Installation Procedure for the Fuel Transfer Kit on the Hydraulic Electronic Unit Injector (HEUI) Pump{1256} Caterpillar

Agricultural Tractor:

65 (S/N: 4ZF1-UP)

MT735 (S/N: AKN1-UP)

MT745 (S/N: ALA1-UP)

MT755 (S/N: ALM1-UP)

MT765 (S/N: AMS1-UP)

MTC735 (S/N: 8121-UP)

MTC745 (S/N: 8131-UP)

MTC755 (S/N: 8141-UP)

MTC765 (S/N: 8151-UP)

Asphalt Paver:

AP-1000D (S/N: EAD1-UP)

AP-1055D (S/N: FAC1-UP; A6P1-UP)

AP-755 (S/N: B3T1-UP)

BG-2455D (S/N: BNW1-UP; BXW1-UP)

BG-260D (S/N: BPW1-UP)

Cold Planer:

PM-102 (S/N: Z2X1-UP)

Combine:

Lexion 470 R (S/N: 7651-UP)

Lexion 475 R (S/N: 7671-UP)

Landfill Compactor:

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

Soil Compactor:

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

Engine:

C-9 (S/N: CLJ1-UP)

C7 (S/N: JRA1-UP; JTF1-UP; FML1-UP; KAL1-UP; FMM1-UP; C7P1-UP; C7T1-UP)

C9 (S/N: MTB1-UP; 9DG1-UP; CKP1-UP; X3R1-UP)

Generator Set:

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

C9 MARINE GEN (S/N: SJB1-UP)

C9 MARINE GS (S/N: C9A1-UP)

Industrial Engine:

C9 (S/N: JSC1-UP; MBD1-UP; JLW1-UP)

Marine Engine:

C7 (S/N: M7A1-UP; C7B1-UP; C7D1-UP; M7G1-UP; C7X1-UP; C7Z1-UP)

C9 (S/N: C9B1-UP; CSN1-UP; X9X1-UP; Z9X1-UP; X9Y1-UP)

Petroleum Engine:

C7 (S/N: K2A1-UP)

C9 (S/N: P9L1-UP; KLW1-UP)

Truck Engines:

3126E (S/N: HEP1-UP)

Excavator:

324D (S/N: LAB1-UP; EJC1-UP; T2D1-UP; BYE1-UP; JJG1-UP; ECH1-UP; JGK1-UP; SYM1-UP; AWN1-UP; DFP1-UP; JKR1-UP; JLS1-UP; CJX1-UP)

325D (S/N: GPB1-UP; NAC1-UP; KBE1-UP; PKE1-UP; KDG1-UP; C4H1-UP; DBH1-UP; PEH1-UP; C7K1-UP; RJK1-UP; C8L1-UP; LAL1-UP; MCL1-UP; PAL1-UP; CJM1-UP; C9M1-UP; AZP1-UP; DAP1-UP; A3R1-UP; GBR1-UP; SCR1-UP; T2S1-UP; CYW1-UP)

328D (S/N: BYH1-UP; GTN1-UP; MKR1-UP)

330C (S/N: CYA1-UP; HAA1-UP; MCA1-UP; JAB1-UP; D3C1-UP; JCD1-UP; KDD1-UP; GAG1-UP; RBH1-UP; B1K1-UP; JNK1-UP; B2L1-UP; B3M1-UP; MKM1-UP; B4N1-UP; CAP1-UP; GKX1-UP; DKY1-UP; CGZ1-UP)

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

M325D (S/N: EDF1-UP; KGG1-UP; KAY1-UP)

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

Track Feller Buncher:

511 (S/N: 5111-UP)

521 (S/N: 5211-UP)

522 (S/N: 5221-UP)

532 (S/N: 5321-UP)

541 (S/N: 5411-UP)

551 (S/N: 5511-UP)

552 (S/N: 5521-UP)

TK711 (S/N: 1011-UP)

TK721 (S/N: 1021-UP)

TK722 (S/N: 1031-UP)

TK732 (S/N: 1041-UP)

TK741 (S/N: 2021-UP)

TK751 (S/N: 3011-UP)

TK752 (S/N: 3021-UP)

Integrated Toolcarrier:

IT62H (S/N: M5G1-UP)

Motor Grader:

12H (S/N: CBK1-UP; AMZ1-UP; 1251-UP)

140M (S/N: B9D1-UP; B9M1-UP)

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

Mobile Hydraulic Power Unit:

324D MHPU (S/N: KJR1-UP)

325D MHPU (S/N: SRC1-UP; C3N1-UP)

330C MHPU (S/N: MSD1-UP; MSL1-UP)

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

Transmission:

TH31-E61 (S/N: SKY1-UP)

Paving Compactor:

CS74 (S/N: CZJ1-UP)

Track-Type Loader:

973C (S/N: BCP1-UP; LDX1-UP)

973D (S/N: LCP1-UP)

Track-Type Tractor:

D6R Series II (S/N: BNC1-UP; AFD1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-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; SMC1-UP; JWD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; KJL1-UP; SKL1-UP; GCT1-UP; LAY1-UP; PEZ1-UP)

Wheel Dozer:

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

Wheel Loader:

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

Wheel Skidder:

535C (S/N: 5351-UP)

545C (S/N: 5451-UP)

Wheel Tractor-Scraper:

627G (S/N: CEZ1-UP)

637G (S/N: CEJ1-UP; CEM1-UP)

Introduction

This Special Instruction provides the rework procedure for the replacement of the fuel transfer pump that is located on the HEUI pump. The procedure calls for a temporary bolt that is used during the removal of the fuel transfer pump in order to prevent the body of HEUI pump from separating. Once the fuel transfer pump has been reinstalled onto the HEUI pump, the temporary bolt is then removed.

