTORS AND FUEL LINES
STATIC INJECTION TIMING
MEASURE
SETUP
STC OIL CONTROL VALVE (MECHANICAL)
INITIAL CHECK
INSTALL
REMOVE
STC OIL DELIVERY SYSTEM BLOCKAGE
INITIAL CHECK
LEAK TEST
STC OIL DELIVERY SYSTEM DIAGNOSTICS
TEST
LUBRICATING OIL SYSTEM - GROUP 07
FLOW DIAGRAM, LUBRICATING OIL SYSTEM
LUBRICATING OIL AND FILTERS
INSPECT
LUBRICATING OIL CONTAMINATION
FLUORESCENT DYE TRACER
FUEL PRESSURE TEST
LUBRICATING OIL COOLER
CLEAN
INSTALL
PRESSURE TEST
REMOVE
LUBRICATING OIL DIPSTICK
CALIBRATE
LUBRICATING OIL DIPSTICK HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL FILTER (CANISTER-TYPE)
LEAK TEST
LUBRICATING OIL FILTER HEAD
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL FILTER (SPIN ON)
GENERAL INFORMATION
INSTALL
REMOVE
LUBRICATING OIL HIGH PRESSURE RELIEF VALVE
INTIAL CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL LEAKS
MAINTENANCE CHECK
EXTERNAL
LUBRICATING OIL PAN
CLEAN
DRAIN
FILL
INSPECT FOR REUSE
INSTALL
FRONT SUMP PAN
REAR SUMP PAN
REMOVE
FRONT SUMP PAN
REAR SUMP PAN
LUBRICATING OIL PRESSURE GAUGE
TEST
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL PUMP
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL SYSTEM
PRIME
LUBRICATING OIL SYSTEM - GENERAL INFORMATION
LUBRICATING OIL TEMPERATURE GAUGE
TEST
LUBRICATING OIL THERMOSTAT
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL TRANSFER TUBE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
LUBRICATING OIL VISCOSITY SENSOR
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
LUBRICATING OIL SYSTEM
SPECIFICATIONS
CUMMINS/FLEETGUARD FILTER SPECIFICATIONS
LUBRICATING OIL FILTERS
LUBRICATING OIL SYSTEM
COOLING SYSTEM - GROUP 08
COOLANT FILTER
INSTALL
REMOVE
COOLANT FILTER HEAD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT HEATER HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT TEMPERATURE GAUGE
INITIAL CHECK
COOLANT THERMOSTAT
INSPECT FOR REUSE
INSTALL
LEAK TEST
REMOVE
COOLANT THERMOSTAT HOUSING SUPPORT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT THERMOSTAT SEAL
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
COOLANT VENT LINES
INITIAL CHECK
COOLING SYSTEM
CLEAN
DRAIN
FILL
PRESSURE TEST
COOLING SYSTEM - AIR OR COMBUSTION GAS TEST
INITIAL TEST
AIR COOLING SYSTEM
LEAK TEST
AIR COMPRESSOR
COMBUSTION GAS LEAK
FAN, SHUTTER, OR HEATER AIR CONTROL VALVE
COOLING SYSTEM - GENERAL INFORMATION
COOLING SYSTEM DIAGNOSTICS
ANALYZING THE DATA
GENERAL INFORMATION
SETUP
TEST
OPERATIONAL WORKSHEET
COOLING SYSTEM PRECHARGE
CUSTOMER PRECHARGE METHOD
FACTORY PRECHARGE METHOD
GENERAL INFORMATION
DRIVE BELT, COOLING FAN
INSPECT FOR REUSE
INSTALL
