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

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

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  1. Service Repair Manual Models C9IndustrialEngine

  2. w 1/5(W) 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  3. w 2/5(W) 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) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  4. w 3/5(W) Illustration 2 g02140852 5. Disconnect fittings (3) and (7) . 6. Remove bolts (5) , (6) , and (8) and remove tube assembly (4) . 7. Remove bolt (9) . Illustration 3 g02140971 8. Remove nuts (10) and remove bracket (11) . 9. Disconnect harness assemblies (12) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  5. w 4/5(W) Illustration 4 g02141940 Typical Example Illustration 5 g02141948 Illustration 6 g02156903 10. Position harness assembly (13) out of the way with cable straps. 11. Disconnect tube assembly (16) and remove fitting (15) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  6. w 5/5(W) 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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. Mon Jun 8 11:08:28 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  7. w 1/7(W) 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 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  8. w 2/7(W) 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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. Illustration 1 g02351981 3. Remove plug (1) and remove O-ring seal (2). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  9. w 3/7(W) Illustration 2 g06163397 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. Illustration 3 g02025176 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  10. w 4/7(W) Illustration 4 g02029098 9. Disconnect tube assemblies (9). 10. Disconnect hose assemblies (10) and (11). 11. Remove bolts (8). Illustration 5 g02029093 12. Disconnect tube assembly (12). Illustration 6 g02025262 13. Remove bolts (13) and remove fuel pump (14). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  11. w 5/7(W) Installation Procedure Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary. Illustration 7 g02025262 1. Position fuel pump (14) and install bolts (13). Illustration 8 g02029093 2. Connect tube assembly (12). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  12. w 6/7(W) Illustration 9 g02029098 3. Install bolts (8). 4. Connect tube assembly (9) and connect both hose assemblies (10) and (11). Illustration 10 g02025176 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  13. w 7/7(W) Illustration 11 g06163397 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. Illustration 12 g02351981 12. Install O-ring seal (2) and plug (1). Tighten the plug to a torque of 9 ± 1 N·m (80 ± 9 lb in). Copyright 1993 - 2020 Caterpillar Inc. Mon Jun 8 11:09:24 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  14. w 1/4(W) 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 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". https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  15. w 2/4(W) Illustration 1 g01264292 Illustration 2 g01264293 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. Illustration 3 g02161166 Typical Example https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  16. w 3/4(W) 2. Disconnect harness assembly (3) from the unit injector. Illustration 4 g02161316 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  17. w 4/4(W) Illustration 5 g02161361 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. Copyright 1993 - 2020 Caterpillar Inc. Mon Jun 8 11:10:20 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  18. w 1/6(W) 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 i05829824 Unit Injector - Install SMCS - 1290-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty B - Scotch Brite 1 1U-5718 Vacuum Pump 1 169-7372 Bottle Assembly 1 Clear Plastic Tubing 7.92 mm (0.312 inch) OD C 4C-4057 1 Clear Plastic Tubing 6.35 mm (0.250 inch) OD 4C-4055 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  19. w 2/6(W) Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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. Illustration 1 g01355602 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  20. w 3/6(W) 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". Illustration 2 g02161415 Illustration 3 g01264293 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  21. w 4/6(W) Illustration 4 g02161316 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). Illustration 5 g02161166 7. Connect harness assembly (3) to the unit injector. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  22. w 5/6(W) Illustration 6 g01355441 Illustration 7 g01355608 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. Illustration 8 g02077582 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

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  24. w 6/6(W) 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". Copyright 1993 - 2020 Caterpillar Inc. Mon Jun 8 11:11:15 UTC+0800 2020 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

  25. w 1/2(W) 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 i06788311 Unit Injector Sleeve - Remove SMCS - 1713-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A - 7/8-9 NC Tap 1 1A-5576 Bolt 1 B 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/8

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