c9.3 engine

SEBU8570-01August 2010

Operation andMaintenanceManualC9.3 Industrial EngineC9N1-Up (Engine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU8570-01 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 9

Burn Prevention .................................................... 12

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 15

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

Engine Stopping ................................................... 16

Electrical System .................................................. 16

Engine Electronics ................................................ 17

Product Information Section

Model Views ......................................................... 18

Product Identification Information ........................ 23

Operation Section

Lifting and Storage ................................................ 25

Features and Controls .......................................... 27

Engine Diagnostics ............................................... 32

Engine Starting ..................................................... 45

Engine Operation .................................................. 49

Engine Stopping ................................................... 53

Cold Weather Operation ....................................... 54

Maintenance Section

Refill Capacities .................................................... 56

Maintenance Recommendations .......................... 61

Maintenance Interval Schedule ............................ 63

Warranty Section

Warranty Information .......................................... 100

Reference Information Section

Engine Ratings ................................................... 101

Customer Service ............................................... 103

Reference Materials ............................................ 105

Index Section

Index ................................................................... 108

4 SEBU8570-01Foreword

ForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Caterpillarpublications. The English used facilitates translationand consistency in electronic media delivery.

Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Caterpillar dealer for the latestavailable information.

SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.

OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby fuel consumption, service hours and/or calendartime maintenance intervals. Items in the maintenanceschedule are referenced to detailed instructions thatfollow.

Use fuel consumption or service hours to determineintervals. Calendar intervals shown (daily, annually,etc.) may be used instead of service meter intervalsif they provide more convenient schedules andapproximate the indicated service meter reading.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples of theoriginal requirement. Each level and/or individualitems in each level should be shifted ahead or backdepending upon your specific maintenance practices,operation and application. We recommend thatthe maintenance schedules be reproduced anddisplayed near the engine as a convenient reminder.We also recommend that a maintenance record bemaintained as part of the engine's permanent record.

See the section in the Operation and MaintenanceManual, Maintenance Records for informationregarding documents that are generally acceptedas proof of maintenance or repair. Your authorizedCaterpillar dealer can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered in theOperation and Maintenance Manual except for theinterval and the maintenance items in that interval.Major repairs are best left to trained personnel oran authorized Caterpillar dealer. Your Caterpillardealer offers a variety of options regarding overhaulprograms. If you experience a major engine failure,there are also numerous after failure overhaul optionsavailable from your Caterpillar dealer. Consult withyour dealer for information regarding these options.

SEBU8570-01 5Foreword

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

6 SEBU8570-01Safety SectionSafety Messages

Safety Sectioni04022036

Safety MessagesSMCS Code: 1000; 7405

There may be several specific safety messages onyour engine. The exact location and a description ofthe safety messages are reviewed in this section.Please become familiar with all safety messages.

Ensure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if the words cannot be read or if theillustrations are not visible. Use a cloth, water,and soap to clean the safety messages. Do notuse solvents, gasoline, or other harsh chemicals.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety messages. Thesafety messages that are loosened could drop offthe engine.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partof the engine that is replaced, install a new safetymessage on the replacement part. Your Caterpillardealer can provide new safety messages.

SEBU8570-01 7Safety Section

Safety Messages

g02199153Illustration 1

View of the left side and view of the right side of a C9.3 Industrial Engine

8 SEBU8570-01Safety SectionSafety Messages

Universal Warning (1)


One safety message is located on the left side of thefront housing. One safety message is located on thebase for the oil filter, on the right side of the engine.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManual. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

High Pressure (2)


One safety message for high pressure (2) is locatedon the bottom of the fuel pump. Two messages arelocated on the fuel rail.

Contact with high pressure fuel may cause fluidpenetration and burn hazards. High pressure fu-el spray may cause a fire hazard. Failure to fol-low these inspection, maintenance and service in-structions may cause personal injury or death.


General Hazard Information

Sulfuric Acid Burn (3)


The safety message for sulfuric acid burn (3) islocated on top of the exhaust cooler.

Sulfuric Acid Burn Hazard may cause serious per-sonal injury or death.

The exhaust gas cooler may contain a smallamount of sulfuric acid. The use of fuel with sul-fur levels greater than 15 ppm may increase theamount of sulfuric acid formed. The sulfuric acidmay spill from the cooler during service of theengine. The sulfuric acid will burn the eyes, skinand clothing on contact. Always wear the appro-priate personal protective equipment (PPE) thatis noted on a material safety data sheet (MSDS)for sulfuric acid. Always follow the directions forfirst aid that are noted on a material safety datasheet (MSDS) for sulfuric acid.

i03704500

General Hazard InformationSMCS Code: 1000; 7405


Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controlsbefore the engine is serviced or before the engine isrepaired. These warning tags (Special Instruction,SEHS7332) are available from your Caterpillardealer. Attach the warning tags to the engine and toeach operator control station. When it is appropriate,disconnect the starting controls.

Do not allow unauthorized personnel on the engine,or around the engine when the engine is beingserviced.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is in an enclosed area, vent theengine exhaust to the outside.

Cautiously remove the following parts. To helpprevent spraying or splashing of pressurized fluids,hold a rag over the part that is being removed.

Filler caps

Grease fittings

Pressure taps

Breathers

Drain plugs

Use caution when cover plates are removed.Gradually loosen, but do not remove the last twobolts or nuts that are located at opposite ends ofthe cover plate or the device. Before removing thelast two bolts or nuts, pry the cover loose in order torelieve any spring pressure or other pressure.

10 SEBU8570-01Safety SectionGeneral Hazard Information


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

When work is performed around an engine that isoperating, wear protective devices for ears in orderto help prevent damage to hearing.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

Ensure that all protective guards and all covers aresecured in place on the engine.

Never put maintenance fluids into glass containers.Glass containers can break.

Use all cleaning solutions with care.

Report all necessary repairs.

Unless other instructions are provided, performthe maintenance under the following conditions:

The engine is stopped. Ensure that the enginecannot be started.

The protective locks or the controls are in theapplied position.

Disconnect the batteries when maintenanceis performed or when the electrical system isserviced. Disconnect the battery ground leads.Tape the leads in order to help prevent sparks.

For initial start-up of a new engine or for starting anengine that has been serviced, make provisions tostop the engine if an overspeed occurs. This maybe accomplished by shutting off the fuel supplyand/or the air supply to the engine.

Start the engine with the operator controls. Nevershort across the starting motor terminals or thebatteries. This could bypass the engine neutralstart system and/or the electrical system could bedamaged.

Pressurized Air and WaterPressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi) when the air nozzleis deadheaded. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog or refer to Special Pub-lication, PECJ0003, Caterpillar Shop Supplies andTools Catalog for tools and supplies suitable to col-lect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.


General Hazard Information

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillarrecommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust thatcontains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.

Lines, Tubes, and HosesDo not bend or strike high pressure lines. Do notinstall lines, tubes, or hoses that are damaged.

