Caterpillar Cat C9.3 Industrial Engine (Prefix CS9) Service Repair Manual Instant Download

Service Repair Manual

Models

C9.3 Industrial Engine

w

1/9(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05834261

Unit Injector - Remove and Install SMCS - 1290-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

268-1968

Pry Bar

1

B

-

Scotch Brite

1

1U-5718

Vacuum Pump

1

169-7372

Bottle Assembly

1

4C-4057

Clear Plastic Tubing 7.92 mm (0.312 inch) OD

1

C

Clear Plastic Tubing 4C-4055 6.35 mm (0.250 inch) OD D

9U-5470

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

Start By:

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

2/9(W)

A. Remove the valve mechanism cover.

B. Remove the fuel injection line.

C. Remove Compression Brake (If Equipped).

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.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

3/9(W)

Illustration 3

g02161166

Typical Example

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... 2020/6/7

w

4/9(W)

Illustration 5

g02161361

Typical Example

Note: Do not damage the unit injector during removal. Side loading may damage to the unit injector.

5. Position Tooling (A) under unit injector clamp (6) . Carefully remove unit injector (4) from the cylinder head.

Installation Procedure 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 (C) to remove the fuel and oil from the cylinder.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

5/9(W)

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 of 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 in order 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 6

g01355602

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".

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

6/9(W)

Illustration 7

g02161415

Illustration 8

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... 2020/6/7

w

7/9(W)

Illustration 9

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) in order to secure unit injector (4) .

Illustration 10

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... 2020/6/7

w

8/9(W)

Illustration 11

g01355441

Illustration 12

g01355608

Note: Check the O-ring seal for wear or for damage. If necessary, replace the O-ring seal.

8. If the O-ring seal was damaged, perform Step 8.a and Step 8.b.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

9/9(W)

Illustration 13

g02077582

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 seal (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).

End By: a. Install Compression Brake (If Equipped). b. Install the valve mechanism cover. c. Install the fuel injection line.

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:42:58 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... 2020/6/7

w

1/3(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05282771

Unit Injector Sleeve - Remove and Install SMCS - 1713-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A

-

Part Description

Qty

Tap 7/8-9 NC

1

1A-5576

Bolt

1

8C-6913

Hard Washer

7

C

221-9803

Rubber Stopper

1

D

1P-0510

Driver Gp

1

E

4C-5552

Large Bore Brush

1

F

4C-9507

Retaining Compound

1

B

Start By: a. Remove the unit injectors.

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... 2020/6/7

w

2/3(W)

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".

Illustration 1

g02163825

2. Position Tooling (C) at the bottom of the unit injector sleeve (1).

3. Coat Tooling (A) (not shown) with clean grease. Use Tooling (A) to cut threads into unit injector sleeve (1).

4. Use Tooling (B) in order to remove unit injector sleeve (1). Discard the unit injector sleeve (1).

Installation Procedure 1. Thoroughly clean the bores for the unit injectors with Tooling (E).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

3/3(W)

Illustration 2

g02164118

2. Apply clean engine oil to O-ring seals (2). Install O-ring seals (2) on unit injector sleeve (1).

3. Apply a thin coating of Tooling (F) around the outer circumference of unit injector sleeve (1) at Area (G).

4. Position unit injector sleeve (1) in the cylinder head. Use a hammer and Tooling (D) in order to install unit injector sleeve (1) in the cylinder head.

Note: Allow Tooling (F) to cure for 2 hours at 21 °C (70 °F) before filling the engine with fuel or coolant. Longer curing time is required for lower temperatures.

5. Fill the cooling system with coolant to the correct level. Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".

End By: a. Install the unit injectors.

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:43:54 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... 2020/6/7

w

1/3(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05831969

Turbocharger - Remove and Install - Cooled by Coolant SMCS - 1052-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

QTY

A

-

Loctite C5A Copper Anti-Seize

1

1. Drain the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

Illustration 1

g02377418

2. Disconnect tube assemblies (1) and (2) .

3. Disconnect hose (3) .

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

2/3(W)

Illustration 2

g02377458

4. Disconnect hose assemblies (4) and (5) .

Illustration 3

g02377876

5. Remove four nuts (7) and remove turbocharger (6) . Discard nuts (7) and remove the gasket.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

3/3(W)

Illustration 4

g02377938

Note: Band clamps (8) , (9) and (10) , are one time use parts. Discard the clamp assemblies if the clamps are loosened.

6. Remove band clamp (8) in order to separate the adaptor from the turbine housing. Discard band clamp (8) .

7. Remove band clamp (9) in order to separate the turbine housing from the cartridge assembly. Discard band clamp (9) .

8. Remove band clamp (10) in order to separate the compressor housing from the cartridge assembly. Discard band clamp (10) .

9. Remove adapters (11) from the cartridge assembly.

Installation Procedure Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

1. Install the turbocharger (6) in the reverse order of removal. a. Install new band clamp (9) . Tighten band clamp (9) to a torque of 18 N·m (159 lb in).

