Caterpillar Cat 621F WHEEL SCRAPER (Prefix 5JK) Service Repair Manual (5JK00001 and up)

1
Service Repair Manual
Models 621F WHEEL SCRAPER
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090022
Rocker Shaft Assemblies Push Rods SMCS - 1102
1208-012 1208-011 Remove Rocker Shaft Assemblies
Push Rods
Start By a. remove valve covers NOTE Call out
(1) and (2) are not used in this removal
procedure. Call outs begin with number (3).
1. Remove bolts (3) that hold the valve cover
bases to the cylinder head assembly. Remove valve
cover bases (4).
3
NOTICE To prevent damage to the fuel injection
nozzle, hold adapter assembly (5) in position at
the of injection nozzle (6) when fuel line nut
(7) is loosened or tightened.
4
2. Use Tool (A) and a 7/8 5P0328 Crow Foot ( in)
to loosen the fuel injection line nut at the
nozzle end.
3. Use Tool (B) to loosen the nut at the fuel
injection line adapter end. Remove inner fuel
injection lines (8). Install caps and plugs on
all fuel injection line openings to keep dirt out
of the fuel system.

1. Remove bolts (9) that hold the rocker shaft
   assemblies to the cylinder head assembly.
2. Remove rocker shaft assemblies (10).

6. Put identification marks on the push rods as
to their location in the engine. Remove push rods
(11).
5
7. Put identification marks on the bridges as to
their location in the engine. Remove bridges (12)
from the dowels on the cylinder head assembly.
Install Rocker Shaft Assemblies Push Rods

• Put clean engine oil on the bridges and dowels.
• NOTE Install the original bridges in their
  respective locations. New bridges can be mixed.
• Install bridges (1) on the bridge dowels. While
  firmly pressing 0.5 to 4.5 kg (1 to 10 lb)
  straight down on the top contact surface of the
  bridge, turn the adjusting screw clockwise until
  contact is made with the valve stem. Turn the
  screw an additional 1/31/2 20 to 30 degrees ( to
  of 1 hex on nut). This will straighten the dowel
  in the guide and compensate for the slack in the
  threads. Hold the adjusting screw in this
  position and tighten the locknut to a torque of
  30 4 Nm (22 3 lb ft).

NOTE Install the original push rods in their
respective locations in the engine. New push rods
can be mixed.
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3. Install push rods (2).

1. Put rocker shaft assemblies (3) in position on
   the cylinder head assembly.
2. Put clean engine oil on the threads of the bolts
   that hold the rocker shaft assemblies in place.
   Tighten the bolts first to a torque of 270 25
   Nm (200 18 lb ft). Start with the bolt in the
   center of the rocker shaft assembly. Tighten the
   bolts again to a torque of 450 20 Nm (330 15
   lb ft). Tighten the bolts again by hand to a
   torque of 450 20 Nm (330 15 lb ft).

NOTICE Do not cause damage to the O-ring seals on
the inner fuel lines.
6. Install inner fuel injection lines (4).
Tighten the fuel injection line adapter nuts (5)
to a torque 40 7 Nm (30 5 lb ft) with Tool
(A). NOTICE Do not let the tops of the fuel
nozzles turn when the fuel lines are tightened.
The nozzles will be damaged if the top of the
nozzles turns in the body.

1. Tighten fuel injection line nut (6) to a torque
   of 40 7 Nm (30 5 lb ft) with Tool (B) and a
   7/8 5P0328 ( in) Crow Foot wrench.
2. Make adjustments to the valves until the intake
   valve clearance is 0.38 mm (.015 in) and the
   exhaust valve clearance 0.76 mm (.030 in). See
   the topic "Valve Clearance Setting" in Testing

8
Adjusting Manual SENR6471. Tighten the locknut to
a torque of 30 4 Nm (22 3 lb ft) and check
the adjustments.
9. Install valve cover bases (7) on the cylinder
head assembly. Install bolts that hold the valve
cover bases in place. Tighten the bolts to a
torque of 14 3 Nm (10 2 lb ft). End By a.
install valve covers
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090023
Rocker Shaft Assemblies SMCS - 1102-015
1102-016 Disassemble Rocker Shaft
Assemblies Start By a. remove rocker shaft
assemblies and push rods