Repair any fuel lines, oil lines, tubes, or hoses thatare loose or damaged. Leaks can cause fires.

Inspect all lines, tubes and hoses carefully. Donot use bare hands to check for leaks. Alwaysuse a board or cardboard for checking enginecomponents for leaks. Tighten all connections to therecommended torque.

Check for the following conditions:

End fittings that are damaged or leaking

Outer covering that is chafed or cut

Wire that is exposed in reinforced hose

Outer covering that is ballooning locally

Flexible part of the hose that is kinked or crushed

Armoring that is embedded in the outer covering

Ensure that all of the clamps, the guards, and theheat shields are installed correctly. This will help toprevent these effects: vibration, rubbing against otherparts, and excessive heat during operation.

12 SEBU8570-01Safety SectionBurn Prevention

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01480768

Burn PreventionSMCS Code: 1000; 7405

Do not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i03649377

Fire Prevention and ExplosionPreventionSMCS Code: 1000; 7405


Use of personal protection equipment (PPE) may beneeded.

All fuels, most lubricants, and some coolant mixturesare flammable.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operatea product when a fire hazard exists. Contact yourCaterpillar dealer for service.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.


Fire Prevention and Explosion Prevention

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence of combustiblegases, consult your Caterpillar dealer for additionalinformation about suitable protection devices.

Remove all flammable materials such as fuel, oil, anddebris from the engine. Do not allow any flammablematerials to accumulate on the engine.

All fluids that are captured in the fluid spillcontainment basin should be cleaned up immediately.Failure to clean up spilled fluids can cause a fire. Firemay cause personal injury and property damage.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.

Wiring must be kept in good condition. All electricalwires must be properly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and properlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or fordeterioration. The hoses must be properly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.

Oil filters and fuel filters must be properly installed.The filter housings must be tightened to the propertorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.


14 SEBU8570-01Safety SectionCrushing Prevention and Cutting Prevention

Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

EtherEther is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theengine compartment. Do not store ether cylindersin direct sunlight or in temperatures above 49 C(120 F). Keep ether cylinders away from openflames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the engine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i01359666

Crushing Prevention andCutting PreventionSMCS Code: 1000; 7405

Support the component properly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.


Mounting and Dismounting

i01372247

Mounting and DismountingSMCS Code: 1000; 7405

Inspect the steps, the handholds, and the work areabefore mounting the engine. Keep these items cleanand keep these items in good repair.

Mount the engine and dismount the engine only atlocations that have steps and/or handholds. Do notclimb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine ordismount the engine. Maintain a three-point contactwith the steps and handholds. Use two feet and onehand or use one foot and two hands. Do not use anycontrols as handholds.

Do not stand on components which cannot supportyour weight. Use an adequate ladder or use a workplatform. Secure the climbing equipment so that theequipment will not move.

Do not carry tools or supplies when you mount theengine or when you dismount the engine. Use a handline to raise and lower tools or supplies.

i03560601

Before Starting EngineSMCS Code: 1000

NOTICEFor initial start-up of a new or rebuilt engine, and forstart-up of an engine that has been serviced, makeprovision to shut the engine off should an overspeedoccur. This may be accomplished by shutting off theair and/or fuel supply to the engine.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controlsif there is a DO NOT OPERATE warning tag orsimilar warning tag attached to the start switch or tothe controls.

Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work properly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i04021433

Engine StartingSMCS Code: 1000

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Start the engine from the operator's compartment orfrom the engine start switch.

Always start the engine according to the procedurethat is described in this Operation and MaintenanceManual, Engine Starting topic (Operation Section).Knowledge of the correct procedure will help toprevent major damage to the engine components.Knowledge of the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingproperly, check the water temperature gauge and theoil temperature gauge during the heater operation.

Engine exhaust contains products of combustionthat can be harmful to your health. Always start theengine and operate the engine in a ventilated area.If the engine is started in an enclosed area, vent theengine exhaust to the outside.

16 SEBU8570-01Safety SectionEngine Stopping

i01462046

Engine StoppingSMCS Code: 1000

Stop the engine according to the procedure inthe Operation and Maintenance Manual, EngineStopping (Operation Section) in order to avoidoverheating of the engine and accelerated wear ofthe engine components.

Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.

Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.

To stop an electronically controlled engine, cut thepower to the engine.

i02469632

Electrical SystemSMCS Code: 1000; 1400

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative jump start cable should be connectedlast from the external power source to the negative terminal of the starting motor. If the starting motoris not equipped with a negative terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Refer tothe Engine Starting section of this Operation andMaintenance Manual for specific starting instructions.

Grounding Practices


Typical exampleGrounding Stud To Battery Ground


Engine Electronics


Typical example

Alternate Grounding Stud To Battery Ground

Proper grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Improper grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function properly, an engine-to-frame groundstrap with a direct path to the battery must be used.This path may be provided by way of a starting motorground, a starting motor ground to the frame, or adirect engine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative- battery terminal with a wire that is adequate tohandle the full charging current of the alternator.

i04021529

Engine ElectronicsSMCS Code: 1000; 1400; 1900

Tampering with the electronic system installationor the OEM wiring installation can be dangerousand could result in personal injury or death and/orengine damage.

The Electronic Control Module (ECM) provides acomprehensive, programmable engine monitoringsystem for this engine. The ECM monitors specificengine operating parameters in order to detectabnormal conditions that may develop. The ECM willgenerate an event code if a specific engine parameterexceeds an acceptable range that is defined by theengine monitoring system. The ECM will react withan action that is dependent on the severity of thecondition. For information on event codes, refer tothis Operation and Maintenance Manual, EventCodes topic (Operation Section) The followingactions may be initiated by the ECM. These actionsare dependent on the severity of the condition:

Illumination of a warning lamp or warning alarm

Engine derate

Engine protection shutdown

The Engine Monitoring package can vary for differentengine models and different engine applications.However, the monitoring system and the enginemonitoring control will be similar for all engines.

Note:Many of the engine control systems and displaymodules that are available for Caterpillar Engineswill work in unison with the Engine MonitoringSystem. Together, the two controls will provide theengine monitoring function for the specific engineapplication. Refer to the Troubleshooting Manual formore information.

