(1) Removal of the main bearing cap, lower bearing shell, and thrust bearing 

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① Rotate the engine on the test bench so that the oil pan mounting flange faces upward. The markings on the main bearing cap must match the numbers on the cylinder block oil pan flange, see Figure 2-134. During installation, the numbers on the main bearing cap and oil pan flange should match, and the locating tongue of the main bearing cap must be aligned with the locating tongue. 

 

② Use the ST-1178 main bearing cap puller to remove the main bearing cap, see Figure 2-135. The No. 4 main bearing cap is connected to the cylinder block by a locating pin, and the No. 4 main bearing shell is fitted with a thrust bearing. During disassembly, it is strictly forbidden to shake the main bearing cap; only the puller can be used to pull the main bearing cap vertically upward.

 

 

 

 

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 ③ Remove the lower bearing shell from the main bearing cover and mark the journal number at the time of disassembly on the surface of the locating tongue, as shown in Figure 2-136. 

 

 ④ Remove the lower thrust bearing from the No. 4 main bearing cover and mark it with the letters "L" and "front" or "rear", as shown in Figure 2-137.

 

 

 

 

 

 Remove the upper thrust bearing from spindle journal No. 4 and mark it with the letters "U" and either "front" or "rear", as shown in the figure.  2-138。

 

 

(2) Crankshaft and Upper Bearing Removal

 ① Place nylon slings on connecting rod journals No. 3 and No. 4, and use a crane to remove the crankshaft, as shown in Figure 2-139. 

 

 ② Remove the upper bearing and mark the journal number at the time of removal on the surface of the bearing locating tongue, as shown in Figure 2-140.

 

 

 

 

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How to disassemble the pistons and connecting rods of a Cummins M11 series engine

 (1) Installing the Engine Turning Tool: Install the engine turning tool onto the flywheel end of the crankshaft using two bolts, see Figure 2-123. 

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 (2) Removing the Piston Cooling Nozzles: Before disassembling the piston and connecting rod assembly, the piston cooling nozzles must be removed to avoid damaging them. Use the turning tool to continuously rotate the crankshaft to remove all nozzles. Remove each retaining screw and nozzle, see Figure 2-124. 

(3) Removing the Piston and Connecting Rod: ① Rotate the crankshaft to expose the carbon deposits above the piston inside the cylinder liner. Remove the carbon deposits using a fine-fiber abrasive pad (such as Scotch-Brite 7448, part number 3823258 or equivalent) and solvent, see Figure 2-125.

 

 

  Figure 2-122 Removing the Gear Chamber Housing

 

 ② Use a crankshaft turning tool to rotate the crankshaft and fix the connecting rod at the bottom dead center (BDC) position so that the connecting rod bolts can be removed and loosened, as shown in Figure 2-126.

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 ③ Use a hammer to tap the connecting rod bolt head to loosen the connecting rod cap from the annular locating pin. Remove the connecting rod bolt and connecting rod cap, see Figure 2-127. 

 

 ④ Mark the cylinder number and the letter "L" on the surface of the lower bearing locating tongue, see Figure 2-128. However, it is strictly forbidden to make marks on the mating surface between the bearing and the crankshaft, to avoid damaging the crankshaft if the bearing continues to be used.

 Install the connecting rod guide pin (part number 3376038) in the connecting rod bolt hole. Use a wooden dowel and a hammer to push the connecting rod away from the crankshaft, as shown in Figure 2-129. Continue pushing the connecting rod until the piston rings protrude from the cylinder block.

  

 Remove the piston and connecting rod assembly and mark it, as shown in Figure 2-130. If the removed piston and connecting rod assembly is still usable, it must be reassembled with the original cylinder number.

Remove the piston and connecting rod assembly and mark it, as shown in Figure 2-130. If the removed piston and connecting rod assembly is still usable, it must be reassembled with the original cylinder number. Place the piston and connecting rod assembly on a special test bench to prevent damage, as shown in Figure 2-131.

 

8. Mark the connecting rod and its mating connecting rod cap with special markings, as shown in Figure 2-132. During assembly, the markings on the connecting rod and connecting rod cap must match and be on the same side of the engine. 

 

Remove the upper connecting rod bearing and mark the cylinder number and the letter "u" on the flat surface of the locating tongue, as shown in Figure 2-133.

 

 

 

 

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Desmontagem da polia da cambota, do amortecedor e do conjunto da cambota do motor Cummins série M11 (8107).

(1) Removal of the oil pump: When removing the oil pump, it is strictly forbidden to pry the gear pump flange to avoid damaging the oil pump. Remove the three mounting bolts and two spacers, screw the two M8-

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1.25 bolts into the puller, and remove the oil pump from the engine, as shown in Figure 2-117.