1. Remove retainer (2) from the end of the shafts.
2. Remove the washers and rocker arms (1).

3. Remove pins (6) that hold the brackets to each
end of the shaft. NOTE The center bracket does
not have a pin.
10
4. Remove bracket (3), rocker arm (4) and spring
(5).
Assemble Rocker Shaft Assemblies

1. Put clean engine oil on the shaft.
2. Install the bracket and rocker arms for the
   center bracket.
3. Install spring (1), rocker arm (2) and bracket
   (3). Install the pin that holds the brackets on
   each end of the rocker shaft. Install the pin
   until it extends 12.7 1.0 mm (.50 .04 in)
   from the surface of the bracket.

4. Install rocker arm (4) on each end of the
shaft. Install washers (5) as needed to get an
assembled clearance of .030 to 1.40 mm (.0012 to
.055 in) at each end of the shaft. Install the
retainer on each end of the shaft. End By a.
install rocker shaft assemblies and push rods
Copyright 1993 - 2021 Caterpillar Inc. All Rights
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090024
Valve Lifters SMCS - 1209-011 1209-012 Remove
Valve Lifters
Start By a. remove valve covers
NOTICE
12
Do not let the tops of the fuel nozzles turn when
the fuel lines are loosened. The nozzles will be
damaged if the top of the nozzles turns in the
body.

1. Loosen the fuel injection line nut at the nozzle
   end with tool (A) and a 7/8 5P0328 ( in) Crow
   Foot Wrench.
2. Loosen the fuel line nut at the fuel injection
   line adapter with Tool (B). Remove inner fuel
   injection lines (1). Install caps and plugs on
   all fuel line openings to keep dirt out of the
   fuel system.

• Typical Example
• NOTE If necessary, use Tool (D) to turn the
  engine so the valves do not make contact with the
  pistons when the valves are opened with Tool (C)
  to remove the push rods.
• Put compression on the valve springs with Tool
  (C), and remove push rods (2). Put identification
  marks on the push rods as to their location in
  the engine.
• Push the push rod end of the rocker arms down.

• Remove the intake valve lifter with Tool (E) as
  follows
• Install 5P2685 Nut (3) and 5P6601 Collet (4) on
  5P2408 Outer Handle Assembly (5).
• Install 5P6599 Inner Handle Assembly (6) in
  5P2408 Outer Handle Assembly (5).

13
Typical Example c. Install Tool (E) in the
intake valve lifter. Hold the 5P2408 Outer Handle
Assembly and tighten the 5P6599 Inner Handle
Assembly until the 5P6601 Collet is tight against
the inside of the intake valve lifter.
Typical Example d. Remove intake valve lifters
(7) from the cylinder block with Tool (E). Put
identification marks on the lifters as to their
location in the engine.

• Typical Example
• Remove the exhaust valve lifters with Tool (E) as
  follows
• Install 5P2685 Nut (3) and 5P6601 Collet (4) on
  5P2408 Outer Handle Assembly (5).
• NOTE The opening in the cylinder head assembly
  for the intake valve lifter is larger than the
  opening in the exhaust valve lifter side. The
  tooling and each valve lifter must be installed
  and removed from the intake valve lifter side.
• Install the outer handle assembly in the intake
  valve lifter side of the cylinder head assembly.
  Slide the flat area of 5P2408 Outer Handle
  Assembly (5) through the head casting and install
  the 5P6601 Collet in the exhaust valve lifters.

14

• Typical Example
• Install 5P6599 Inner Handle Assembly (6) in
  5P2408 Outer Handle Assembly (5). Hold the 5P2408
  Handle Assembly and tighten the 5P6599 Handle
  Assembly until the 5P6601 Collet is tight against
  the inside of the exhaust valve lifter.
• Pull the exhaust valve lifter up until the spring
  on the exhaust valve lifter is free from the
  cylinder block.
• Remove the 5P6599 Inner Handle Assembly. Slide
  the 5P2408 Outer Handle Assembly
• through the head casting and remove it from the
  intake valve lifter side of the cylinder head.