18 SEBU8570-01Product Information SectionModel Views

Product InformationSection

Model Viewsi04025350

Model View IllustrationsSMCS Code: 1000

SEBU8570-01 19Product Information Section

Model Views


View of the left side of a typical C9.3 Industrial Engine

(1) Fuel pressure sensor pre-filter(2) Fuel pressure sensor post-filter(3) Oil filler(4) Fuel rail pressure sensor(5) Atmospheric pressure sensor(6) Balance valve solenoid

(7) Open crankcase ventilation filter(8) Engine crankcase breather(9) NRS valve(10) NRS temperature sensor(11) Engine control module (ECM)(12) Crankcase pressure sensor

(13) Charge air cooler outlet sensor(14) Engine speed sensor(15) Fuel pump(16) Secondary fuel filter base(17) Fuel temperature sensor



View of the right side of a typical C9.3 Industrial Engine

(18) NRS cooler (19) Turbocharger (20) Oil filter base


Model Views

i04021094

Engine DescriptionSMCS Code: 1000

The Caterpillar C9.3 Industrial Engine has thefollowing characteristics:

Four-stroke cycle

High pressure common rail fuel system

Turbocharged

Engine SpecificationsNote: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.

g01387009Illustration 17Cylinder and valve location

(A) Exhaust valve(B) Inlet valve

Table 1

C-9.3 Engine Specifications

Arrangement andCylinders In-Line six cylinder

Bore 115.0 mm (4.53 inch)

Stroke 149.0 mm (5.87 inch)

ATAAC(1)Aspiration

SCAC (2)

Displacement 9.3 L (568 in3)

Firing Order 1-5-3-6-2-4

Rotation (flywheel end) Counterclockwise(1) Air-to-air aftercooled(2) Separate circuit after cooling

Electronic Engine FeaturesThe Caterpillar C9.3 Engine is designed for electroniccontrols. The integral on board computer controlsthe operation of the engine. Current operatingconditions are monitored. The Electronic ControlModule (ECM) controls the response of the engine tothese conditions and to the demands of the operator.These conditions and operator demands determinethe precise control of fuel injection by the ECM.The electronic engine control system provides thefollowing features:

Engine speed governor

Automatic air/fuel ratio control

Torque rise shaping

Injection timing control

System diagnostics

Aftertreatment regeneration control

NOX reduction system control

Additional Features

The following additional features provide increasedengine fuel economy and serviceability:

Cold starting capability

Tampering detection

Diagnostics

Common Rail Fuel Injection System

The common rail fuel injection system performs thefollowing functions:

Pump the fuel.

Meter the fuel.

Time the fuel injection.

The fuel pump pressurizes the fuel. The fuel pumppumps the fuel to the common fuel rail. The commonrail fuel injectors inject the fuel into the cylinders ata precise time. The fuel is injected into the cylinderswith the appropriate volume. Electronic sensorson the engine determine time and volume of fuelinjection.


Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants, andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.

Expected engine life is predicted by the averagepower that is demanded. The average power thatis demanded is based on fuel consumption of theengine over a time. Reduced hours of operationat full throttle and/or operating at reduced throttlesettings result in a lower average power demand.Reduced hours of operation will increase the lengthof operating time before an engine overhaul isrequired. For more information, refer to the Operationand Maintenance Manual, Overhaul Considerationstopic (Maintenance Section).

Aftermarket Products andCaterpillar Engines

NOTICEIn order to maximize fuel system life and preventpremature wear out from abrasive particles in the fuel,a four micron[c] absolute high efficiency fuel filter isrequired for all Caterpillar common rail fuel systems.Caterpillar High Efficiency Fuel Filters meet theserequirements. Consult your Caterpillar dealer for theproper part numbers.

When auxiliary devices, accessories, or consumables(filters, additives, catalysts, etc.) which are madeby other manufacturers are used on Caterpillarproducts, the Caterpillar warranty is not affectedsimply because of such use.

However, failures that result from the installationor use of devices, accessories, or consumablesfrom other manufacturers are NOT Caterpillardefects. Therefore, the defects are NOT coveredunder the Caterpillar warranty.


Product Identification Information

Product IdentificationInformation

i04021087

Plate Locations and FilmLocationsSMCS Code: 1000


View of the left side of a C9.3 Industrial EngineThe serial number plate is located on the left side of the cylinderblock. The engine control module will obstruct the view of theserial number plate.


Serial number plate

The following information is stamped on the serialnumber plate: engine serial number, engine model,and arrangement number.

g02201394Illustration 20View of the top of a C9.3 Industrial Engine

The engine information plate is located toward the rear of thevalve cover. The engine information plate may be read from theright side of the engine.


Engine information plate

The following information is on the informationplate: engine serial number, engine model, enginearrangement number, maximum altitude of theengine that is necessary to achieve the rated power,horsepower, high idle, full load rpm, fuel settings, andother information

24 SEBU8570-01Product Information SectionProduct Identification Information

g02236893Illustration 22View of the exhaust system of a C9.3 Industrial Engine


CEM plate

The Clean Emission Module (CEM) identificationplate contains the following information: part number,serial number, change level, and configuration IDcode. This information may be needed by the Catdealer when inquiries are being made on the CEM.

i01028428

Engine IdentificationSMCS Code: 1000

Caterpillar engines are identified with serial numbers,with performance specification numbers, and witharrangement numbers. In some of the cases,modification numbers are used. These numbersare shown on the Serial Number Plate and theInformation Plate that are mounted on the engine.

Caterpillar dealers need these numbers in order todetermine the components that were included withthe engine. This permits accurate identification ofreplacement part numbers.

i00610276

Reference NumbersSMCS Code: 1000

Information for the following items may be needed toorder parts. Locate the information for your engine.Record the information on the appropriate space.Make a copy of this list for a record. Retain theinformation for future reference.

Record for ReferenceEngine Model _______________________________________________

Engine Serial No. __________________________________________

Engine Arrangement No. _________________________________

Modification No. ____________________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Performance Specification No. _________________________

Primary Fuel Filter No. ____________________________________

Water Separator Element No. ___________________________

Secondary Fuel Filter Element No. ____________________

Lubrication Oil Filter Element No. ______________________

Auxiliary Oil Filter Element No. _________________________

Supplemental Coolant Additive Maintenance ElementNo. (Optional) _______________________________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element No. _________________________________

Fan Drive Belt No. _________________________________________

Alternator Belt No. _________________________________________

SEBU8570-01 25Operation SectionLifting and Storage

Operation Section

Lifting and Storagei04037083

Product LiftingSMCS Code: 1000; 1404; 7002


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for the specificengine arrangement. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat proper lifting devices are provided. Consult yourCaterpillar dealer for information regarding fixturesfor proper engine lifting.

Engine Lifting with a Fuel Tank

Lift eyes or tank can fail when lifting tank con-taining fluids resulting in possible personal injury.Drain tank of all fluids before lifting.

Lifting the engine with a fuel tank that is mountedto the engine requires special equipment andprocedures. Do not lift the unit with fuel in the fueltank. Consult your Caterpillar dealer for informationregarding fixtures for proper lifting of your completepackage.

Clean Emission Module Lifting


The Clean Emission Module (CEM) should only belifted by the designated lifting eyes (1). Lifting eyelocations will be different depending on the CEMarrangement. Do not attempt to lift the CEM usingstraps around the diesel particulate filter.

26 SEBU8570-01Operation SectionLifting and Storage

i02068367

Product StorageSMCS Code: 1000; 1404; 7002

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderliner surface. Rust on the cylinder liner surface willcause increased engine wear and a reduction inengine service life.

To help prevent excessive engine wear, use thefollowing guidelines:

Complete all of the lubrication recommendationsthat are listed in this Operation and MaintenanceManual, Maintenance Interval Schedule(Maintenance Section).

