Caterpillar C11, C13 KCA, KCB, JAM Diesel Engine Service Manual Download

Caterpillar C11, C13 KCA, KCB, JAM Diesel Engine Service Manual Download

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Caterpillar C11, C13 KCA, KCB, JAM Diesel Engine Service Manual PDF

Covers: Caterpillar C11, C13 Truck Diesel Engines with serial number prefixes-

  • KCA
  • KCB
  • JAM

Manuals included:

  • C11, C13 Specifications Manual
  • C11, C13 Operation and Maintenance Manual
  • C11, C13 Systems Operation Manual
  • C11, C13 Testing and Adjusting Manual
  • C11, C13 Troubleshooting Manual
  • C11, C13 Disassembly and Assembly Shop Manual
  • C11, C13 Wiring Schematic
  • C11, C13 Special Instructions
  • C11, C13 On-Highway Engines Electronic PTO Installation and Application Guide
  • And more…

This download includes complete Cat C11 and C13 (KCA, KCB, JAM) service, repair, troubleshooting, and specification manuals for your truck equipped with the diesel engine. This service manual set includes bookmarks for quick navigation to save you time. In this manual set you will find over 4,000 pages of detailed specifications, illustrations, operational information and service procedures to aid with any repair or maintenance the engine may need. Print off pages or entire manuals for the shop without restriction.

Content dated 07/2005.

Topics in the Caterpillar C11, C13 KCA, KCB, JAM Diesel Engine Complete Service Manual:

Specifications Manual

  • Engine Design
  • Fuel Transfer Pump
  • Electronic Unit Injector
  • Electronic Unit Injector Mechanism
  • Electronic Unit Injector Rocker Arm
  • Electronic Unit Injector Wiring
  • Lifter Group
  • Rocker Shaft
  • Valve Mechanism
  • Cylinder Head Valves
  • Cylinder Head
  • CAT Compression Brake
  • Turbocharger
  • Air Lines
  • Exhaust Manifold
  • Camshaft
  • Engine Oil Filter Base
  • Engine Oil Cooler
  • Engine Oil Pump
  • Engine Oil Pan
  • Precooler
  • Water Temperature Regulator Housing
  • Water Temperature Regulator
  • Water Pump
  • Cylinder Block
  • Cylinder Liner
  • Cylinder Liner Projection
  • Crankshaft
  • Crankshaft Seals
  • Connecting Rod Bearing Journal
  • Main Bearing Journal
  • Connecting Rod
  • Connecting Rod
  • Piston and Rings
  • Piston Cooling Jet
  • Housing (Front)
  • Gear Group (Front)
  • Gear Group (Rear)
  • Flywheel Housing
  • Flywheel Housing
  • Engine to Transmission Adapter
  • Belt Tensioner
  • Electric Starting Motor
  • Coolant Temperature Sensor
  • Fuel Temperature Sensor
  • Engine Oil Pressure Sensor
  • Boost Pressure Sensor
  • Atmospheric Pressure Sensor
  • Inlet Manifold Temperature Sensor
  • Speed/Timing Sensor

Systems Operation Manual

  • Engine Design
  • Engine Design
  • General Information
  • Electronic Control System Components
  • Fuel System
  • Air Inlet and Exhaust System
  • Lubrication System
  • Cooling System
  • Basic Engine
  • CAT Compression Brake
  • Electrical System

