How to disassemble the starter and air compressor of a Cummins M11 series engine

 (1) Removal of the starter motor: Use a wrench to remove the three bolts and the starter motor, see Figure 2-57. 

(2) Removal of the air compressor: ① Remove the bolts, loosen the hose clamps, and disconnect the air supply pipe, see Figure 2-58.

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Figure 2-53 Disconnecting the Atmospheric Pressure Sensor and Connecting Wires 1—Atmospheric Pressure Sensor

Figure 2-54 Removing the actuator harness and sensor harness from the ECM 1, 2 - Position on the ECM bracket

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 Figure 2-55 Remove ECM mounting bolts,                             Figure 2-56 Remove ECM cooling plate         washers, and ECM.                                                                    and mounting bracket.

   Figure 2-57 shows the removal of three bolts and the starter motor. 

 

 Figure 2-57 Remove the three bolts and the starter motor.

Figure 2-58 Removing the air supply pipe from the air compressor: 1 - Bolt; 2 - Clamp

 

② Remove the coolant inlet/outlet pipes from the air compressor, remove the mounting bolts, and remove the air compressor, as shown in Figure 2-59. 

 ③ Remove the coolant inlet pipe and connector, and remove the coolant outlet pipe positioning screw and outlet pipe, as shown in Figure 2-60.

 

 Figure 2-60 Removal of inlet and outlet pipes, connectors, and positioning screws 1—Inlet pipe 2—Connector 3—Positioning screw

 

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How to disassemble the fuel system and ECM cooling plate of a Cummins M11 series engine

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  (1) Install the engine on the test bench 

① Using an engine overhaul test bench (part number 3375194) and a connecting plate (part number 3376432), install the connecting plate onto the test bench using five bolts with part number 5/8-11x2in. Tighten to a torque of 180 N·m, see Figure 2-43. 

 ② Install two guide pins (part number 3376488) at bolt holes 1 and 2 on the water channel cover. Use a lifting device to install the engine onto the connecting plate on the test bench, see Figure 2-44.

 

 Figure 2-43 shows the connection plate being installed onto the overhaul stand using 5 bolts.

 

 

 

 

Figure 2-44 shows the engine being mounted onto the connecting plate. 1, 2—bolt holes.

③ Secure the connecting plate to the cylinder block using 8 bolts (part number 3376434), tightening to a torque of 47 N·m, see Figure 2-45. ④ Remove the lifting lugs from the engine cylinder block, see Figure 2-46.

  

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 Figure 2-45 shows the connecting plate being secured to the cylinder block with bolts. 

 

  3—Connecting plate 4, 5, 6—Bolt holes 7, 8—Hole Remove the fan hub bracket, see Figure 2-47.

(2) Fuel system component disassembly ①Remove the fuel supply hose and fuel filter housing, see Figure 2-48. 

 

Figure 2-47 Remove the fan hub bracket

 

Figure 2-48 Removing the fuel hose and filter housing 1, 2—Hose connectors

 

② Remove the fuel supply pipe and return pipe from the cylinder head, and remove the fuel gear pump cooling pipe, as shown in Figure 2-49. 

 

 ③ Remove the actuator wiring harness from the fuel pump fuel cut-off valve and label the wires for easy identification, as shown in Figure 2-50.

 

 

 

 

 Figure 2-49 Removal of fuel supply pipe, return pipe, and gear pump cooling pipe 1 - Supply pipe 2 - Return pipe 3 - Cooling pipe

 

 

Figure 2-50 Remove the fuel shut-off valve actuator harness and label it.

 

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④ Remove the four mounting bolts connected to the fuel pump, the fuel pump, the gasket, and the star coupling, as shown in Figure 2-51. 

5 Remove the access cover and gasket on the fuel pump side, as shown in Figure 2-52. 

 

Figure 2-51 shows the removal of the fuel pump, gasket, and coupling.

 

 

 

Figure 2-52 shows the removal of the access cover and gasket on the fuel pump side.

 

(3) Removal of ECM and ECM Cooling Plate 

① If an atmospheric pressure sensor is installed on the engine, remove the atmospheric pressure sensor and connecting wires from the front bracket of the ECM, see Figure 2-53. 

 

② Remove the wiring harness clamps from positions 1 and 2 on the ECM bracket, loosen the AMP connector mounting bolts on the sensor wiring harness, and remove the actuator wiring harness and sensor wiring harness from the ECM, see Figure 2-54. 

 

 ③ Remove the ECM mounting bolts, star washers, and the ECM, see Figure 2-55. 

 

 ④ Remove the four fixing bolts, the ECM cooling plate, and the mounting bracket, see Figure 2-56.

 

 

How to Disassemble the Cummins M11 series engine water pump and accessories

 (1) Disassembly of the water pump 

 ① Remove the two inlet pipe connector bolts and the three water pump mounting bolts. Rotate the water pump outwards to remove the inlet pipe connector, see Figure 2-36. 

