Caterpillar Cat D9N TRACK-TYPE TRACTOR (Prefix 1JD) Service Repair Manual (1JD00001 and up).pdf

Service Repair Manual
Models
D9N TRACK-TYPE TRACTOR

Shutdown SIS
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Product: TRACK-TYPE TRACTOR
Model: D9N TRACK-TYPE TRACTOR 1JD
Configuration: D9N TRACTOR 1JD00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly
3408E and 3412E Engines for Caterpillar Built Machines
Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016
i02161082
Rocker Arm and Shaft - Install
SMCS - 1102-012
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 1 g01095626
1. Lubricate the wear pad on top of valve bridges (4) with clean engine oil. Install valve
bridges (4).
2. Install the pushrods.
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D9N TRACTOR 1JD00001-UP (MACHINE) POWERED BY 3408 ENGINE(SEBP1...
2021/10/12
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3. Install the O-ring seal and rocker arm assembly (3).
4. Install cylinder head bolt (1) and bolt (2). Do not tighten bolt (2) at this time.
5. Tighten cylinder head bolt (1) to a torque of 270 ± 15 N·m (199 ± 11 lb ft). Tighten cylinder
head bolt (1) again to a torque of 450 ± 15 N·m (332 ± 11 lb ft). Tighten cylinder head bolt
(1) again to a torque of 450 ± 15 N·m (332 ± 11 lb ft). Tighten bolt (2) to the standard
torque value.
End By:
a. Install the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Install".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Oct 12 01:32:27 UTC+0800 2021
2/2
2021/10/12

Shutdown SIS
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i02184090
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 5P-8700 Lifting Bracket 2
Start By:
a. Remove the unit injector sleeves. Refer to Disassembly and Assembly, "Unit Injector Sleeve
- Remove".
b. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
NOTICE
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.
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. Remove hose assembly (1) from the front of the fuel manifold.
2. Remove hose assembly (2) from the rear of the fuel manifold.
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3. Remove tube assembly (3).
4. Remove cylinder head bolts (5). Remove bolts (4).
5. Attach Tooling (A) and a suitable lifting device to fuel manifold (6). The weight of the fuel
manifold for the 3412E is approximately 60 kg (131 lb). The weight of the fuel manifold for
the 3408E is approximately 39 kg (86 lb). Remove bolts (7). Remove fuel manifold (6).
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vO
6. Attach Tooling (B) and a suitable lifting device to the cylinder head. The weight of the
cylinder head for the 3412E is approximately 172 kg (380 lb). The weight of the cylinder
head for the 3408E is approximately 90 kg (200 lb). Remove cylinder head nuts (8).
7. Remove cylinder head (9) and the gasket.
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8. Remove seals (10).
9. Remove spacer plate (11).
10. Remove O-ring seals (12) and gasket (13).
Tue Oct 12 01:33:26 UTC+0800 2021
5/5
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Shutdown SIS
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i02184092
Cylinder Head - Install
SMCS - 1100-012
Table 1
Required Tools
A 138-7573 Link Bracket 2
B 5P-8700 Lifting Bracket 2
C 8C-8422 Sealant 2
NOTICE
Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head. A new
spacer plate gasket must be installed when the cylinder head is removed.
Note: Apply a thin film of clean engine oil on the seals and the O-ring seals prior to installation.
1/7
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1. Install O-ring seals (12) and gasket (13).
2. Install spacer plate (11).
3. Install seals (10).
4. Position the gasket on the engine. Attach Tooling (B) and a suitable lifting device to the
cylinder head. The weight of the cylinder head for the 3412E is approximately 172 kg
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(380 lb). The weight of the cylinder head for the 3408E is approximately 90 kg (200 lb).
Install cylinder head (9).
5. Install cylinder head nuts (8). Remove Tooling (B).
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6. Apply Tooling (C) to the shaded area of the fuel manifold. Tooling (C) is applied to the
bottom portion of the fuel manifold. Tooling (C) is permitted on the entire face of the fuel
manifold.
7. Attach Tooling (A) and a suitable lifting device to fuel manifold (6). The weight of the fuel
manifold for the 3412E is approximately 60 kg (131 lb). The weight of the fuel manifold for
the 3408E is approximately 39 kg (86 lb). Install fuel manifold (6). Install bolts (7).
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Note: Apply clean engine oil to the bolts for the cylinder head.
8. Install cylinder head bolts (5). Install bolts (4).
9. Tighten the bolts in the following sequence:
In a numerical sequence, tighten the bolts 1 through 26 for the 3412E.
In a numerical sequence, tighten the bolts 1 through 18 for the 3408E.
a. In a numerical sequence, tighten the bolts to a torque of 270 ± 15 N·m
(200 ± 11 lb ft).
b. In a numerical sequence, tighten the bolts to a torque of 450 ± 15 N·m
(330 ± 11 lb ft).
c. In a numerical sequence, again tighten the bolts to a torque of 450 ± 15 N·m
(330 ± 11 lb ft).
d. Tighten the upper row of nuts that are on the cylinder head in the following sequence:
In a numerical sequence, tighten nuts 27 through 39 for the 3412E to a torque of
45 ± 7 N·m (33 ± 5 lb ft).
In a numerical sequence, tighten nuts 19 through 27 for the 3408E to a torque of
45 ± 7 N·m (33 ± 5 lb ft).
10. Install tube assembly (3).
6/7
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11. Install hose assembly (2) on the rear of the fuel manifold.
12. Install hose assembly (1) on the front of the fuel manifold.
End By:
a. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
b. Install the unit injector sleeves. Refer to Disassembly and Assembly, "Unit Injector Sleeve -
Install".
Tue Oct 12 01:34:25 UTC+0800 2021
7/7
2021/10/12