Testing and Adjusting Manual

  • Fuel System
  • Fuel System – Inspect
  • Air in Fuel – Test
  • Electronic Unit Injector – Adjust
  • Electronic Unit Injector – Test
  • Finding Top Center Position for No. 1 Piston
  • Fuel Quality – Test
  • Fuel System – Prime
  • Fuel System Pressure – Test
  • Gear Group (Front) – Time
  • Air Inlet and Exhaust System
  • Air Inlet and Exhaust System – Inspect
  • Turbocharger – Inspect
  • Inlet Manifold Pressure – Test
  • Aftercooler – Test
  • Engine Crankcase Pressure (Blowby) – Test
  • Compression – Test
  • Engine Valve Lash – Inspect/Adjust
  • Variable Valve Actuators – Inspect/Adjust
  • Lubrication System
  • Engine Oil Pressure – Test
  • Engine Oil Pump – Inspect
  • Excessive Bearing Wear – Inspect
  • Excessive Engine Oil Consumption – Inspect
  • Increased Engine Oil Temperature – Inspect
  • Cooling System
  • Cooling System – Check (Overheating)
  • Cooling System – Inspect
  • Cooling System – Test
  • Water Temperature Regulator – Test
  • Water Pump – Test
  • Basic Engine
  • Piston Ring Groove – Inspect
  • Connecting Rod Bearings – Inspect
  • Main Bearings – Inspect
  • Cylinder Block – Inspect
  • Cylinder Liner Projection – Inspect
  • Flywheel – Inspect
  • Flywheel Housing – Inspect
  • Vibration Damper – Check
  • Compression Brake
  • CAT Compression Brake Lash – Adjust
  • Electrical System
  • Battery – Test
  • Charging System – Test
  • Electric Starting System – Test
  • Pinion Clearance – Adjust

Disassembly and Assembly Manual

  • Fuel Filter Base – Remove and Install
  • Fuel Transfer Pump – Remove
  • Fuel Transfer Pump – Install
  • Electronic Unit Injector – Remove
  • Electronic Unit Injector – Install
  • Electronic Unit Injector Sleeve – Remove
  • Electronic Unit Injector Sleeve – Install
  • Turbocharger – Remove (Low Pressure Turbocharger)
  • Turbocharger – Remove (High Pressure Turbocharger)
  • Turbocharger – Install (Low Pressure Turbocharger)
  • Turbocharger – Install (High Pressure Turbocharger)
  • Exhaust Manifold – Remove and Install
  • Inlet and Exhaust Valve Springs – Remove and Install
  • Inlet and Exhaust Valves – Remove and Install
  • Inlet and Exhaust Valve Guides – Remove and Install
  • Inlet and Exhaust Valve Seat Inserts – Remove and Install
  • Engine Oil Filter Base – Remove
  • Engine Oil Filter Base – Disassemble
  • Engine Oil Filter Base – Assemble
  • Engine Oil Filter Base – Install
  • Engine Oil Cooler – Remove
  • Engine Oil Cooler – Install
  • Engine Oil Pump – Remove
  • Engine Oil Pump – Disassemble
  • Engine Oil Pump – Assemble
  • Engine Oil Pump – Install
  • Diverter Valve (Oil) – Remove
  • Diverter Valve (Oil) – Install
  • Diverter Valve (Coolant) – Remove
  • Diverter Valve (Coolant) – Install
  • Water Pump – Remove
  • Water Pump – Install
  • Water Temperature Regulator – Remove and Install
  • Precooler – Remove
  • Precooler – Install
  • Flywheel – Remove
  • Flywheel – Install
  • Flywheel Housing – Remove and Install
  • Front Cover – Remove
  • Front Cover – Install
  • Gear Group (Front) – Remove
  • Gear Group (Front) – Install
  • Housing (Front) – Remove
  • Housing (Front) – Install
  • Accessory Drive – Remove
  • Accessory Drive – Install
  • Valve Mechanism Cover Base – Remove and Install
  • Valve Actuator (Variable) – Remove
  • Valve Actuator (Variable) – Install
  • Rocker Shaft and Pushrod – Remove
  • Rocker Shaft – Disassemble
  • Rocker Shaft – Assemble
  • Rocker Shaft and Pushrod – Install
  • Cylinder Head – Remove
  • Cylinder Head – Install
  • Lifter Group – Remove and Install
  • Camshaft – Remove
  • Camshaft – Install
  • Camshaft Gear – Remove and Install
  • Camshaft Bearings – Remove
  • Camshaft Bearings – Install
  • Engine Oil Pan – Remove and Install
  • Cylinder Liner – Remove
  • Cylinder Liner – Install
  • Piston Cooling Jets – Remove and Install
  • Pistons and Connecting Rods – Remove
  • Pistons and Connecting Rods – Disassemble
  • Pistons and Connecting Rods – Assemble
  • Pistons and Connecting Rods – Install
  • Connecting Rod Bearings – Remove
  • Connecting Rod Bearings – Install
  • Crankshaft Main Bearings – Remove
  • Crankshaft Main Bearings – Install
  • Crankshaft – Remove
  • Crankshaft – Install
  • Crankshaft Gear – Remove and Install
  • Engine Sensors – Remove and Install
  • Fan Drive Mounting Group – Remove and Install
  • Engine Control Module – Remove and Install
  • Air Compressor – Remove and Install
  • Air Compressor Drive Gear – Remove and Install

