SENR9703-05

July 2005

Systems Operation
Testing and Adjusting m
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C11 and C13 On-highway Engines

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KCA1-Up (Engine)
KCB1-Up (Engine)
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JAM1-Up (Engine)
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Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

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Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
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presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
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Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
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procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
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The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
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affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
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When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR9703-05 3
Table of Contents

Table of Contents Vibration Damper - Check .................................... 77

Compression Brake
CAT Compression Brake Lash - Adjust ................ 79
Systems Operation Section
Electrical System
Engine Design ....................................................... 4
Battery - Test ......................................................... 81
Engine Design ....................................................... 4
Charging System - Test ........................................ 82
General Information ................................................ 5
Electric Starting System - Test .............................. 83
Electronic Control System Components ................. 6
Pinion Clearance - Adjust ..................................... 83
Fuel System ........................................................... 7
Air Inlet and Exhaust System ............................... 15
Lubrication System .............................................. 19 Index Section
Cooling System .................................................... 22
Basic Engine ......................................................... 26 Index ..................................................................... 85
CAT Compression Brake ...................................... 28
Electrical System ................................................. 30

Testing and Adjusting Section

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Fuel System
Fuel System - Inspect ........................................... 34
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Air in Fuel - Test .................................................... 34
Electronic Unit Injector - Adjust ............................. 35
Electronic Unit Injector - Test ................................ 36
Finding Top Center Position for No. 1 Piston ........ 36
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Fuel Quality - Test ................................................. 37
Fuel System - Prime ............................................. 38
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Fuel System Pressure - Test ................................. 39

Gear Group (Front) - Time .................................... 42

Air Inlet and Exhaust System

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Air Inlet and Exhaust System - Inspect ................. 44

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Turbocharger - Inspect .......................................... 48

Inlet Manifold Pressure - Test ............................... 50
Aftercooler - Test ................................................... 51
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Engine Crankcase Pressure (Blowby) - Test ........ 54

Compression - Test ............................................... 54
Engine Valve Lash - Inspect/Adjust ...................... 54
Variable Valve Actuators - Inspect/Adjust ............. 56
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Lubrication System
Engine Oil Pressure - Test .................................... 59
Engine Oil Pump - Inspect .................................... 61
Excessive Bearing Wear - Inspect ........................ 62
Excessive Engine Oil Consumption - Inspect ....... 62
Increased Engine Oil Temperature - Inspect ........ 62

Cooling System
Cooling System - Check (Overheating) ................ 63
Cooling System - Inspect ...................................... 65
Cooling System - Test ........................................... 66
Water Temperature Regulator - Test ..................... 70
Water Pump - Test ................................................ 70

Basic Engine
Piston Ring Groove - Inspect ................................ 72
Connecting Rod Bearings - Inspect ...................... 72
Main Bearings - Inspect ........................................ 72
Cylinder Block - Inspect ........................................ 72
Cylinder Liner Projection - Inspect ........................ 73
Flywheel - Inspect ................................................. 74
Flywheel Housing - Inspect ................................... 75
4 SENR9703-05
Systems Operation Section

Systems Operation Section The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
rotation .......................................... Counterclockwise
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Note: The front of the engine is opposite of the
Engine Design flywheel end of the engine. The left side of the engine
and the right side of the engine are viewed from the
SMCS Code: 1000 flywheel end of the engine. The No. 1 cylinder is the
front cylinder.
S/N: KCA1-Up

C11 i02377343

Engine Design
SMCS Code: 1000
S/N: KCB1-Up
S/N: JAM1-Up

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C13
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g00935559
Illustration 1
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(A) Exhaust valves

(B) Inlet valves

Bore ............................................................. 130 mm

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(5.12 inch)
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Stroke .......................................................... 140 mm

(5.51 inch)
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g00935559
Illustration 2
Displacement ................................................... 11.1 L
(A) Exhaust valves
(680 cu in) (B) Inlet valves
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Cylinder arrangement ..................................... In-line Bore ............................................................. 130 mm

