Caterpillar cat 16 h na motor grader (prefix 6zj) service repair manual (6zj00001 and up)

Service Repair Manual
Models
16H NA Motor Grader

Shutdown SIS
Previous Screen
Product: MOTOR GRADER
Model: 16H NA MOTOR GRADER 6ZJ
Configuration: 16H Motor Grader 6ZJ00001-UP (MACHINE) POWERED BY 3406C Engine
Disassembly and Assembly
3406C DIESEL ENGINES FOR CATERPILLAR BUILT MACHINES
Media Number -SENR6409-02 Publication Date -01/07/2006 Date Updated -19/05/2015
SENR64090038
Timing Gears & Plate
SMCS - 1162-010; 1206
Remove & Install Timing Gears & Plate
Start By:
a. remove timing gear cover
b. remove fuel injection pump housing and governor
1. Remove four bolts (2), plate (3) and idler gear (1).
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16H Motor Grader 6ZJ00001-UP (MACHINE) POWERED BY 3406C Engine(SEBP2...
2020/12/2
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2. If the camshaft is not going to be removed, use Tool (A) to remove camshaft gear (4).
NOTICE
Do not turn the crankshaft with the camshaft gear removed. Damage
can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.
4. Remove timing gear plate (6).
5. Use Tool (B) to remove the bearing from the idler gear.
NOTE: The following steps are for the installation of the timing gears and plate.
6. Install a new gasket on the timing gear plate.
7. Put timing gear plate (6) in position on the cylinder block and install the bolts that hold the
timing gear plate to the cylinder block.
8. Heat camshaft gear (4) to a maximum temperature of 205° C (400° F) for no longer than three
hours and install it on the camshaft.
2/3
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9. Use Tool (B) and install the bearing in the idler gear.
NOTE: Set the gear on the front face (face with the timing marks). Drive the bearing from the
rear face toward the front face of the gear. Install the bearing to a depth of 1.5 ± 0.5 mm (.06 ± .02
in) below the rear face of the idler gear.
10. Install the idler gear, plate and bolts.
NOTE: Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so
"V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K"
marks (8) on the camshaft gear can be seen at the outer edges of the idler gear.
End By:
a. install fuel injection pump housing and governor
b. install timing gear cover
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Dec 2 15:12:49 UTC+0800 2020
3/3
2020/12/2

Shutdown SIS
Previous Screen
SENR64090039
Camshaft
SMCS - 1210-010
Remove & Install Camshaft
Start By:
b. remove valve lifters
1. Turn the engine to top center compression stroke for the No. 1 piston.
1/3
2020/12/2

2. Remove four bolts (2) and plate (1) that hold the idler gear in place.
3. Remove idler gear (3).
4. Remove two bolts (4) and retainer (5) that holds the camshaft to the cylinder block.
5. Carefully remove the camshaft assembly from the cylinder block.
6. Remove camshaft gear (6) from the camshaft with tooling (A).
NOTE: The following steps are for the installation of the camshaft.
7. Heat camshaft gear (6) to a maximum temperature of 205° C (400° F) for no more than three
hours.
8. Put the key in the camshaft in alignment with the groove (keyway) in gear (6). Install gear (6)
on the camshaft.
9. Put clean engine oil on the lobes and journals of the camshaft.
10. Carefully install the camshaft assembly in the cylinder block.
11. Install the retainer that holds the camshaft in the cylinder block.
12. Install idler gear (3) on its shaft. Be sure the "V" mark on the idler gear (3) is in alignment
with the "B" mark on the crankshaft gear. The "K" marks on the camshaft gear can be seen at the
edge of the idler gear.
2/3
2020/12/2

NOTE: It will be necessary to check the timing of the governor and fuel pump drive. See the
topic, "Camshaft Timing For Fuel Injection Pump", in Testing & Adjusting Manual SENR6471.
End By:
a. install valve lifters
b. install timing gear cover
Wed Dec 2 15:13:45 UTC+0800 2020
3/3
2020/12/2