Troubleshooting Manual

  • System Overview
  • Electronic Service Tools
  • Replacing the ECM
  • Sensors and Electrical Connectors
  • Programming Parameters
  • Dyno Mode
  • Test ECM Mode
  • Customer Passwords
  • ECM Date/Time Stamped Information
  • ECM Snapshot
  • Factory Passwords
  • Factory Passwords Worksheet
  • Flash Programming
  • Service Information Report
  • Customer Specified Parameters
  • Customer Specified Parameters Table
  • Customer Specified Parameters Worksheet
  • Cruise Control Parameters
  • Data Link Parameters
  • Dedicated PTO Parameters
  • Driver Reward
  • ECM Identification Parameters
  • Engine/Gear Parameters
  • Engine Monitoring Parameters
  • Idle Parameters
  • Input Selections
  • Maintenance Parameters
  • Output Selections
  • Security Access Parameters
  • Selected Engine Rating
  • Smart Idle Parameters
  • Timer Parameters
  • Trip Parameters
  • Vehicle Activity Report Parameters
  • Vehicle Speed Parameters
  • System Configuration Parameters
  • System Configuration Parameters
  • Troubleshooting without a Diagnostic Code
  • Can Not Reach Top Engine RPM
  • Can Not Reach Vehicle Speed Limit
  • Check Engine Lamp or Warning Lamp Is
  • Malfunctioning
  • Cooling Fan Is Always ON
  • Cruise Control, Idle, or PTO Can Not Be Set
  • Driver Questionnaire
  • Driver Questionnaire Response
  • ECM Will Not Accept Factory Passwords
  • Electronic Service Tool Will Not Communicate with
  • ECM
  • Engine Cranks but Will Not Start
  • Engine Misfires, Runs Rough or Is Unstable
  • Engine Retarder (Compression Brake) Will Not Turn
  • ON
  • Engine Vibration
  • Engine Will Not Crank
  • Excessive Black Smoke
  • Excessive Fuel Consumption
  • Excessive White Smoke
  • Intermittent Cruise Control, Idle, or PTO Kickout
  • Intermittent Low Power or Power Cutout
  • Low Power/Poor or No Response to Throttle
  • Poor Acceleration or Response
  • Troubleshooting with a Diagnostic Code
    • No Diagnostic Code Detected (55)
    • 0001-05 Cylinder #1 Injector current low (72)
    • 0001-06 Cylinder #1 Injector current high (72)
    • 0002-05 Cylinder #2 Injector current low (72)
    • 0002-06 Cylinder #2 Injector current high (72)
    • 0003-05 Cylinder #3 Injector current low (73)
    • 0003-06 Cylinder #3 Injector current high (73)
    • 0004-05 Cylinder #4 Injector current low (73)
    • 0004-06 Cylinder #4 Injector current high (73)
    • 0005-05 Cylinder #5 Injector current low (74)
    • 0005-06 Cylinder #5 Injector current high (74)
    • 0006-05 Cylinder #6 Injector current low (74)
    • 0006-06 Cylinder #6 Injector current high (74)
    • 0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
    • 0022-13 Engine Speed Signal Calibration Not Performed (42)
    • 0030-08 PTO Throttle signal invalid (29)
    • 0030-13 PTO Throttle out of calibration (29)
    • 0041-03 8 Volt Supply voltage high (21)
    • 0041-04 8 Volt Supply voltage low (21)
    • 0043-02 Key Switch Fault (71)
    • 0052-11 Air Inlet Shutoff Shutdown (00)
    • 0054-05 Auxiliary Output #06 current low (66)
    • 0054-06 Auxiliary Output #06 current high (66)
    • 0055-05 Auxiliary Output #07 current low (67)
    • 0055-06 Auxiliary Output #07 current high (67)
    • 0064-08 Secondary Engine Speed loss of signal
    • 0071-00 Idle Shutdown Override (01)