Shutdown SIS
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i05933135
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Table 1
Required Tools
A 5P-7433 Valve Lifter Tool Group 1
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head -
Remove".
NOTICE
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1. Install Tooling (A) in lifter assembly (1) .
2. Remove lifter assembly (1) from the lifter bore.
3. Remove lifter guide spring (2) from the lifter assembly.
2/4
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Table 2
Required Tools
A 5P-7433 Valve Lifter Tool Group 1
Note: Install new valve lifter guide springs on the valve lifter when the valve lifters are
removed from the engine.
Note: Apply clean engine oil to the ball socket for the pushrod and the bore for the valve
lifter assembly.
1. Make an alignment of the new lifter guide spring (2) in Tooling (A) .
2. Install lifter assembly (1) in the cylinder block with Tooling (A) .
3/4
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End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
Tue Oct 12 01:35:24 UTC+0800 2021
4/4
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Shutdown SIS
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i06177964
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Table 1
Required Tools
A 1P-0510 Driver Group 1
Start By:
a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
b. Remove the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and
Install".
c. Remove the flywheel housing. Refer to Disassembly and Assembly, " Flywheel Housing -
NOTICE
NOTICE
1/6
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performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
1. Remove four bolts (1) and plate (2) from the rear of the camshaft. Remove gear (3) from the
camshaft.
2. Rotate the engine until the “V” marks on the front of the timing gears are in alignment.
2/6
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3. Remove two bolts (5) and plate (4) from the camshaft.
4. Remove camshaft (6) from the cylinder block.
5. If necessary, remove camshaft gear (7) with Tool (A) and press.
3/6
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NOTICE
Note: The key for gear (7) must be in position on the camshaft (6) before gear (7) is
installed.
1. Do not use a torch to heat camshaft gear (7). Raise the temperature of camshaft gear (7) by
one of the following methods.
◦ Use a suitable oven to raise the temperature of camshaft gear (7). Do not exceed
150° C (302° F) for more than four hours.
◦ Use a suitable induction heater to raise the temperature of the hub of camshaft gear
(7). Do not exceed 150° C (302° F) at bottom of gear teeth root radius.
2. Install camshaft gear (7) to camshaft (6).
3. Put 8T-2998 Lubricant on the camshaft lobes and the rollers for the valve lifter. Put clean
engine oil on the bearing journals of the camshaft.
4/6
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4. Install camshaft (6) until the rear of the camshaft is even with the rear of the cylinder block.
5. Make an alignment of the “V” marks on the camshaft gear and the idler gear.
6. Install plate (4) on the cylinder block.
5/6
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7. Install gear (3) and plate (2) on the rear of the camshaft.
End By:
a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
b. Install the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and
Install".
c. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
Tue Oct 12 01:36:24 UTC+0800 2021
6/6
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Shutdown SIS
Previous Screen
i01519738
Camshaft Bearings - Remove and Install
SMCS - 1211-010
Removal Procedure
Table 1
Required Tools
A
8S-2241 Camshaft Bearing Tool Group 1
8S-8293 Extension 1
5P-1667 Tube 1
Start By:
A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
B. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
C. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".
NOTICE
1/5
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NOTICE
performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
1. Remove the rear camshaft bearing with Tool (A) .
2. Remove the remainder of the camshaft bearings with Tool (A) through the rear of the
engine block. Start from the rear of the cylinder block and move toward the front.
Table 2
Required Tools
A
8S-2241 Camshaft Bearing Tool Group 1
8S-8293 Extension 1
5P-1667 Tube 1
2/5
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NOTICE
Note: Ensure that the inside of the cylinder block is clean. Inspect the camshaft bore for
metal burrs. Put a thin film of clean engine oil on the inside of the camshaft bearing bores
and on each camshaft bearing prior to installation.
Note: Two different camshaft bearings are used. Install the wider camshaft bearings in the
front and rear camshaft bores. Install the narrow camshaft bearings in the inner bores.
1. Install all the camshaft bearings with Tool (A) so that the oil hole in the camshaft bearing is
in a horizontal position. Installation angle (1) is 90 ± 15°.
2. Install the camshaft bearings with Tool (A) on the front side of the engine. Start the bearing
that is being installed from the rear of each bore. Pull the bearing into the bore with Tool
(A). Use the following procedure for achieving the proper installation depth for the
bearings.
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a. Install the rear camshaft bearing. Pull the bearing into the bore until the front face of
the bearing is flush with the front face of bore (2).
b. Install the narrow internal camshaft bearings. Start at the rear of the engine and work
forward. Pull each bearing into the bore until the front face of the bearing is flush
with the front face of the bore.
Measure the depth of the front camshaft bearing.
c. Install the front camshaft bearing with Tool (A) until the bearing is at the specified
depth. the depth is measured from the front of the engine block.
The front camshaft bearing for the 3412E should be 7.4 ± 0.5 mm (0.29 ± 0.02 inch)
from the front face of the engine block.
The front camshaft bearing for the 3408E should be 4.6 ± 0.5 mm (0.18 ± 0.02 inch)
from the front face of the engine block.
Note: Refer to Specifications, "Camshaft Bearings" for more information about camshaft
bearings.
4/5
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End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
b. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
c. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
Tue Oct 12 01:37:23 UTC+0800 2021
5/5
2021/10/12

