Installation Procedure for the Fuel Transfer Kit on the Hydraulic Electronic Unit

Injector (HEUI) Pump{1256}

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.

NOTICE
The correct procedures and tooling specifications must always be
used. Failure to follow any of the procedures may result in damage,
malfunction, or possible engine failure.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.

Table 1

Required Tools

Callout Part Number Description

A 193-9199 T27 Torx bit

B 194-3536 T40 Torx bit

C 6 mm Hex Key Wrench

Flat head screwdriver

Torque Wrench

Torque Wrench

1U-6396 O-Ring Assembly Compound

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.

Table 2

Required Components

Part Number Description Qty

326-1006, 326-1007 or 326-1008 Fuel Transfer Pump Kit 1

Table 3

326-1006 Fuel Transfer Pump Kit

Part Number Description Quantity

256-0302 Bolt 1

239-2402 Seal 3 (1)

179-8128 Seal 2

318-6357 Fuel Transfer Pump Gp 1

313-4620 Screw 4 (1)

227-5904 O-Ring Seal 1

185-3241 O-Ring Seal 1

(1)
There is one extra part that is included in the kit.
Table 4

Effectivity for 326-1006 Fuel Transfer Pump Kit

Table 5

326-1007 Fuel Transfer Pump Kit

Part Number Description Quantity

312-0617 Fuel Transfer Pump Gp 1

256-0302 Bolt 1

179-8128 O-Ring Seal 2

239-2402 O-Ring Seal 3 (2)

313-4620 Screw 4 (2)

227-5904 O-Ring Seal 1

 185-3241 O-Ring Seal 1
(2)
There is one extra part that is included in the kit.
Table 6

326-1008 Cover Kit

Part Number Description Quantity

318-5227 Cover As 1

256-0302 Bolt 1

239-2402 O-Ring Seal 3 (3)

313-4620 Screw 4 (3)

227-5904 O-Ring Seal 1

185-3241 O-Ring Seal 1

(3)
There is one extra part that is included in the kit.

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

g01077607
Illustration 1
 (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.

g01132938
Illustration 2
(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) .

g01132944
Illustration 3
(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

Ver imagen

g01458639
Illustration 4
(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.

g01470031
Illustration 5
 (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.

g01132969
Illustration 6

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.

g01132938
Illustration 7
 (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.

g01133005
Illustration 8
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

Ver imagen

g01133027
Illustration 9
(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.