(2) Camshaft Removal ① Rotate the camshaft until the camshaft gear hole aligns with the thrust bracket bolt hole. Remove the two thrust bracket bolts, then remove the three bolts, the rear cover plate, and the gasket, as shown in Figure 2-118. ② Install the camshaft installation guide tool (part number 3376388). Insert the expander (part number 3376923) through the opening in the rear cover plate into the camshaft. Rotate the bolt inside the expander clockwise to open the expansion plug, as shown in Figure 2-119.

 

 

③ Place the mandrel bushing onto the expander, and install the positioning guide extension rod on the expander, as shown in Figure 2-120. 

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 ④ Slowly rotate the camshaft by hand to pull it out of the cylinder block, as shown in Figure 2-121. Support the removed camshaft with your other hand and remove the camshaft guide tool. 

 

(3) Removal of the gear housing: Remove all bolts from the gear housing and the gear housing itself, as shown in Figure 2-122, and remove the rear rectangular seal ring.

 

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How to disassemble the crankshaft pulley, shock absorbers, and crankshaft assembly of a Cummins M11 engine.

(1) Disassembly of the crankshaft pulley and damper: When disassembling, first remove one mounting bolt and install one guide pin, then remove the remaining bolts, pulley, and damper, as shown in Figure 2-110. Do not use hammers or screwdrivers when disassembling the viscous damper to avoid damaging it.

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  (2) Disassembly of the idler assembly: Remove the crankshaft front oil seal, as shown in Figure 2-111.

 

 

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② Remove the front engine mount, see Figure 2-112. 

 

 ③ Remove the gear chamber cover and rectangular seal, see Figure 2-113. 

 

 ④ The engine has three idler assemblies, see Figure 2-114. These three idler assemblies are the water pump and oil pump idler, the camshaft idler, and the hydraulic pump idler. Remove the camshaft idler and water pump idler in the order shown in Figure 2-115. If using an SAE "B" type hydraulic pump drive, mark the position of the idler shafts when removing them. During reassembly, each shaft should be reinstalled in its original position. Remove the hydraulic pump drive in the order shown in Figure 2-116.

 

 

 

  

 

   

 

 

 

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Caterpillar Engine Ignition Failure, Smooth or Unstable Operation Troubleshooting

 Note: If the fault is intermittent and does not repeat, please refer to the "Intermittent Low Power or Power Cut-off" section. If the fault is continuous and recurring, continue with this procedure.

  (1) Possible Causes. 

1) Diagnostic Codes. 

 2) Electrical Connectors. 

 3) Cold Mode. 

 4) Throttle Signal. 

 5) Injection Drive Pressure. 

 6) Individual Injectors. 

 7) Fuel Supply. 

 8) Intake and Exhaust Systems.

 (2) Recommended Actions. Note: If the fault only occurs under certain operating conditions (high idle, full load, and engine operating temperature, etc.), test the engine under these conditions. Diagnosing and troubleshooting the fault symptoms outside of these conditions can be misleading.

 

  1) Diagnostic Codes. Check the Caterpillar Electronic Technology (Cat ET) for self-diagnostic codes. Before continuing this procedure, troubleshoot and resolve all self-diagnostic codes. 

 2) Electrical Connectors. Check that ECM connectors J1/P1 and J2/P2, as well as the unit injector connectors, are installed correctly. 

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 3) Cold Mode. Use Cat ET to verify that the engine has exited cold mode. Operating in cold mode can cause engine instability and limit engine power. 

4) Throttle Signal. Monitor the throttle signal on Cat ET. Verify that the throttle signal is stable from low idle to high idle. 5) Injection Drive Pressure.

  ① Check the engine oil level. Engine oil supplies the injection drive pressure circuit. The engine oil level must be maintained at the correct level for fuel injection. Note: If oil has been drained from the unit injector hydraulic pump, the pump must be primed. 

 ② If the engine has recently undergone maintenance, there may be air in the injection drive pressure circuit. 

① Fully warm up the engine and operate it under load to purge air from the fuel injection drive pressure circuit.

  ② Compare the actual drive pressure on the CAT ET with the required drive pressure. If the two readings do not exceed 2000 kPa during the fault, the problem is not in the fuel injection drive pressure circuit. ③ Check the seal on the fuel injection drive pressure control valve. If the seal is faulty, replace it and repeat step 

③. ④ Check the wiring harness connected to the fuel injection drive pressure control valve for open circuits and/or short circuits. 