Shutdown SIS
Previous Screen
i01057286
Engine Oil Pan - Remove and Install
SMCS - 1302-010
Removal Procedure
NOTICE
performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
NOTICE
1/4
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Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
1. Drain the oil from the engine oil pan into a suitable container for storage or disposal.
Typical example
2. Remove tube assembly (1). Remove the gaskets.
Typical example
3. Remove bolts (2) from engine oil pan (3).
4. Use two technicians in order to remove engine oil pan (3).
The weight of the engine oil pan for the 3408E is approximately 14 kg (31 lb).
5. Thoroughly remove gasket (4) from the engine oil pan and the cylinder block.
2/4
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Make sure that all of the old gasket material has been removed from the mating surfaces of
the engine oil pan and the cylinder block. Make sure that all surfaces are clean and free of
dirt and debris.
NOTICE
1. Use 5H-2471 Adhesive to install a new gasket on the engine oil pan.
Typical example
2. Put new gasket (4) into position on engine oil pan (3).
3. Use two technicians in order to put engine oil pan (4) in position on the engine.
4. Install bolts (2) that hold engine oil pan (3) to the cylinder block.
3/4
2021/10/12

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Typical example
5. Install tube assembly (1).
6. Fill the engine to the correct level with the recommended oil. Refer to the Operation and
Maintenance Manual.
Tue Oct 12 01:38:22 UTC+0800 2021
4/4
2021/10/12

Shutdown SIS
Previous Screen
i05661411
Cylinder Liner - Remove
SMCS - 1216-011
Removal Procedure
Table 1
Required Tools
A
5P-8665 Cylinder Liner Puller Gp 1
6V-9448(1)
Cylinder Pack Puller Gp 1
373-1438(2)
Cylinder Pack Puller Gp 1
(1)
Alternative option to remove liner, piston, and connecting rod as an assembly for 137 mm (5.4 inch) and 140 mm
(5.5 inch) bore diameters.
(2)
Alternative option to remove liner, piston, and connecting rod as an assembly for 145 mm (5.7 inch) bore
diameter.
Start By:
a. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Remove".
NOTICE
1/2
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1. Remove cylinder liner (1) with Tooling (A).
Tue Oct 12 01:39:21 UTC+0800 2021
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Caterpillar Cat D9N TRACK-TYPE TRACTOR (Prefix 1JD) Service Repair Manual (1JD00001 and up).pdf

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