Caterpillar cat 16 g motor grader (prefix 93u) service repair manual (93u01179 02678)

Service Repair Manual
Models
16G MOTOR GRADER

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Product: MOTOR GRADER
Model: 16G MOTOR GRADER 93U
Configuration: 16G MOTOR GRADER 93U01179-02678 (MACHINE) POWERED BY 3406 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
SENR64090010
Fuel Injection Pump Housing
SMCS - 1253-015; 1253-016
Disassemble Fuel Injection Pump Housing
Start By:
a. disassemble governor
b. remove fuel injection pumps
1. Remove the six lifters from the fuel pump housing.
2. Remove rack (1) and camshaft (2) from the fuel pump housing. If necessary, use a soft hammer
to push the camshaft out the governor end.
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2020/12/6
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3. Use Tool (A) and remove the three camshaft bearings from the fuel pump housing.
4. Remove rack bearing (4) and the other rack bearing from the fuel pump housing.
5. Remove dowel (3) from the fuel pump housing.
6. Remove bolts (6), cover (5) and the gasket from the fuel pump housing.
Assemble Fuel Injection Pump Housing
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1. Install gasket (7) and cover (5) on the side of the fuel pump housing.
2. Use Tool (B) and install the D shaped rack bearing into the governor and fuel pump drive side
of the fuel pump housing 87.0 ± 0.5 mm (3.42 ± .02 in) from outside surface (X).
3. The inside flat diameter after assembly must be 11.178 ± 0.050 mm (.440 ± .002 in) and the
inside large diameter must be 12.767 ± 0.058 mm (.503 ± .002 in).
4. Install dowel (3) in the fuel pump housing 6.0 ± 0.5 (.24 ± .02 in) above the outside surface.
5. Use Tool (C) and install the rack bearing into the fuel pump housing 7.16 ± 0.13 mm (.282
± .005 in) below the surface of the pump housing.
6. The inside diameter of the bearing after assembly must be 12.746 ± 0.045 (.502 ± .002 in).
7. Use Tool (A) and install the three camshaft bearings in the fuel pump housing with the oil holes
in the bearings 30 ± 3 degrees from the horizontal center line toward the plugged holes in the fuel
pump housing.
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8. The inside diameter of all three bearings after assembly must be 68.399 ± 0.038 mm (2.6905
± .0015 in).
9. Make sure bearing (8) on the governor and fuel pump drive is installed 1.0 ± 0.5 mm (.04 ± .02
in) below surface (Y).
10. Make sure middle bearing (9) is 218 ± 0.3 mm (8.6 ± .01 in) below surface (Y).
11. Make sure bearing (10) governor side is 1.00 ± 0.25 mm (.040 ± .010 in) below the outside
surface.
12. Remove the plugs from the side of the fuel pump housing. The oil holes in the bearings must
in alignment with holes (11) in the fuel pump housing. If the bearings are not in alignment,
remove them and install again.
13. Make an alignment of rack (1) and install it in the fuel pump housing.
14. Install the six lifters in the fuel pump housing. Make sure the pins in the lifter are on the same
side as the dowels in the fuel pump housing.
End By:
a. install fuel injection pumps
b. assemble governor
Sun Dec 6 09:05:11 UTC+0800 2020
4/5
2020/12/6

