773E Off-Highway Truck PRB00001-UP (MACHINE) POWERED BY 3412E Engine(M...

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Product: QUARRY TRUCK

Model: 773E QUARRY TRUCK PRB
Configuration: 773E Off-Highway Truck PRB00001-UP (MACHINE) POWERED BY 3412E Engine

Disassembly and Assembly

3408E and 3412E Engines for Caterpillar Built Machines
Media Number -RENR2336-06 Publication Date -01/08/2018 Date Updated -10/08/2018

i02355730

Unit Injector - Remove

SMCS - 1290-011

Removal Procedure
Table 1
Tool Part Number Part Description Qty
A 131-3921 Puller Assembly 1
B 4C-4057 Tube 1
C 1U-5718 Vacuum Pump 1
D 1U-5814 Bottle Assembly 1

Start By:

A. Evacuate the fuel system.

B. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Evacuating Fuel From The Fluid Manifold

1. Prior to removing the injector, evacuate as much fuel as possible from the manifold.

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Illustration 1 g00484352

(A) Top view. (B) Front view.

2. Remove the fuel line (1) that is routed from the T-connector on the front of the engine to the
front of the manifold.

3. Place the loose end of the fuel line (1) into an appropriate container in order to collect the fuel.

4. Use an air gun with a rubber tip in order to evacuate the fuel with pressurized air.

a. Place the rubber tip of the air gun in the fuel line opening of the manifold.

b. Approximately 138 to 207 kPa (20 to 30 psi) of pressurized air should be enough to
evacuate the fuel from both manifolds without damaging the injectors.

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5. When the fuel in the system has been evacuated, reconnect the fuel line to the manifold.

6. Fuel and oil will still need to be removed from the cylinder after the injectors are removed.

Removal Of The Injector

NOTICE

The injector tip was made very hard to provide a long life. This
hardness also makes the tip brittle. Side loading during the installation
or striking the tip against a hard object or dropping the injector can
cause the tip to break or crack. Installing an injector with a cracked tip
may result in major engine damage.

NOTICE

After removing the injector, a certain amount of fuel and oil runs down
the cylinder. Most of the fuel must be removed before the injector is
reinstalled in order to avoid the possibility of hydraulic lock and severe
engine damage when the engine is next cranked. In order to minimize
the amount of fuel running into the cylinder, the fuel supply shutoff
valve should be closed before injector removal.

NOTICE

The injector must not be damaged when the injector is returned for a
warranty. The injector must also be returned in the original protective
packaging. The warranty or remanufacturing core credit may be
reduced or denied if the injector is not returned in the original
packaging. An injector with possible damage to the tip must be
returned in the original package. The damaged injector must be clearly
identified as having "possible tip damage".

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Illustration 2 g00811184

(2) Terminals of wire harness

(3) Bolts

(4) Adapter

(5) Injector jumper tube

(6) Socket head cap screw

(7) Bolt

(8) Clamp

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(9) Injector

(10) O-ring seal

(11) Injector sleeve

(12) O-ring seal

1. Close the shut off valve for the fuel supply.

2. Remove the valve cover assembly.

Illustration 3 g00811209

3. Mark the terminals of the wire harness (2) with the number of the cylinder. This will help to
ensure correct reassembly.

4. Remove the terminals of the wire harness (2) for the unit injector.

5. Remove the bolts (3) from the injector jumper tube (5) . Remove socket head cap screws (6)
from the adapter (4) . Remove the injector jumper tube (5) and adapter (4) .

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Illustration 4 g00811215

6. Remove O-ring seals (13) and (14) . Remove the clamp bolt (7) and the clamp (8) .

NOTICE

The correct injector removal procedures and tooling specified in this

Special Instruction MUST ALWAYS be used. Any leverage applied
below the injector valve body can cause deformation of the poppet
valve bore and possible failure. Do NOT pry on the injector.

7. Remove the injector by using one of the following methods:

Illustration 5 g00337715

This is an example of a manual removal of the injector.

a. When you are removing the injector by hand, grasp the injector and twist. The carbon
that has built up on the seat should break loose. The injector can then be lifted out. If the
seat cannot be broken loose by hand, the 131-3921 Injector Puller should be used.

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Illustration 6 g00811227

131-3921 Injector Puller

(15) 093-0386 Plated Washer

(16) 131-8196 Handle

(17) 131-8198 Stud Assembly

(18) 131-8197 Bridge Assembly

(19) 0S-1616 Bolts

(20) 4B-4276 Washers

Illustration 7 g00337716

This photo shows the proper position of the injector puller.

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b. Refer to Illustration 7. Install the 131-3921 Injector Puller on the injector. Install the 0S-
1616 Bolts in the threaded holes in the top of the injector.

c. Turn the 131-8196 Handle in order to remove the injector.

Illustration 8 g00811298

8. Remove the O-ring Seal (10) and the O-ring Seal (12) from the injector.

9. Repeat Step 3 through Step 8 for the remainder of the injectors.

Copyright 1993 - 2020 Caterpillar Inc. Wed Mar 18 11:23:55 PDT 2020
All Rights Reserved.
Private Network For SIS Licensees.

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