REMOVE
FAN CLUTCH, AIR-DISENGAGED
GENERAL INFORMATION
MAINTENANCE CHECK
FAN CLUTCH, AIR-ENGAGED
GENERAL INFORMATION
MAINTENANCE CHECK
FAN CLUTCH, ELECTRIC
INSPECT FOR REUSE
INSTALL
REMOVE
FAN CLUTCH, ON-OFF
GENERAL INFORMATION
INITIAL CHECK
FAN CLUTCH, VISCOUS
GENERAL INFORMATION
INITIAL CHECK
INSTALL
REMOVE
FAN, COOLING
INSPECT FOR REUSE
INSTALL
REMOVE
FAN DRIVE IDLER PULLEY ASSEMBLY
INITIAL CHECK
INSTALL
REMOVE
FAN HUB, BELT DRIVEN
INITIAL CHECK
INSTALL
REMOVE
FAN SHROUD ASSEMBLY
INITIAL CHECK
FAN SPACER AND PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
FLOW DIAGRAM, COOLING SYSTEM
RADIATOR
INITIAL CHECK
RADIATOR HOSES
INSPECT FOR REUSE
RADIATOR PRESSURE CAP
INSPECT FOR REUSE
RADIATOR SHUTTER ASSEMBLY
INITIAL CHECK
SERVICE TOOLS
COOLING SYSTEM
SPECIFICATIONS
COOLANT REPLACEMENT REQUIREMENTS
COOLING SYSTEM
COOLING SYSTEM SEALING ADDITIVES
COOLING SYSTEM SOLUBLE OILS
FLEETGUARD DCA4 SERVICE FILTERS AND LIQUID PRECHARGE
FULLY FORMULATED COOLANT/ANTIFREEZE
GENERAL INFORMATION
SUPPLEMENTAL COOLANT ADDITIVE (SCA)
TEST INTERVALS
TESTING SCA CONCENTRATION LEVEL CC-2602 TEST KIT
PRECAUTIONS AND INSTRUCTIONS FOR PROPER KIT USE
THERMO CONTROL SETTINGS
TORQUE CONVERTER COOLER
GENERAL INFORMATION
WATER PUMP
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
WIRING HARNESS, CUMMINS ELECTRIC FAN CLUTCH
GENERAL INFORMATION
INITIAL CONNECTIONS
INSTALL
REMOVE
DRIVE UNITS - GROUP 09
ACCESSORY DRIVE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ACCESSORY DRIVE PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
ALTERNATOR DRIVE PULLEY
INSPECT FOR REUSE
INSTALL
REMOVE
HYDRAULIC PUMP DRIVE
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE TOOLS
DRIVE UNITS
AIR INTAKE SYSTEM - GROUP 10
AFTERCOOLER
CLEAN
INSPECT FOR REUSE
INSTALL
PRESSURE TEST
REMOVE
AIR INTAKE MANIFOLD
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
AIR INTAKE RESTRICTION
MEASURE
AIR INTAKE SYSTEM - GENERAL INFORMATION
GENERAL INFORMATION
AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS
MAINTENANCE CHECK
CHARGE AIR COOLER (CAC)
CLEAN
INSPECT FOR REUSE
LEAK TEST
PRESSURE DIFFERENTIAL TEST
TEMPERATURE DIFFERENTIAL TEST
FLOW DIAGRAM, AIR INTAKE SYSTEM
SERVICE TOOLS
AIR INTAKE SYSTEM
SPECIFICATIONS
AIR INTAKE SYSTEM
TURBOCHARGER
CHECK FOR CORRECT COMPONENT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
TURBOCHARGER AXIAL CLEARANCE
MEASURE
TURBOCHARGER BLADE DAMAGE
INSPECT FOR REUSE
TURBOCHARGER COMPRESSOR SEAL LEAKS
LEAK TEST
TURBOCHARGER RADIAL BEARING CLEARANCE
MEASURE
TURBOCHARGER TURBINE SEAL LEAKS
LEAK TEST
EXHAUST SYSTEM - GROUP 11
EXHAUST MANIFOLD, DRY