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SENR64090011
Fuel Ratio Control
SMCS - 1278-010; 1278-017
Remove & Install Fuel Ration Control
1. Disconnect air line (1) from the fuel ratio control.
2. Remove wire seal (4) from the bolts.
3. Remove bolts (3) that hold fuel ratio control (2).
4. Remove the fuel ratio control by pulling down and out from the collar.
NOTE: The following steps are for the installation of the fuel ratio control.
5. Put fuel ratio control (2) in position on the governor. Make sure the valve head of the fuel ratio
control is connected in the groove of the collar.
6. Install bolts (3) that hold the fuel ratio control to the governor. Connect air line (1) to the fuel ratio
control.
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7. To make an adjustment to the fuel ratio control, see the topic "Governor Adjustment For The Air
Fuel Ratio Control" in, Testing & Adjusting Manual SENR6471.
8. Install wire seal (4) on the bolts with Tool (A).
Disassemble & Assemble Fuel Ratio Control
Start By:
a. remove fuel ratio control
1. Put Tool (A) in a vise so that the station being used is not over the vise jaw. Place the fuel ratio
control over the pins in Tool (A). Remove bolts (3) and remove cover (26) and gasket (24).
NOTICE
There is spring force behind cover (7). Hold cover (7) in position, and
slowly remove the bolts that hold it to release the spring force.
2/4
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2. Remove bolts (6). Remove cover (7) from housing (10).
3. Remove nut (5) and stop (4) from cover (7).
4. Remove spring (8), washer (9) and diaphragm (21) from retainer (25). Remove retainer (25) from
housing (10).
5. Remove tube (1) from the end of extension (19). Remove nut (2) from extension (19) and remove
the extension from retainer (25). Remove valve (16), spring (22) and O-ring seal (23) from the
extension.
6. Remove spring (20), retainer (18) and spring (17) from housing (10).
7. Remove piston (12) and valve assembly (14) from the housing.
8. Use Tool (B) and remove snap ring (13) and washer (15) from the valve assembly. Remove piston
(12) from the valve assembly.
9. Remove seal (11) from piston (12).
10. If necessary, remove the stem portion from valve assembly (14).
11. Clean and inspect all parts. Make a replacement of all parts that are worn and damaged.
NOTE: The following steps are for the assembly of the fuel ratio control.
12. If removed during disassembly, assemble the stem portion of valve assembly (14) on the valve
using 9S3265 Retaining Compound.
13. Lubricate seal (11) lightly with the lubricant being sealed. Put seal (11) on piston (12) and put
piston (12) on valve assembly (14).
14. Put washer (15) in position on the valve assembly and use Tool (B) to install snap ring (13) on
the valve assembly.
15. Place housing (10) on Tool (A), and put Tool (C) into the bore of the housing. Lubricate Tool
(C) with clean engine oil.
16. Push piston (12) into position with a smooth swift motion. Remove Tool (C) from the housing.
Place spring (17), retainer (18) and spring (20) in housing (10).
17. Put O-ring seal (23) on extension (19). Put spring (22) and valve (16) in position on the
extension.
18. Lubricate the bore of retainer (25) and O-ring seal (23) with clean engine oil. Install extension
(19) in retainer (25). Install nut (2) on extension (19).
19. Place tube (1) on the end of extension (19). Heat the tube to a temperature of 149°C (300°F) or
until the tube shrinks.
20. Put diaphragm (21), washer (9) and spring (8) in position on retainer (25). Install retainer (25) in
housing (10).
21. Install stop (4) and nut (5) in cover (7). Hold retainer (25) in position and install cover (7) on
housing (10). Install bolts (6) that hold the cover and tighten them to a torque of 9 ± 3 N·m (7 ± 2 lb
ft).
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22. Make a replacement of gasket (24) and install the gasket and cover (26) with bolts (3).
End By:
a. install fuel ratio control
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Dec 6 09:06:07 UTC+0800 2020
4/4
2020/12/6

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SENR64090012
Fuel Injection Lines
SMCS - 1252-010
Remove & Install Fuel Injection Lines
If fuel line clamps are not installed in their exact location, vibration can
cause the fuel lines to break and cause possible personal injury, or
damage to the machine.
1/2
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1. Disconnect front fuel injection lines (1), disconnect middle fuel injection lines (2) and rear fuel
injection lines (3) from the fuel injection pump and the cylinder head assembly.
2. Remove fuel injection lines (1), (2) and (3). Put caps or plugs on all fuel line connections to
keep foreign material out of the fuel system.
3. If a separation of the fuel lines has to be made, make sure the exact location of the clamps are
marked for assembly purposes. Remove the clamps and make a separation of the fuel lines.
NOTE: The following steps are for the installation of the fuel injection lines.
4. Remove the caps or plugs for the fuel injection line connections.
5. If removed, connect the fuel lines with the clamps. Make sure the clamps are installed back in
their correct location. Use Tool (A) to tighten the clamp bolts to a torque of 2.3 N·m (20 lb in).
For more information, see Specifications Manual SENR6470, of Testing & Adjusting Manual
SENR6471.
6. Install front fuel injection lines (1) on the fuel injection pump and cylinder head assembly.
7 Install middle fuel injection lines (2) on the fuel injection pump and the cylinder head assembly.
8. Install rear fuel injection lines (3) on the fuel injection pump and the cylinder head assembly.
9. Tighten the fuel injection line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
Sun Dec 6 09:07:03 UTC+0800 2020
2/2
2020/12/6