Shutdown SIS
Previous Screen
SENR64090040
Camshaft Bearings
SMCS - 1211-010
Remove & Install Camshaft Bearings
Start By:
a. remove camshaft
b. remove flywheel housing
c. remove pistons and connecting rod assemblies
d. remove timing gears and plate
1. Use Tool (A) to remove the camshaft bearings from the cylinder block starting with the rear
bearing.
NOTE: The following steps are for the installation of the camshaft bearings.
1/2
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2. Use Tool (A) to install the camshaft bearings in the cylinder block.
3. All camshaft bearings must be installed so that the holes in the bearings are 90 ± 15 degrees
from the oil holes in the cylinder block. Make sure the bearing joint position is above the oil holes.
4. The installation depth of dimension A of the front bearing from the front face of the block is 2.8
± 0.5 mm (.11 ± .02 in).
5. Install the remainder of the bearings to the dimensions given from the front face of the block: B.
181.9 ± 0.5 mm (7.16 ± .02 in), C. 353.3 ± 0.5 mm (13.91 ± .02 in), D. 524.8 ± 0.5 mm (20.66
± .02 in), E. 696.2 ± 0.5 (27.41 ± .02 in), F. 867.7 ± 0.5 mm (34.16 ± .02 in), G. 1039.1 ± 0.5
mm (40.91 ± .02 in).
6. After assembly the inside diameter of bearings (1) must be 69.969 ± 0.048 mm (2.7500 ± .0019
in). The remainder of the bearing must have an inside diameter of 69.982 ± 0.061 mm (2.7552
± .0024 in).
End By:
a. install timing gears and plate
b. install pistons and connecting rod assemblies
c. install flywheel housing
d. install camshaft
Wed Dec 2 15:14:40 UTC+0800 2020
2/2
2020/12/2

Shutdown SIS
Previous Screen
SENR64090041
Connecting Rod Bearings
SMCS - 1219-010
Remove & Install Connecting Rod Bearings
Start By:
a. remove oil pump
1. Check the connecting rods and caps for their identification and location.
2. Turn the crankshaft until the connecting rod caps are in position.
3. Remove two bolts (1) and the cap from the connecting rod. Remove the lower half of the
bearing from the cap.
4. Push the connecting rod away from the crankshaft. Remove the upper half of the bearing from
the connecting rod.
1/3
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NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on the
bearings for final assembly.
5. Install the upper half of the bearing in the connecting rod.
6. Pull the connecting rod slowly on to the crankshaft.
7. Install the lower half of the bearing in the cap.
NOTE: Be sure the tabs in the back of bearings are in the tab grooves of the connecting rod and
cap.
The serviceman must be very careful to use Plastigage, Tool (A) correctly. The following points
must be remembered:
Make sure that the backs of the bearings and the bores are clean and dry.
Make sure that the bearing locking tabs are properly seated in their slots.
The crankshaft must be free of oil where the Plastigage touches it.
Put a piece of Plastigage (A) on the crown of the bearing half that is in the cap. Do not allow the
Plastigage to extend over the edge of the bearing.
Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench.
Be careful not to dislodge the bearing when the cap is installed.
Do not turn the crankshaft with the Plastigage installed.
Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage
while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the
package. Record the measurements.
Remove the Plastigage before reinstalling the cap.
When using Plastigage, the readings can sometimes be unclear. For example, all parts of the
Plastigage are not the same width. Measure the major widths to make sure that they are within the
specification range. Also, experience has shown that when checking clearances tighter than 0.10
mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round
journals can give faulty readings. Also, journal taper may be indicated when one end of the
Plastigage is wider that the other.
For complete details concerning measuring bearing clearance, see the topic, "Engine Bearings &
Crankshafts", SEBD0531.
2/3
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8. Use Plastigage (A) to check the bearing clearance.
9. Put Plastigage (A) on the bearing.
10. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
NOTE: Be sure the cylinder numbers on the rod cap and rod are the same and are on the same
side of connecting rod. Numbers are on the same side of the rod and cap as are the bearing tab
slots. If new rods are installed, put the cylinder number on the rod and cap.
NOTE: Do not turn the crankshaft when Plastigage (A) is in position.
11. Install rod caps (2). Install the two bolts. Tighten each bolt to a torque of 90 ± 8 N·m (67 ± 6
lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra 90° ± 5° from the mark.
Remove the rod cap. Remove Plastigage (A), and check the bearing clearance. The bearing
clearance must be 0.071 to 0.168 mm (.0028 to .0066 in) for new bearings. Maximum clearance
with used bearings is 0.25 mm (.010 in).
12. Put clean engine oil on lower half of the bearing. Install the rod cap again. Tighten each nut to
a torque of 90 ± 8 N·m (67 ± 6 lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra
90 ± 5 degrees from mark.
13. Do Steps 1 through 12 for the remainder of the connecting rod bearings.
End By:
a. install oil pump
Wed Dec 2 15:15:36 UTC+0800 2020
3/3
2020/12/2

