Procedure for Installing the New Unit Injector Hydraulic Pump Gp on Certain C9 Engines {1714} Caterpillar

Engine

C9 (S/N: X3R1-UP)

Excavator

330D (S/N: RDA1-UP; KAB1-UP; GBC1-UP; PFC1-UP; NBD1-UP; R2D1-UP; GGE1-UP; NEF1-UP; B6H1-UP; EAH1-UP; LCJ1-UP; THJ1-UP; C5K1-UP; E4K1-UP; FFK1-UP; H3K1-UP; L2K1-UP; PCK1-UP; RDK1-UP; PEL1-UP; JJM1-UP; LEM1-UP; LRM1-UP; ERN1-UP; JLP1-UP; MWP1-UP; LDR1-UP; HAS1-UP; RAS1-UP; EDX1-UP; MEY1-UP; T2Y1-UP)

336D (S/N: PTB1-UP; SKE1-UP; J2F1-UP; JBF1-UP; PRF1-UP; LMG1-UP; MYG1-UP; KDJ1-UP; W3K1-UP; WRK1-UP; MPL1-UP; ZML1-UP; PPN1-UP; MYP1-UP; JER1-UP; JWR1-UP; DTS1-UP; MDS1-UP; NLS1-UP; JBT1-UP; KKT1-UP; M4T1-UP; WET1-UP; PGW1-UP; EMX1-UP)

340D (S/N: JTN1-UP)

Generator Set

C9 GEN SET (S/N: C9E1-UP; NBP1-UP)

Industrial Engine

C9 INDUSTRIAL (S/N: JSC1-UP; MBD1-UP)

Landfill Compactor

816F Series 2 (S/N: BZR1-UP)

Mobile Hydraulic Power Unit

330D MHPU (S/N: D3D1-UP; H3D1-UP; M3D1-UP; GMN1-UP)

336D MHPU (S/N: J6D1-UP; L5K1-UP; M3M1-UP; M3N1-UP; M2P1-UP; M3S1-UP; JRX1-UP; L5X1-UP; NBZ1-UP)

Motor Grader

140M (S/N: B9G1-UP; D9G1-UP)

160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

Soil Compactor

815F Series 2 (S/N: BYN1-UP)

Track Feller Buncher

541 (S/N: 5411-UP)

541 Series 2 (S/N: F7D1-UP)

551 (S/N: 5511-UP)

552 (S/N: 5521-UP)

552 Series 2 (S/N: F7G1-UP)

Track-Type Loader

973D (S/N: LCP1-UP)

Track-Type Tractor

D6R (S/N: A6M1-UP; S6T1-UP; S6X1-UP; S6Y1-UP; C6Z1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6T (S/N: JHB1-UP; ZEB1-UP; SMC1-UP; JWD1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; SNK1-UP; KJL1-UP; SKL1-UP; GCT1-UP; RLW1-UP; LAY1-UP; PEZ1-UP)

D7R (S/N: DSH1-UP; DLN1-UP; DJR1-UP)

Wheel Dozer

814F Series 2 (S/N: BXG1-UP)

Wheel Tractor-Scraper

627G (S/N: DBZ1-UP)

637G (S/N: DFJ1-UP; DEX1-UP; DEY1-UP)

Wheeled Excavator

M330D (S/N: KRE1-UP; MBR1-UP)

Introduction

The following special instruction outlines the parts and steps needed to update to the new dual tapered roller bearing HEUI pump. The new Hydraulic Electronic Unit Injector (HEUI) pump has physical dimensions that are different than the previous pump. The new HEUI pump may require the addition of new fuel and oil lines along with the pump in most applications. Refer to the parts table and rework instruction for the machine or engine model being updated.

Do not perform any procedure that is outlined in this publication without reading this article first.

Safety Information

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Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately.

Removal Procedure

Refer to the Disassembly and Assembly Manual for the procedure used on the equipment being worked on.