Typical Example f. Use a magnet and remove
exhaust valve lifters (8) from the intake valve
lifter side of the cylinder head assembly. Put
identification makes on the lifters as to their
location in the engine. 7. Remove the guide
springs from the lifters.
Install Valve Lifters
NOTE Steps 1 and 2 must be done to install
intake or exhaust valve lifters.
15
NOTICE Make sure guide spring (1) is not damaged
or worn. If the guide spring is damaged or worn,
replace the guide spring. See Guideline For
Reusable Parts, Form No. SEBF8066.
1. Install guide spring (1) on the valve lifters.
2. Put the intake or exhaust valve lifter in
position in 5P2395 Holder (5) of Tool (A).
Install 5P2685 Nut (4) and 5P2400 Compressor (3)
on 5P2408 Outer Handle Assembly (2). Install
the 5P2400 Compressor on the lifter over the
guide spring. NOTE Immerse the lifter assembly
in engine oil before installing it in the
cylinder block lifter bore. NOTE The opening in
the cylinder head assembly for the intake valve
lifter is larger than the opening in the exhaust
valve lifter side. All tooling and valve lifters
must be installed and removed from the intake
valve lifter side.
Typical Example 3. Install the exhaust valve
lifters with Tool (A) as follows
16
NOTE Be sure to install the original valve
lifter in their respective bores. New valve
lifters can be mixed. a. Install exhaust valve
lifter (6) and the handle assembly in the
cylinder head opening on the intake valve lifter
side. Slide the flat area of the 5P2408 Outer
Handle Assembly through the casting in the
cylinder head assembly.

• Typical Example
• b. Put the exhaust valve lifter in the valve
  lifter bore of the cylinder block. Install 5P6599
  Inner Handle Assembly (7) in the 5P2408 Outer
  Handle Assembly and push the exhaust valve lifter
  from Tool (A).
• c. Remove the 5P6599 Inner Handle Assembly from
  the 5P2408 Outer Handle Assembly. Slide the
  5P2408 Outer Handle Assembly to the intake valve
  lifter side of the cylinder head and remove it.
• Install the intake valve lifters with Tool (A) as
  follows
• NOTE Be sure to install original valve lifters
  in their respective bores. New valve lifters can
  be mixed.
• Install 5P6599 Inner Handle Assembly (7) in the
  5P2408 Outer Handle Assembly.
• Install the intake valve lifter into the valve
  lifter bore of the cylinder block with Tool (A).
  Use the 5P6599 Inner Handle Assembly to push the
  lifter from Tool (A). Remove Tool (A).

Typical Example
NOTICE If necessary use Tool (C) to turn the
engine so the valves do not make contact with the
pistons when the valves are opened with Tool (B)
to install the push rods.
17
5. Turn the rocker arms up and use Tool (B) to
install push rods (9).
NOTICE Do not let the tops of the fuel nozzles
turn when the fuel lines are tightened. The
nozzles will be damaged if the top of the nozzles
turn in the body.
6. Install inner fuel lines (10). Use Tool (D) to
tighten the nuts on the adapter assemblies in the
cylinder head assembly and use Tool (E) to
tighten the nuts on the fuel injection nozzles to
a torque of 40 7 Nm (30 5 lb ft). End By a.
install valve covers
Copyright 1993 - 2021 Caterpillar Inc. All Rights
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Sat Mar 20 093202 UTC0800 2021
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090025
Fuel Injection Nozzles Adapters SMCS -
1106-010 1254 Remove Install Fuel Injection
Nozzles Adapters
Start By a. remove valve covers
19
1. Use Tool (A) and disconnect fuel line (1) at
each end. Remove the fuel line from the engine.

• Use Tool (B) and remove retainer (2) from the
  adapter.
• Remove the fuel injection nozzles with Tool (C)
  as follows
• Install the 6V6983 Adapter and the 8T3199 Screw
  into nozzle assembly (3).
• Install the 8T3198 Tube over the 8T3199 Screw.
• Use the 1B4206 Nut on the 8T3199 Screw to pull
  the fuel injection nozzle (3).
• Remove compression seal (4) and carbon dam seal
  (8) from fuel injection nozzle (3).
• Use Tool (D) and remove adapter (6) from the
  cylinder head.
• Remove gasket (7) and seal (5) from adapter (6).
• NOTE The following steps are for the
  installation of the fuel injection nozzles and
  adapters.