If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. See this Operation and MaintenanceManual, Refill Capacities and Recommendations(Maintenance Section).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

For more detailed information on engine storage, seeSpecial Instruction, SEHS9031, Storage ProcedureFor Caterpillar Products.

Your Caterpillar dealer can assist in preparing theengine for extended storage periods.

SEBU8570-01 27Operation Section

Features and Controls

Features and Controlsi04026921

Monitoring SystemSMCS Code: 1900; 7400; 7402; 7450; 7451

The monitoring system is designed to alert theoperator to an immediate problem with any of theengine systems that are monitored. The MonitoringSystem is also designed to alert the operator to animpending problem with any of the engine systemsthat are monitored.

The monitoring system parameters can be accessedvia the Cat ET service tool. Many of the parameterswithin the monitoring system can be tailored to suitthe operation of the engine.

An example of adjustments that may be made withinthe monitoring system is changing the setpoint of theengine overspeed indicator from the factory defaultsetting.

Indicators and GaugesThe instrument panel may look like the instrumentpanel that is pictured in illustration 26 or theinstrument panel may look like the instrument panelthat is pictured in illustration 27. The instrument panelmay not include all of the instruments that are shownin the illustration.



Circuit Breaker (1) Reset the circuitbreaker if a circuit breaker trips. Press thebutton in order to reset the circuit breaker. If

the electrical system is working properly, the buttonwill remain pressed. If the button does not remainpressed or if the circuit breaker trips soon after beingreset, check the appropriate electrical circuit. Repairthe electrical circuit, if necessary.

Resetting the circuit breakers in a flammable at-mosphere or a combustible atmosphere may leadto fire hazards or explosion hazards whichmay re-sult in personal injury or death. DO NOT reset thecircuit breaker when a flammable atmosphere or acombustible atmosphere is present and the pow-er has not been removed from the equipment.

Diesel Particulate Filter Lamp (2) The DPF lamp will illuminate when aregeneration of the DPF is needed. Refer

to this Operation and Maintenance Manual, DieselParticulate Filter Regeneration for more informationon this lamp.

High Exhaust Temperature Lamp (3) This lamp is illuminated when a DPFregeneration is active.

Regeneration Disabled (4) This lampwill be illuminated if the regeneration ismanually disabled through the regeneration

switch or through the Cat (ET) service tool.

28 SEBU8570-01Operation SectionFeatures and Controls

Start Switch (5) The start switch hasthree positions: OFF, RUN, and START.When the start switch is turned clockwise to

the RUN position, the lamps will flash for 5 secondsduring the system test. The lamps will then shut off.In the RUN position, the ECM and electronic systemsare powered up.

Diagnostic Lamp (6) The diagnosticlamp will illuminate when an active faultcode is present.

Shutdown Lamp (7) The shutdownlamp will illuminate when a critical engineevent occurs which requires that the engine

be shut down. The event should be addressed asquickly as possible.

Shutdown Switch (8) Use the engineshutdown switch in order to stop the engine.Push the shutdown switch in order to put

the switch in the OFF position. Moving the switch tothe OFF position will stop the engine. After the enginestops, turn the knob clockwise. Turning the knob willreset the engine shutdown switch to the ON position.

Service Hour Meter (9) This gaugeindicates the total number of clock hoursof engine operation. Hours of operation

are logged in the ECM. A service tool is needed toretrieve the hours from the ECM. A Service HourMeter may be installed on the engine.

Idle Speed Switch (10) When the switchis in the up position, the engine speedincreases to HIGH IDLE. When the switch

is in the down position, the engine speed decreasesto LOW IDLE.

Regeneration Switch (11) Usedto activate a forced regeneration ormanually disable regeneration. Refer to

this Operation and Maintenance Manual, DieselParticulate Filter Regeneration for more informationon this switch.


High Speed Regeneration Enable Switch (12) Used to allow for high speed regeneration. If switchis pressed and locked, high speed regenerationsare active. If switch is disengaged, only low speedautomatic regenerations will be active. See thisOperation and Maintenance Manual, DieselParticulate Filter Regeneration for more information

Tachometer (13) This gauge indicatesengine speed (rpm). When the throttlecontrol lever is moved to the full throttle

position without load, the engine is running at highidle. The engine is running at the full load rpm whenthe throttle control lever is at the full throttle positionwith maximum rated load.

Voltmeter (14) This gauge indicates thevoltage of the electrical system. The needlein the red range indicates low voltage or

high voltage.

Fuel Pressure (15) This gauge indicatesfuel pressure to the fuel injection pump fromthe fuel filter. A decrease in fuel pressure

usually indicates a dirty fuel filter or a plugged fuelfilter. As the fuel filter becomes plugged, there willbe a noticeable reduction in the performance of theengine.

Engine Oil Pressure (16) The oilpressure should be greatest after acold engine is started. The pressure will

decrease as the engine warms up. The pressure willincrease when the engine rpm is increased. Thepressure will stabilize when the engine rpm is stable.



A lower oil pressure is normal at low idle. If the loadis stable and the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. An overspeed can result in serious dam-age to the engine. The engine can be operated at highidle without damage, but the engine should never beallowed to exceed the high idle rpm.

Note: The high idle rpm and the full load rpm arestamped on the Information Plate.

Jacket Water Coolant Temperature (17) Typical temperature range is 87 to 98C(189 to 208F). Higher temperatures

may occur under certain conditions. The watertemperature reading may vary according to load. Thereading should never exceed the boiling point for thepressurized system that is being used.

Coolant Temperature (18) When thecoolant temperature is above the normaloperating value, the coolant temperature

gauge will be in the red zone. Refer to the Messengerpanel for any additional information that may beavailable.

Warning Lamp (19) There is a generalfault in the engine. Refer to the Messengerdisplay for any additional information that

may be available.

Service Tool Connector (20) For moreinformation regarding the use of Cat ET and the PCrequirements for Cat ET, refer to the documentationthat accompanies your Cat ET software.

Mini Industrial Power Display(MIPD)The mini industrial power display provides for ameans to view various types of engine information.The information that can be viewed is describedbelow.


OK/Select button (1) The OK/Selectbutton isused to confirm the selections that were made withthe scroll left/right buttons.

Backlight button (2) This button is used to turnthe backlight of the display on or off.

Scroll left/right button (3) This button is usedto advance through the various screens of the MIPD.

The MIPD comes with three preset user interfaces.The interfaces are labeled as Operator_1,Operator_2, and Operator_3.

Operator_1 user interface is preset with variousengine, aftertreatment, and transmission informationover 14 screens. Diagnostic and system informationis also included. The information in Operator_1 isdisplayed via ISO symbols and metric display units.

Operator_2 user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

Operator_3 user interface is preset with variousengine, aftertreatment, and transmission informationover 12 screens. Diagnostic and system informationis also included. The information is displayed inanalog style gauges and English display units.

