Installation of a Dual Tapered Roller Bearing HEUI Hydraulic Pump onto Certain C7 ACERT Engines {1714} Caterpillar

Asphalt Paver

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

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

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

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

Excavator

324D (S/N: LAB1-UP; EJC1-UP; MND1-UP; T2D1-UP; BYE1-UP; JJG1-UP; ECH1-UP; TRH1-UP; BTK1-UP; GPK1-UP; JGK1-UP; SYM1-UP; AWN1-UP; TSN1-UP; DFP1-UP; JZR1-UP; JAT1-UP; PYT1-UP; CJX1-UP)

324D MHPU (S/N: LBW1-UP)

325D (S/N: GPB1-UP; NAC1-UP; KBE1-UP; PKE1-UP; KDG1-UP; C4H1-UP; DBH1-UP; PEH1-UP; ERK1-UP; RJK1-UP; LAL1-UP; MCL1-UP; PAL1-UP; CJM1-UP; AZP1-UP; DAP1-UP; A3R1-UP; GBR1-UP; T2S1-UP; CYW1-UP)

326D (S/N: PJM1-UP)

328D (S/N: SWF1-UP; BYH1-UP; GTN1-UP; MKR1-UP; RMX1-UP)

329D (S/N: MNB1-UP; XDB1-UP; BFC1-UP; BBF1-UP; CZF1-UP; DJF1-UP; JHJ1-UP; WDK1-UP; TZL1-UP; EBM1-UP; TPM1-UP; BYS1-UP; WLT1-UP; LFW1-UP; YFW1-UP; SCY1-UP; TAY1-UP; DTZ1-UP)

Forest Machine

324D FM (S/N: JKR1-UP; JLS1-UP)

325D (S/N: C7K1-UP; C8L1-UP; C9M1-UP)

Forwarder

584 (S/N: PAK1-UP)

584HD (S/N: PBK1-UP)

Industrial Engine

C7 (S/N: JRA1-UP; JTF1-UP)

Mobile Hydraulic Power Unit

323D MHPU (S/N: DCY1-UP)

324D MHPU (S/N: M4A1-UP; KJR1-UP)

325D MHPU (S/N: SRC1-UP; C3N1-UP; H3N1-UP; X3N1-UP)

328D MHPU (S/N: JTC1-UP)

329D MHPU (S/N: J8D1-UP; J9D1-UP; L5G1-UP; L5H1-UP)

Motor Grader

120K (S/N: SZN1-UP)

120K Series 2 (S/N: SZS1-UP)

12K (S/N: SZP1-UP)

12M (S/N: B921-UP)

140K (S/N: JPA1-UP; SZL1-UP)

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

160K (S/N: SZM1-UP)

Wheel Loader

950H (S/N: N1A1-UP; JAD1-UP; M1G1-UP; J5J1-UP; K5K1-UP; MXL1-UP; JLX1-UP)

962H (S/N: N4A1-UP; SSA1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP; L5S1-UP; PCW1-UP)

Wheel Skidder

525C (S/N: 5251-UP)

535C (S/N: 5351-UP)

545C (S/N: 5451-UP)

Introduction

This Special Instruction details instructions to change the present unit injector hydraulic pump for a HEP pump that adds an opposing tapered roller bearing The additional bearing counters gear torsional loads that can lift the rollers off the race and lead to high contact stresses. The new pump design is longer than the current pump. Certain applications will require replacing additional components due to the longer HEP pump. A new high-pressure oil line and adapter are required to connect the pump to the cylinder head.

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.

Cylinder Head Rework Procedure

Note: There is a potential for interference between the new Dual Tapered Roller Bearing (DTRB) Hydraulic Electronic Unit Injector (HEUI) pump and the cylinder head intake flange on C7 ACERT engines built before KHX47176. Engines with build dates after the date above have cylinder heads that do not present this condition. For engines with build dates prior to the date above go to the next step.

Illustration 1	g03389031

Test fitting the pump for clearance at location (1) is recommended in Illustration 1. If the new DTRB (HEUI) pump is in contact with the cylinder head after mounting bolts are snugged, modify the cylinder head per the following instructions.

Note: Do not modify the HEUI pump. Removing material from the HEUI pump may create an unsafe condition.

