Caterpillar Cat C9 Industrial Engine (Prefix D9N) Service Repair Manual (D9N00001 and up).pdf

Service Repair Manual
Models
C9 Industrial Engine

Shutdown SIS
Previous Screen
Product: INDUSTRIAL ENGINE
Model: C9.3 INDUSTRIAL ENGINE D9N
Configuration: C9 Industrial Engine D9N00001-UP
Disassembly and Assembly
C9.3 Industrial Engine
Media Number -KENR8164-02 Publication Date -01/11/2017 Date Updated -14/11/2017
i05346018
Relief Valve (Fuel) - Remove and Install
SMCS - 1702-010-PV
Removal Procedure
Start By:
A. Remove the exhaust sensor lines.
NOTICE
Contact with high pressure fuel may cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow fuel pressure to
purge before any service or repair is performed on the engine fuel
lines.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...

of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and mandates.
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
1. Turn the fuel supply to the OFF position.
2. Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery
Cable - Disconnect".
3. Remove all components in order to access to the wiring harness.
Illustration 1 g02140798
4. Loosen clamp assemblies (1) and remove hose (2) .
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5. Disconnect fittings (3) and (7) .
6. Remove bolts (5) , (6) , and (8) and remove tube assembly (4) .
7. Remove bolt (9) .
8. Remove nuts (10) and remove bracket (11) .
9. Disconnect harness assemblies (12) .
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Typical Example
10. Position harness assembly (13) out of the way with cable straps.
11. Disconnect tube assembly (16) and remove fitting (15) .
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Note: Relief valve (14) is a two-piece valve which should not be disassembled.
Note: Do not loosen at Location (X) .
12. Remove relief valve (14) .
Installation Procedure
NOTICE
1. Install relief valve (14) in the reverse order of removal.
a. Tighten relief valve (14) to a torque of 95 ± 3 N·m (70 ± 2 lb ft).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Jun 8 11:08:28 UTC+0800 2020
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Shutdown SIS
Previous Screen
i07039625
Fuel Injection Pump - Remove and Install
SMCS - 1251-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Name Qty
A
(1) 350-7549 Engine Turning Tool 1
B 294-3031 Fuel Pump Pinch Bolt 1
(1)
The tooling is designed to turn the crankshaft in engines that have limited access to the flywheel housing. The tool
engages all four bolt heads which are located in the front vibration damper.
Note: Cleanliness is a critical factor. Clean the exterior of the components before you begin the
removal procedure. This action will help to prevent dirt from entering the internal mechanism.
NOTICE
Contact with high pressure fuel may cause personal injury or death.
Wait 60 seconds after the engine has stopped to allow fuel pressure to
purge before any service or repair is performed on the engine fuel
lines.
NOTICE
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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.
Dispose of all fluids according to local regulations and mandates.
NOTICE
Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.
1. Ensure that the No. 1 cylinder is at top center compression stroke. Refer to "Testing and
Adjusting", Finding Top Center Position for No. 1 Piston.
2. Remove all necessary components to access the fuel injection pump.
3. Remove plug (1) and remove O-ring seal (2).
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4. Using Tooling (A) and a 3/4" ratchet, rotate the crankshaft until the timing mark on the fuel
pump is visible through the inspection hole. Install Tooling (B) and tighten to a torque of
9 ± 1 N·m (80 ± 9 lb in).
Note: Mark the damper in relation to the front timing cover as a visual reference to ensure
that the crankshaft has not moved while the fuel injection pump is removed.
Note: The pump will not function while Tooling (B) is installed. Running the fuel injection
pump with the tooling installed will result in pump damage and system contamination.
Note: For installation purposes, mark and note the orientation of each harness assembly (3).
5. Disconnect harness assemblies (3).
6. Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
7. Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
8. Disconnect hose assembly (6).
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9. Disconnect tube assemblies (9).
10. Disconnect hose assemblies (10) and (11).
11. Remove bolts (8).
12. Disconnect tube assembly (12).
13. Remove bolts (13) and remove fuel pump (14).
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Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.
1. Position fuel pump (14) and install bolts (13).
2. Connect tube assembly (12).
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3. Install bolts (8).
4. Connect tube assembly (9) and connect both hose assemblies (10) and (11).
Note: During installation, make sure that the fuel line caps remain in position until the fuel
line is positioned near the corresponding ports to prevent contamination. Ensure that the
areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If
any parts are worn or damaged, use new parts for replacement. Cleanliness is an important
factor. Ensure that no debris gets introduced into the fuel system during the installation
procedure. If any parts are worn or damaged, use new parts for replacement.
5. Connect harness assemblies (3).
6. Install a new fuel line. Hand tighten nuts (4) and (7).
7. Position the clamp assembly and install nut (5). Hand tighten the nut. Failure to place the
grommet correctly on the fuel line could result in a failed fuel line.
Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use
excessive force or bending to assemble the fuel lines.
8. Tighten nut (4) at the fuel rail to a torque of 27 ± 3 N·m (239 ± 27 lb in).
9. Tighten nut (7) to a torque of 27 ± 3 N·m (239 ± 27 lb in).
10. Tighten nut (5) to a torque of 12 ± 3 N·m (105 ± 27 lb in).
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11. Remove Tooling (B).
Note: The pump will not function while Tooling (B) is installed. Running the fuel injection