Installation Procedure for C9 Industrial Engines

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Illustration 1	g03700737

1. Remove the injection actuation pressure sensor (2) from the cylinder head. Install 6V-3305 O-Ring Adapter (3) with 214-7567 O-Ring Seal (1). Install Injection actuation pressure sensor (2) onto the adapter using a new 214-7567 O-Ring Seal (1).
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   Illustration 2	g03700766

2. Install the 384-0678 Unit Injector Hydraulic Pump Gp (4) using a 227-5904 O-Ring Seal (5). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 3	g03700858

3. Install new 6V-7981 Bolts (6) and 6V-5839 Washers (7). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 4	g03700768

4. Install 360-3679 Connector Plug (8) and 214-7568 O-Ring Seal (9). Install 6V-8636 Connector (10) with 214-7568 O-Ring Seal (9) and 228-7089 O-Ring Seal (11).
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   Illustration 5	g03700801

5. Install 6V-8636 Connector (13) using 228-7089 O-Ring Seal (14) and 214-7568 O-Ring Seal (12).
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   Illustration 6	g03700774

6. Install 128-6841 Elbow (16) using 238-5082 O-Ring Seal (17) and 228-7092 O-Ring Seal (15).
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   Illustration 7	g03700777

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   Illustration 8	g03700781

7. Install 6V-8629 Elbow (19) using 238-5081 O-Ring Seal (18) and 228-7092 O-Ring Seal (20). Orient the fitting as shown in Illustration 8.
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   Illustration 9	g03700783

8. Install 416-2653 Tube As (21) and 387-7159 Tube As (22).
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   Illustration 10	g03399746

9. Install the fuel connection fittings that were removed from the previous HEUI pump onto the new pump.

10. Install the remaining components to the engine that were removed to allow access for the pump replacement.

Installation Procedure for C9 Gensets

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Illustration 11	g03700787

1. Remove the injection actuation pressure sensor (2) from the cylinder head. Install 6V-3305 O-Ring Adapter (3) with 214-7567 O-Ring Seal (1). Install Injection actuation pressure sensor (2) onto the adapter using a new 214-7567 O-Ring Seal (1).
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   Illustration 12	g03700790

2. Install the 384-0678 Unit Injector Hydraulic Pump Gp (4) using a 227-5904 O-Ring Seal (5). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear .
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   Illustration 13	g03700858

3. Install new 6V-7981 Bolts (6) and 6V-5839 Washers (7). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 14	g03700768

4. Install 360-3679 Connector Plug (8) and 214-7568 O-Ring Seal (9). Install 6V-8636 Connector (10) with 214-7568 O-Ring Seal (9) and 228-7089 O-Ring Seal (11).
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   Illustration 15	g03700801

5. Install 6V-8636 Connector (13) using 228-7089 O-Ring Seal (14) and 214-7568 O-Ring Seal (12).
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   Illustration 16	g03700774

6. Install 128-6841 Elbow (16) using 238-5082 O-Ring Seal (17) and 228-7092 O-Ring Seal (15).
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   Illustration 17	g03700777

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   Illustration 18	g03399662

7. Install 6V-8629 Elbow (19) using 238-5081 O-Ring Seal (18) and 228-7092 O-Ring Seal (20). Orient the fitting as shown in Illustration 18.
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   Illustration 19	g03700808

8. Install 2R-6806 O-Ring Connectors (22) with 214-7568 O-Ring Seals (21).
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   Illustration 20	g03700813

9. Install 424-4946 Hose As (23) between the fuel transfer pump and the secondary fuel filter.
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   Illustration 21	g03700817

10. Install 416-2653 Tube As (24) and 387-7159 Tube As (25).
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    Illustration 22	g03700821

11. Install the remaining fuel lines and other components that were removed in order to change the HEUI pump.

Installation Procedure for 330D, 336D, M330D, 330D MHPU, 336D MHPU, and 340D Hydraulic Excavators

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Illustration 23	g03700787

1. Remove the injection actuation pressure sensor (2) from the cylinder head. Install 6V-3305 O-Ring Adapter (3) with 214-7567 O-Ring Seal (1). Install Injection actuation pressure sensor (2) onto the adapter using a new 214-7567 O-Ring Seal (1).
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   Illustration 24	g03841652