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
INSTALL
REMOVE
EXHAUST RESTRICTION
MEASURE
FLOW DIAGRAM, EXHAUST SYSTEM
SPECIFICATIONS
EXHAUST SYSTEM
COMPRESSED AIR SYSTEM - GROUP 12
AIR COMPRESSOR
INSPECT FOR REUSE
INSTALL
REMOVE
AIR COMPRESSOR CARBON BUILDUP
INITIAL CHECK
AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS)
ASSEMBLE
QE, EUROPEAN
QE, NON-EUROPEAN
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS)
ASSEMBLE
CLEAN
DISASSEMBLE
INSPECT FOR REUSE
AIR COMPRESSOR PIN BORE WEAR
INITIAL CHECK
AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY
CLEAN
INITIAL CHECK
INSPECT FOR REUSE
INSTALL
HOLSET QE MODELS
HOLSET SS, E-TYPE, AND ST MODELS
REMOVE
HOLSET QE MODELS
HOLSET SS, E-TYPE, AND ST MODELS
AIR GOVERNER (AIR COMPRESSOR PUMPS CONTINUOUSLY)
INITIAL CHECK
AIR GOVERNOR (AIR COMPRESSOR WILL NOT PUMP)
INITIAL CHECK
AIR LEAKS, COMPRESSED AIR SYSTEM
INITIAL CHECK
COMPRESSED AIR SYSTEM - GENERAL INFORMATION
SERVICE TOOLS
COMPRESSED AIR SYSTEMS
SPECIFICATIONS
COMPRESSED AIR SYSTEM
HOLSET SS296/SS296E/QE296A/C MODELS
HOLSET SS338/QE338 A/C MODELS
HOLSET ST676 A/C MODEL
ELECTRICAL EQUIPMENT - GROUP 13
ALTERNATOR
INITIAL CHECK
INSTALL
REMOVE
BATTERIES
INITIAL CHECK
BATTERY CABLES AND CONNECTIONS
INITIAL CHECK
DRIVE BELT, ALTERNATOR
ADJUST
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
INSTALL
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
REMOVE
ADJUSTMENT LINK TYPE
AUTOMATIC BELT TENSIONER
ELECTRICAL EQUIPMENT - GENERAL INFORMATION
SERVICE TOOLS
ELECTRICAL EQUIPMENT
SPECIFICATIONS
ELECTRICAL SYSTEM
STARTER MAGNETIC SWITCH
CURRENT CHECK
STARTER SOLENOID
VOLTAGE CHECK
STARTER SWITCH
VOLTAGE
STARTING MOTOR
INSTALL
REMOVE
ENGINE TESTING - GROUP 14
DYNAMOMETER WORKSHEET
ENGINE RUN-IN (CHASSIS DYNAMOMETER)
RUN-IN INSTRUCTIONS
ENGINE RUN-IN (ENGINE DYNAMOMETER)
RUN-IN INSTRUCTIONS
ENGINE RUN-IN (WITHOUT DYNAMOMETER)
RUN-IN INSTRUCTIONS
OFF-HIGHWAY APPLICATIONS
ON-HIGHWAY APPLICATIONS
ENGINE TESTING - GENERAL INFORMATION
FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER
ENGINE TESTING (CHASSIS DYNAMOMETER)
SETUP
TEST
ENGINE TESTING (ENGINE DYNAMOMETER)
SETUP
ENGINE TESTING (PORTABLE DYNAMOMETER OR LOAD BANK)
GENERAL INFORMATION
SERVICE TOOLS
ENGINE TESTING
SPECIFICATIONS
ENGINE TESTING
MOUNTING ADAPTATIONS - GROUP 16
ENGINE LIFTING BRACKETS
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
ENGINE SUPPORT BRACKET, FRONT
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
FLYWHEEL
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
BORE RUN OUT
FACE RUN OUT
REMOVE
FLYWHEEL HOUSING