pump with the tooling installed will result in pump damage and system contamination.
12. Install O-ring seal (2) and plug (1). Tighten the plug to a torque of 9 ± 1 N·m (80 ± 9 lb in).
Mon Jun 8 11:09:24 UTC+0800 2020
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Shutdown SIS
Previous Screen
i06585248
Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tooling
Tool Part Number Part Description Qty
A 268-1968 Pry Bar 1
B - Guide Stud (M8 x 1.25 x 3 inch) 1
C 276-7018 Plug/Cap Kit 1
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
b. Remove the fuel injection line. Refer to Disassembly and Assembly, "Fuel Lines - Remove
and Install".
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Note: Do not remove the quill tube. This action will reduce the risk of contamination to the
system.
1. Fully loosen quill tube nut (1). Pull quill tube (1) out of the bore until you see O-ring seal
(2). This action will ensure that the injector does not contact the quill tube during removal.
At this time, inspect O-ring seal (2) for wear or for damage. Replace the O-ring seal if
necessary.
Typical Example
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2. Disconnect harness assembly (3) from the unit injector.
Typical Example
3. Remove bolt (5) from clamp (6).
Note: When possible, remove the unit injector by hand by twisting the unit injector and
pulling upward. Be sure not to strike the unit injector during the removal procedure.
4. If unit injector (4) cannot be removed by hand, go to Step 5.
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Typical Example
Note: Do not damage the unit injector during removal. Side loading may damage to the unit
injector.
5. Install Tooling (B) in unit injector clamp (6) and position Tooling (A) under unit injector
clamp (6). Carefully remove unit injector (4) from the cylinder head.
Mon Jun 8 11:10:20 UTC+0800 2020
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Shutdown SIS
Previous Screen
i05829824
Unit Injector - Install
SMCS - 1290-012
Table 1
Required Tools
B - Scotch Brite 1
C
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
D 457-1623 Reamer 1
E 4C-6161 Tube Brush 1
F 9U-6862 Tapered Brush 1
G 4C-6774 Vacuum Gun Kit 1
H 4C-5027 Tap Wrench 1
J 276-7018 Plug/Cap Kit 1
NOTICE
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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 (C) to remove the fuel and oil
from the cylinder.
Note: Tooling (F) is available to clean loose material from the sleeve bore and the cylinder.
2. Clean the carbon from the sleeve, the sleeve bore, and the end of the unit injector. Clean the
carbon from the seat area that is inside the cylinder head. A fine grade of Tooling (B) is
preferred. Clean the carbon from the cylinder head. If the sleeve of the unit injector has been
removed, use Tooling (D) to remove only carbon from the surface of the sleeve. If the
sleeve of the unit injector is installed, use Tooling (E) to clean the carbon deposit from the
inside of the sleeve.
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 (F).
Twist Tooling (F) with Tooling (H) 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 to remove any loose carbon particles.
Note: Tooling (G) 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.
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Note: Replace the O-ring seals on the injector.
3. Install O-ring seal (9) and O-ring seal (10) on unit injector (4). Lubricate O-ring seal (9), O-
ring seal (10), and the sleeve bore of the unit injector sparingly with clean engine oil.
4. Record the serial number for the injector and the injector confirmation code. When you
install a new unit injector, the E-Trim value must be programmed into the Engine Control
Module. For more information, refer to Troubleshooting, "Injector Trim File - Install".
Note: Verify quill tube (1) is positioned out of the bore enough to see O-ring seal (2). This
action will ensure that the injector does not contact the quill tube during installation.
5. Place unit injector (4) into the bore. Make sure that the key (7) for the unit injector fits into
slot (8) in the cylinder head.
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Note: Use new socket head bolt (5).
6. Position unit injector clamp (6) with the label "C9" in the up position. Install socket head
bolt (5) into unit injector clamp (6). Tighten socket head bolt (5) to a torque of 28 ± 3 N·m
(21 ± 2 lb ft) to secure unit injector (4).
7. Connect harness assembly (3) to the unit injector.
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Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.
8. If the O-ring was damaged, perform Step 8.a and Step 8.b.
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a. Inspect the sealing surface (A) for damage. Replace quill tube (1) if damage was
found.
b. Lubricate new O-ring seal (2) with clean engine oil. Install new O-ring (2).
9. Lubricate the O-ring seal, the nut face, and the threads with clean engine oil. Insert quill
tube (1) into the bore with the ball on the right side. Once the quill tube has bottomed out,
rotate the quill tube until the ball engages with the slot. The quill tube should drop slightly
when the ball is engaged with the slot. This action will install quill tube (1). Ensure that the
ball is in alignment with the slot for quill tube (1). Tighten the nut for quill tube (1) to a
torque of 70 ± 3 N·m (52 ± 2 lb ft).
Note: After service is complete, perform a fuel system verification test. Refer to
Troubleshooting, Fuel System Verification Test for the correct procedure.
End By:
a. Install the fuel injection line. Refer to Disassembly and Assembly, "Fuel Lines - Remove
and Install".
b. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Mon Jun 8 11:11:15 UTC+0800 2020
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Shutdown SIS
Previous Screen
i06788311
Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
A - 7/8-9 NC Tap 1
B
1A-5576 Bolt 1
8C-6913 Hard Washer 7
C 221-9803 Rubber Stopper 1
Start By:
a. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
NOTICE
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Caterpillar Cat C9 Industrial Engine (Prefix D9N) Service Repair Manual (D9N00001 and up).pdf

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