Caterpillar Cat C9 Industrial Engine (Prefix C9N) Service Repair Manual (C9N00001 and up).pdf

Service Repair Manual
Models
C9 Industrial Engine

Shutdown SIS
Previous Screen
Product: INDUSTRIAL ENGINE
Model: C9.3 INDUSTRIAL ENGINE C9N
Configuration: C9 Industrial Engine C9N00001-UP
Disassembly and Assembly
C9.3 Industrial Engine
Media Number -KENR8164-02 Publication Date -01/11/2017 Date Updated -14/11/2017
i06584460
Disconnecting Snap To Connect Fittings
SMCS - 7554-X6
Disconnection Procedure
Illustration 1 g02145423
Table 1
304-1165 Tool Kit
Item Part No. description Fitting Size
1 304-1166 STC Wrench -06
2 304-1167 STC Wrench -08 and -10
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3 304-1168 STC Wrench -12 and -16
4 341-2603 Warning Film -
5 276-7018 Plug/Cap Kit -
- 304-2721 Tool Pouch -
Personal injury can result from removing hoses or fittings in a pressure
system.
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the
system has been relieved.
NOTICE
Using the incorrect size snap to connect (STC) wrench can cause
slippage, resulting in personal injury. Always verify that the STC
wrench size matches the size fitting to be disconnected.
1. Lower all work tools and attachments to the ground.
2. Release the system pressure. Refer to Disassembly and Assembly, "System Pressure -
Release".
3. Clean the connection that is to be disassembled. Clean the surrounding area to ensure that
the connection is free of all dirt, dust, and grit.
4. Pressure can be trapped in circuits after the engine has stopped. Personal injury or death can
result if all pressures are not released. Ensure that the pressure is zero in the line that is
being disconnected.
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5. Select the designated release tool for the size of the connection. Using the wrong tool may
result in damage to the coupling, or cause slippage, resulting in unsafe conditions.
Note: Prying on the connection may result in damage to the release sleeve, requiring hose
replacement.
6. Insert the release tool behind the release sleeve, so that the release tool is perpendicular to
the connection. Fully insert the release tool to cause the release sleeve to move and separate
the retaining ring. The coupling may now be separated.
7. Pull on the hose in the direction parallel to the axis of connection while keeping the release
tool engaged. Pulling the hose at an angle may result in extra force required to disconnect
the connection.
8. Cover both ends of the connection with recommended plugs or caps to avoid contamination.
Connection Procedure
1. Clean the connection that is to be assembled. Ensure that the connection is free of all dirt,
dust, and grit.
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Note: If the release sleeve is damaged during the connection or disconnection of the STC
connection, the male portion must be replaced with new parts.
Note: Do not use the rubber sleeve as leverage to push the male half into the female half of
the STC connection.
2. Align the STC fitting on the hose assembly with the STC connector. Push the hose fitting
into the mating connector until you feel a definite snap and a solid stop.
3. Pull straight back on the connection. An improperly made connection will disconnect.
Red ring, on an improper connection.
4. Check for a visible red ring. An improper assembly shows the red ring.
Note: For more information on the operation and the maintenance of Snap to Connect wrenches,
refer to Tool Operating Manual, NEHS1083.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jun 6 14:48:17 UTC+0800 2020
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Shutdown SIS
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i03634690
Muffler - Remove and Install
SMCS - 1061-010; 1062-010
Removal Procedure
Start By:
a. Remove the air cleaner housing.
1. Attach a suitable lifting device to muffler (2). The weight of the muffler is approximately
29 kg (64 lb).
2. Disconnect clamp assemblies (1) and (3).
3. Use the suitable lifting device to remove muffler (2).
Installation Procedure
1. Install muffler (2) in reverse order.
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a. Tighten clamp assemblies (1) and (3) to a torque of 12 ± 1 N·m (106 ± 9 lb in).
Sat Jun 6 14:49:12 UTC+0800 2020
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Shutdown SIS
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i04060431
Fuel Priming Pump - Remove and Install
SMCS - 1258-010
Removal Procedure
1. Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Typical Example
2. Disconnect the fuel line (1) to the ARD manifold from both ends.
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Typical Example
3. Disconnect the solenoid harness (2).
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4. Remove the bolts (3) from the manifold.
5. Remove the manifold (4).
6. Remove the two locknuts (5).