(5.12 inch)
Valves per cylinder .................................................. 4
Stroke .......................................................... 157 mm
In order to check the engine valve lash setting, the (6.18 inch)
engine must be cold and the engine must be stopped.
Displacement .................................................. 12.5 L
Engine valve lash (763 cu in)
Inlet ............................................ 0.38 ± 0.08 mm
(0.015 ± 0.003 inch) Cylinder arrangement ..................................... In-line
Exhaust ...................................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch) Valves per cylinder .................................................. 4
Variable valve actuator .......... 0.610 ± 0.075 mm
(0.0240 ± 0.0030 inch) In order to check the engine valve lash setting, the
Cat compression brake .......... 0.864 ± 0.050 mm engine must be cold and the engine must be stopped.
(0.034 ± 0.0020 inch)
Engine valve lash
Type of combustion ............................ Direct injection Inlet ............................................ 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Firing order ............................................. 1-5-3-6-2-4
SENR9703-05 5
Systems Operation Section

Exhaust ...................................... 0.64 ± 0.08 mm The Engine Control Module (ECM) monitors the
(0.025 ± 0.003 inch) components of the engine during operation. In
Variable valve actuator .......... 0.610 ± 0.075 mm the event of a component failure, the operator will
(0.024 ± 0.0030 inch) be alerted to the condition by the use of a check
Cat compression brake .......... 0.864 ± 0.050 mm engine light and an event code will be logged in
(0.034 ± 0.0020 inch) the ECM. Caterpillar Electronic Technician (ET) can
be connected to the engine in order to read any
Type of combustion ............................ Direct injection logged faults. Also, the cruise control switches can
be used to flash the code on the check engine light.
Firing order ............................................. 1-5-3-6-2-4 Intermittent faults are logged and stored in memory.

The crankshaft rotation is viewed from the

flywheel end of the engine. Crankshaft
Starting The Engine
rotation .......................................... Counterclockwise The engine’s ECM will automatically provide the
correct amount of fuel in order to start the engine.
Note: The front end of the engine is opposite of the
Do not hold the throttle down while the engine is
flywheel end of the engine. The left side of the engine cranking. If the engine fails to start in 30 seconds,
and the right side of the engine are viewed from the
release the starting switch. Allow the starting motor
flywheel end of the engine. The No. 1 cylinder is the

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to cool for two minutes before the starting motor is
front cylinder. used again.
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i02205170 NOTICE
Excessive ether (starting fluid) can cause piston and
General Information ring damage. Use ether for cold weather starting pur-
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poses only.
SMCS Code: 1000

The C11 engines are in-line six cylinder

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arrangements. The engine has a bore of 130 mm Cold Mode Operation

(5.12 inch) and a stroke of 140 mm (5.51 inch). The
displacement of the engine is 11.1 L (680 cu in). Each The ECM will set the cold start strategy when the
cylinder has two inlet valves and two exhaust valves. coolant temperature is below 18 °C (64 °F).
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The firing sequence of the engine is 1-5-3-6-2-4.

When the cold start strategy is activated, low idle rpm
The C13 engines are in-line six cylinder will be increased to 1000 rpm and the engine’s power
will be limited.
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arrangements. The engine has a bore of 130 mm

(5.12 inch) and a stroke of 157 mm (6.18 inch). The
displacement of the engine is 12.5 L (763 cu in). Each Cold mode operation will be deactivated when any of
cylinder has two inlet valves and two exhaust valves. the following conditions have been met:
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The firing sequence of the engine is 1-5-3-6-2-4.

• Coolant temperature reaches 18 °C (64 °F).
The engines have two turbochargers. The engines
arrange the two turbochargers in series. The two • The engine has been running for fourteen minutes.
turbochargers allow the engine to have boost
over the entire engine rpm range. The use of Cold mode operation varies the fuel injection amount
two turbochargers increases the maximum boost and the timing for white smoke cleanup. The engine
pressure to 410 kPa (60 psi). The engines also use a operating temperature is usually reached before the
precooler before the air-to-air aftercooler (ATAAC). walk-around inspection is completed. The engine
will idle at the programmed low idle rpm in order to
The Electronic Unit Injector (EUI) provides increased be put in gear.
control of the timing and increased control of the fuel
air mixture. Engine rpm is controlled by adjusting the NOTICE
injection duration. Engine timing is controlled by the Do not move the vehicle with the engine in the cold
precise control of fuel injection timing. mode condition. Engine power could be noticeably re-
duced. At a vehicle speed above 8 km/h (5 mph), low
idle rpm will be reduced to the customer programmed
low idle and the power will still be reduced.
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