- Engines:
- 3408E (S/N: 7PR414-UP)
- 3412E (S/N: 4CR488-UP)
- Compactor:
- 836 (S/N: 7FR243-UP)
- Excavators:
- 5110 (S/N: 8HN99-UP; 7GN124-UP)
- Motor Grader:
- 24H (S/N: 7KK41-UP)
- Off-Highway Trucks:
- 769D (S/N: 5TR324-UP)
- 771D (S/N: 6JR104-UP)
- 773D (S/N: 7ER240-UP)
- 775D (S/N: 6KR108-UP)
- 771D (S/N: 6JR104-UP)
- Paving Products:
- PM-565 (S/N: 3TK113-UP)
- Track-Type Tractors:
- D9R (S/N: 8BL922-UP; 7TL701-UP)
- D10R (S/N: 3KR571-UP)
- Wheel Loaders:
- 988F (S/N: 2ZR471-UP)
- 990 (S/N: 4FR218-UP)
- Wheel Tractor:
- 834B (S/N: 7BR586-UP)
- Wheel Tractor-Scraper:
- 631E Series II (S/N: 1AB1680-UP; 1NB1396-UP)
- 633E Series II (S/N: 2PS1-UP)
- 637E Series II (S/N: 1FB532-UP)
- 651E (S/N: 4YR189-UP)
- 657E (S/N: 5YR223-UP; 6PR101-UP; 6TR201-UP; 7KR217-UP)
- 633E Series II (S/N: 2PS1-UP)
Introduction
This Special Instruction gives detailed instructions on the disassembly and assembly of the 144-0835 Unit Injector Hydraulic Pump . The 144-0835 Unit Injector Hydraulic Pump was not previously serviceable. The pump will have a kit that will contain serviceable parts. The rear bearing and the bearing kits for the pump will be serviceable on an individual basis.
Note: This instruction should also be used when you are servicing the former 134-9405 Unit Injector Hydraulic Pump .
Serviceable Parts
- 154-6732 Fuel Injection Pump Kit
- Control Piston
- Shaft
- Yoke
- Seal Kit
- Front Bearing
- Rotating Group
- Control Piston
- 154-6734 Bearing
- 154-6735 Bearing Kit
Required Tools
Contact the Caterpillar Dealer for the dimensions and specifications that are needed in order to fabricate the tools.
- FT-2606 Yoke Fixture
 | |
| Illustration 1 | g00295533 |
- Two FT-2607 Bearing Installation Tools
 | |
| Illustration 2 | g00295534 |
- FT-2608 Bearing Installation Tool
 | |
| Illustration 3 | g00295535 |
- FT-2609 Valve Block Positioner
 | |
| Illustration 4 | g00295536 |
- FT-2610 Driver Tube
 | |
| Illustration 5 | g00295537 |
- FT-2611 Bearing Support
 | |
| Illustration 6 | g00295538 |
- FT-2612 Bearing Removal Tool
 | |
| Illustration 7 | g00295539 |
Disassembly Of The 144-0835 Unit Injector Hydraulic Pump
- Start by removing the 128-3552 Unit Injection Hydraulic Pump and Mounting Gp from the engine.
Reference: Consult the Service Manual, SENR1063 for additional information.
Note: Do not disconnect the fuel transfer pump from the 128-3552 Unit Injection Hydraulic Pump and Mounting Gp before servicing. The coupling between the two pumps will be used later.
- Remove the four bolts (2) from the fuel transfer pump (1). Remove the fuel transfer pump (1) .
 | |
| Illustration 8 | g00295292 |
(1) Fuel Transfer Pump. (2) Bolts. | |
- Remove the four bolts (4) from the compensator (3). Remove the compensator (3) and the adapter. Do not adjust the compensator (3) .
 | |
| Illustration 9 | g00295294 |
(3) Compensator. (4) Bolt. | |
- Remove the four O-Ring seals (5) from the bottom side of the adapter.
 | |
| Illustration 10 | g00295295 |
(5) O-Ring Seals. (6) O-Ring Seals. | |
- Remove the four O-Ring seals (6) from the two housings.