Note: Only use Operator_1 and Operator_2interfaces on Tier 4 engines. The addedaftertreatment parameters in these interfaces arenecessary to ensure proper operation.

Parameters

Below are a list of all the parameters that areviewable through the three user interfaces usedwithin the MIPD.

Engine Speed Displays the current engine speedin RPM.

30 SEBU8570-01Operation SectionFeatures and Controls

Coolant Temperature Displays the current coolanttemperature of the engine.

Engine Load Displays the amount of load on theengine as a percentage.

Regen Disable Status Displays whether theregeneration is manually disabled.

DPF Lamp Displays when a DPF regeneration isneeded.

Soot Loading Displays the amount of soot withinthe DPF as a percentage.

Air Inlet Temperature Displays the temperatureof the air coming into the engine.

Intake Manifold Air Temperature Displays thetemperature of the air coming into the engine.

Boost Pressure Displays the amount of pressureof the air entering the intake manifold of the engine.

Crankcase Pressure Displays the amount ofpressure within the crankcase of the engine.

Atmospheric Pressure Displays the amount ofatmospheric pressure that the engine is operating in.

Fuel Temp Displays the temperature of the fuelentering the engine.

Fuel Rate Displays the amount of fuel being usedby the engine.

Filtered Fuel Delta Pressure Displays thepressure across the fuel filter.

Low Idle RPM Displays the low idle speed setpointin RPM.

Hi Idle Speed Displays the high idle speedsetpoint in RPM.

Desired Speed Displays the desired engine speedin RPM.

Primary Throttle Displays the primary throttleposition as a percentage.

Secondary Throttle Displays the secondarythrottle position as a percentage.

Auxiliary Pressure Sensor 1 Displays thepressure being measured by the #1 auxiliary sensorif one is being used.

Auxiliary Temperature Sensor 1 Displays thetemperature being measured by the #1 auxiliarysensor if one is being used.

Battery Voltage Displays the battery voltage.

Aftertreatment 1 Regeneration Status Displaysthe status of the regeneration system as manual orautomatic.

HEST Lamp Illuminates when a DPF regenerationis active.

DPF Intake Temperature Displays thetemperature of the exhaust gas entering the DPF.

DPF Outlet Temperature Displays thetemperature of the exhaust gas leaving the DPF.

Transmission Selected Gear Displays thetransmission gear being requested.

Transmission Requested Gear Displays thetransmission gear being requested.

Transmission Oil Pressure Displays the oilpressure inside the transmission.

Transmission Oil Temperature Displays the oiltemperature of the transmission.

Transmission Torque Limit Displays the limit oftorque allowed by the transmission.

System Information

User Name Displays the preset user name thatis selected.

Software Version Displays the version of softwarethat is programmed in the MIPD.

Serial Number Displays the serial number of theMIPD.

Display Units Displays the units of measurementthat is selected for the given user.

Engine Location Displays which engine data isbeing reported if more than one engine is connectedto the MIPD.

Language Displays the selected language.

Alarm Indicates whether audible alarm is set toON or OFF when an audible alarm is connected tothe MIPD.



i03646563

Battery Disconnect Switch(If Equipped)SMCS Code: 1411-B11; 1411

The battery disconnect switch and the engine startswitch perform different functions. Turn off the batterydisconnect switch in order to disable the entireelectrical system. The battery remains connected tothe electrical system when you turn off the enginestart switch.

Turn the battery disconnect switch to the OFFposition and remove the key when you service theelectrical system or any other components.

Also turn the battery disconnect switch to the OFFposition and remove the key when the engine will notbe used for an extended period of a month or more.This will prevent drainage of the battery.

NOTICENever move the battery disconnect switch to the OFFposition while the engine is operating. Serious dam-age to the electrical system could result.

To ensure that no damage to the engine occurs,verify that the engine is fully operational beforecranking the engine. Do not crank an engine that isnot fully operational.

Perform the following procedure in order to check thebattery disconnect switch for proper operation:

1. With the battery disconnect switch in the ONposition, verify that electrical components arefunctioning. Verify that the hour meter is displayinginformation. Verify that the engine will crank.

2. Turn the battery disconnect switch to the OFFposition.

3. Verify that the following items are not functioning:electrical components, hour meter, and enginecranking. If any of the items continue to functionwith the battery disconnect switch in the OFFposition, consult your Caterpillar dealer.

32 SEBU8570-01Operation SectionEngine Diagnostics

Engine Diagnosticsi01563934

Self-DiagnosticsSMCS Code: 1000; 1900; 1901; 1902

Caterpillar Electronic Engines have the capability toperform a self-diagnostics test. When the systemdetects an active problem, the DIAGNOSTIClamp is activated. Diagnostic codes will be stored inpermanent memory in the Electronic Control Module(ECM). The diagnostic codes can be retrieved byusing the following components:

Caterpillar electronic service tools

DIAGNOSTIC lamp

Note: The DIAGNOSTIC lamp must be installed bythe OEM or by the customer.

Some installations have electronic displays thatprovide direct readouts of the engine diagnosticcodes. Refer to the manual that is provided by theOEM for more information on retrieving enginediagnostic codes.

Active codes represent problems that currently exist.These problems should be investigated first. If a codeis active, the DIAGNOSTIC lamp will flash the flashcode at five second intervals.

Logged codes represent the following items:

Intermittent problems

Recorded events

Performance history

The problems may have been repaired since thelogging of the code. These codes do not indicate thata repair is needed. The codes are guides or signalswhen a situation exists. Codes may be helpful totroubleshoot problems.

When the problems have been corrected, thecorresponding logged fault codes should be cleared.

i04031761

Diagnostic Flash CodeRetrievalSMCS Code: 1000; 1900; 1901; 1902

In order to read the diagnostic flash codes throughthe diagnostic lamp, cycle the key switch from off toon twice within 3 seconds.

The codes will be flashing in sequence. For exampleif the flash code equals 133, the diagnostic lamp willflash once, pause, flash three times, pause, and flashthree times.

After the complete code has flashed, a 3 secondpause will take place before the next code will beginto flash (if another code is present).

Note: Always refer to the Troubleshooting guidefor the latest information related to enginediagnostics and troubleshooting. Contact yourlocal Cat dealer for more information.