Loosen band clamp (9) and retighten the clamp to a torque of 13.6 ± 1.2 N·m (120 ± 11 lb in). b. Install new band clamp (10) . Tighten band clamp (10) to a torque of 13.6 ± 1.2 N·m (120 ± 11 lb in). c. Install new band clamp (8) . Tighten band clamp (8) to a torque of 12 ± 4 N·m (106 ± 35 lb in). d. Apply Tooling (A) to the threads of new nuts (7) prior to installation. e. Tighten nuts (7) to a torque of 70 ± 5 N·m (52 ± 4 lb ft). f. Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation. This action will provide lubrication during start-up and during storage.

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:44:50 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... 2020/6/7

w

1/1(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i03907730

Solenoid Valve (Exhaust Balance) - Remove and Install SMCS - 1052-010-VL

Removal Procedure

Illustration 1

g02148775

1. Disconnect harness assembly (2). Disconnect tube assemblies (1) and (3).

2. Remove solenoid balance valve (4).

Installation Procedure 1. Install the solenoid balance valve (4) in the reverse order.

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:45:45 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... 2020/6/7

w

1/2(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05295284

Air Control Valve - Remove and Install SMCS - 108A-010

Removal Procedure

Illustration 1

g02161617

View of the Air Control Valve which is located on the Clean Emissions Module.

1. Remove cable straps (2). Disconnect harness assemblies (1) and position the harness assembly out of the way.

2. Remove tube assembly (3).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

2/2(W)

Illustration 2

g02161618

3. Loosen clamp assembly (5). Remove bolts (4) and remove air control valve (6).

Illustration 3

g02161693

4. Remove bolts (11). Separate housings (10) and (7) from the air control valve actuator (8).

Remove both seals (9) from the housings.

Installation Procedure 1. Install air control valve (8) in the reverse order of removal.

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:46:41 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... 2020/6/7

w

1/3(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05295410

Exhaust Cooler (NRS) - Remove and Install SMCS - 1087; 108C-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

207-1600(1)

Rubber Lubricant

1

207-1601

Rubber Lubricant

1

A (1)

For Use in EAME

Note: Due to various machine configurations, components will need to be removed that are not called out in this procedure. Refer to the appropriate manual to remove the necessary components.

1. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the proper draining and filling procedures.

Note: Step 2 through Step 4 may not apply to all engine configurations. If so, then start with Step 5.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

2/3(W)

Illustration 1

g02763336

2. Disconnect hose assembly (2).

3. Remove hose (1), hose (3), the adapters, and the clips.

Illustration 2

g02763418

4. Position oil level gauge (4) out of the way. Remove bracket assembly (5).

Illustration 3

g02763456

5. Loosen band clamps (6) and the hose.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

3/3(W)

Note: The band clamps and hose are one-time use components. Discard upon removal and install new.

6. Loosen clamps (10). Remove bolts (8) and (11).

7. Remove exhaust cooler (7). Remove bellows (9) and clamps (10) from exhaust cooler (7).

Note: Note the orientation of the bellows. The arrow should point toward the exhaust cooler.

8. Remove tubes (12). Remove the O-ring seals from tubes (12).

Installation Procedure 1. Install exhaust cooler (7) in the reverse order of removal. a. Apply a light coating of Tooling (A) to the bores and the O-ring seals for tubes (12). b. Install new bellows (9) and clamps (10). Tighten clamp assemblies (10) to a torque of 7.5 ± 1 N·m (66 ± 9 lb in).

Note: The arrow on the bellows should point toward the exhaust cooler. Total misalignment for the bellows is 1.50 mm (0.06 inch) lateral and 1.50 mm (0.06 inch) axial. c. Tighten bolts (11) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:47:37 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... 2020/6/7

w

1/2(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i05295411

Exhaust Gas Valve (NRS) - Remove and Install SMCS - 108N-010; 5510

Removal Procedure

Illustration 1

g02150623

1. Disconnect clamp assembly (1). Disconnect harness assemblies (2) and disconnect hose assemblies (4). Disconnect clamp assembly (3).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7

w

2/2(W)

Illustration 2

g02150662

2. Remove four bolts (5) and remove exhaust gas valve (6).

Installation Procedure 1. Install exhaust gas valve (6) in reverse order of removal. a. Tighten clamp assembly (3) to a torque of 8.5 ± 2 N·m (75 ± 18 lb in).

Copyright 1993 - 2020 Caterpillar Inc.

Sun Jun 7 18:48:33 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... 2020/6/7

Suggest: If the above button click is invalid.

Please download this document first, and then click the above link to download the complete manual.

Thank you so much for reading

w

1/2(W)

Shutdown SIS Previous Screen Product: INDUSTRIAL ENGINE Model: C9.3 INDUSTRIAL ENGINE CS9 Configuration: C9.3 Industrial Engine CS900001-UP

Disassembly and Assembly C9.3 Industrial Engine Media Number -UENR0183-02

Publication Date -01/06/2014

Date Updated -06/06/2014

i03513485

Exhaust Gas Valve (NRS) - Disassemble SMCS - 108N-015; 5510

Disassembly Procedure Start By: a. Remove the Exhaust Gas Valve.

Illustration 1

g01845346

1. Remove temperature sensor (1).

2. Remove bolts (2). Separate actuator assembly (3) from the valve housing (4).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe... 2020/6/7