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

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.

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…
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 CodeNo 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)
And much more…

Covers: Caterpillar C11, C13 Truck Diesel Engines with serial number prefixes-
KCA
KCB
JAM
Pages: 4,098
Format: PDF
File size: 67mb
Compatibility: Windows/Mac/Tablet
Notes: Instant download only

Caterpillar C11 C13 KCA KCB JAM Diesel Engine Full Complete Service Manual