SEBU8570-01 33Operation SectionEngine Diagnostics

Table 2

Cross Reference for Diagnostic Codes and Event Codes

FlashCode SPN

(1)/FMI CodeDiagnostic Code

orEvent Code

Description of Code

1074-05 1248-05 Retarder Solenoid current below normal14

1074-06 1248-06 Retarder Solenoid current above normal626-05 2417-05 Ether Injection Control Solenoid current below normalo

16626-06 2417-06 Ether Injection Control Solenoid current above normal678-03 41-03 8 Volt DC Supply voltage above normal678-04 41-04 8 Volt DC Supply voltage below normal620-03

1079-03262-03 5 Volt Sensor DC Power Supply voltage above normal

620-04

21

1079-04262-04 5 Volt Sensor DC Power Supply voltage below normal

100-03 100-03 Engine Oil Pressure Sensor voltage above normal100-04 100-04 Engine Oil Pressure Sensor voltage below normal24

100-10 100-10 Engine Oil Pressure Sensor abnormal rate of change102-03 1785-03 Intake Manifold Pressure Sensor voltage above normal102-04 1785-04 Intake Manifold Pressure Sensor voltage below normal10

102-10 1785-10 Intake Manifold Pressure Sensor abnormal rate of change108-03 274-03 Atmospheric Pressure Sensor voltage above normal

26108-04 274-04 Atmospheric Pressure Sensor voltage below normal110-03 110-03 Engine Coolant Temperature Sensor voltage above normal

27110-04 110-04 Engine Coolant Temperature Sensor voltage below normal

28 91-13 91-13 Throttle Position Sensor calibration required32 91-08 91-08 Throttle Position Sensor abnormal frequency, pulse width, or period

190-08 190-08 Engine Speed Sensor abnormal frequency, pulse width, or period34

723-08 342-08 Secondary Engine Speed Sensor abnormal frequency,pulse width, or period190-15 E362 (1) Engine Overspeed Warning190-00 E362 (3) Engine Overspeed Shutdown174-15 E363 (1) High Fuel Supply Termperature Warning174-16 E363 (2) High Fuel Supply Termperature Derate174-0 E363 (3) High Fuel Supply Termperature Shutdown614-15 E390 (1) Fuel Filter Restriction Warning

614-16 E390 (2) Fuel Filter Restriction Shutdown157-15 E396 (1) Low Fuel Rail Pressure

35

157-17 E398 (1) High Fuel Rail Pressure

94-03 94-03 Fuel Delivery Pressure Sensor voltage above normal37

94-04 94-04 Fuel Delivery Pressure Sensor voltage below normal105-03 172-03 Intake Manifold Air Temperature Sensor voltage above normal

38105-04 172-04 Intake Manifold Air Temperature Sensor voltage below normal

42 228-13 261-13 Engine Timing Calibration calibration required(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code

164-02 164-02 Injector Actuation Pressure signal erratic

164-03 164-03 Injector Actuation Pressure Sensor voltage above normal

164-04 164-04 Injector Actuation Pressure Sensor voltage below normal43

164-11 164-11 Injector Actuation Pressure system fault

100-17 E360 (1) Low Engine Oil Pressure Warning

100-18 E360 (2) Low Engine Oil Pressure Derate46

100-01 E360 (3) Low Engine Oil Pressure Shutdown

729-05 617-05 Inlet Air Heater Relay current below normal49

729-06 617-06 Inlet Air Heater Relay current above normal

168-00 168-00 Electrical System Voltage high - most severe (3)

168-01 168-01 Electrical System Voltage low - most severe (3)51

168-02 168-02 Electrical System Voltage erratic, intermittent, or incorrect

56 630-02 268-02 Programmed Parameter Fault erratic, intermittent, or incorrect

59 234-02 253-02 Personality Module erratic, intermittent, or incorrect

110-15 E361 (1) High Engine Coolant Temperature Warning

110-16 E361 (2) High Engine Coolant Temperature Derate61

110-00 E361 (3) High Engine Coolant Temperature Shutdown

111-17 E2143 (1) Low Engine Coolant Level Warning

111-18 E2143 (2) Low Engine Coolant Level Derate62

111-01 E2143 (3) Low Engine Coolant Level Shutdown

94-15 E096 (1) High Fuel Pressure Warning

94-17 E198 (1) Low Fuel Pressure Warning63

94-18 E198 (2) Low Fuel Pressure Shutdown(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code

1636-15 E539 (1) High Intake Manifold Air Temperature Warning

1636-00 E539 (2) High Intake Manifold Air Temperature Derate

1636-00 E539 (3) High Intake Manifold Air Temperature Shutdown

3711-31 E593 (2) Aftertreatment Insufficient Temperature to Complete Regeneration

3715-31 E991 (3) DPF Active Regeneration Inhibited Due to PermanentSystem Lockout

3714-31 E992 (3) DPF Active Regeneration Inhibited Due to TemporarySystem Lockout3703-13 E993 (3) DPF Active Regeneration Inhibited Due to Inhibit Switch

3719-16 E995 (2) High DPF #1 Soot Loading

3719-0 E995 (3) High DPF #1 Soot Loading

3242-15 E1008 (1) High DPF #1 Intake Temperature

3242-16 E1008 (2) High DPF #1 Intake Temperature

3242-18 E1014 (2) Low DPF #1 Intake Temperature

3473-31 E1025 (2) Aftertreatment #1 Loss of Ignition

3474-31 E1026 (2) Aftertreatment #1 Loss of Ignition

101-15 E1036 (1) High Crankcase Pressure

101-16 E1036 (2) High Crankcase Pressure

102-18 E1045 (2) Low Intake Manifold Pressure

3480-15 E1050 (1) Aftertreatment #1 Fuel Pressure #1


64

4077-15 E1051 (1) Aftertreatment #1 Fuel Pressure #2(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code


3480-17 E1052 (1) Low Aftertreatment #1 Fuel Pressure #1




3556-7 E1070 (1) Aftertreatment Fuel Injector #1 not responding

3358-16 E1090 (2) High Engine Exhaust Gas Recirculation Intake Pressure

412-16 E1092 (2) High Engine Exhaust Gas Recirculation Temperature

411-18 E1093 (2) Low Engine Exhaust Gas Recirculation Differential Pressure

411-16 E1094 (2) High Engine Exhaust Gas Recirculation Differential Pressure

2659-18 E1095 (2) Low Engine Exhaust Gas Recirculation Mass Flow Rate

2659-15 E1096 (1) High Engine Exhaust Gas Recirculation Mass Flow Rate

2659-16 E1096 (2) High Engine Exhaust Gas Recirculation Mass Flow Rate

3609-18 E1154 (2) Low DPF #1 Intake Pressure

520211-7 E1187 (2) Engine Exhaust Manifold Bank #1 Flow BalanceValve Stuck Closed520212-7 E1188 (2) Engine Exhaust Manifold Bank #1 Flow Balance Valve Stuck Open

94-16 E1218 (2) High Unfiltered Fuel Pressure

614-31 E1970 (1) Operator did not provide regeneration opportunity

520200-16 E1971 (2) Low cranking fuel pressure

64

615-2 E1972 (2) RF calibration out of range

0441-15 E445 (1) High Auxiliary Temperature Warning

0441-16 E445 (2) High Auxiliary Temperature Derate

0441-00 E445 (3) High Auxiliary Temperature Shutdown

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt

67

1836-04 1836-04 Auxiliary Temperature Sensor short to ground

1387-15 E443 (1) High Auxiliary Pressure Warning

1387-16 E443 (2) High Auxiliary Pressure Derate

1387-00 E443 (3) High Auxiliary Pressure Shutdown

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt

68

1835-04 1835-04 Auxiliary Pressure Sensor short to ground

651-05 001-05 Cylinder #1 Injector open circuit71

651-06 001-06 Cylinder #1 Injector short






654-06 004-06 Cylinder #4 Injector short(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code