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
FACE ALIGNMENT
BORE ALIGNMENT
REMOVE
FLYWHEEL HOUSING, REPTO
CLEAN
INSPECT FOR REUSE
INSTALL
MEASURE
BORE ALIGNMENT
FACE ALIGNMENT
REMOVE
FLYWHEEL RING GEAR
INSTALL
REMOVE
SERVICE TOOLS
MOUNTING ADAPTATIONS
MISCELLANEOUS HARDWARE - GROUP 17
CUP PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
PIPE PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
STRAIGHT THREAD PLUG
CLEAN
INSPECT FOR REUSE
INSTALL
REMOVE
VEHICLE BRAKING - GROUP 209
ENGINE BRAKE
ADJUST
CLEAN
INITIAL CHECK
INSPECT FOR REUSE
INSTALL
REMOVE
SERVICE LITERATURE
ADDITIONAL SERVICE LITERATURE
LITERATURE ORDER FORM
SERVICE LITERATURE ORDERING LOCATION
COMPONENT MANUFACTURERS
COMPONENT MANUFACTURERS' ADDRESSES
AIR COMPRESSORS
AIR CYLINDERS
AIR HEATERS
AIR STARTING MOTORS
ALTERNATORS
AUXILIARY BRAKES
BELTS
CATALYTIC CONVERTORS
CLUTCHES
COOLANT HEATERS
COOLANT LEVEL SWITCHES
DRIVE PLATES
ELECTRIC STARTING MOTORS
ELECTRONIC SWITCHES
ENGINE PROTECTION SWITCHES
FAN CLUTCHES
FANS
FAULT LAMPS
FILTERS
FLEXPLATES
FUEL COOLERS
FUEL WARMERS
GAUGES
GOVERNORS
HEAT SLEEVES
HYDRAULIC AND POWER STEERING PUMPS
IN-LINE CONNECTORS
OIL HEATERS
PRELUBRICATION SYSTEMS
READIATORS
THROTTLE ASSEMBLIES
TORQUE CONVERTERS
SPECIFICATIONS
AIR INTAKE SYSTEM - SPECIFICATIONS
AIR INTAKE RESTRICTION
TURBOCHARGER AXIAL CLEARANCE
TURBOCHARGER RADIAL BEARING CLEARANCE
AIR INTAKE SYSTEM - TORQUE VALUES
AFTERCOOLER
AIR INTAKE MANIFOLD
AIR LEAKS, AIR INTAKE AND EXHAUST SYSTEMS
TURBOCHARGER
CAM FOLLOWERS/TAPPETS - SPECIFICATIONS
CAM FOLLOWER ASSEMBLY
CAM FOLLOWERS/TAPPETS - TORQUE VALUES
CAM FOLLOWER ASSEMBLY
CAPSCREW MARKINGS AND TORQUE VALUES
CAPSCREW MARKINGS AND TORQUE VALUES - METRIC
CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY
COMPRESSED AIR SYSTEM - TORQUE VALUES
AIR COMPRESSOR
AIR COMPRESSOR CYLINDER HEAD (HOLSET QE MODELS)
AIR COMPRESSOR CYLINDER HEAD (HOLSET SS AND E-TYPE MODELS)
AIR COMPRESSOR CYLINDER HEAD (HOLSET ST MODELS)
AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY
COOLING SYSTEM - SPECIFICATIONS
COOLANT THERMOSTAT
FAN DRIVE IDLER PULLEY ASSEMBLY
FAN HUB, BELT DRIVEN
WATER PUMP
COOLING SYSTEM - TORQUE VALUES
COOLANT FILTER HEAD
COOLANT HEATER HOUSING
COOLANT THERMOSTAT
COOLANT THERMOSTAT HOUSING SUPPORT
DRIVE BELT, COOLING FAN
FAN CLUTCH, ELECTRIC
FAN CLUTCH, VISCOUS
FAN, COOLING
FAN HUB, BELT DRIVEN
FAN SPACER AND PULLEY
WATER PUMP
CYLINDER BLOCK - SPECIFICATIONS
BEARINGS, CONNECTING ROD
BEARINGS, MAIN
BEARINGS, THRUST
CAMSHAFT
CAMSHAFT BUSHINGS
CAMSHAFT GEAR (CAMSHAFT INSTALLED)
CONNECTING ROD
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)
