- Engine (Captive)
- C9.3 (S/N: MME1-UP)
- Industrial Engine
- C9.3 (S/N: C9N1-UP)
Introduction
Do not perform any procedure that is outlined in this Special Instruction until you read and understand the information that is contained in this document.
Safety
| NOTICE |
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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. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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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. |
Required Tools
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Name | Qty |
| A
(1) |
Engine Turning Tool | 1 | |
| B
(2) |
Engine Turning Tool | 1 | |
| Shaft Housing | 1 | ||
| C
(3) |
Engine Turning Tool | 1 | |
| D | Timing Pin | 1 | |
| Adapter | 1 | ||
| Timing Pin Adapter | 1 | ||
| Timing Pin Optional Longer Pin | 1 | ||
| E | Fuel Pump Pinch Bolt | 1 | |
| (1) | The tooling is designed to turn the crankshaft in engines that are equipped with rear PTO. The tool engages the forward spline of upper gear of the PTO. |
| (2) | The tooling is designed to turn the crankshaft in engines that are equipped with standard electric starters. |
| (3) | 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. |
Removing the Fuel Injection Pump
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.
Note: Do not remove the valve mechanism cover at any time during this procedure.
- Remove plug (X) from the timing hole that is located in the flywheel housing. Install the assembled timing pin (D) into the timing hole.
- Use Tooling (A) or (B) to rotate the flywheel. Turn the flywheel in the direction of engine rotation. The direction of engine rotation is clockwise, as the engine is viewed from the vibration damper. Turn the vibration damper and the flywheel until the timing pin engages with the threaded hole in the flywheel.
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is reverse of normal engine rotation. Turn the flywheel by approximately 30 degrees. Then turn the flywheel in the direction of normal rotation until the timing pin engages with the threaded hole.
- Remove all necessary components to access the fuel injection pump.
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Illustration 4 g02351981 - Remove plug (1) and remove O-ring seal (2).
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Illustration 5 g02351995 - Install Tooling (E). Tighten Tooling (E) to a torque of
9 ± 1 N·m (80 ± 9 lb in) .Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
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Illustration 6 g02025176 - Disconnect harness assemblies (3).
- Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
- Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
- Disconnect hose assembly (6).
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Illustration 7 g02029098 - Disconnect tube assemblies (9).
- Disconnect hose assemblies (10) and (11).
- Remove bolts (8).
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Illustration 8 g02029093 - Disconnect tube assembly (12).
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Illustration 9 g02025262 - Remove bolts (13) and remove fuel pump (14).
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| Illustration 1 | g02112896 |
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Flywheel housing | |
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| Illustration 2 | g06012763 |
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| Illustration 3 | g02112894 |
Installing the Fuel Injection Pump
- Position fuel pump (14) and install bolts (13).
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Illustration 12 g02029093 - Connect tube assembly (12).
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Illustration 13 g02029098 - Install bolts (8).
- Connect tube assembly (9) and connect both hose assemblies (10) and (11).
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Illustration 14 g02025176 Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order 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.
- Connect harness assemblies (3).
- Install a new fuel line. Hand tighten nuts (4) and (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 in order to assemble the fuel lines.
- Tighten nut (4) at the fuel rail to a torque of
27 ± 3 N·m (239 ± 27 lb in) . - Tighten nut (7) to a torque of
27 ± 3 N·m (239 ± 27 lb in) . - Tighten nut (5) to a torque of
12 ± 3 N·m (105 ± 27 lb in) .Show/hide table
Illustration 15 g02351995 - Remove Tooling (E) and warning tag (Z).
Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
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Illustration 16 g02351981 - Install O-ring seal (2) and plug (1). Tighten the plug to a torque of
9 ± 1 N·m (80 ± 9 lb in) .Show/hide table
Illustration 17 g02112896 - Remove all tooling. Reinstall plug (X) into the timing hole that is located in the flywheel housing.
- Connect Caterpillar Electronic Technician (ET). Perform a “Fuel System Functional Test ”and a “Fuel System Verification Test”.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
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| Illustration 10 | g02385860 |
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Service replacement pump | |
Note: Service replacement pump is shipped pinned with warning tag (Z) installed under pinch bolt (E).
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| Illustration 11 | g02025262 |