105-15 539 (1) Engine Intake Manifold #1 Temperature : High - least severe (1)

105-16 539 (2) Engine Intake Manifold #1 Temperature : High -moderate severity (2)110-3 110-3 Engine Coolant Temperature : Voltage Above Normal

110-4 110-4 Engine Coolant Temperature : Voltage Below Normal

157-3 1797-3 Engine Injector Metering Rail #1 Pressure : Voltage Above Normal

157-4 1797-4 Engine Injector Metering Rail #1 Pressure : Voltage Below Normal

172-3 2526-3 Engine Air Inlet Temperature : Voltage Above Normal

133

172-4 2526-4 Engine Air Inlet Temperature : Voltage Below Normal

135 102-18 1045 (2) Engine Intake Manifold #1 Pressure : Low - moderate severity (2)

190-8 190-8 Engine Speed : Abnormal Frequency, Pulse Width, or Period

190-0 362 (3) Engine Speed : High - most severe (3)141

190-15 362 (1) Engine Speed : High - least severe (1)

142 723-8 342-8 Engine Speed Sensor #2 : Abnormal Frequency,Pulse Width, or Period637-11 261-11 Engine Timing Sensor : Other Failure Mode

143637-13 261-13 Engine Timing Sensor : Calibration Required

100-3 100-3 Engine Oil Pressure : Voltage Above Normal

100-4 100-4 Engine Oil Pressure : Voltage Below Normal

108-3 274-3 Barometric Pressure : Voltage Above Normal152

108-4 274-4 Barometric Pressure : Voltage Below Normal

100-1 360 (3) Engine Oil Pressure : Low - most severe (3)

100-17 360(1) Engine Oil Pressure : Low - least severe (1)157

100-18 360 (2) Engine Oil Pressure : Low - moderate severity (2)

159 157-17 398 (1) Engine Injector Metering Rail #1 Pressure : Low - least severe (1)

1347-5 1779-5 Engine Fuel Pump Pressurizing Assembly #1 :Current Below Normal162

1347-6 1779-6 Engine Fuel Pump Pressurizing Assembly #1 :Current Above Normal

1348-5 1780-5 Engine Fuel Pump Pressurizing Assembly #2 :Current Below Normal163

1348-6 1780-6 Engine Fuel Pump Pressurizing Assembly #2 :Current Above Normal174-3 174-3 Engine Fuel Temperature 1 : Voltage Above Normal

174-4 174-4 Engine Fuel Temperature 1 : Voltage Below Normal165

174-15 363 (1) Engine Fuel Temperature 1 : High - least severe (1)

110-15 361 (1) Engine Coolant Temperature : High - least severe (1)168

110-16 361 (2) Engine Coolant Temperature : High - moderate severity (2)(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code

729-5 617-5 Engine Inlet Air Heater Driver #1 : Current Below Normal178

729-6 617-6 Engine Inlet Air Heater Driver #1 : Current Above Normal

3241-4 3485-4 Exhaust Gas Temperature 1 : Voltage Below Normal186

3241-3 3485-3 Exhaust Gas Temperature 1 : Voltage Above Normal

100-13 100-13 Engine Oil Pressure : Calibration Required

108-13 274-13 Barometric Pressure : Calibration Required

3358-13 3385-13 Engine Exhaust Gas Recirculation Inlet Pressure: Calibration Required

3563-3 1785-3 Engine Intake Manifold #1 Absolute Pressure :Voltage Above Normal

3563-4 1785-4 Engine Intake Manifold #1 Absolute Pressure :Voltage Below Normal

197

3563-13 1785-13 Engine Intake Manifold #1 Absolute Pressure :Calibration Required168-2 168-2 Battery Potential / Power Input 1 : Erratic, Intermittent, or Incorrect

168-3 168-3 Battery Potential / Power Input 1 : Voltage Above Normal422

168-4 168-4 Battery Potential / Power Input 1 : Voltage Below Normal

439 158-2 1834-2 Keyswitch Battery Potential : Erratic, Intermittent, or Incorrect

3509-3 262-3 Sensor Supply Voltage 1 : Voltage Above Normal

3509-4 262-4 Sensor Supply Voltage 1 : Voltage Below Normal

3510-3 2131-3 Sensor Supply Voltage 2 : Voltage Above Normal516

3510-4 2131-4 Sensor Supply Voltage 2 : Voltage Below Normal

527 630-2 268-2 Calibration Memory : Erratic, Intermittent, or Incorrect

651-5 1-5 Engine Injector Cylinder #01 : Current Below Normal

651-6 1-6 Engine Injector Cylinder #01 : Current Above Normal

651-7 1-7 Engine Injector Cylinder #01 : Not Responding Properly111/139

651-2 1-2 Engine Injector Cylinder #01 : Erratic, Intermittent, Incorrect












654-2 4-2 Engine Injector Cylinder #04 : Erratic, Intermittent, Incorrect(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code









NA 94-16 1218 (2) Engine Fuel Delivery Pressure : High - moderate severity (2)

NA 101-3 101-3 Engine Crankcase Pressure : Voltage Above Normal

NA 101-4 101-4 Engine Crankcase Pressure : Voltage Below Normal

NA 101-13 101-13 Engine Crankcase Pressure : Calibration Required

NA 101-15 1036 (1) Engine Crankcase Pressure : High - least severe (1)

NA 101-16 1036 (2) Engine Crankcase Pressure : High - moderate severity (2)

NA 105-0 539 (3) Engine Intake Manifold #1 Temperature : High - most severe (3)

NA 108-21 274-21 Barometric Pressure : Data Drifted Low

NA 110-0 361 (3) Engine Coolant Temperature : High - most severe (3)

NA 152-0 254-0 Number Of ECU Resets : High - most severe (3)

NA 152-1 254-1 Number Of ECU Resets : Low - most severe (3)

NA 152-2 254-2 Number Of ECU Resets : Erratic, Intermittent, or Incorrect

NA 152-3 254-3 Number Of ECU Resets : Voltage Above Normal

NA 152-4 254-4 Number Of ECU Resets : Voltage Below Normal

NA 152-5 254-5 Number Of ECU Resets : Current Below Normal

NA 152-6 254-6 Number Of ECU Resets : Current Above Normal

NA 152-7 254-7 Number Of ECU Resets : Not Responding Properly

NA 152-8 254-8 Number Of ECU Resets : Abnormal Frequency,Pulse Width, or PeriodNA 152-9 254-9 Number Of ECU Resets : Abnormal Update Rate

NA 152-10 254-10 Number Of ECU Resets : Abnormal Rate of Change

NA 152-11 254-11 Number Of ECU Resets : Other Failure Mode

NA 152-12 254-12 Number Of ECU Resets : Failure

NA 152-13 152-13 Number Of ECU Resets : Calibration Required

NA 173-15 E194(2) High Exhaust Temperature

NA 174-0 363 (3) Engine Fuel Temperature 1 : High - most severe (3)