20

• Use Tool (E) to clean the bore in adapter (6).
  Use an open end wrench or tap driver to turn Tool
  (E).
• Inspect seal (5) for damage or wear. Replace the
  seal if necessary.
• Put washer (7) and seal (5) in position on
  adapter (6).
• Put liquid soap in the bores of the cylinder head
  and on seals (5) in the adapters.
• Put 5P3931 Anti-Seize Compound on the threads of
  adapter (6) and install the adapter in the
  cylinder head assembly.
• Use Tool (D) and tighten the adapter to a torque
  of 205 14 Nm (150 10 lb ft).
• NOTICE
• Make sure the correct compression seal washer (4)
  is used when the nozzle assembly is installed in
  the adapter. Only copper washers are to be used
  with this adapter.

• Install compression seal washer (4) and use Tool
  (F) to install carbon dam seal (8) on the fuel
  injection nozzle.
• Put fuel injection nozzle (3) in position in the
  adapter and install retainer (2).
• Use Tool (B) to tighten retainer (2) to a torque
  of 48 7 Nm (35 5 lb ft).
• Install fuel line (1). Tighten the nuts on the
  fuel line with Tool (A) to a torque of 40 7 Nm
  (30 5 lb ft).
• End By
• a. install valve covers

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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090026

• Cylinder Head Assembly
• SMCS - 1100-011 1100-012
• Remove Cylinder Head Assembly
• Start By
• remove rocker shaft assemblies and push rods
• remove water temperature regulator
• remove aftercooler housing
• remove fuel injection lines
• remove exhaust manifold

• Typical Example
• Remove bolts (1) from the alternator bracket.
• Remove the bolts that hold plate (3) and remove
  the plate.
• Disconnect water line (2) from the air
  compressor.
• NOTE Turn the water line tee toward the lifting
  bracket in order to provide clearance to remove
  the head bolt.

22

• Remove bolts (4) and (5) that hold the cylinder
  head assembly to the cylinder block.
• Fasten a hoist and remove the cylinder head
  assembly. The weight is approximately 135 kg (300
  lb).
• NOTICE
• Do not put the cylinder head assembly down on a
  flat surface. This can cause damage to the fuel
  injection valves.

6. Remove the gasket and seals from the spacer
plate. Install Cylinder Head Assembly NOTE Be
sure a new gasket has been installed between the
spacer plate and the cylinder block. See topic,
"Remove Install Spacer Plate".
1. Thoroughly clean the spacer plate and the
bottom surface of the cylinder head assembly.
Install a new head gasket, new seals (1) and two
O-ring seals (2).

1. Fasten a hoist and put the cylinder head assembly
   (3) in position on the cylinder block.
2. Tighten the bolts in sequence shown in
   Illustration D11970.

23

• Large bolts (3/4 inch). Put 6V4876 Molycoat Paste
  Lubricant on bolt threads and between washers and
  underside of bolt heads.
• Small bolts (3/8 inch). See Step 4h.
• Install the cylinder head bolts and washers.
  Tighten the bolts in sequence shown.
• Tighten bolts 1 through 14 in number sequence to
  270 25 Nm (200 20 lb ft).
• Tighten bolts 1 through 14 in number sequence to
  470 20 Nm (345 15 lb ft).
• Tighten bolts 1 through 14 in number sequence
  again to 470 20 Nm (345 15 lb ft).
• Install the rocker arm shafts for the engine
  valves and the remaining (3/4 in) bolts and/or
  compression brake studs.
• Tighten bolts 15 through 26 in number sequence to
  270 25 Nm (200 20 lb ft).
• Tighten bolts 15 through 26 in number sequence to
  450 20 Nm (330 15 lb ft).
• Tighten bolts 15 through 26 in number sequence
  again to 450 20 Nm (330 15 lb ft).
• Tighten the thirteen small bolts (2) to 45 7
  Nm (33 5 lb ft).
• Make an adjustment to the valves to have a
  clearance of 0.38 mm (.015 in) for intake and
  0.76 mm (.030 in) for exhaust. Tighten the
  locknuts for the valve adjustment screws to a
  torque of 28 4 Nm (21 3 lb ft).
• Install the valve cover bases and the inner fuel
  lines. See topic, "Install Rocker Shaft
  Assemblies Push Rods".
• Install the valve covers. See topic, "Install
  Valve Covers".