CYLINDER LINER PROTRUSTION
GEAR HOUSING, FRONT
IDLER GEAR, CAMSHAFT
IDLER GEAR, HYDRAULIC PUMP
IDLER GEAR, WATER PUMP
PISTON COOLING NOZZLE
PISTON RINGS
CYLINDER BLOCK - TORQUE VALUES
ACCESSORY DRIVE SEAL
ALTERNATOR DRIVE SEAL
BEARINGS, MAIN
CAMSHAFT
CRANKSHAFT PULLEY
CRANKSHAFT SEAL, FRONT
CRANKSHAFT SEAL, REAR
CYLINDER LINER PROTRUSION
GEAR COVER, FRONT
GEAR HOUSING, FRONT
IDLER GEAR, CAMSHAFT
IDLER GEAR, HYDRAULIC PUMP
IDLER GEAR, WATER PUMP
PISTON AND CONNECTING ROD ASSEMBLY
PISTON COOLING NOZZLE
WATER HEADER PLATE, CYLINDER BLOCK
CLYINDER HEAD - SPECIFICATIONS
CYLINDER HEAD
CYLINDER HEAD - TORQUE VALUES
CYLINDER HEAD
DRIVE BELT TENSION
DRIVE UNITS - SPECIFICATIONS
ACCESSORY DRIVE
HYDRAULIC PUMP DRIVE
DRIVE UNITS - TORQUE VALUES
ACCESSORY DRIVE
ACCESSORY DRIVE PULLEY
ALTERNATOR DRIVE PULLEY
HYDRUALIC PUMP DRIVE
ELECTRICAL EQUIPMENT - TORQUE VALUES
ALTERNATOR
DRIVE BELT, ALTERNATOR
STARTING MOTOR
EXHAUST SYSTEM - SPECIFICATIONS
EXHAUST RESTRICTION
EXHAUST SYSTEM - TORQUE VALUES
EXHAUST MANIFOLD, DRY
FRACTION, DECIMAL, MILLIMETER CONVERSIONS
FUEL SYSTEM - SPECIFICATIONS
FUEL FLOW
FUEL SYSTEM - TORQUE VALUES
FUEL PUMP
FUEL PUMP GEAR PUMP CHECK VALVE
FUEL PUMP PULSATION DAMPER
FUEL PUMP VS THROTTLE SHAFT HOUSING
FUEL SHUTOFF VALVE
INJECTION TIMING CODES
INJECTORS AND FUEL LINES - SPECIFICATIONS
FUEL DRAIN LINE RESTRICTION
FUEL INLET RESTRICTION
INJECTORS AND FUEL LINES - TORQUE VALUES
ECM COOLING PLATES
INJECTOR
STC OIL CONTROL VALVE (MECHANICAL)
LUBRICATING OIL SYSTEM - SPECIFICATION
LUBRICATING OIL HIGH PRESSURE RELIEF VALVE
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
LUBRICATING OIL PUMP
LUBRICATING OIL SYSTEM - TORQUE VALUES
LUBRICATING OIL COOLER
LUBRICATING OIL DIPSTICK HOUSING
LUBRICATING OIL FILTER HEAD
LUBRICATING OIL PAN
LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE)
LUBRICATING OIL PUMP
LUBRICATING TRANSFER TUBE
LUBRICATING OIL VISCOSITY SENSOR
MISCELLANEOUS - SPECIFICATIONS
MOUNTING ADAPTATIONS - SPECIFICATIONS
FLYWHEEL HOUSING
MOUNTING ADAPTATIONS - TORQUE VALUES
ENGINE LIFTING BRACKETS
ENGINE SUPPORT BRACKET, FRONT
FLYWHEEL
FLYWHEEL HOUSING
FLYWHEEL HOUSING, REPTO
NEWTON-METER TO FOOT-POUND CONVERSION CHART
PIPE PLUG TORQUE VALUES
ROCKER LEVERS - SPECIFICATIONS
OVERHEAD SET
ROCKER LEVER ASSEMBLY
ROCKER LEVERS - TORQUE VALUES
CRANKCASE BREATHER (INTERNAL
ROCKER LEVER ASSEMBLY
ROCKER LEVER COVER
ROCKER LEVER HOUSING
TAP-DRILL CHART - U.S. CUSTOMARY AND METRIC
VEHICLE BRAKING - TORQUE VALUES
ENGINE BRAKE
WEIGHT AND MEASURES - CONVERSION FACTORE
INDEX

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