NA 174-16 363 (2) Engine Fuel Temperature 1 : High - moderate severity (2)

NA 411-3 3387-3 Engine Exhaust Gas Recirculation Differential Pressure: Voltage Above Normal

NA 411-4 3387-4 Engine Exhaust Gas Recirculation Differential Pressure: Voltage Below Normal

NA 411-13 3387-13 Engine Exhaust Gas Recirculation Differential Pressure: Calibration Required(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code

NA 411-15 1094 (1) Engine Exhaust Gas Recirculation Differential Pressure: High - least severe (1)

NA 411-17 1093 (1) Engine Exhaust Gas Recirculation Differential Pressure: Low - least severe (1)

NA 412-3 3386-3 Engine Exhaust Gas Recirculation Temperature :Voltage Above Normal

NA 412-4 3386-4 Engine Exhaust Gas Recirculation Temperature :Voltage Below Normal

NA 412-15 1092 (1) Engine Exhaust Gas Recirculation Temperature :High - least severe (1)

NA 412-16 1092 (2) Engine Exhaust Gas Recirculation Temperature : High- moderate severity (2)NA 626-5 2417-5 Engine Start Enable Device 1 : Current Below Normal

NA 626-6 2417-6 Engine Start Enable Device 1 : Current Above Normal

NA 678-3 41-3 ECU 8 Volts DC Supply : Voltage Above Normal

NA 678-4 41-4 ECU 8 Volts DC Supply : Voltage Below Normal

NA 1239-0 499 (3) Engine Fuel Leakage 1 : High - most severe (3)

NA 2630-3 3372-3 Engine Charge Air Cooler Outlet Temperature :Voltage Above Normal

NA 2630-4 3372-4 Engine Charge Air Cooler Outlet Temperature :Voltage Below Normal

NA 2659-15 1096 (1) Engine Exhaust Gas Recirculation (EGR) Mass FlowRate : High - least severe (1)

NA 2659-17 1095 (1) Engine Exhaust Gas Recirculation (EGR) Mass FlowRate : Low - least severe (1)

NA 2791-5 3405-5 Engine Exhaust Gas Recirculation (EGR) Valve Control: Current Below Normal

NA 2791-6 3405-6 Engine Exhaust Gas Recirculation (EGR) Valve Control: Current Above NormalNA 3242-3 2452-3 Particulate Trap Intake Gas Temperature : Voltage Above Normal

NA 3242-4 2452-4 Particulate Trap Intake Gas Temperature : Voltage Below Normal

NA 3242-15 1008 (1) Particulate Trap Intake Gas Temperature : High - least severe (1)

NA 3242-16 1008 (2) Particulate Trap Intake Gas Temperature : High- moderate severity (2)

NA 3242-18 1014 (2) Particulate Trap Intake Gas Temperature : Low- moderate severity (2)

NA 3251-2 2458-2 Particulate Trap Differential Pressure : Erratic,Intermittent, or IncorrectNA 3251-3 2458-3 Particulate Trap Differential Pressure : Voltage Above NormalNA 3251-4 2458-4 Particulate Trap Differential Pressure : Voltage Below NormalNA 3251-13 2458-13 Particulate Trap Differential Pressure : Calibration Required

NA 3358-3 3385-3 Engine Exhaust Gas Recirculation Inlet Pressure :Voltage Above Normal

NA 3358-4 3385-4 Engine Exhaust Gas Recirculation Inlet Pressure :Voltage Below Normal

NA 3358-16 1090 (2) Engine Exhaust Gas Recirculation Inlet Pressure :High - moderate severity (2)(continued)


(Table 2, contd)


FlashCode SPN


orEvent Code

Description of Code

NA 3358-21 3385-21 Engine Exhaust GasRecirculation Inlet Pressure : DataDrifted Low

NA 3473-31 1025 (2) Aftertreatment #1 Failed to Ignite

NA 3474-14 1026 (1) Aftertreatment #1 Loss of Combustion : Special Instruction

NA 3474-31 1026 (2) Aftertreatment #1 Loss of Combustion

NA 3479-5 2461-5 Aftertreatment #1 Fuel Pressure Control : Current Below Normal

NA 3479-6 2461-6 Aftertreatment #1 Fuel Pressure Control : Current Above Normal

NA 3480-3 2460-3 Aftertreatment #1 Fuel Pressure #1 : Voltage Above Normal

NA 3480-4 2460-4 Aftertreatment #1 Fuel Pressure #1 : Voltage Below Normal

NA 3480-15 1050 (1) Aftertreatment #1 Fuel Pressure #1 : High - least severe (1)

NA 3480-16 1050 (2) Aftertreatment #1 Fuel Pressure #1 : High - moderate severity (2)

NA 3480-17 1052 (1) Aftertreatment #1 Fuel Pressure #1 : Low - least severe (1)

NA 3480-18 1052 (2) Aftertreatment #1 Fuel Pressure #1 : Low - moderate severity (2)

NA 3483-11 1305 (1) Aftertreatment #1 Regeneration Status : Other Failure Mode

NA 3484-5 2465-5 Aftertreatment #1 Ignition : Current Below Normal

NA 3484-6 2465-6 Aftertreatment #1 Ignition : Current Above Normal

NA 3487-5 2489-5 Aftertreatment #1 Air Pressure Control : Current Below Normal

NA 3487-6 2489-6 Aftertreatment #1 Air Pressure Control : Current Above Normal

NA 3487-7 2489-7 Aftertreatment #1 Air Pressure Control : Not Responding Properly

NA 3487-8 2489-8 Aftertreatment #1 Air Pressure Control : AbnormalFrequency, Pulse Width, or Period

NA 3488-3 2490-3 Aftertreatment #1 Air Pressure Actuator Position :Voltage Above Normal

NA 3488-4 2490-4 Aftertreatment #1 Air Pressure Actuator Position :Voltage Below NormalNA 3511-3 3482-3 Sensor Supply Voltage 3 : Voltage Above NormalNA 3511-4 3482-4 Sensor Supply Voltage 3 : Voltage Below NormalNA 3556-7 1070 (1) Aftertreatment Fuel Injector #1 : Not Responding ProperlyNA 3563-21 1785-21 Engine Intake Manifold #1 Absolute Pressure : Data Drifted LowNA 3609-3 3464-3 DPF #1 Intake Pressure : Voltage Above NormalNA 3609-4 3464-4 DPF #1 Intake Pressure : Voltage Below NormalNA 3609-13 3464-13 DPF #1 Intake Pressure : Calibration RequiredNA 3609-15 1156 (1) DPF #1 Intake Pressure : High - least severe (1)NA 3609-17 1154 (1) DPF #1 Intake Pressure : Low - least severe (1)NA 3609-21 3464-21 DPF #1 Intake Pressure : Data

c9.3 engine

Documents