Caterpillar Cat C9 Industrial Engine (Prefix MBD) Service Repair Manual (MBD00001 and up).pdf

Service Repair Manual
Models
C9 Industrial Engine

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Product: INDUSTRIAL ENGINE
Model: C9 INDUSTRIAL ENGINE MBD
Configuration: C9 Industrial Engine MBD00001-UP
Disassembly and Assembly
C9 Industrial Engines
Media Number -RENR7460-07 Publication Date -01/07/2014 Date Updated -15/11/2017
i02538070
Fuel Priming Pump - Remove and Install
SMCS - 1258-010
Removal Procedure
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.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...

Illustration 1 g01270491
1. Remove bolts (3) and the washers.
2. Remove fuel priming pump (2) and the gasket from fuel filter base (1).
Installation Procedure
NOTICE
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1. Position the gasket and fuel priming pump (2) on fuel filter base (1).
2. Install bolts (3) and the washers.
3. Purge the air from the fuel system.
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All Rights Reserved.
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Thu Jun 4 15:50:22 UTC+0800 2020
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i02538087
Fuel Filter Base - Remove and Install
SMCS - 1262-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench Assembly 1
NOTICE
NOTICE
containing fluids.
Cat®
products.
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1. Use Tooling (A) to remove fuel filter (2).
2. Disconnect hose assemblies (4) and (5) from fuel filter base (1). Immediately cap all
openings or plug all openings in order to prevent contamination.
3. Disconnect fuel sensor (3) from fuel filter base (1).
4. Remove bolts (6) and the washers from fuel filter base (1). Remove fuel filter base (1) from
the bracket.
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1. Position fuel filter base (1) on the bracket. Install bolts (6) and the washers.
2. Connect hose assemblies (4) and (5) to fuel filter base (1).
3. Connect fuel sensor (3) to the fuel filter base.
4. Install fuel filter (2). Refer to the Operation and Maintenance Manual, "Fuel System
Secondary Filter - Replace" topic for more information.
5. Prime the fuel system. Refer to the Operation and Maintenance Manual, "Fuel System -
Prime" topic for more information.
Thu Jun 4 15:51:18 UTC+0800 2020
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i04892113
Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
A 367-3070 Fuel Injector Installer and Removal Tooling 2
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
containing fluids.
Cat®
products.
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NOTICE
1. Remove the plug at the rear of the cylinder head. Allow the engine oil to drain from the hole
in the cylinder head before the unit injector is removed.
2. Use a small flat head screwdriver to disconnect harness assembly (2) from unit injector (1).
3. Remove socket head bolts (3).
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4. Install Tooling (A). Use Tooling (A) to remove unit injector (1) from the cylinder head.
Note: Do not use a wire brush on the tip of the unit injector. Damage to the unit injector will
occur.
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5. Remove O-ring seals (6), (7), and (8) from unit injector (1). Remove backup rings (4), (5),
and (9) from unit injector (1).
Thu Jun 4 15:52:13 UTC+0800 2020
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i04902499
Unit Injector - Install
SMCS - 1290-012
Table 1
Required Tools
A 367-3070 Fuel Injector Installer and Removal Tooling 2
E 149-2955 Seal Protector 1
F 149-2956 Seal Installer 1
G
1U-5718 Vacuum Pump 1
169-7372 Bottle Assembly 1
4C-4057
Clear Plastic Tubing
7.92 mm (0.312 inch) OD
1
4C-4055
Clear Plastic Tubing
6.35 mm (0.250 inch) OD
1
H 417-4368 Reamer 1
J 4C-6161 Tube Brush 1
K 9U-6862 Tapered Brush 1
L 4C-6774 Vacuum Gun Kit 1
M 4C-5026 Tap Wrench 1
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NOTICE
1. Evacuate as much fuel and oil as possible from the cylinder head before installing the unit
injector. Several evacuations may be necessary. Use Tooling (G) to remove the fuel and oil
from the cylinder head.
Note: Tooling (L) is available to clean loose material from the sleeve bore and the cylinder.
2. Inspect the unit injector sleeve for damage and carbon deposits.
3. Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector, if the unit
injector is being reused. Clean the carbon from the seat area that is inside of the cylinder
head. A fine grade of Scotch Brite material is preferred. Use Tooling (H) to clean the bore
of the unit injector tip. Use the Surface Reconditioning Pad in order to clean the carbon in
the cylinder head. Use Tooling (J) in order to remove the carbon from the surface of the
sleeve.
Note: Using power tools in order to rotate the material should not be necessary. The carbon
in the sleeve is more removable than the carbon at locations that are exposed to higher
temperatures.
The following procedure is the preferred method of cleaning the sleeve bore.
Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of Tooling (K) .
Twist Tooling (K) with Tooling (M) against the lower surface of the sleeve bore.
The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore
should be cleaned in order to remove any loose carbon particles.
Note: Tooling (J) is available to clean loose material from the sleeve bore and the cylinder.
NOTICE
The correct procedures and tooling specifications must always be used.
Failure to follow any of the procedures may result in damage,
malfunction, or possible engine failure.
Note: New seals should be installed after each removal of the unit injector from the engine.
To order O-ring seals for the unit injector, refer to the Parts Manual.
NOTICE
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The O-ring seals and the backup rings must be installed in the correct
orientation. Damaged seals will result in excessive oil consumption or
excessive leakage under the valve cover. Use care to prevent nicks or
damage to the seals.
4. Lubricate O-ring seals (6) , (7) , and (8) and the sleeve bore of the unit injector sparingly
with clean engine oil.
5. Use Tooling (E) and Tooling (F) to install the backup rings (4) and (5) first. Install O-ring
seal (6) .
6. Use Tooling (E) and Tooling (F) to install backup ring (9) . Install O-ring seal (8) .
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7. Install O-ring seal (7) .
8. Lubricate the O-ring seals and the backup rings on unit injector (1) with clean engine oil
before installation.
Note: Proper installation of the unit injector is important. Damage to the upper high-
pressure seals can cause excessive oil leakage under the valve cover. This may cause the
engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals
may allow high-pressure oil to leak into the fuel supply passage. This will result in
excessive oil consumption.
Note: Do not hit or strike the unit injector during installation. Do not use a wire brush to
clean the tip of the unit injector. Damage to the unit injector will occur.
9. When you install a new unit injector the E-Trim value must be programmed into the
Electronic Control Module. The E-Trim value is a six digit alphanumeric code that is
supplied with the data sheet that comes with the new unit injectors. Use the following menu
to program the E-Trim value.
◦ ECM Summary Screen
◦ Service Menu
◦ Calibration
◦ Injector Code Calibration
10. Use Tooling (A) to install unit injector (1) in the cylinder head.
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11. Install socket head bolt (3) on the exhaust side of the bracket. Tighten the exhaust side of
socket head bolt (3) until the bolt is seated. Tighten the inlet side of socket head bolt (3) to a
torque of 12 ± 1 N·m (106 ± 9 lb in) .
12. Connect harness assembly (2) to unit injector (1) .
13. Install the plug at the rear of the cylinder head.
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
Thu Jun 4 15:53:09 UTC+0800 2020
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i06737900
Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
A 1P-3042 Plug Tap 1
B 221-0052 Guide Sleeve 1
C
9U-6858 Bridge Plate 1
1B-2886 Bolts 2
221-9778 Puller Stud 1
4K-0367 Full Nut 1
5P-8247 Hard Washer 1
9U-6877 Thrust Bearing 1
D 221-9803 Rubber Stopper 1
Start By:
a. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
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NOTICE
containing fluids.
Cat®
products.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".
2. Position Tooling (D) at the bottom of the unit injector sleeve.
3. Coat Tooling (A) with clean grease. Use Tooling (A) and Tooling (B) to cut threads into the
unit injector sleeve.
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4. Install Tooling (C) in unit injector sleeve (1).
5. Remove unit injector sleeve (1). Remove the O-ring seals.
Thu Jun 4 15:54:04 UTC+0800 2020
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i03742983
Unit Injector Sleeve - Install
SMCS - 1713-012
Table 1
Required Tools
E 221-9777 Sleeve Installer 1
F 4C-5552 Large Bore Brush 1
G 4C-9507 Retaining Compound 1
NOTICE
1. Thoroughly clean the unit injector sleeves and the bores for the unit injectors with Tooling
(F) .
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2. Apply clean engine oil to O-ring seals (2) . Install O-ring seals (2) on unit injector sleeve
(1) .
3. Position unit injector sleeve (1) on Tooling (E) .
4. Apply a thin coating of Tooling (G) around the outer circumference of unit injector sleeve
(1) at Area (C) .
5. Position unit injector sleeve (1) in the cylinder head. Use a hammer to install unit injector
sleeve (1) in the cylinder head.
Note: Allow Tooling (G) to cure for two hours at 21 °C (70 °F) before filling the engine
with fuel or coolant. Longer curing time is required for lower temperatures.
6. Fill the cooling system with coolant to the correct level. Refer to Operation and
Maintenance Manual, "Refill Capacities and Recommendations".
End By: Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Install".
Thu Jun 4 15:55:00 UTC+0800 2020
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i05701078
Unit Injector Hydraulic Pump - Remove
SMCS - 1714-011
Removal Procedure for Non-Dual Tapered Roller Bearing
HEUI Pump
Start By:
A. Remove fuel filter base, if necessary.
NOTICE
NOTICE
containing fluids.
Cat products.
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Caterpillar Cat C9 Industrial Engine (Prefix MBD) Service Repair Manual (MBD00001 and up).pdf

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