- Remove the eleven bolts (8) from the valve block (7) .
 | |
| Illustration 11 | g00295297 |
(7) Valve Block. (8) Bolt. | |
- Remove the valve block (7), the control piston (10) and the housing gasket (9) from the pump group.
 | |
| Illustration 12 | g00295298 |
(7) Valve Block. (9) Housing Gasket. (10) Control Piston. | |
- Invert the pump group in order to remove the rotating group (11). Minor twisting may be necessary.
 | |
| Illustration 13 | g00295299 |
(11) Rotating Group. (12) Snap Ring. | |
- Install the FT-2610 Driver Tube (13) .
 | |
| Illustration 14 | g00295307 |
(13) FT-2610 Driver Tube | |
- Use the press (14) to remove the shaft (15) from the front bearing. Hold the pump housing while you are removing the shaft in order to prevent damage to the pump housing.
 | |
| Illustration 15 | g00295309 |
(13) FT-2610 Driver Tube . (14) Hydraulic Press. (15) Shaft. | |
- Remove the eight bolts (16) from the two bearing kit covers (17). Remove the covers (17) .
 | |
| Illustration 16 | g00295311 |
(16) Bolt. (17) Bearing Kit Cover. | |
- Remove the O-Ring seal (19) from the 154-6735 Bearing Kit (20) that is opposite the spring seat (18). Install the 4D-3120 Bolt (21) into the 154-6735 Bearing Kit (20) finger tight.
 | |
| Illustration 17 | g00295312 |
(18) Spring Seat. (19) O-Ring Seal. (20) 154-6735 Bearing Kit . (21) 4D-3120 Bolt . | |
- Thread the 4D-3120 Bolt (21) into the 154-6735 Bearing Kit (20) that is opposite the spring seat (18) until the bearing kit (20) is removed. An impact wrench may be used. Visually inspect the 154-6735 Bearing Kit (20). Replace the bearing with a new 154-6735 Bearing Kit only if the bearing is worn.
- Hold the yoke firmly so that no damage will occur during the removal of the bearing kit. Thread the 4D-3120 Bolt (21) into the second 154-6735 Bearing Kit on the spring side of the pump until the bearing kit is removed. An impact wrench may be used. Visually inspect the 154-6735 Bearing Kit . Replace the bearing with a new 154-6735 Bearing Kit only if the bearing is worn.
- Remove the yoke (22) .
 | |
| Illustration 18 | g00295313 |
(22) Yoke | |
- Remove the spring seat (18) and the spring.
 | |
| Illustration 19 | g00295314 |
(18) Spring Seat | |
- Remove the snap ring (24) and the front bearing (23) .
Note: Protect the housing surface by placing the face on a soft surface.
 | |
| Illustration 20 | g00295315 |
(23) Front Bearing. (24) Snap Ring. | |
- Remove the snap ring (26) and the shaft seal (25) .
 | |
| Illustration 21 | g00295316 |
(25) Shaft Seal. (26) Snap Ring | |
- Visually inspect the 154-6734 Bearing . Replace the bearing only if the bearing is worn. Do not remove the bearing as a part of the normal disassembly. Use the FT-2612 Bearing Removal Tool (27) and the press (14) in order to remove the 154-6734 Bearing .
Note: Protect the face of the valve block by placing the face on a soft surface.
 | |
| Illustration 22 | g00295317 |
(14) Hydraulic Press. (27) FT-2612 Bearing Removal Tool | |
Assembly Of The 144-0835 Unit Injector Hydraulic Pump
- Thoroughly clean both the housing and the valve block before reassembling the unit injector pump.
- Use the FT-2608 Bearing Installation Tool (28), the FT-2609 Valve Block Positioner (30), and the press (14) to install the 154-6734 Bearing (29) .
 | |
| Illustration 23 | g00295318 |
(14) Hydraulic Press. (28) FT-2608 Bearing Installation Tool . (29) 154-6734 Bearing . (30) FT-2609 Valve Block Positioner . | |
- Install the front bearing (23) and the snap ring (24) .
| | |
| Illustration 24 | g00295315 |
(23) Front Bearing. (24) Snap Ring. | |
- Install the spring, the spring seat (18) and the yoke (22) .
 | |
| Illustration 25 | g00295339 |
(18) Spring Seat. (22) Yoke. | |
- Use the FT-2606 Yoke Fixture (31), the FT-2607 Bearing Installation Tool (30) and the press (14) to install the spring side 154-6735 Bearing Kit (20) .
 | |
| Illustration 26 | g00295342 |
(14) Hydraulic Press. (20) 154-6735 Bearing Kit . (30) FT-2607 Bearing Installation Tool . (31) FT-2606 Yoke Fixture . | |
- Ensure that the outer race of the second 154-6735 Bearing Kit (20) is started in the pump housing that is opposite the spring. Use the two FT-2607 Bearing Installation Tools (30) and the press (14) to install the bearing kit into the pump housing that is opposite the spring. Moderately oil the yoke with clean engine oil. Ensure that the yoke moves freely.
 | |
| Illustration 27 | g00295343 |
(14) Hydraulic Press. (20) 154-6735 Bearing Kit . (30) FT-2607 Bearing Installation Tools . | |
- Install the two O-Ring seals (19) and the two bearing kit covers (17). Tighten the bolts (16) to a torque of 20 ± 1 N·m (15 ± 1 lb ft).