Shutdown SIS
Previous Screen
SENR64090042
Crankshaft Main Bearings
SMCS - 1203-010
Remove & Install Crankshaft Main Bearings
Start By:
a. remove oil pump
1. Check the main bearing caps for identification for their location and direction in the block. The
caps must be installed in the same location and direction from which they were removed.
2. Remove number 2 through number 6 bearing caps (1). Remove thrust plates from the number 4
main bearing.
NOTICE
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If the crankshaft is turned in the wrong direction, the tab of the
bearing will be pushed between the crankshaft and cylinder block. This
can cause damage to either the crankshaft or cylinder block or both.
3. Remove the upper halves of the main bearings by putting Tool (A) in oil hole (2) in the
crankshaft. Turn the crankshaft in the direction which will push the end of the bearing with a tab
out first.
4. Remove the lower halves of the bearings from the caps.
NOTE: Install the bearings dry when the clearance checks are made. Put clean engine oil on the
bearings for final assembly.
5. Install the new bearings in the caps.
6. Install the upper halves of the bearings in the cylinder with Tool (A).
NOTICE
Be sure tabs (3) on the back of the bearings fit in the tab slots of the
caps and cylinder block. The serviceman must be very careful to use
Plastigage, Tool (B) correctly. The following points must be
remembered.
Make sure that the backs of the bearings and the bores are clean and dry.
Make sure that the bearing locking tabs are properly seated in their slots.
The crankshaft must be free of oil where the Plastigage touches it.
2/4
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If the main bearing clearances are checked with the engine upright or on its side, the crankshaft
must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft
against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft
will cause incorrect readings.
Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the
Plastigage to extend over the edge of the bearing.
Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench.
Be careful not to dislodge the bearing when the cap is installed.
Do not turn the crankshaft with the Plastigage installed.
Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage
while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the
package. Record the measurements.
Remove the Plastigage before reinstalling the cap.
When using Plastigage, the readings can sometimes be unclear. For example, all parts of the
Plastigage are not the same width. Measure the major widths to make sure that they are within the
specification range. Also, experience has shown that when checking clearances tighter than 0.10
mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round
journals can give faulty readings. Also, journal taper may be indicated when one end of the
Plastigage is wider that the other.
For complete details concerning measuring bearing clearance, see Engine Bearings & Crankshafts,
SEBD0531.
7. Check the bearing clearance with Plastigage (B). Put Plastigage (B) on the bearings.
Typical Example
NOTICE
3/4
2020/12/2

Be sure the main bearing caps are installed so the numbers on the side
of the cylinder block are the same as the numbers on the bearing caps,
and the arrows (4) on the bearing caps are toward the front of the
cylinder block.
8. Install the bearing caps for No. 2 through No. 6 main bearings. Put 2P2506 Thread Lubricant
on the bolts. Install the bolts, and tighten bolts at end with tab first to a torque of 260 ± 14 N·m
(190 ± 10 lb ft). Turn the bolts an extra 120 ± 5 degrees first at the end opposite of the tab.
Remove the bearing caps for No. 2 through No. 6 main bearings. Remove Plastigage (B) from the
caps. Check the thickness of Plastigage (B) to find the bearing clearance. The bearing clearance
must be 0.091 to 0.185 mm (.0036 to .0073 in) with new bearings. Maximum clearance with used
bearings is 0.25 mm (.010 in).
9. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the bearing caps for No. 2
through No. 6 main bearings. Install the bolts, and tighten the bolts at the end with the tab first to a
torque of 260 ± 14 N·m (190 ± 10 lb ft). Put a mark on the bolts and caps. Turn the bolts at the
opposite end of the tab first an extra 120 ± 5 degrees from the mark.
10. Remove the No. 1 and No. 7 main bearing caps. Do Steps 3 through 9 for the No. 1 and No. 7
caps.
11. Install the thrust plates for the No. 4 main bearing.
NOTE: Install the thrust plates with the identification "BLOCK SIDE" toward the cylinder block.
12. Check the end play of the crankshaft with Tool (C). Be sure the dial indicator is against a
machined surface. The end play is control by the thrust plates of No. 4 (center) main bearing. The
end play with new thrust plates must be 0.15 to 0.51 mm (.006 to .020 in). The maximum
permissible end play used thrust plates is 0.89 mm (.035 in).
End By:
a. install oil pump
Wed Dec 2 15:16:32 UTC+0800 2020
4/4
2020/12/2