2. Install 7D-9984 Elbow (29) with 238-5080 O-Ring Seal (30) into the ECM. Install the 381-6796 Hose and Tube As (5). Secure the fuel line to the engine using 325-6994 Clip, 325-6995 Clip and two 3K-1787 Grommets (4).
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   Illustration 25	g03700859

3. Install the 384-0677 Unit Injector Hydraulic Pump Gp (6) using 227-5904 O-Ring Seal (7). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 26	g03700862

4. Install new 6V-7981 Bolts (8) and 6V-5839 Washers (9). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 27	g03700866

5. Install 360-3679 Connector Plug (10) and 214-7568 O-Ring Seal (11). Install 6V-8636 Connector (12) with 214-7568 O-Ring Seal (11) and 228-7089 O-Ring Seal (13).
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   Illustration 28	g03700874

6. Install 6V-8636 Connector (15) using 228-7089 O-Ring Seal (14) and 214-7568 O-Ring Seal (16).
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   Illustration 29	g03700877

7. Install 128-6841 Elbow (18) using 238-5082 O-Ring Seal (19) and 228-7092 O-Ring Seal (17).
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   Illustration 30	g03700917

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   Illustration 31	g03399662

8. Install 6V-8629 Elbow (21) using 238-5081 O-Ring Seal (20) and 228-7092 O-Ring Seal (22). Orient the fitting as shown in Illustration 31.
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   Illustration 32	g03700918

9. Install 396-0385 Connector (25) using 214-7568 O-Ring Seal (23) and 228-7089 O-Ring Seal (26). Install 6V-8724 Elbow (24) using 214-7568 O-Ring Seals (23) and 228-7089 O-Ring Seals (26).
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   Illustration 33	g03700920

10. Install 387-7151 Tube As (28) and 387-7153 Tube As (27).

11. Connect the fuel lines to the fuel transfer pump and reinstall the remaining engine components that were removed during the replacement of the HEUI pump.

Installation Procedure for 140M AWD, 160M and 160M AWD Motor Graders

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Illustration 34	g03700921

1. Install the 384-0622 Unit Injection Hydraulic Pump and Mounting Gp (2) using 227-5904 O-Ring Seal (1). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 35	g03700924

2. Install new 6V-7981 Bolts (3) and 6V-5839 Washers (4). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 36	g03400404

3. Install the 6V-8636 Connector (7) using 214-7568 O-Ring Seal (6) and 228-7089 O-Ring Seal (8). Install 360-3679 Connector Plug (5) using 214-7568 O-Ring Seal (6).
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   Illustration 37	g03700927

4. Install 8T-5389 Elbow (10) using 228-7092 O-Ring Seal (11) and 238-5081 O-Ring Seal (9).
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   Illustration 38	g03700933

5. Install 128-6841 Elbow (13) using 238-5082 O-Ring Seal (16) and 228-7092 O-Ring Seal (12). Install 6V-8636 Connector (15) using 214-7568 O-Ring Seal (14) and 228-7089 O-Ring Seal (17).
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   Illustration 39	g03700931

6. Install 387-7154 Tube As (18) and 387-7159 Tube As (19).

7. Reinstall the remaining engine components that were removed during the replacement of the HEUI pump.

Installation procedure for D6R Series III, D6T, D6R, and D7R Track Type Tractors

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Illustration 40	g03700934

1. Install the 384-0678 Unit Injector Hydraulic Pump Gp (2) using 227-5904 O-Ring Seal (1). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 41	g03700924

2. Install new 6V-7981 Bolts (3) and 6V-5839 Washers (4). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 42	g03400653

3. Install 6V-8724 Elbow (8) using 214-7568 O-Ring Seal (10) and 228-7089 O-Ring Seal (7). Install 396-0385 Connector (9) using 214-7568 O-Ring Seal (10) and 228-7089 O-Ring Seal (7). Install 6V-8636 Connector (6) using 214-7568 O-Ring Seal (10) and 228-7089 O-Ring Seal (7). Install 360-3679 Connector Plug (5) using 214-7568 O-Ring Seal (10).
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   Illustration 43	g03700937

4. Install 128-6841 Elbow (13) using 238-5082 O-Ring Seal (15) and 228-7092 O-Ring Seal (12). Install connector 6V-8636 Connector (14) using 214-7568 O-Ring Seal (11) and 228-7089 O-Ring Seal (16).

