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

1
Service Repair Manual
Models C9.3 Industrial Engine
2
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 Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 268-1968 Pry Bar 1
B - Scotch Brite 1
C 1U-5718 Vacuum Pump 1
C 169-7372 Bottle Assembly 1
C 4C-4057 Clear Plastic Tubing 7.92 mm (0.312 inch) OD 1
C 4C-4055 Clear Plastic Tubing 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
3

1. Remove the valve mechanism cover.
2. Remove the fuel injection line.
3. 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.
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com
5
Illustration 3
g02161166
Typical Example 2. Disconnect harness assembly
(3) from the unit injector.
Illustration 4
g02161316

• Typical Example
• 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.
• If unit injector (4) cannot be removed by hand,
  go to Step 5.

6
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.
7
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.
• 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.
• 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".

8
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.
9
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 Nm (21 2
lb ft) in order to secure unit injector (4) .
Illustration 10 g02161166 7. Connect harness
assembly (3) to the unit injector.
10
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.
11

• Illustration 13 g02077582
• Inspect the Sealing Surface (A) for damage.
  Replace quill tube (1) if damage was found.
• 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 Nm (52 2 lb ft).
• End By
• Install Compression Brake (If Equipped).
• Install the valve mechanism cover.
• Install the fuel injection line.

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184258 UTC0800 2020
12
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 Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A - Tap 7/8-9 NC 1
B 1A-5576 Bolt 1
B 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
Start By a. Remove the unit injectors. NOTICE K
eep all parts clean from contaminants. Contaminant
s may cause rapid wear and shortened component
life.
13
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
• Position Tooling (C) at the bottom of the unit
  injector sleeve (1).
• Coat Tooling (A) (not shown) with clean grease.
  Use Tooling (A) to cut threads into unit injector
  sleeve (1).
• Use Tooling (B) in order to remove unit injector
  sleeve (1). Discard the unit injector sleeve (1).
• Installation Procedure
• Thoroughly clean the bores for the unit injectors
  with Tooling (E).

14

• Illustration 2 g02164118
• Apply clean engine oil to O-ring seals (2).
  Install O-ring seals (2) on unit injector sleeve
  (1).
• Apply a thin coating of Tooling (F) around the
  outer circumference of unit injector sleeve
• (1) at Area (G).
• 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.
• 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. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184354 UTC0800 2020
15
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 Required Tools Required Tools 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

1. Disconnect tube assemblies (1) and (2) .
2. Disconnect hose (3) .

16
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.
17

• Illustration 4 g02377938
• Note Band clamps (8) , (9) and (10) , are one
  time use parts. Discard the clamp assemblies if
  the clamps are loosened.
• Remove band clamp (8) in order to separate the
  adaptor from the turbine housing. Discard band
  clamp (8) .
• Remove band clamp (9) in order to separate the
  turbine housing from the cartridge assembly.
  Discard band clamp (9) .
• Remove band clamp (10) in order to separate the
  compressor housing from the cartridge assembly.
  Discard band clamp (10) .
• 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.
• Install the turbocharger (6) in the reverse order
  of removal.
• Install new band clamp (9) . Tighten band clamp
  (9) to a torque of 18 Nm (159 lb in). Loosen
  band clamp (9) and retighten the clamp to a
  torque of 13.6 1.2 Nm (120 11 lb in).
• Install new band clamp (10) . Tighten band clamp
  (10) to a torque of 13.6 1.2 Nm (120 11 lb
  in).
• Install new band clamp (8) . Tighten band clamp
  (8) to a torque of 12 4 Nm (106 35 lb in).
• Apply Tooling (A) to the threads of new nuts (7)
  prior to installation.
• Tighten nuts (7) to a torque of 70 5 Nm (52
  4 lb ft).
• 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. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184450 UTC0800 2020
18
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
• Disconnect harness assembly (2). Disconnect tube
  assemblies (1) and (3).
• Remove solenoid balance valve (4).
• Installation Procedure
• Install the solenoid balance valve (4) in the
  reverse order.

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184545 UTC0800 2020
19
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.
• Remove cable straps (2). Disconnect harness
  assemblies (1) and position the harness assembly
  out of the way.
• Remove tube assembly (3).

20
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. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184641 UTC0800 2020
21
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 Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 207-1600(1) Rubber Lubricant 1
A 207-1601 Rubber Lubricant 1
(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.
22
Illustration 1
g02763336

1. Disconnect hose assembly (2).
2. 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.
23

• Note The band clamps and hose are one-time use
  components. Discard upon removal and install new.
• Loosen clamps (10). Remove bolts (8) and (11).
• 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.
• Remove tubes (12). Remove the O-ring seals from
  tubes (12).
• Installation Procedure
• Install exhaust cooler (7) in the reverse order
  of removal.
• Apply a light coating of Tooling (A) to the bores
  and the O-ring seals for tubes (12).
• Install new bellows (9) and clamps (10). Tighten
  clamp assemblies (10) to a torque of
• 7.5 1 Nm (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 Nm
  (41 7 lb ft).

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184737 UTC0800 2020
24
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).
25

• Illustration 2 g02150662
• 2. Remove four bolts (5) and remove exhaust gas
  valve (6).
• Installation Procedure
• Install exhaust gas valve (6) in reverse order of
  removal.
• Tighten clamp assembly (3) to a torque of 8.5 2
  Nm (75 18 lb in).

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Jun 7 184833 UTC0800 2020
26
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
27
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).

28
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com