1. Remove HEUI pump and apply suitable protection to the front cover opening and any open fluid lines and fittings to prevent debris entry during this process. Removing the inlet cover group is not required to perform this procedure. If the intake air lines have been disconnected, protect the opening from debris entry.
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   Illustration 2	g03395855

2. Scribe a line (2), parallel to the cylinder head top surface, at the center of the port plug. Refer to Illustration 2.

3. Scribe a line along the edge of the inlet air cover group at edge (3). Refer to Illustration 2.

4. Scribe a line (4) parallel to line (2) the distance of 48.7 mm (1.9 inch) from line (2) as shown in Illustration 2.
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   Illustration 3	g03390056

5. Scribe a line 15 degrees (B) from the inlet air cover mounting surface (3) as shown in Illustration 3.
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   Illustration 4	g03421397

6. Using suitable tooling remove the pie shaped section of cylinder head casting outlined by the previous steps to provide clearance for the new pump. Do not remove more material than defined by the lines. The area inside the circle in Illustration 4 shows the cylinder head with the section (5) removed.

Procedures for 324D, 324D FM, 324D FM HEEL, 324D L, 324D LN, 325D, 325D FM Butt N, 325D FM HEEL, 325D L, 325D MH FCR, 326D, 328D, 328D LCR, 329D, 329D L, 329D LN Excavators, AP-1055D, AP-1000D, BG-260D, BG-2455D, 950H, 962H and for C7 JTF and JRA Industrial Engines

Removal Procedure

1. Refer to Disassembly and Assembly manual for instructions on removal of HEUI pump.

2. Remove the breather assembly and other components to gain access to the HEUI pump if necessary.

3. Refer to Table 2 for the list of parts that can be reused.

Installation Procedure

Illustration 5	g03390258

1. Install 214-7568 O-Ring Seal (6) to Straight Thread O-Ring (STOR) 321-8635 Plug (5) and three adapters (4, 7, 8). The 90 degree 6V-8724 Elbow (7) can be transferred from the removed pump.

2. Install 228-7089 O-Ring Seals (3) to face side of the three adapters.

3. Install 321-8638 Plug As (5), 6V-8636 Connector (4), 396-0385 Connector (8) and 6V-8724 Elbow (7) adapters to pump ports.

4. Tighten the 396-0385 Connector (for the fuel transfer pump) (8) and 6V-8724 Elbow (7) to 24 ± 2 N·m (18 ± 1 lb ft) in the transfer pump ports.

5. Tighten the 6V-8636 Connector (4) in the port to 48 ± 5 N·m (35 ± 4 lb ft).

6. Install 191-0522 Adapter (2) using the 238-5081 O-Ring Seal (1) on the STOR end.
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   Illustration 6	g03421433

7. Install the 227-5904 O-Ring Seal (9). If the locator dowel pin (10), is in front cover or in the pump mounting flange, remove before installing the pump onto the engine.
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   Illustration 7	g03391871

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   Illustration 8	g03391876

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   Illustration 9	g03391878

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   Illustration 10	g03391881

8. Install the 384-0677 Unit Injector Hydraulic Pump Gp. If needed rotate the pump downward, for easier installation. Refer to Illustrations 15 through 18.
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   Illustration 11	g03391953

9. Install new 6V-7981 Bolts (11) and 6V-5839 Washers (12). Hand tighten the bolts until snug.
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   Illustration 12	g03391964

10. Install new 387-7149 Tube As (high-pressure oil) (13). The tube nuts should be started by hand. If the tube nuts do not start onto the adapters by hand, adjusting the position of the pump may improve alignment of the fittings. Without the alignment dowel in place and the mounting bolts installed, the pump has a small amount of rotational movement. Loosen the pump mounting bolts from Step 9 and connect the high-pressure tube nuts. Hand tighten the high-pressure tube nuts until snug.

11. Tighten the pump mounting bolts (11). Torque to 55 ± 10 N·m (41 ± 7 lb ft).

12. Tighten tube ends (14) to 40 ± 4 N·m (30 ± 3 lb ft).

13. Connect the 205-1280 Hose As (for the low-pressure oil line) (16). Insert the 205-1280 Hose As (16) into the 191-0522 Adapter (2) until engaged.