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 ⑤ Measure the coil resistance on the fuel injection drive pressure control valve. If the coil resistance exceeds (10 ± 5) Ω, replace the fuel injection drive pressure control valve. Note: Leaking liquid under pressure, even at the size of a pinhole, can penetrate human tissue, causing serious injury or even death. If liquid sprays into the skin, seek immediate treatment from a doctor familiar with this type of injury.

 Always use a wooden board or cardboard when checking for leaks.

 ⑦ Perform a fuel injection drive pressure overload test using the ET. If the fuel injection drive pressure is low, there may be a leak in the high-pressure fuel supply circuit.

 a. Remove the plug from the fuel injection drive pressure control valve and the unit injector connector. 

 b. Stop the unit injector operation using the ET and/or engine stop switch. 

 c. Remove the valve cover. d. While checking for leaks at the drain port of the unit injector connector and the bridging cylinder block seal, crank the engine. 

 e. Repair any leaks and repeat step ③. 

 f. If the fuel injection drive pressure is still low during cranking, the pump compensator flow controller may be faulty. Replace the pump compensator controller assembly and repeat step ③.

  6) Unit Injector. 

 ① Perform an injector solenoid coil test on a Cat ET to ensure all injector solenoid coils are energized by the ECM. 

  7) Fuel Supply. 

① Check the fuel lines for the following problems: throttling, broken lines, and clamped lines. If a problem is found, repair and/or replace the fuel line. 

 ② Check the fuel tank for foreign objects that could block the fuel supply. 

 ③ When performing any procedure such as replacing the fuel filter, repairing the low-pressure fuel supply circuit, or replacing individual injectors, check the low-pressure fuel supply system for air. 

 ④ Purge air from the low-pressure fuel supply circuit. Note: The sight glass in the low-pressure fuel supply line can help diagnose air in the fuel. 

⑤ Check the fuel quality. If the temperature is below 0°C, check for solidified fuel (waxy substances). 

 ⑥ Check the fuel pressure when starting the engine. If the fuel pressure is low, replace the fuel filter. If the fuel pressure is still low, check the following components: fuel pump, fuel pump coupling, and fuel pressure regulating valve.

 

8) Intake and Exhaust System 

① Check the air filter throttling indicator. Clean or replace any clogged air filters. 

② Check the intake and exhaust systems for blockages and/or leaks.

 ② Perform a cylinder shut-off test on a Cat ET to identify any cylinders that are not firing.

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Troubleshooting Caterpillar Starter Failure

  (1) Possible Causes 

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1) Diagnostic Codes 

2) Event Codes 

 3) ECM Power Supply

 4) Oil Level 

5) Starter Assist Devices 

6) Engine Stop Switch 

7) Engine Speed/Timing 

8) Injection Drive Pressure

 9) Individual Injectors 

10) Fuel Supply

 11) Combustion Fault

 

 (2) Recommended Actions. 

 1) Diagnostic Codes, Event Codes, and ECM Power Supply. Some diagnostic codes and/or event codes can prevent the engine from starting. Connect the Caterpillar Electronics Technology (Cat ET) and check for any current and/or recorded codes. Before continuing this procedure, troubleshoot and resolve any existing codes. Note: If the Cat ET cannot communicate with the ECM, the problem is most likely with the power supply to the ECM; see the "Testing the Power Supply Circuit" section. 

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 2) Oil Level. Check the engine oil level. Add oil if necessary. Note: Engine oil supplies the fuel injection drive pressure circuit. Maintaining the correct engine oil level is necessary for fuel injection.

  3) Starting Assist Devices.

 ① Intake Air Heater. Verify that the intake air heater is set to the ON position. 

 ② Engine Stop Switch (if equipped). The engine stop switch should be in the OFF position. Use the Cat ET to check the status of the stop switch. When parking, the key switch should be turned to the OFF position for at least 15 seconds before restarting the engine.

 

 Note: If the Cat ET cannot communicate with the ECM, the problem is most likely with the power supply to the ECM. Please refer to the "Testing the Power Supply Circuit" section.

 4) Engine Speed/Timing.

 ① Rotate the engine and observe the engine speed on the Cat ET status screen. If the Cat ET displays Or/min, please refer to the "Testing the Engine Speed/Timing Sensor Circuit" section. Note: On the first rotation, the engine status may show an abnormal engine speed signal. Once the ECM can calculate the engine speed from the signal, this information will be replaced by the engine speed. 

 ② Verify that the timing reference gear is installed correctly. If the gear is installed backwards, the engine will not start. Check the alignment between the crankshaft and camshaft drive gears. If necessary, correct the alignment and/or replace the drive gears.

 

 5) Injection Drive Pressure. 