Typical Example 8. Install plate (4).
24

• Connect the water line to the air compressor.
• Install bolts (5) for the alternator bracket. End
  By
• install exhaust manifold
• install fuel injection lines
• install aftercooler housing
• install water temperature regulator
• install rocker shaft assemblies and push rods

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Sat Mar 20 093354 UTC0800 2021
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090027
Spacer Plate SMCS - 1221-011 1221-012 Remove
Spacer Plate Start By a. remove cylinder head
assembly
1. Remove spacer plate (1) from the cylinder
block. NOTICE Do not cause damage to the dowels.
2. Remove the spacer plate gasket and two O-ring
seals.
Install Spacer Plate
26
1. Thoroughly clean the spacer plate and cylinder
block surface. Install two O-ring seals (1) in
the cylinder block.
NOTICE Both surfaces of the spacer plate, top of
cylinder block and both sides of the spacer plate
gasket must be clean and dry. Gasket adhesives or
other substances must not be used on these
surfaces.

• Install a new gasket between the spacer plate and
  cylinder block. Put spacer plate (2) in position
  on the cylinder block.
• Check cylinder liner projection. See topic,
  "Install Cylinder Liners". End By
• a. install cylinder head assembly

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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090028
Valves SMCS - 1105-011 1105-012 Remove Valves
Start By a. remove cylinder head assembly

• Use Tool (A) to compress springs (1).
• Remove the locks.
• Remove Tool (A), the valve, the rotocoil, and the
  spring.
• NOTE If a valve can be used again, put
  identification on the valve for location at
  installation.

28

1. Use Tool (B) to check spring force. The
   specifications for the spring are given in
   Specifications Manual, SENR6470.
2. Do Steps 1 through 4 again for the remainder of
   the valves.

Install Valves
1. Put clean engine oil on the valve stem.
Install washer (3), spring (2), rotocoil (1) and
the valve.

1. Use Tool (A) to compress the spring.
2. Install locks (4) with the thick end up.

Locks can be thrown from valve when compressor is
released, if they are not in their correct
position on the valve stem.
29

• Remove the compressor and hit the valve with a
  soft faced hammer to be sure locks are in their
  correct position on the valve.
• Do Steps 1 through 4 again for the remainder of
  the valves. End By
• a. install cylinder assembly

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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090029
Valve Seat Inserts SMCS - 1103-010 Remove
Install Valve Seat Inserts
Start By a. remove valves

• Use Tool (A) to remove the valve seat inserts
  from the cylinder head.
• Clean and remove any burrs from the valve seat
  bores.
• NOTE For reconditioning information of the
  cylinder head, see Service Training Meeting
  Guide, SESV1202.
• NOTE The following steps are for the
  installation of the valve seat inserts.

31
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3. Lower the temperature of the new valve seat
inserts. Use Tool (B) to install the new valve
seat inserts in the cylinder head. End By a.
install valves
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Product WHEEL SCRAPER Model 621F WHEEL SCRAPER
5JK Configuration 621F Wheel Tractor Scraper
5JK00001-UP (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
SENR64090030
Bridge Dowels SMCS - 1121-011 1121-012 Remove
Bridge Dowels
Start By a. remove valves
1. Use Tool (A) to remove bridge dowel (1).
Install Bridge Dowels
34
1. Use Tool (A) to install the bridge dowel. End
By a. install valves
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Reserved. Private Network For SIS Licensees.
Sat Mar 20 093737 UTC0800 2021
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Friend! Thank you very much for visiting. Full
manual if required, please enter the following
URL into your browser. https//www.aservicemanual
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