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

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

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  1. Service Repair Manual Models C9IndustrialEngine

  2. w 1/3(W) Shutdown SIS Previous Screen 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  3. w 2/3(W) 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 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  4. w 3/3(W) Illustration 2 g01270491 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. Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:50:22 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... 2020/6/4

  5. w 1/5(W) Shutdown SIS Previous Screen 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 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 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  6. w 2/5(W) Dispose of all fluids according to local regulations and mandates. Illustration 1 g01167050 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  7. w 3/5(W) Illustration 2 g01270505 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. Installation Procedure https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  8. w 4/5(W) Illustration 3 g01270505 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  9. w 5/5(W) Illustration 4 g01270530 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. Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:51:18 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... 2020/6/4

  10. w 1/4(W) Shutdown SIS Previous Screen 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 i04892113 Unit Injector - Remove SMCS - 1290-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  11. w 2/4(W) NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 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. Illustration 1 g01148880 2. Use a small flat head screwdriver to disconnect harness assembly (2) from unit injector (1). 3. Remove socket head bolts (3). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  12. w 3/4(W) Illustration 2 g03030620 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  13. w 4/4(W) Illustration 3 g01137291 5. Remove O-ring seals (6), (7), and (8) from unit injector (1). Remove backup rings (4), (5), and (9) from unit injector (1). Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:52:13 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... 2020/6/4

  14. w 1/5(W) Shutdown SIS Previous Screen 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 i04902499 Unit Injector - Install SMCS - 1290-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 367-3070 Fuel Injector Installer and Removal Tooling 2 E 149-2955 Seal Protector 1 F 149-2956 Seal Installer 1 1U-5718 Vacuum Pump 1 169-7372 Bottle Assembly 1 Clear Plastic Tubing 7.92 mm (0.312 inch) OD 4C-4057 1 G Clear Plastic Tubing 4C-4055 1 6.35 mm (0.250 inch) OD 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  15. w 2/5(W) NOTICE 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 (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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  16. w 3/5(W) 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. Illustration 1 g01137291 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) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  17. w 4/5(W) 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 Illustration 2 g03031660 10. Use Tooling (A) to install unit injector (1) in the cylinder head. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  18. w 5/5(W) Illustration 3 g01148880 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". Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:53:09 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... 2020/6/4

  19. w 1/3(W) Shutdown SIS Previous Screen 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 i06737900 Unit Injector Sleeve - Remove SMCS - 1713-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-3042 Plug Tap 1 B 221-0052 Guide Sleeve 1 9U-6858 Bridge Plate 1 1B-2886 Bolts 2 221-9778 Puller Stud 1 C 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 Keep all parts clean from contaminants. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  20. w 2/3(W) 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 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. 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  21. w 3/3(W) Illustration 1 g01137445 4. Install Tooling (C) in unit injector sleeve (1). 5. Remove unit injector sleeve (1). Remove the O-ring seals. Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:54:04 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... 2020/6/4

  22. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

  23. w 1/2(W) Shutdown SIS Previous Screen 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 i03742983 Unit Injector Sleeve - Install SMCS - 1713-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty E 221-9777 Sleeve Installer 1 F 4C-5552 Large Bore Brush 1 G 4C-9507 Retaining Compound 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Thoroughly clean the unit injector sleeves and the bores for the unit injectors with Tooling (F) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

  24. w 2/2(W) Illustration 1 g02021929 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". Copyright 1993 - 2020 Caterpillar Inc. Thu Jun 4 15:55:00 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... 2020/6/4

  25. w 1/8(W) Shutdown SIS Previous Screen 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 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 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 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/4

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