Note: Use the following procedure when you install the 326-1006 Fuel Transfer Pump Kit , 326-1007 Fuel Transfer Pump Kit or 326-1008 Cover Kit . The 326-1006 Fuel Transfer Pump Kit is a replacement for the 178-2357 Fuel Transfer Pump Gp . The 326-1007 Fuel Transfer Pump Kit is a replacement for the 272-0617 Fuel Transfer Pump Gp . The 326-1008 Cover Kit is a replacement for the 201-4227 Cover As . Reference parts identification in SISWeb for the engine serial number that is being repaired in order to verify the part number of the fuel transfer pump that is currently installed on the engine.

Removal of the HEUI Pump

Prior to removing the HEUI pump, wash the engine in order to remove all of the dirt from the area that surrounds the HEUI pump. Remove the HEUI pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump - Remove" for the correct procedure.

Note: Do not allow any debris to enter the HEUI pump or the HEUI pump parts. Allowing debris to enter the HEUI pump will cause pump failure.

Note: Do not attempt to perform this rework procedure while the HEUI pump is still on the engine.

Removing the Fuel Transfer Pump from the HEUI Pump

Show/hide table



Illustration 1	g01077607
(1) HEUI pump (2) Fuel transfer pump (3) Vise (4) Drive gear

1. Use a vise (3) in order to secure the HEUI pump (1) vertically with the drive gear (4) on the bottom. Make sure that the vise has jaws that are made from aluminum or some other soft material. Do not clamp on the gear or the front mounting flange. Do not rest the pump with the drive gear (4). Refer to Illustration 1.

   Note: If any debris remains on the pump, plug all of the ports on the pump and spray the external parts of the pump with an appropriate cleaner. Do not use a wire wheel or a die grinder to clean the surface. Using a wire wheel can affect the flatness of the mating surface. A high pressure leak could result from using a wire wheel. Use a clean towel to clean the surface.

Show/hide table



Illustration 2	g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal

2. Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 2. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.

3. Replace tie bolt (6) with the temporary bolt (9) that is provided in the service kit.

   Note: The temporary bolt that is provided in the kit has an undersized bolt head. The temporary bolt prevents the body of the HEUI pump from separating during service. Do not remove the temporary bolt until the fuel transfer pump has been completely reinstalled.

4. Tighten the temporary bolt (9) to 10 N·m (7.4 lb ft) by using Tooling (C) .

   Note: Do not place an excessive torque on the temporary bolt. The aluminum housing of the pump could be damaged.

5. After installing the temporary bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .

6. Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .

Show/hide table



Illustration 3	g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Temporary bolt (10) Seals (11) Seal

7. Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.

Installing the Fuel Transfer Pump onto the HEUI Pump

Show/hide table



Illustration 4	g01458639
(1) HEUI pump (10) 239-2402 Seals

1. Install the three new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.

Show/hide table



Illustration 5	g01470031
(2) Fuel transfer pump (11) 179-8128 Seal

2. Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.

Show/hide table



Illustration 6	g01132969

3. Do not remove the temporary bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.

   Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.

   Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.

Show/hide table



Illustration 7	g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal

4. Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten the bolts to a torque of 6.0 N·m (50 lb in) by using Tooling (A). Start torquing the bolt in the top right corner and go in a clockwise rotation. Do not remove the temporary bolt (9) . Refer to Illustration 7.

5. Install the three tie bolts (8). Tighten the bolts to a snug fit by using Tooling (B). Refer to Illustration 7.

6. Remove the temporary bolt (9) that is located in the upper left hole by using Tooling (C). Install the remaining tie bolt (6) and tighten the tie bolt to a snug fit by using Tooling (B). Refer to Illustration 7.

Show/hide table



Illustration 8	g01133005
Tightening sequence for installing the fuel transfer pump

7. Tighten bolts 1 through 4 in a numerical sequence to a torque of 32 ± 5 N·m (24 ± 4 lb ft) by using Tooling (B). Refer to Illustration 8.

8. Tighten bolts 5 through 7 in a numerical sequence to a torque of 8.0 ± 0.4 N·m (70 ± 3.5 lb in) by using Tooling (A). Refer to Illustration 8.

9. Loosen the bolt at location (7). Torque the bolt at location (7) to 10 ± 1 N·m (90 ± 9 lb in).

10. Loosen the bolt at location (5). Torque the bolt at location (5) to 10 ± 1 N·m (90 ± 9 lb in).

11. Loosen the bolt at location (6). Torque the bolt at location (6) to 10 ± 1 N·m (90 ± 9 lb in).

12. In order to ensure that the gasket completely compresses, repeat Step 7 through Step 11.

Reinstalling the HEUI Pump

Illustration 9	g01133027
(5) 227-5904 O-Ring Seal (12) 185-3241 O-Ring Seal

Install the HEUI pump on the engine. Refer to the Disassembly and Assembly Manual for the correct procedure. Ensure that the system does not have any leaks.

Note: Be sure to use the appropriate seal for your individual application. Use a new 185-3241 O-Ring Seal (12 ) on the 204-4944 Unit Injector Hydraulic Pump Gp , the 220-4276 Unit Injector Hydraulic Pump Gp , and the 220-6214 Unit Injector Hydraulic Pump Gp . Use a new 227-5904 O-Ring Seal (5) on all other unit injector hydraulic pumps. Refer to Illustration 9. Discard the old seal and install the new seal.