Caterpillar Cat C13 Industrial Engine (Prefix JR9) Service Repair Manual (JR900001 and up).pdf

Service Repair Manual
Models
C13 Industrial Engine

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Product: INDUSTRIAL ENGINE
Model: C13 INDUSTRIAL ENGINE JR9
Configuration: C13 Industrial Engine JR900001-UP
Disassembly and Assembly
Media Number -UENR6571-00 Publication Date -01/01/2015 Date Updated -13/01/2015
i03533151
Valve Mechanism Cover Base - Remove and Install
SMCS - 1120-010
Removal Procedure
Start By:
a. Remove the valve cover.
Illustration 1 g01861473
1. Disconnect harness assembly (1).
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2. Loosen hose clamp (4). Remove bolts (3) and remove breather (2).
3. Remove element (5).
4. Disconnect harness assemblies (6) and (8). Remove valve cover base (7).
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5. Remove seal (9) from valve cover base (7).
Installation Procedure
1. Install valve cover base (7) in reverse order of removal.
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Wed Jun 10 15:26:04 UTC+0800 2020
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i07074651
Rocker Arm and Shaft - Remove and Install
SMCS - 1102-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 293-2989 Lift Bracket As 1
Start By:
a. Remove the valve cover.
1. Remove bolts (1).
2. Use Tooling (A) to remove rocker arm and shaft (2). Remove pushrods (3).
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1. Install rocker arm and shaft (2) in the reverse order of removal.
a. Lubricate the contact points of pushrods (3) with clean engine oil. Install pushrods
(3).
b. Tighten bolts (1) to standard torque.
c. Adjust the electronic unit injectors. Refer to Testing and Adjusting, "Electronic Unit
Injector - Adjust".
d. Adjust the engine valve lash. Refer to Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust".
Wed Jun 10 15:27:00 UTC+0800 2020
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i03552706
Rocker Arm - Disassemble
SMCS - 1123-015
Disassembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Gp 1
Start By:
a. Remove the rocker arm and shaft.
Note: Place an identification mark on all components for assembly purposes.
Note: Stand (5) has an offset hole.
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1. Remove stands (1).
2. Remove rocker arms (2), rocker arms (3), rocker arms (4), and stand (5) from shaft (6).
3. Use Tooling (A) to remove the bushings from the rocker arms (3).
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i03552709
Rocker Arm - Assemble
SMCS - 1123-016
Assembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Gp 1
1. Use Tooling (A) to install the bushings for rocker arms (3). For correct bearing dimensions,
refer to Specifications, "Electronic Unit Injector Rocker Arm" and Specifications, "Valve
Mechanism".
2. Install stand (5), rocker arms (4), rocker arms (3), and rocker arms (2) onto shaft (6).
Note: Stand (5) has an offset hole.
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3. Install stands (1).
End By:
a. Install the rocker arm and shaft.
Wed Jun 10 15:28:51 UTC+0800 2020
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i07071018
Cylinder Head - Remove and Install
SMCS - 1100-010
Removal Procedure
Table 1
Required Tools
A - Loctite Graphite- 50 Anti-Seize -
Start By:
a. Remove the accessory drive.
b. Remove the intake manifold.
c. Remove the fumes disposal group.
d. Remove the electronic unit injectors.
e. Remove the exhaust gas valve (NRS).
f. Remove the exhaust cooler (NRS).
g. Remove the exhaust manifold.
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1. Disconnect tube assembly (1). Disconnect the tube and hose assemblies (2). Remove bolts (3) and bracket
(4).
2. Remove tube assembly (5). Disconnect hose assembly (8).
3. Remove bolts (6) and nut (9). Reposition harness assembly (7).
4. Remove housing (10) and tube (11).
5. Attach a suitable lifting device to cylinder head (14). The weight of cylinder head (14) is approximately
204 kg (450 lb).
6. Remove bolts (12) and (13). Remove cylinder head (14) and the cylinder head gasket.
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1. Inspect the cylinder head and the cylinder block for flatness. Refer to Guideline for Reusable Parts and
Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and
Related Components".
2. Install cylinder head (14) in reverse order of removal.
a. Install a new head gasket.
b. Apply Tooling (A) to the threads of bolts (12), (13), and both sides of the washers.
c. Install bolts (12) and (13). Refer to Guideline for Reusable Parts and Salvage Operations,
SEBF8301, "Inspection and Reuse of Critical Fasteners Used in All Engines".
d. Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 170 ± 10 N·m
(125 ± 7 lb ft).
e. Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 170 ± 10 N·m
(125 ± 7 lb ft).
f. Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in a numerical sequence
for an additional 120 ± 5 degrees (1/3 turn).
g. Loosen bolt (1) through bolt (26) until the washers are loose under the Bolt heads.
h. Tighten bolt (1) through bolt (26) in a numerical sequence to a torque of 170 ± 10 N·m
(125 ± 7 lb ft).
i. Tighten bolt (1) through bolt (26) again in a numerical sequence to a torque of 170 ± 10 N·m
(125 ± 7 lb ft).
j. Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in a numerical sequence
for an additional 120 ± 5 degrees (1/3 turn).
k. Tighten bolt (27) through bolt (34) in a numerical sequence to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Wed Jun 10 15:29:47 UTC+0800 2020
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i03554743
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Start By:
a. Remove the cylinder head.