Shutdown SIS
Previous Screen
SENR64090043
Crankshaft
SMCS - 1202-011; 1202-012
Remove Crankshaft
Start By:
b. remove flywheel housing*
c. remove engine oil cooler**
d. remove oil filter base**
1/8
2020/12/2

*Put the engine in time before the flywheel housing is removed. See the topic, "Finding Top
Center Compression Position For No. 1 Piston" in Testing & Adjusting Manual SENR6471.
**These operations must be done to install Tool (A) on the engine.
Typical Example
1. Fasten the engine on Tool (A). The weight of the engine is 1362 kg (3000 lb).
2. Remove the bolts and nuts that hold air cleaner group (1), pipe assembly (3), bracket assembly
(4) and lifting plate (5) as a unit to the engine. Fasten a hoist to the unit and remove it from the
engine. The weight of the unit is approximately 39 kg (85 lb).
3. Remove tube assembly (2) from the engine.
Typical Example
4. Install the two bolts to hold the primary fuel filter bracket (6) in place while the engine is turned
with Tool (A).
5. Turn the engine to the position shown with Tool (A). Remove rod bearing caps (8) from the
ends of the connecting rods. Push the connecting rods away from the crankshaft.
6. Remove the bolts and remove main bearing caps (7) from the crankshaft.
2/8
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7. Remove thrust plates (9) from the center main bearing journal.
8. Fasten a hoist to crankshaft (10) with tooling (B). Remove crankshaft (10) from the engine
block. The weight of the crankshaft is 159 kg (350 lb).
9. Use Tool (C) to remove outer gear (2) from the end of the crankshaft.
10. Use a hammer and chisel to remove the spacer from the crankshaft.
11. Use Tool (D) to remove the gear alignment dowel from the crankshaft.
12. Use Tool (C) to remove inner gear (11) from the end of the crankshaft.
3/8
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NOTE: If new main bearings are not to be installed, put identification on the old main bearings as
to their location in the cylinder block and to which main bearings caps they belong.
13. Remove main bearings (13) from the cylinder block and the main bearing caps.
Install Crankshaft
1. If the dowel was removed from the flywheel end of the crankshaft, install it in the crankshaft to
a maximum dimension of 6.4 mm (.25 in).
2. Heat the crankshaft gears to a maximum temperature of 205° C (400° F).
3. The centerline of inner gear key must be in alignment with the centerline of the dowel hole
within 0.51 mm (.020 in). Install crankshaft inner gear (14) on the crankshaft.
4. Install the spacer on the crankshaft.
5. Install the dowel in the crankshaft. The dowel must be extended no more than 4.1 ± 0.5 mm
(.16 ± .02 in) from the surface of the crankshaft.
NOTE: The dowel in the crankshaft must be in alignment with the notch in crankshaft gear (15).
6. Make sure the "V" mark on the crankshaft gear is toward the outside, and install crankshaft gear
(15).
4/8
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7. Thoroughly clean the cylinder block and main bearing caps.
NOTICE
Make sure the upper and lower halves of the main bearings are
installed so the bearing tabs fit into the notch in the cylinder block and
main bearing caps.
NOTE: Install the main bearings dry when the clearance checks are made. Put clean engine oil on
the main bearings for final assembly.
8. Install the upper half of main bearings (13) (bearings with oil holes) in the cylinder block.
9. Fasten a hoist to crankshaft (10) with tooling (B) and put it in position on the cylinder block.
Make sure the "V" marks on the crankshaft and the idler gear are in alignment and the "K" marks
on the camshaft gear can be seen at the outer edges of the idler gear. The timing gears are in
correct position.
10. Install thrust plates (9) on both sides of the center main bearing journal. Make sure the plates
are installed with side marked "BLOCK SIDE" toward the cylinder block.
11. Install the lower half of main bearings (13) in main bearing caps (7).
5/8
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NOTE: When the bearing clearance is checked and the engine is vertical position, such as in the
vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main
bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight
of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not
necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position
to check clearances.
12. Put a piece of Plastigage on the surface of the lower main bearing half.
13. Install main bearing caps (7) with the arrow on the bottom surface of the cap toward the front
of the cylinder block. Also, the stamped number on the cap must be the same as the cast number
on the left side of the cylinder block.
NOTICE
Do not use an impact wrench to tighten the bolts the additional 120 ± 5
degrees of a turn more.
14. Put 2P2506 Thread Lubricant on the threads of the main bearing cap bolts. Install the bolts
and tighten them as follows:
a. Tighten the tab end bolt to a torque of 258 ± 14 N·m (190 ± 10 lb ft).
b. Tighten the opposite end bolt to a torque of 258 ± 14 N·m (190 ± 10 lb ft).
c. Turn the opposite end bolt an additional 120 ± 5 degrees.
d. Turn the tab end bolt an additional 120 ± 5 degrees.
15. Remove the main bearing caps and measure the Plastigage. The main bearing clearance must
be 0.091 - 0.185 mm (.0036 - .0073 in) with new bearings. Maximum clearance with used
bearings is 0.25 mm (.010 in).
16. Install the main bearing caps again and tighten the bolts as in Step 13.
6/8
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17. Put the connecting rods in position on the crankshaft. Install rod bearing caps (8) with the bolts
and nuts to hold them. See the topic, "Remove & Install Connecting Rod Bearings", for the correct
bolt tightening procedure and bearing clearance check procedure.
18. Check the crankshaft end play with tooling (E). The end play is controlled by the thrust plates
on the center main bearing. End play with new plates is 0.15 - 0.51 mm (.006 - .020 in). The
maximum permissible end play with used bearings is 0.89 mm (.035 in).
19. Use Tool (A) to turn the engine back to its vertical position as shown.
20. Install tube assembly (2) on the engine.
21. Fasten a hoist to and install air cleaner group (1), pipe assembly (3), bracket assembly (4) and
lifting plate (5) as a unit on the engine.
End By:
a. install oil filter base
b. install engine oil cooler
c. install flywheel housing
d. install timing gear cover
Wed Dec 2 15:17:28 UTC+0800 2020
7/8
2020/12/2