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SENR64090013
Fuel Transfer Pump
SMCS - 1256-010; 1256-017
Remove & Install Fuel Transfer Pump
1. Disconnect fuel line (3) from the fuel transfer pump. Cap or plug immediately.
2. Disconnect fuel line (4) from the fuel transfer pump. Cap or plug immediately.
3. Remove bolts (1).
4. Remove fuel transfer pump (2). Check the condition of the O-ring seal on the fuel transfer
pump. If necessary, make a replacement. Put clean engine oil on the O-ring seal when assembling
fuel transfer pump.
NOTE: For installation of the fuel transfer pump, reverse the removal steps.
Disassemble & Assemble Fuel Transfer Pump
Start By:
a. remove fuel transfer pump
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1. Remove seal (1) from the fuel transfer pump.
Cover (2) is under spring tension. Remove the bolts that hold cover (2)
slowly to prevent injury.
2. Remove bolts (3) and cover (2) the housing.
3. Remove seals (4) and valve (5) from cover (2).
4. Remove spring (6) from the piston.
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NOTICE
Mark the orientation of valve (8) as to its location in the housing.
5. Remove washer (7) and valve (8) from the housing.
6. Remove piston (9) and sleeve (10) from the housing.
7. Remove seal (11) from sleeve (12).
8. Remove guide and tappet assembly (13) from the housing.
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9. Remove seal (14) from guide (15).
NOTICE
If tappet (17) or guide (15) are damaged or worn, they must be
replaced as a unit.
10. Remove ring (16) from tappet (17) and the tappet from guide (15).
11. Remove the bolts and cover (18) from the housing.
12. Remove seal (19) from cover (18).
4/5
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13. Remove valve (20) from the housing.
NOTE: The following steps are for the assembly of the fuel transfer pump.
14. Install valve (20) in the housing. Put clean fuel on seal (19) and install it on cover (18). Install
the cover on the housing.
15. Install tappet (17) in guide (15). Install ring (16) on tappet (17) to hold the tappet in the guide.
16. Put clean fuel on seal (14) and install it on the guide and tappet assembly (13). Install guide
and tappet assembly (13) in the housing.
17. Put clean fuel on seal (11) and install it on sleeve (12). Install sleeve (12) in the housing.
18. Install piston (9) in the housing. Install valve (8) and washer (7) in the housing. Install spring
(6) in the piston.
19. Install valve (5) in cover (2).
20. Put clean fuel on seals (4) and put them in position on cover (2). Install cover (2) on the
housing.
21. Put seal (1) in position on the fuel transfer pump.
End By:
a. install fuel transfer pump
Sun Dec 6 09:07:59 UTC+0800 2020
5/5
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SENR64090014
Oil Filter & Base Assembly
SMCS - 1306-017; 1306-010; 1318
Remove & Install Oil Filter & Base Assembly
1. Use Tool (A) to remove oil filter (3) from oil filter base assembly (2). Upon installation, follow
the instructions on the oil filter for the correct installation procedure.
2. Remove four bolts (1).
3. Remove oil filter base assembly (2).
4. Check the gasket between the oil filter base and the adapter for wear or damage. Replace with a
new part if necessary.
NOTE: For installation of the oil filter & base, reverse the removal steps.
5. Check the engine oil level. See the Operation & Maintenance Manual.
1/3
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Disassemble & Assemble Oil Filter Base
Start By:
a. remove oil filter base
1. Remove bolts (1) and cover (2) from oil filter base.
2. Remove spring (3) and valve (4) from oil filter base.
3. Remove bolts (5) and cover (6).
4. Remove gasket (7) and replace if necessary.
NOTE: For assembly of the oil filter base, reverse the disassembly steps.
End By:
2/3
2020/12/6

a. install oil filter base
Sun Dec 6 09:08:54 UTC+0800 2020
3/3
2020/12/6

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SENR64090015
Shutoff Solenoid
SMCS - 1259-010
Remove & Install Shutoff Solenoid
1. Disconnect wires (3) to shutoff solenoid (4). (Previously disconnected).
2. Remove two bolts (1) and spacers (2).
3. Remove shutoff solenoid (4).
NOTE: For installation of the shutoff solenoid, reverse the removal steps.
Sun Dec 6 09:09:50 UTC+0800 2020
1/1
2020/12/6

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SENR64090016
Exhaust Manifold
SMCS - 1059-010
Remove & Install Exhaust Manifold
Start By:
a. remove turbocharger
Typical Example
1. Loosen hose clamp (1). Remove bolt (2) that holds the pipe to the engine block.
2. Turn breather tube (3) away from the exhaust manifold.
Typical Example
1/2
2020/12/6

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3. Remove nuts (4) and the spacers that hold the exhaust manifold to the cylinder head.
4. Remove exhaust manifold (5) and the gaskets.
NOTE: The following steps are for the installation of the exhaust manifold.
5. To install, put new gaskets in position on the cylinder head. Put exhaust manifold (5) in position
on the studs.
6. Put 5P3931 AntiSeize Compound on the studs. Install spacers and nuts (4) that hold the
exhaust manifold. Tighten the nuts in the numerical sequence shown to a torque of 51 ± 7 N·m (38
± 5 lb ft).
7. Put breather tube (3) in position and install pipe clamp with bolt (2) and hose clamp (1).
End By:
a. install turbocharger
Sun Dec 6 09:10:46 UTC+0800 2020
2/2
2020/12/6

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SENR64090017
Vibration Damper
SMCS - 1205-010
Remove & Install Vibration Damper
1. Attach a strap and a suitable lifting device to vibration damper (1).
2. Remove six bolts (2) and washers. Remove vibration damper (1). The weight of the vibration
damper is approximately 25 kg (55 lb).
NOTE: For installation of the vibration damper, reverse the removal steps.
Sun Dec 6 09:11:42 UTC+0800 2020
1/1
2020/12/6

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SENR64090018
Water Temperature Regulator
SMCS - 1355-010
Remove & Install Water Temperature Regulator
1. Drain the coolant from the engine below the level of the water temperature regulator into a
suitable container for storage or disposal.
Turbocharger outlet hose removed only for photographic purposes.
2. Disconnect the upper radiator hose (previously removed).
3. Remove two bolts and elbow (2). Remove the gasket and O-ring seal from the elbow. Check the
O-ring and gasket for wear or damage. Replace if necessary.
4. Disconnect turbocharger water line (1) from the cover assembly.
5. Remove three bolts (3) that hold the water temperature regulator housing (4) to cylinder head
assembly (5).
1/2
2020/12/6

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