 ① Rotate the engine and monitor the injection drive pressure and the output pressure of the injection drive pressure control valve. If the pressure output is not lower than 6MPa, the high-pressure fuel system is considered to be operating normally. 

 ② If the displayed pressure is higher than the current pressure, disconnect the fuel injection drive pressure sensor and try starting the engine. If the engine starts, refer to the "Testing the Fuel Injection Drive Pressure Sensor" section.

 6) Individual Injectors. Perform an "Injector Solenoid Coil Test" on a Cat ET to determine if all injector solenoid coils are energized by the ECM.

 

 

7) Fuel Supply. 

 ① Visually check the fuel level. Do not rely solely on the fuel gauge. Add fuel if necessary. If the engine runs out of fuel, air must be purged from the fuel system. 

② Check the fuel lines for the following problems: throttling, collapsed, and clamped lines. If any fuel lines are faulty, repair and/or replace them. 

③ Check the fuel tank for foreign objects, which can block the fuel supply. 

 ④ If any of the following procedures have been performed: replacing the fuel filter, repairing the low-pressure fuel supply circuit, or replacing the individual injectors, check for air in the low-pressure fuel supply system. Note: The sight glass in the low-pressure fuel supply line helps diagnose air in the fuel. Note: Do not crank the engine continuously for more than 30 seconds. Allow the starter motor to cool down for 2 minutes before cranking the engine again. 

 

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 ⑤ Bleed the air from the low-pressure fuel supply circuit. 

 

 ⑥ Check the fuel quality. If the temperature is below 0°C, check for solidified fuel (waxy substances). 

 

 ⑦ While cranking the engine, check the fuel pressure after the fuel filter. If the fuel pressure is low, replace the fuel filter. If the fuel pressure is still low, check the following: fuel pump, fuel pump coupling, and fuel pressure regulating valve. 

 

 8) Combustion problems. Check for combustion problems.

Troubleshooting Steps for Caterpillar Electronic Service Tool (Caterpillar Adapter) Not Communicating with ECM

  (1) Possible Causes

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 1) Communication Adapter Configuration 

2) Electrical Connector 

 3) Communication Adapter and/or Cable 

4) Power Supply to Service Tool Connector 

5) Caterpillar Electronic Technology (Cat ET) and Related Hardware 

 6) Power Supply to ECM

 7) Personal Module (Flash File) 8) Caterpillar Automatic Data Transmitter

  (2) Recommended Actions. Start the engine. If the ECM does not communicate with Cat ET after the engine starts, continue with this procedure. If the engine cannot start, refer to the "Rolling Start Engine, but Engine Does Not Start" section. If rolling start is ineffective, refer to the "Engine Cannot Roll Start" section.

 1) Communication Adapter Configuration 1) **On the Cat ET:** ① Select "Preferences" from the "Utilities" menu.

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  ② Confirm that the correct "Communications Interface Device" has been selected. 

③ Verify that the correct communication adapter "Port" has been selected. Note: The most commonly used port is "COM1". 

④ Check if any hardware and communication adapters are using the same port. If any device is set to use the same port, exit or close the software program for that device.

 2) **Electrical Connectors:** Check that ECM connectors J1/P1 and J2/P2 and the service tool connector are installed correctly. 

 3) **Communication Adapter and/or Cable:**

 ① If using Communication Adapter II, confirm that the communication adapter's microprogram language and driver files are up-to-date. If the microprogram language and driver files are incompatible, the communication adapter will not be able to communicate with the Cat ET. 

② Disconnect the communication adapter and cable from the service tool connector. Then reconnect the communication adapter to the service tool connector. 

③ Verify that the cable used between the communication adapter and the service tool connector is correct. 4) Power supply to the service tool connector. Check the battery voltage between terminals A and B of the service tool connector. If the communication adapter is not powered, the display on the communication adapter will be blank.

 5) Caterpillar Electronics Technology (Cat ET) and related hardware. To verify the Cat ET and related hardware are functioning correctly, connect the Cat ET to another engine. If the other engine also experiences the same problem, check the Cat ET and related hardware to determine the cause of the fault.

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6) Power supply to the ECM. Check the power supply to the ECM; see the "Testing the Power Supply Circuit" section. Note: If the ECM does not receive battery voltage, it will not be able to communicate. 

7) Personalization Module (Flash File). Verify that the correct personalization module is correctly installed in the ECM. Note: The personalization module in a new ECM is blank. The engine will not start or communicate until the personalization module is flashed; see the "Flash Programming" section.

  8) Caterpillar Automatic Data Transmitter. For diagnosing and troubleshooting faults in Caterpillar Automatic Data Transmitters, please refer to the "Testing CAT Data Transmission Circuits" section.