14. Reconnect low-pressure fuel lines to the fuel transfer pump.

15. Reinstall breather assembly and any other components removed to install the new pump.

Procedure for 584 Forwarder with C7 S/N:JTF Engines

Removal Procedure

1. Refer to Disassembly and Assembly manual for instructions on removal of HEUI pump.

2. Remove the breather assembly and other components to gain access to the HEUI pump if necessary.

3. Remove 227-5956 Tube As and 2R-6806 Adapters.

4. Refer to Table 2 for the list of parts that can be reused.

Installation Procedure

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Illustration 13	g03748697

1. Install 214-7568 O-Ring Seal (6) to Straight Thread O-Ring (STOR) 321-8635 Plug (5) and three adapters (4, 7, 8).

2. Install 228-7089 O-Ring Seals (3) to face side of the three adapters.

3. Install 321-8638 Plug As (5), 6V-8636 Connector (4), 396-0385 Connector (8) and 030-7947 Elbow (7) adapter to pump ports.

4. Tighten the 396-0385 Connector (for the fuel transfer pump) (8) and 030-7947 Elbow (7) to 24 ± 2 N·m (18 ± 1 lb ft) in the transfer pump ports.

5. Tighten the 6V-8636 Connector (4) in the port to 48 ± 5 N·m (35 ± 4 lb ft).

6. Install 191-0522 Adapter (2) using the 238-5081 O-Ring Seal (1) on the STOR end.
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   Illustration 14	g03421433

7. Install the 227-5904 O-Ring Seal (9). If the locator dowel pin (10), is in front cover or in the pump mounting flange, remove before installing the pump onto the engine.
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   Illustration 15	g03391871

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   Illustration 16	g03391876

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   Illustration 17	g03391878

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   Illustration 18	g03391881

8. Install the 384-0677 Unit Injector Hydraulic Pump Gp. If needed rotate the pump downward, for easier installation. Refer to Illustrations 15 through 18.
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   Illustration 19	g03391953

9. Install new 6V-7981 Bolts (11) and 6V-5839 Washers (12). Hand tighten the bolts until snug.
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   Illustration 20	g03748945

10. Install new 387-7149 Tube As (high-pressure oil) (13). The tube nuts should be started by hand. If the tube nuts do not start onto the adapters by hand, adjusting the position of the pump may improve alignment of the fittings. Without the alignment dowel in place and the mounting bolts installed, the pump has a small amount of rotational movement. Loosen the pump mounting bolts from Step 9 and connect the high-pressure tube nuts. Hand tighten the high-pressure tube nuts until snug.

11. Tighten the pump mounting bolts (11). Torque to 55 ± 10 N·m (41 ± 7 lb ft).

12. Tighten tube ends (14) to 40 ± 4 N·m (30 ± 3 lb ft).

13. Connect the 205-1280 Hose As (for the low-pressure oil line) (16). Insert the 205-1280 Hose As (16) into the 191-0522 Adapter (2) until engaged.
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    Illustration 21	g03749000

14. Install 030-7947 Elbow (7) with new 214-7568 O-Ring Seal (6) on the fuel filter base.
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    Illustration 22	g03749013

15. Fabricate a secondary hose assembly with 21 cm (8.27 inch) 122-6879 Hydraulic Hose, 124-1956 Permanent Coupling, and 124-1980 Permanent Coupling.

    Note: Flex hose fuel line must not fowl with fuel filter or other connecting lines to HEP. Align 030-7947 Elbow to align flex hose to prevent fouling.

16. Install new secondary hose assembly between the fuel pump and fuel filter base.

17. Reconnect low-pressure fuel lines to the fuel transfer pump.

18. Reinstall breather assembly and any other components removed to install the new pump.

Procedures for 525C, 535C, 545C Wheel Skidders

Removal Procedure

1. Refer to Disassembly and Assembly manual for instructions on removal of HEUI pump.
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   Illustration 23	g03391971

2. Remove the 253-9886 Heater Wiring Gp (1), 237-9308 Base As (secondary fuel filter) (3), 253-2682 Bracket As (2), secondary filter to cylinder head fuel line (4), 8M-2773 Clip (6), 5G-7817 Boss (5) and attaching bolt.