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Illustration 44	g03700954

1. Install 8T-5389 Elbow (18) using 238-5081 O-Ring Seal (17) and 228-7092 O-Ring Seal (19).
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   Illustration 45	g03700964

2. Install 387-7154 Tube As (20) and 387-7159 Tube As (21).

3. Connect the fuel lines and install the remaining engine components that were removed during the HEUI pump replacement.

Installation procedure for 627G and 637G Wheel Tractor Scrapers (DBD and DFJ prefixes only)

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Illustration 46	g03401125

1. Install the 384-0678 Unit Injector Hydraulic Pump Gp (2) using 227-5904 O-Ring Seal (1). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 47	g03700924

2. Install new 6V-7981 Bolts (3) and 6V-5839 Washers (4). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 48	g03401170

3. Install 6V-8724 Elbow (6) using 214-7568 O-Ring Seal (5) and 228-7089 O-Ring Seal (7).
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   Illustration 49	g03401174

4. Install the 416-1774 Fuel Tube (8). Secure to fuel line to the 338-8439 Clip (9).
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   Illustration 50	g03700967

5. Install 396-0385 Connector (14) using 214-7568 O-Ring Seal (11) and 228-7089 O-Ring Seal (13). Install 6V-8636 Connector (12) using 214-7568 O-Ring Seal (11) and 228-7089 O-Ring Seal (13). Install 360-3679 Connector Plug (10) using 214-7568 O-Ring Seal (11).
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   Illustration 51	g03401274
   Left side of engine

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   Illustration 52	g03700976

6. Install 416-1771 Fuel Tube (15). Secure the fuel tube to engine using the two 338-8439 Clips (16).
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   Illustration 53	g03700987

7. Install 8T-5389 Elbow (18) using 238-5081 O-Ring Seal (17) and 228-7092 O-Ring Seal (19)
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   Illustration 54	g03700994

8. Install 128-6841 Elbow (22) using 238-5082 O-Ring Seal (24) and 228-7092 O-Ring Seal (21). Install connector 6V-8636 Connector (23) using 214-7568 O-Ring Seal (25) and 228-7089 O-Ring Seal (20).
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   Illustration 55	g03401389

9. Install tube 387-7159 Tube As (27) and 387-7154 Tube As (26).

10. Install the remaining components that were removed during the HEUI pump replacement procedure.

Installation Procedure For 973D Track Type Loader

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Illustration 56	g03700998

1. Install the 6V-3305 O-Ring Adapter (2) using 214-7567 O-Ring Seal (1). Also install the new 214-7567 O-Ring Seal with the injection actuation pressure sensor.
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   Illustration 57	g03700999

2. Install 384-0677 Unit Injector Hydraulic Pump Gp (4) using 227-5904 O-Ring Seal (3). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 58	g03701002

3. Install new 6V-7981 Bolts (5) and 6V-5839 Washers (6). Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 59	g03401987

4. Install 6V-8724 Elbow (10) using 214-7568 O-Ring Seal (12) and 228-7089 O-Ring Seal (9). Install 396-0385 Connector (11) using 214-7568 O-Ring Seal (12) and 228-7089 O-Ring Seal (9). Install 6V-8636 Connector (8) using 214-7568 O-Ring Seal (12) and 228-7089 O-Ring Seal (9). Install 360-3679 Connector Plug (7) using 214-7568 O-Ring Seal (12).
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   Illustration 60	g03402038

5. Install 6V-8629 Elbow (14) using 238-5081 O-Ring Seal (13) and 228-7092 O-Ring Seal (15).
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   Illustration 61	g03402063

6. Install 6V-8636 Connector (19) using 214-7568 O-Ring Seal (18) and 228-7089 O-Ring Seal (20). Install 128-6841 Elbow (17) using 238-5082 O-Ring Seal (21) and 228-7092 O-Ring Seal (16).
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   Illustration 62	g03701029

7. Install 387-7151 Tube As (22).
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   Illustration 63	g03701031

8. Install 387-7153 Tube As (23).
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   Illustration 64	g03701033

9. Install 415-8017 Fuel Tube (24).
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   Illustration 65	g03701035

10. Install the hybrid 426-1500 Hose and Tube As (25).
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    Illustration 66	g03701044

11. Secure the hybrid Hose and Tube As using 325-6994 Clips (half) with 325-6995 Clips (half) (26) and 353-7956 Grommets (27).