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 ② Rotate the top of the water pump outwards to tilt the rear of the pump downwards, and remove the water pump from the thermostat housing bracket, see Figure 2-37.

 (2) Disassembly of water pump accessories

 ① Disconnect the wiring harness from the coolant temperature sensor, loosen the air compressor return pipe connector, remove the four bolts and the thermostat housing bracket, see Figure 2-38. 

② Remove the four bolts, the coolant heater housing, and the gasket, see Figure 2-39. 

③ Remove the three bolts, remove the coolant filter seat and the two O-rings, see Figure 2-40. 

④ Remove the water channel cover mounting bolts, sealing gasket, and guide pin, see Figure 2-41. 

⑤ Remove the inspection hole cover and oil dipstick tube bracket, see Figure 2-36. Remove the connector bolts and mounting bolts, and remove the water inlet pipe connector.

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Figure 2-37 shows the water pump being removed from the thermostat housing. 

 

 

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Figure 2-38 Removing the thermostat housing bracket 

 

 

Figure 2-39 Removal of coolant heater housing and gasket

 

Figure 2-40 Remove the coolant filter housing and two O-rings. 

 

 

 

Figure 2-41 Removing the drain cover 1, 2—Bolts 

 

 

Figure 2-42 Remove the access cover and oil dipstick bracket. Bolts 1 and 2 

 

How to disassemble the Cummins M11 series engine generator drive pulley and drive unit oil seal

① Remove the locating bolts on the pulley, see Figure 2-33. 

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② Use an ST-647 puller and two (5/16-18x2 1/2) bolts to remove the alternator drive pulley, see Figure 2-34. 

 ③ Remove the 5 bolts, pressure ring, oil seal, and gasket, see Figure 2-35.

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 Figure 2-32 Removing the oil filter housing and gasket

 

 

 Figure 2-33 Removing the locating bolts on the alternator pulley

 

  Figure 2-34 Removing the drive pulley with a puller and two bolts

 

 

     Figure 2-35 Removing the bolts, pressure ring, oil seal, and gasket.

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How to check the engine oil in a JCB bucket loader

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1 Make sure the park brake is engaged and the
transmission set to neutral. Lower the loader arms and
backhoe to the ground, switch OFF the engine and
remove the starter key.

2  Open the bonnet, see Engine Panels, Opening and
Closing the Bonnet.

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3 Check that the oil level is between the two marks on
the dipstick A.

4  If necessary, remove the side panel and add oil through
filler B. Make sure that the dipstick and filler cap are
fully inserted and tightened.

How to handle the problem of elevated oil temperature in the loader's transmission oil pan?

 What are the possible causes of elevated oil temperature in the loader's transmission oil pan due to a large amount of aluminum shavings or metal shavings?

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(1) A large amount of aluminum shavings in the oil pan indicates mutual wear between the torque converter's working wheels, resulting in reduced transmission efficiency and overheating of the working oil. 

 (2) A large amount of copper shavings in the oil pan indicates friction or slippage between the driving and driven friction plates. The transmission oil level and shift pressure should be checked. If normal, the problem is likely due to improper assembly or deformation of the driving and driven friction plates.

 

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 (3) Iron shavings in the oil pan indicate slippage of the overrunning clutch. When the loader transitions from high speed with light load to low speed with heavy load, there is a metallic friction sound in the transmission, and the machine lacks power.

 (4) Bearing fragments in the oil pan generally indicate bearing damage in the dual-transmission assembly. The situation should be assessed, and the damaged parts should be disassembled, inspected, and replaced. If the above phenomena are found, a judgment should be made based on the specific situation. The torque converter or gearbox should be disassembled and the damaged parts replaced. Do not continue to use it.

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How to prevent excavator from "pulling out the cylinder"

 What is the "unplugging" phenomenon? What's the harm? How to prevent it?

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 (1) Cylinder pullout: When the bucket is in the downturn limit position, the extended part of the piston rod of the bucket cylinder is the shortest.

When the boom reaches a certain height, the limit surface of the boom contacts the limit surface of the bucket. If the boom continues to be raised, the bucket will 

The bucket cannot flip downwards as the boom is raised, but at this time the relative positions of the support points on both sides of the bucket cylinder are different. 

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To change as the boom continues to lift, this forces the piston rod of the bucket cylinder to extend outward. Because the boom lift During the lifting process, the front and rear chambers of the bucket cylinder are in a closed state, and the extension of the piston rod will inevitably cause a rapid increase in the pressure in the front chamber.

The phenomenon of this kind of bucket lifting the boom when the bucket is fully unloaded causes the piston rod of the bucket to extend outward is called "pull-out".

   "tank" phenomenon. (2) Hazards: bending deformation of the bucket tie rod; damage to the spherical bearing of the bucket cylinder: bucket oil

 

The locking nut of the cylinder piston is loose. (3) Preventive measures: After unloading, retract the bucket first and then raise the boom.