3. Discard the 253-2682 Bracket As (2), 195-0800 Hose As (secondary filter to cylinder head fuel line) (4), 8M-2773 Clip (6), 5G-7817 Boss (5) and attaching bolt. Retain the 237-9308 Base As (3) and 253-9886 Heater Wiring Gp (1) for later use.

   Note: If necessary remove the fuel pressure sensors from the filter base. The sensors will be retained in the same location in the base when the filter base is reinstalled later in this procedure.

4. Remove the 260-4861 Wiring Harness (for fuel pressure sensor) .

5. Refer to Table 3 for the list of parts that can be reused.

Installation Procedure

Illustration 24	g03392222

1. Install 253-9886 Heater Wiring Gp (1) with two 132-7551 Spacers (2) and two 208-9284 Bolts (3).

2. Place the 132-7551 Spacers (2) between the relay bracket and the inlet air cover as.

3. Install 208-9282 Bolt (4).

4. Install 5A-3604 Bolt (5) with 9M-1974 Hard Washer (6).
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   Illustration 25	g03392232

5. Install 214-7568 O-Ring Seal (11) to STOR side of 321-8635 Plug (12) and 6V-8636 Connector (10). Install 228-7089 O-Ring Seals (9) to face side of 6V-8636 Connectors (10).

6. Install 321-8635 Plug (2) to pump port. Tighten the adapters to the ports 48 ± 5 N·m (35 ± 4 lb ft).

7. Install 191-0522 Adapter (8) using 238-5081 O-Ring Seal (7) on STOR end.

   Note: The 191-0522 Adapter (90 degree elbow) (8) can be transferred from the removed pump.

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   Illustration 26	g03392241

8. Install 227-5904 O-Ring Seal (13) onto the pump mounting flange. If locator dowel pin (14) is present in the front cover or in the pump mounting flange, remove the dowel pin before installing the pump onto the engine.
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   Illustration 27	g03392617

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   Illustration 28	g03392621

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   Illustration 29	g03392624

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   Illustration 30	g03392626

9. Install 384-0607 Unit Injector Hydraulic Pump Gp. If needed rotate the pump downward for easier installation. Refer to Illustrations 27 through 30.
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   Illustration 31	g03392659

10. Install the new 6V-7981 Bolts (15) and 6V-5839 Washers (16). Hand tighten the mounting bolts until snug.
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    Illustration 32	g03392668

11. Install the new 387-7149 Tube As (high-pressure oil) (17). The tube nuts (18) should be started by hand. If the tube nuts do not start onto the adapters by hand, adjusting the position of the pump may improve alignment of the fittings. Without the alignment dowel in place and the mounting bolts installed, the pump has a small amount of rotational movement. Loosen the pump mounting bolts from step 10 and connect new high-pressure tube nuts. Hand tighten the high-pressure tube nuts until snug.

12. Tighten the pump mounting bolts (15). Torque to 55 ± 10 N·m (41 ± 7 lb ft).

13. Tighten tube nuts (18) to 40 ± 4 N·m (30 ± 3 lb ft).

14. Connect the 205-1280 Hose As (low-pressure oil line) (20). Insert the 205-1280 Hose As (20) into the 191-0522 Adapter (90 degree elbow) (19) until engaged.
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    Illustration 33	g03392693

15. Install 214-7568 O-Ring Seal (21) to STOR side of 6V-8636 Connector (22). Install connector into cylinder head port.

16. Tighten the connector (22) to the port 48 ± 5 N·m (35 ± 4lb ft).

17. Install 228-7089 O-Ring Seal (23) to face side of adapter.
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    Illustration 34	g03392697

18. Remove existing bolt and install 145-2264 Stud (24) and 6V-3964 Hard Washer (25) to the front housing cover.
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    Illustration 35	g03392758

19. Install 422-9397 Bracket As (26) to front housing with 6V-1820 Bolts (27) and 8T-7934 Hard Washers (28), 5P-7970 Nut (29), and 9M-1974 Hard Washer (30).
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    Illustration 36	g03392774

20. Install 237-9308 Base As (Fuel Filter) (31) to mounting bracket with 6V-5842 Bolt (32), 287-3049 Stud (34) and washers 8T-4121 Hard Washer (33).