1. Remove bolts (1).
2. Remove lifter group (2).
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1. Install lifter group (2) in reverse order of removal.
Wed Jun 10 15:30:43 UTC+0800 2020
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i05331988
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Table 1
Required Tools
A 1U-7638 Magnetic Holding Tool 18
B
201-4211 Camshaft Pilot 1
201-4212 Camshaft Pilot 1
Start By:
a. Remove the rocker arms and shafts.
b. Remove the front cover.
c. Remove the camshaft position sensor.
1. Turn the crankshaft to top center compression stroke for the No. 1 piston. Install the timing
bolt in the flywheel.
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2. Install Tooling (A) in order to support the lifter. Repeat for all the remaining lifters.
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3. Remove bolts (1). Remove bolt (2) and idler gear (3) for assembly purposes.
4. Remove tube assembly (6) and hose assembly (5). Remove cover (4).
5. Install Tooling (B) onto the camshaft.
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Note: Lubricate Tooling (B) for easier removal of the camshaft. Lubrication also prevents
damaging the camshaft lobes and the camshaft bearings.
6. Use two people to remove camshaft (7). The weight of camshaft (7) and the camshaft gear
is approximately 34 kg (75 lb). Carefully remove camshaft (7) from the engine. Support the
weight of the camshaft during removal.
Note: Rotate the camshaft during removal. This action will prevent the camshaft from
binding in the camshaft bearings.
NOTICE
When installing the camshaft, make sure the number one cylinder is at
top center of the compression stroke with the timing bolt installed in
the flywheel. The camshaft timing is very important. The timing mark
on the camshaft drive gear must line up with the timing mark on the
idler gear. Refer to the Specifications Manual for more information.
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Note: Ensure that camshaft (6) and Tooling (B) are clean. Apply clean engine oil to the lobes and
journals of camshaft (6) and Tooling (B).
Note: During installation of camshaft (6), rotate the camshaft in both directions in order to prevent
binding in the camshaft bearing bores.
1. Install camshaft (6) in the reverse order of removal.
a. Ensure that the timing Marks (X) on the idler gear aligned with the timing marks on
the crankshaft gear and the camshaft drive gear.
Wed Jun 10 15:31:38 UTC+0800 2020
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i05351535
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Start By:
A. Remove the camshaft.
1. Wrap the camshaft with a protective covering in order to prevent damage to the camshaft.
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NOTICE
Do not allow the camshaft to fall to the floor when pressing it from the
drive gear. Also make sure that the camshaft lobes do not catch on the
press plates.
2. Use a suitable press to remove drive gear (1) from camshaft (3) .
3. Remove woodruff key (2) .
1. Install drive gear (1) in the reverse order of removal.
a. Raise the temperature of drive gear (1) to a temperature of 315° C (600° F).
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i05332615
Camshaft Bearings - Remove and Install
SMCS - 1211-010
Removal Procedure
Table 1
Required Tools
A
201-4214 Receiving Sleeve 1
201-4213 Puller Plate 1
201-4209 Bearing Pilot 1
201-4208 Backup Plate 1
6F-7032 Bolt 1
8M-8778 Taperlock Stud 1
8S-8292 Extension (Short) 2
8S-8293 Extension (Long) 1
B 185-3989 Thread Lubricant 1
Start By:
a. Remove the lifter group.
b. Remove the camshaft.
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1. Install Tooling (A). Apply Tooling (B) on the threads.
2. Remove camshaft bearings (1).
Table 2
Required Tools
A
201-4214 Receiving Sleeve 1
201-4213 Puller Plate 1
201-4209 Bearing Pilot 1
201-4208 Backup Plate 1
6F-7032 Bolt 1
8M-8778 Taperlock Stud 1
8S-8292 Extension (Short) 2
8S-8293 Extension (Long) 1
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1. Position new camshaft bearing (1) in Tooling (A) and install the bearing from the rear to the
front of the engine.
2. The camshaft bearings are installed with Tooling (A). Measure the depth of the camshaft
bearings from the front face of the cylinder block to the following distances:
a. Dimension (A) is 36.50 mm (1.437 inch).
b. Dimension (B) is 192.50 mm (7.579 inch).
c. Dimension (C) is 348.50 mm (13.720 inch).
d. Dimension (D) is 504.50 mm (19.862 inch).
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