12. Install the remaining components that were removed during the HEUI pump replacement procedure.

Installation Procedure For 814F, 815F, and 816F Wheeled Dozer and Compactor Machines

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Illustration 67	g03701287

1. Install 384-0678 Unit Injector Hydraulic Pump Gp (2) using 227-5904 O-Ring Seal (1). If necessary, rotate the pump to the position shown in the Illustration 67 when looking at the engine from the rear.
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   Illustration 68	g03701289

2. Install new 6V-7981 Bolts (3) and 6V-5839 Washers (4). Torque to 55 ± 10 N·m (41 ± 7 lb ft)
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   Illustration 69	g03701295

3. Install 360-3679 Connector Plug (5) using 214-7568 O-Ring Seal (9). Install 6V-8636 Connector (6) using 214-7568 O-Ring Seal (9) and 228-7089 O-Ring Seal (7). Install 8T-9041 Connector (8) using 214-7568 O-Ring Seal (9) and 228-7089 O-Ring Seal (7). Install 6V-8724 Elbow (10) using 214-7568 O-Ring Seal (9) and 228-7089 O-Ring Seal (7).
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   Illustration 70	g03402776

4. Install 8T-5389 Elbow (12) using 238-5081 O-Ring Seal (11) and 228-7092 O-Ring Seal (13)
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   Illustration 71	g03701313

5. Install 6V-8636 Connector (17) using 214-7568 O-Ring Seal (16) and 228-7089 O-Ring Seal (18). Install 128-6841 Elbow (15) using 238-5082 O-Ring Seal (19) and 228-7092 O-Ring Seal (14).
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   Illustration 72	g03701321

6. Reconnect 209-5526 Hose As (20) to the fuel transfer pump
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   Illustration 73	g03701349

7. Install 387-7154 Tube As (21) and 387-7159 Tube As (22).
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   Illustration 74	g03701355

8. Install 416-9706 Fuel Tube (24) using 338-8439 Clip (23).

9. Install the remaining components that were removed during the HEUI pump replacement procedure.

Installation Procedure for 511, 521, 522, 532, 541 and 552 Track Feller Bunchers

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Illustration 75	g03402944

1. Install 6V-3305 O-Ring Adapter (2) using 214-7567 O-Ring Seal (1). Also install new 214-7567 O-Ring Seal (1) to injection actuation pressure sensor.
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   Illustration 76	g03402955

2. Install 384-0607 Unit Injector Hydraulic Pump Gp (4) using 227-5904 O-Ring Seal (3). If necessary, in order to aid in installation, rotate the pump to an 8 o'clock position when looking at the engine from the rear.
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   Illustration 77	g03402984

3. Install new 6V-7981 Bolts (5) and 6V-5839 Washers (6). Torque to 55 ± 10 N·m (41 ± 7 lb ft)
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   Illustration 78	g03701359

4. Install the 6V-8636 Connector (12) using 214-7568 O-Ring Seal (11) and 228-7089 O-Ring Seal (13). Install 360-3679 Connector Plug (10) using 214-7568 O-Ring Seal (11). Install 6V-8629 Elbow (8) using 238-5081 O-Ring Seal (7) and 228-7092 O-Ring Seal (9).
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   Illustration 79	g03701379

5. Install 128-6841 Elbow (15) using 238-5082 O-Ring Seal (19) and 228-7092 O-Ring Seal (14). Install 6V-8636 Connector (17) using 214-7568 O-Ring Seal (16) and 228-7089 O-Ring Seal (18).
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   Illustration 80	g03701406

6. Install 387-7151 Tube As (21) and 387-7153 Tube As (20).

7. Install the remaining components that were removed during the HEUI pump replacement procedure.