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Shutdown SIS
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16H MOTOR GRADER MACHINE SYSTEMS
SENR85990001
Conventional Duo-Cone Seals
SMCS - 7561-016
Assembly and Installation
Introduction
Disconnect batteries before performance of any service work.
This instruction gives the procedure for installing Conventional Duo-Cone Seals.
It is most important that correct assembly and installation procedures are followed when Duo-
Cone Seals are used. Many of the Duo-Cone Seal failures are the direct result of one or more
mistakes made during assembly or installation of the seal components.
1/7
2020/12/2

(1) Seal
(2) Rubber Toric Ring
(3) Housing Retaining Lip
(4) Housing Ramp
(5) Seal Ring Ramp
(6) Seal Ring Face
(7) Seal Ring Ramp
(8) Seal Ring Retaining Lip
(9) Installation Tool
1. Remove any oil film, dust or other foreign matter from toric rubber rings (2) and from ramps (4)
and (7) and lips (3) and (8) of both seal rings (1) and housings (5). Use isopropyl alcohol and
clean cloth or paper towels for wiping.
NOTICE
2/7
2020/12/2

Never permit oil to get on the toric rings or ramps before both seal
rings are put together in their final assembled position (Step 10).
Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing
the vapors in enclosed areas without adequate ventilation and do not
smoke. Do not use near open flame or welding operations or other
heated surfaces exceeding 482°C (900°F).
2. Put toric ring (2) on seal ring (1), at the bottom of seal ring ramp (7) and against retaining lip
(8).
NOTICE
3/7
2020/12/2

Caterpillar cat 16 h na motor grader (prefix 6zj) service repair manual (6zj00001 and up)

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