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7. Write down the polarity and remove the wires (6) from the terminal studs. The polarity is
designated by “+” and “-” signs around the terminal studs.
8. Remove the seal (7).
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9. Remove the pump assembly (8).
10. Remove the two backup rings (9), seal (10), and seal (11) from the pump assembly.
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Proper orientation of the new fuel priming pump.
1. Use the pump seal installer that is provided in the pump kit to press in the new pump (12)
and seals.
Note: The outlet of the pump should be at the top center position.
2. Reinstall the wires on the terminal studs. Install new locknuts (6). Torque locknuts to
1.3 N·m (1 lb ft).
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3. Install new seal (7).
4. Reinstall the manifold (4).
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5. Reinstall bolts (3). Torque the bolts to 12 ± 3 N·m (9 ± 2 lb ft).
6. Replace the filter connector fitting (13).
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7. Reconnect the solenoid harness (2).
8. Turn the fuel supply to the ON position and turn the power disconnect switch to the ON.
9. Use two people in order to flush the fuel pump and fuel line (1) into a suitable container for
disposal. The fuel pump can be activated by turning on the key or pressing the manual
switch. The manual switch, if available, is located on the primary fuel filter base.
10. Connect fuel line (1) to the ARD manifold.
11. After reassembly, prime the engine by turning on the key or pressing the manual switch.
The manual switch, if available, is located on the primary fuel filter base. Visually check for
leaks around the pump and around the connections on the ARD manifold. If leaks are
observed, resolve the leak issue before proceeding further.
Sat Jun 6 14:50:08 UTC+0800 2020
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Shutdown SIS
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i03963533
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 As 1
B − Loctite 271 −
Typical Example
2. Disconnect harness assemblies (1) (not shown).
3. Disconnect hose assemblies (2).
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4. Use Tooling (A) in order to remove fuel filters (4) from fuel filter base (3).
5. Remove the fuel temperature sensor (5). Remove the Pre filter fuel pressure sensor (6) and
remove the post filter fuel pressure sensor (7).
6. Remove studs (8) from fuel filter base (3).
NOTICE
Check the O-ring seals, the gaskets, and the seals for wear or for
damage. Replace the components, if necessary.
1. Install the fuel filters and the fuel filter base in the reverse order.
a. Lubricate the fuel filter seals with the fluid that is being sealed prior to installation.
Use Tooling (A) in order to tighten the fuel filters (4) to a torque of 35 ± 3 N·m
(26 ± 2 lb ft).
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b. Apply Tooling (B) to the threads of studs (8). Tooling (A) should cover the threads of
the stud, shown as Distance (A), which is a measurement of 7.6 ± 0.8 mm
(0.3 ± 0.03 inch). Tighten studs (8) to a torque of 70 ± 15 N·m (52 ± 11 lb ft).
Sat Jun 6 14:51:04 UTC+0800 2020
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Shutdown SIS
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i03997253
Fuel Filter Base - Remove and Install - Primary
SMCS - 1262-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1
2. Disconnect the harness assembly (not shown).
3. Drain the primary filter and use Tooling (A) in order to remove the primary filter (1). Refer
to Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator)
Element - Replace".
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4. Remove check valve (2). Remove backup ring (3), O-ring seals (4) and (5).
5. Remove nut (6) and remove coil (7).
6. Remove cartridge (8). Remove backup ring (11), and remove O-ring seals (9) and (10).
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
7. Remove plug (15) and remove the O-ring seal. Remove spring (14), valve (12) and O-ring
seal (13). Repeat this step for the other check valve assembly.
8. Remove the Fuel Priming Pump. Refer to Disassembly and Assembly Manual, "Fuel
Priming Pump - Remove and Install".
NOTICE
Check the O-ring seals, the gaskets, and the seals for wear or for
damage. Replace the components, if necessary.
1. Install the fuel filter and the fuel filter base in the reverse order.
a. Tighten plug (15) to a torque of 95 ± 10 N·m (70 ± 7 lb ft).
b. Tighten check valve (2) to a torque of 28 ± 3 N·m (21 ± 2 lb ft).
c. Tighten cartridge (8) to a torque of 28 ± 3 N·m (21 ± 2 lb ft).
d. Tighten nut (6) to a torque of 6.5 ± 0.5 N·m (58 ± 4 lb in).
Sat Jun 6 14:52:00 UTC+0800 2020
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Caterpillar Cat C9 Industrial Engine (Prefix C9N) Service Repair Manual (C9N00001 and up).pdf

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