Caterpillar Cat C13 Industrial Engine (Prefix KWJ) Service Repair Manual (KWJ00001 and up).pdf

Service Repair Manual
Models
C13 Industrial Engine

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Product: INDUSTRIAL ENGINE
Model: C13 INDUSTRIAL ENGINE KWJ
Configuration: C13 Industrial Engine KWJ00001-UP
Disassembly and Assembly
C13 Engine and C13 Industrial Engine
Media Number -KENR8165-03 Publication Date -01/11/2017 Date Updated -14/11/2017
i03551630
Camshaft - Install
SMCS - 1210-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7638 Magnetic Holding Tool 18
B
201-4211 Camshaft Pilot 1
201-4212 Camshaft Pilot 1
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Illustration 1 g01292428
1. Install Tooling (B).
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.
2. Carefully install camshaft (6) in the engine.
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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3. Ensure that the timing Marks (X) on the idler gear aligned with the timing marks on the
crankshaft gear and the camshaft drive gear.
4. Remove Tooling (A) and Tooling (B).
5. Install cover (2). Install hose assembly (3) and tube assembly (4).
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6. Install bolts (1).
End By:
a. Install the camshaft position sensor.
b. Install the front cover.
c. Install the rocker arm and shaft.
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Wed Jun 10 23:06:17 UTC+0800 2020
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i04587192
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 woodruff key (2) in camshaft (3) .
2. Raise the temperature of drive gear (1) to a temperature of 315° C (600° F).
3. Install drive gear (1) on the end of camshaft (3) .
End By: Install the camshaft.
Wed Jun 10 23:07:12 UTC+0800 2020
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i03551900
Camshaft Bearings - Remove
SMCS - 1211-011
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).
Wed Jun 10 23:08:08 UTC+0800 2020
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i03551921
Camshaft Bearings - Install
SMCS - 1211-012
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
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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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e. Dimension (E) is 660.50 mm (26.004 inch).
f. Dimension (F) is 816.50 mm (32.146 inch).
g. Dimension (G) is 972.50 mm (38.287 inch).
NOTICE
Camshaft bearings must be installed into their correct position. Failure
to do so will result in engine damage.
(2) Bearing joint
(3) Oil hole
(H) Bearing oil hole is located at a 45 degree angle from vertical. All seven bearings have the
same angle.
End By:
a. Install the camshaft.
b. Install the lifter group.
Wed Jun 10 23:09:04 UTC+0800 2020
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i04970472
Engine Oil Pan - Remove and Install
SMCS - 1302-010
Removal Procedure
Table 1
Required Tools
A - Loctite 596 1
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the oil into a suitable container. Refer to Operation and Maintenance Manual, "Refill
Capacities and Recommendations".
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2. Remove bolts (1), washers (2), fastener assemblies (3) and remove oil pan (4) .
Note: Ensure that the oil pan and mating surfaces are clean and free of oil.
1. Apply Tooling (A) at four locations marked (A). Tooling (A) should be applied in 4 ± 1 mm
(0.16 ± 0.04 inch) diameter beads.
Note: All joints using Tooling (A) must be assembled within ten minutes of the application.
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2. Install fastener assemblies (3) and the gasket (not shown) onto oil pan (4) .
Torque Sequence
3. Position oil pan (4), washers (2), and bolts (1) into place.
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4. Tighten bolts (1) in the above sequence.
5. Fill the engine with oil. Refer to Operation and Maintenance Manual, "Refill Capacities and
Recommendations".
Wed Jun 10 23:10:00 UTC+0800 2020
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i03551963
Cylinder Liner - Remove
SMCS - 1216-011
Removal Procedure
Table 1
Required Tools
A 5P-8665 Cylinder Liner Puller Gp 1
Start By:
a. Remove the pistons and the connecting rods.
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1. Use Tooling (A) to remove cylinder liner (1).
2. Remove the O-ring seals from cylinder liner (1).
Wed Jun 10 23:10:55 UTC+0800 2020
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i03551988
Cylinder Liner - Install
SMCS - 1216-012
Table 1
Required Tools
B 2P-8260 Cylinder Liner Installer 1
C 5P-3975 Rubber Lubricant 1
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1. Install the O-ring seals on cylinder liner (1).
2. Apply Tooling (C) on the O-ring seals.
Note: Refer to Testing and Adjusting, "Cylinder Liner Projection" for more information.
Note: If you are installing a cylinder pack, ensure that the corresponding crankshaft throw is
at bottom center.
3. Use Tooling (B) to install cylinder liner (1).
End By:
a. Install the pistons and the connecting rods.
Wed Jun 10 23:11:51 UTC+0800 2020
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i03554761
Piston Cooling Jets - Remove and Install
SMCS - 1331-010
Removal Procedure
Start By:
a. Remove the engine oil pan.
NOTICE
Special care must be taken not to bend the piston cooling jets because
the piston cooling jets are precision aligned with a coolant passage in
the pistons.
There is only one position for each cooling jet. The notch in the bottom
of the piston allows clearance for the piston cooling jet when the piston
is at bottom dead center.
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1. Remove bolt (1) and piston cooling jet (2).
1. Install piston cooling jet (2) in reverse order of removal.
a. Tighten bolt (1) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
Wed Jun 10 23:12:47 UTC+0800 2020
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i03554787
Pistons and Connecting Rods - Remove
SMCS - 1225-011
Removal Procedure
Start By:
a. Remove the cylinder head.
b. Remove the engine oil pan.
1. Place an identification mark on the connecting rod and connecting rod cap (2). The number
should match the cylinder number. The bearing retainer notch should be on the right side.
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2. Remove connecting rod cap (2). Remove the lower half of connecting rod bearing (1) from
connecting rod cap (2).
3. Push the piston and connecting rod away from the crankshaft. Remove the upper half of the
connecting rod bearing.
Note: Careful handling is required for fractured connecting rods. Fractured faces for the
connecting rod and connecting rod cap should not be placed on any surface. The connecting
rod and the connecting rod cap should be placed on the sides in order to prevent damage.
When possible, the connecting rod and the connecting rod cap should be bolted together in
order to prevent damage.
4. Remove the piston and connecting rod from the cylinder block.
Wed Jun 10 23:13:42 UTC+0800 2020
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Caterpillar Cat C13 Industrial Engine (Prefix KWJ) Service Repair Manual (KWJ00001 and up).pdf

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Caterpillar Cat C13 Industrial Engine (Prefix KWJ) Service Repair Manual (KWJ00001 and up).pdf