    • 0071-01 Idle Shutdown (47)
    • 0071-14 PTO Shutdown (47)
    • 0084-00 Vehicle Overspeed Warning (41)
    • 0084-01 Vehicle Speed loss of signal (31)
    • 0084-02 Vehicle Speed signal invalid (36)
    • 0084-08 Vehicle Speed signal out of range (36)
    • 0084-10 Vehicle Speed signal rate of change
    • 0084-14 Quick Stop Occurrence
    • 0091-08 Throttle Position Invalid (32)
    • 0091-13 Throttle Position out of calibration (28)
    • 0100-01 Low Oil Pressure Warning (46)
    • 0100-03 Oil Pressure voltage high (24)
    • 0100-04 Oil Pressure voltage low (24)
    • 0100-11 Very Low Oil Pressure (46)
    • 0102-03 Boost Pressure voltage high (25)
    • 0102-04 Boost Pressure voltage low (25)
    • 0105-00 High Intake Manifold Air Temperature Warning (64)
    • 0105-03 Intake Manifold Air Temperature voltage high (38)
    • 0105-04 Intake Manifold Air Temperature voltage low-38
    • 0105-11 Very High Intake Manifold Air Temperature-64
    • 0108-03 Barometric Pressure voltage high (26)
    • 0108-04 Barometric Pressure voltage low (26)
    • 0110-00 High Coolant Temperature Warning-61
    • 0110-03 Coolant Temperature voltage high-27
    • 0110-04 Coolant Temperature voltage low (27)
    • 0110-11 Very High Coolant Temperature (61)
    • 0111-01 Low Coolant Level Warning (62)
    • 0111-02 Coolant Level signal invalid (12)
    • 0111-03 Coolant Level voltage high (12)
    • 0111-04 Coolant Level voltage low (12)
    • 0111-11 Very Low Coolant Level (62)
    • 0111-14 Low Coolant Level Warning
    • 0121-05 Low/High Retarder current low (14)
    • 0121-06 Low/High Retarder current high (14)
    • 0122-05 Med/High Retarder current low (14)
    • 0122-06 Med/High Retarder current high (14)
    • 0166-14 Rated Engine Power Special Instructions
    • 0168-01 Low ECM Battery Power (17)
    • 0171-03 Ambient Air Temperature voltage high
    • 0171-04 Ambient Air Temperature voltage low
    • 0171-11 Ambient Air Temperature Data Lost
    • 0174-00 High Fuel Temperature Warning (65)
    • 0174-03 Fuel Temperature voltage high (13)
    • 0174-04 Fuel Temperature voltage low (13)
    • 0190-00 Engine Overspeed Warning (35)
    • 0190-08 Primary Engine Speed Loss of Signal-34
    • 0191-07 Transmission Not Responding (68)
    • 0212-03 5 Volt Sensor Supply #1 voltage high
    • 0212-04 5 Volt Sensor Supply #1 voltage low
    • 0224-11 Theft Deterrent Active (00)
    • 0224-14 Theft Deterrent Active with Engine Cranking
    • 0231-02 J1939 Data Incorrect (58)
    • 0231-12 J1939 Device Not Responding
    • 0246-11 Brake Pedal Switch #1 Fault
    • 0247-11 Brake Pedal Switch #2 Fault
    • 0252-11 Engine Software Incorrect (59)
    • 0253-02 Check Customer or System Parameters-56
    • 0253-11 Check Transmission Customer Parameters-56
    • 0283-05 Intake Valve Actuation System Oil Pressure Solenoid current low (97)
    • 0283-06 Intake Valve Actuation System Oil Pressure Solenoid current high (97)
    • 0283-07 Intake Valve Actuation Oil Pressure not responding (91)
    • 0284-05 Engine Coolant Diverter current low-98
    • 0284-06 Engine Coolant Diverter current high-98
    • 0285-05 Intake Valve Actuator #1 current low-92
    • 0285-06 Intake Valve Actuator #1 current high-92
    • 0285-07 Intake Valve Actuator #1 not responding-92
    • 0286-05 Intake Valve Actuator #2 current low-92