21. Install the 271-5584 Clip (wire harness dual ladder) (36) with 8T-4133 Nut (35) and washer 8T-4121 Hard Washer (33) as shown in Illustration 36.
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    Illustration 37	g03392794

22. Install 238-5080 O-Ring Seal (39) to STOR side of 6V-8634 Connector (38).

23. Install connector to filter base outlet.

24. Install 228-7089 O-Ring Seal (37) to face side of adapter.
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    Illustration 38	g03392804

25. Install a 134 mm length of protective 8C-5064 Flexible Conduit (40) onto the 391-6328 Hose As (fuel ) (42) and secure with two 3S-2093 Cable Straps (41).
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    Illustration 39	g03392825
    (A) 45 ± 5 degrees

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    Illustration 40	g03392827
    (B) 45 ± 5 degrees

26. Install and align 391-6328 Hose As (Fuel) (42) ends to 45 deg at the cylinder head and the filter base. Refer to Illustrations 39 and 40.
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    Illustration 41	g03392861

27. Install the 352-3964 Clip (43) with the 6V-3940 Bolt (44).
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    Illustration 42	g03392882

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    Illustration 43	g03392886

28. Install 424-7630 Sensor Harness As (45) and secure with 3S-2093 Cable Strap (46) at ten points as shown in Illustrations 42 and 43.

29. Install the new fuel filter and install 345-5457 Hose As to the filter base.

30. Prime fuel system.

31. Reinstall breather assembly and any other components removed to install the new pump.

Procedures for 12K, 120K, 140K, 160K, 12M, and 140M Motor Graders

Removal Procedure

1. Refer to Disassembly and Assembly manual for instructions on removal of HEUI pump. If necessary, remove the breather assembly and other components to gain access to the HEUI pump.

2. Refer to Table 4 for the list of parts that can be reused.

Installation Procedure

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Illustration 44	g03393152

1. Install 214-7568 O-Ring Seal (5) to STOR side of 321-8635 Plug (6) and 6V-8636 Connectors (4).

2. Install 228-7089 O-Ring Seal (3) to face side of 6V-8636 Connector (4).

3. Install 321-8635 Plug (2) to pump port. Tighten the adapters to the ports 48 ± 5 N·m (35 ± 4 lb ft).

4. Install 191-0522 Adapter (2) using O-ring 238-5081 O-Ring Seal (1) on STOR end.
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   Illustration 45	g03393157

5. Install 227-5904 O-Ring Seal (7) onto pump mounting flange. If locator dowel pin (8) is present in front cover or in pump mounting flange, remove before installing pump onto engine.
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   Illustration 46	g03392617

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   Illustration 47	g03392621

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   Illustration 48	g03392624

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   Illustration 49	g03392626

6. Install 384-0607 Unit Injector Hydraulic Pump Gp. If needed rotate the pump downward for easier installation. Refer to Illustrations 46 through 49.
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   Illustration 50	g03393161

7. Install new 6V-7981 Bolt (9) and 6V-5839 Washer (10). Hand tighten the mounting bolts until snug.
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   Illustration 51	g03393166

8. Install new 387-7149 Tube As (high-pressure oil) (11). The tube nuts (12) should be started by hand. If the tube nuts do not start onto the adapters by hand, adjusting the position of the pump may improve alignment of the fittings. Without the alignment dowel in place and the mounting bolts installed, the pump has a small amount of rotational movement. Loosen the pump mounting bolts from Step 7 and connect new high-pressure tube nuts. Hand tighten the high-pressure tube nuts until snug.

9. Tighten the pump mounting bolts (9). Torque to 55 ± 10 N·m (41 ± 7 lb ft).

10. Tighten tube ends (12) to 40 ± 4 N·m (30 ± 3 lb ft).

11. Connect 205-1280 Hose As (low-pressure oil) (14).

12. Insert 205-1280 Hose As (14) into 191-0522 Adapter (2) until engaged.
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    Illustration 52	g03395918
    New oil gauge assembly

13. Remove the existing 194-5131 Bracket and 1F-7567 Clip.

14. Attach the new oil gage support 154-6626 Bracket As (17) to the front housing cover using 5P-7970 Nut (15) and 3E-4352 Hard Washer (16). Refer to Illustration 52.

15. Attach new bracket assembly to the existing oil gauge tube using 5P-9297 Clip (18), 6V-6317 Bolt (19), and 6V-5839 Washer (20) as shown in Illustration 52.