 | |
| Illustration 28 | g00295344 |
(16) Bolt. (17) Bearing Kit Cover. (19) O-Ring Seal. | |
- Install the FT-2611 Bearing Support (32) into the pump housing.
 | |
| Illustration 29 | g00295346 |
(32) FT-2611 Bearing Support | |
- Use the coupling (33) from the fuel transfer pump to press the shaft back into the proper position.
 | |
| Illustration 30 | g00295347 |
(14) Hydraulic Press. (32) FT-2611 Bearing Support . (33) Coupling. | |
- Install the rotating group (11) .
- Position the housing so that the internal end of the shaft (15) is angled downward.
- Slide the rotating group (11) over the shaft (15) and into the housing. Ensure that the shoes of the rotating group (11) are seated against the yoke.
- Once the rotating group is installed, turn the rotating group in order to ensure that the three pins (34) are still in the special notches. If the rotating group jams, the pins (34) need to be reinserted into the proper position. The three pins in the rotating group are held in the special notches with a "C" clip retaining ring. The "C" clip applies force against the inside diameter of the rotating group's cylinder block in order to hold the pins in position. See Illustration 32.
Show/hide table
Illustration 32 g00295349
(34) Pins
 | |
| Illustration 31 | g00295348 |
(11) Rotating Group. (15) Shaft. | |
- Install the housing gasket (9) .
 | |
| Illustration 33 | g00295352 |
(7) Valve Block. (9) Housing Gasket. (35) Large Middle Hole. | |
- Moderately oil the face of the valve block (7) with clean engine oil. Place the control piston onto the control shaft.
- Install the valve block (7) .
- Place a finger over the large middle hole (35) in the mounting surface of the valve block (7) in order to create a vacuum. This will hold the control piston in place while you are installing the valve block (7) .
- Ensure that the housing gasket (9) is not damaged while you are aligning the valve block (7) to the pins in the pump housing.
- Start the bolts (8) in the valve block (7) by hand.
 | |
| Illustration 34 | g00295353 |
(7) Valve Block. (8) Bolts. | |
- Torque the bolts (8) by alternating from all four sides. Torque the bolts (8) in the corners first. Tighten the bolts (8) to a torque of 27 ± 2 N·m (20 ± 1 lb ft).
- Install the four O-Ring seals (5) on the bottom side of the adapter.
| | |
| Illustration 35 | g00295295 |
(5) O-Ring Seals. (6) O-Ring Seals. | |
- Install the four O-Ring seals (6) on the two housings.
- Install the compensator (3) and the adapter as a unit vertically so that the O-Ring seals are not damaged. Tighten the bolts (4) to a torque of 7.45 ± .65 N·m (65.94 ± 5.75 lb in).
| | |
| Illustration 36 | g00295294 |
(3) Compensator. (4) Bolts. | |
- Moderately oil the shaft seal.
- Use the FT-2608 Bearing Installation Tool (36) to lower the shaft seal (25) below the edge of the bore.
 | |
| Illustration 37 | g00295354 |
(25) Shaft Seal. (36) FT-2608 Bearing Installation Tool . | |
Note: Step 20 through Step 22 defines the procedure for the installation of the shaft seal. These steps should be followed precisely. The shaft seal should be placed barely below the face of the housing. The snap ring should then be positioned against the seal. Both the snap ring and the seal should be driven into the bore together until the snap ring seats in the groove.
- Place the snap ring against the shaft seal below the edge of the bore.
- Use the FT-2608 Bearing Installation Tool (36) in order to lower the shaft seal (25) and the snap ring (26) until the snap ring (26) snaps into position.
 | |
| Illustration 38 | g00295356 |
(25) Shaft Seal. (26) Snap Ring. (36) FT-2608 Bearing Installation Tool . | |
- Install the fuel transfer pump (1) .
- Ensure that the coupling is installed.
- Tighten the bolts (2) to a torque of 16 ± 1 N·m (12.0 ± 0.5 lb ft).
- Use a 1/2 inch crowfoot wrench.
| | |
| Illustration 39 | g00295292 |
(1) Fuel Transfer Pump. (2) Bolts. | |
Priming The 144-0835 Unit Injector Hydraulic Pump
 | |
| Illustration 40 | g00313283 |
(1) Inlet | |
In order to prime the 144-0835 Unit Injector Hydraulic Pump , add a quart of engine oil to the reservoir of the pump through the inlet (1) before the hose is reassembled. This adds the necessary amount of oil to the hydraulic injection pump so that the engine will start without excessive cranking and wear.