    • 0286-06 Intake Valve Actuator #2 current high-92
    • 0286-07 Intake Valve Actuator #2 not responding-92
    • 0287-05 Intake Valve Actuator #3 current low-93
    • 0287-06 Intake Valve Actuator #3 current high-93
    • 0287-07 Intake Valve Actuator #3 not responding-93
    • 0288-05 Intake Valve Actuator #4 current low-93
    • 0288-06 Intake Valve Actuator #4 current high-93
    • 0288-07 Intake Valve Actuator #4 not responding-93
    • 0289-05 Intake Valve Actuator #5 current low-94
    • 0289-06 Intake Valve Actuator #5 current high-94
    • 0289-07 Intake Valve Actuator #5 not responding -94
    • 0290-05 Intake Valve Actuator #6 current low -94
    • 0290-06 Intake Valve Actuator #6 current high -94
    • 0290-07 Intake Valve Actuator #6 not responding-94
    • 0385-01 Low Intake Valve Actuation System Oil Pressure
    • 0385-03 Intake Valve Actuation System Oil Pressure voltage high (95)
    • 0385-04 Intake Valve Actuation System Oil Pressure voltage low (95)
  • 5 Volt Engine Pressure Sensor Supply Circuit – Test
  • Accelerator Pedal (Throttle) Position Sensor Circuit – Test 2
  • Air Inlet Shutoff Circuit – Test
  • ATA (SAE J1587 / J1708) Data Link Circuit – Test
  • Auxiliary Brake Circuit – Test
  • Check Engine Lamp Circuit – Test
  • Clutch Pedal Position Switch Circuit – Test
  • Coolant Level Sensor Circuit – Test
  • Cooling Fan Circuit and A/C High Pressure Switch Circuit – Test
  • Cruise Control Switch Circuit – Test
  • Diagnostic Enable Switch Circuit – Test
  • Eaton Top 2 Transmission Circuit – Test
  • ECM Memory – Test
  • Electrical Connectors – Inspect
  • Engine Coolant Diverter Circuit – Test
  • Engine Pressure Sensor Open or Short Circuit – Test
  • Engine Running Output Circuit – Test
  • Engine Shutdown Output Circuit – Test
  • Engine Speed/Timing Sensor Circuit – Test
  • Engine Temperature Sensor Open or Short Circuit – Test
  • Fan Override Switch Circuit – Test
  • Idle Shutdown Timer – Test
  • Ignition Keyswitch Circuit and Battery Supply Circuit – Test
  • Ignore Brake/Clutch Switch Circuit – Test
  • Injector Solenoid Circuit – Test
  • Intake Valve Actuation System Oil Pressure Circuit – Test
  • Intake Valve Actuator Circuit – Test
  • Intake Valve Actuator Response – Test
  • Multi-Torque – Test
  • Neutral Switch Circuit – Test
  • Powertrain Data Link Circuit – Test
  • PTO Engine RPM Set Speed (Input A and Input B)
  • Circuit – Test
  • PTO Shutdown Timer – Test
  • PTO Switch Circuit – Test
  • PTO Switch ON Lamp Circuit – Test
  • Remote PTO Accelerator Position Sensor Circuit – Test
  • Retarder (Compression Brake) Solenoid Circuit – Test
  • Service Brake Pedal Position (Switch 1) Circuit – Test
  • Service Brake Pedal Position (Switch 2) Circuit – Test
  • Starting Aid Output Circuit – Test
  • Starting Aid Switch Circuit – Test
  • Tachometer Circuit – Test
  • Torque Limit Switch Circuit – Test
  • Two Speed Axle Switch Circuit – Test
  • Vehicle Speed and Speedometer Circuit – Test
  • Warning Lamp Circuit – Test
  • Calibration Procedures
  • Engine Speed/Timing Sensor – Calibrate
  • Injector Code – Calibrate
  • Vehicle Speed Circuit – Calibrate

Wiring Schematic (Foldout size – includes engine, harness and connector views)

Pages: 4,098
Format
: PDF
File size: 67mb
Compatibility: Windows/Mac/Tablet
Notes: Instant download only