Application Engineering Bulletin

Subject Cummins Prelub for QST30 and QSK45/60/78 Construction Engines Date December 2000 Engine Models included: QST30, QSK45/60/78 Fuel Systems included: This AEB is for the following applications: Automotive Page 1 of 26 Industrial Power Generation

AEB Number 44.01

PRELUB OVERVIEW
Purpose of Prelub System
The RPM Prelub System was introduced on Cummins high horsepower engines to distribute oil throughout the lubrication system in the engine before starting. This automatic system uses a motor driven pump to supply oil from the sump to the main oil rifle prior to starting the engine. A prelubrication system assures oil pressure in the main rifle and oil availability to all friction surfaces in the engine at startup. Thus, engine wear is reduced. It also reduces the risk of starting the engine without oil in the engine sump or dry oil filters. There are three types of prelubrication systems. Integral Prelub This system is an integral prelubrication pump and engine starter motor. Integral Prelub is mounted at the lower starter bore location. Integral Prelub is available for engine sizes 30 liters and less. Non-Integral Prelub Features a pump and electric motor assembly that can be engine or chassis mounted. The non-integral system is available for engine sizes 19 liters and less. High Volume Pump (HVP) Prelub The Prelub HVP has increased flow capability. The HVP series was mandated for engine sizes of 45 liters and larger. The Prelub HVP can be engine or chassis mounted.

Operation of Prelub System

The Prelub or HVP system is activated when the operator turns the key switch to the start position. With the key in the start position, the Prelub timer relay is energized to provide power to the pump assembly. For integral systems, power is applied only to the motor. The starter solenoid remains de-energized to prevent cranking. The Prelub pump will draw oil from the oil pan, pass through the oil filters, and fill the oil galleries of the engine. Once the main oil rifle is pressurized, a normally closed switch will open. The timer solenoid recognizes the open circuit at the pressure switch and de-energizes the time solenoid relay to stop the motor. For integral and non-integral Prelub systems, the timer relay will delay 3 seconds before the starter circuit is activated to crank the engine. The timer relay will immediately activate the cranking circuit for HVP Prelub systems. The time for the Prelub system to generate sufficient pressure will be affected by oil viscosity. Consequently, for a given oil grade, the time to reach pressure will increase with cold temperatures. In order to maintain acceptable Prelub times apply arctic weather treatments as advised in the engine Operation & Maintenance Manual.

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Table of Contents
Introduction ......................................................................................................................................... 1 Purpose of Prelub System................................................................................................................ 1 Integral Prelub........................................................................................................................... 1 Non-Integral Prelub.................................................................................................................... 1 High Volume Pump (HVP).......................................................................................................... 1 Operation of Prelub System......................................................................................................... 1 Table of Contents................................................................................................................................. 2 Requirements....................................................................................................................................... 3 Pump/Motor..................................................................................................................................... 3 Time Relay Solenoid ........................................................................................................................ 3 Harness .......................................................................................................................................... 3 Standard Plumbing........................................................................................................................... 3 Prelub Application ............................................................................................................................... 4 Prelub System Layout ...................................................................................................................... 5 Prelub Pump Assembly .............................................................................................................. 5 Time Relay ................................................................................................................................ 5 Plumbing................................................................................................................................... 5 Wiring and Harness with Fuse .................................................................................................... 5 Prelub System Arrangements........................................................................................................... 6-8 Integral Prelub System..................................................................................................................... 6 Non-Integral Prelub System.............................................................................................................. 7 Prelub HVP Systems ....................................................................................................................... 8 Installation Requirements............................................................................................................... 9-16 Pump and Motor.............................................................................................................................. 9 Prelub Plumbing .............................................................................................................................. 9 Suction Side Hose ..................................................................................................................... 9 Pressure Side Hose.............................................................................................................. 9-10 Pressure Switch....................................................................................................................... 10 Timer Relay ............................................................................................................................. 10 Torque Recommendations ....................................................................................................... 11 Wire Harness...................................................................................................................... 11-12 HVP Installation.................................................................................................................. 12-16 Reference Documents........................................................................................................................ 16 Appendix ...................................................................................................................................... 17-26 High Volume Pump (HVP) Prelub.................................................................................................... 18 Integral Prelub Pump/Motor Cut Away ............................................................................................. 19 Electrical Components and Sensors ........................................................................................... 20-23 Timer Relay ........................................................................................................................ 20-21 300 AMP Fuse......................................................................................................................... 22 400 AMP Fuse......................................................................................................................... 22 Prelub Pressure Switch............................................................................................................ 23 Pump/Motor Bracket for Chassis Mounted and Engine Mounted ....................................................... 24 Wire Diagrams.......................................................................................................................... 25-26 Integral Prelub System - Single Starter...................................................................................... 25 Integral Prelub System - Dual Starter ........................................................................................ 25 Chassis Mounted Standard Prelub ............................................................................................ 26 HVP Prelub System ................................................................................................................. 26

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GENERAL PRELUB SYSTEM REQUIREMENTS

Pump/Motor
Maximum pump/motor height 12 inches (305mm) above crankshaft centerline

Timer Relay Solenoid

Timer relay solenoid orientation Minimize external forces along relay axis. Should be mounted such that axis of solenoid is parallel to the ground. For mobile equipment such as haul trucks, this axis should be perpendicular to the forward/reverse directions of equipment.

Harness
Fuse is to be mounted in power supply to the timer solenoid relay Prelub: 300 amp fuse HVP: 400 amp fuse Maximum resistance of main power circuit 0.004 ohm (24 volt standard system) 0.003 ohm (HVP system) Minimum wire gage for Prelub motor power circuit Prelub: #4 gage HVP: #0 gage Minimum wire insulation temperature capability o 120 C Wire insulation material Thermoset plastic Do not place excessive strain on any Prelub harness wires or connections

Standard Plumbing
Suction side hose requirements Prelub: #20 hose with 1 1/8" ID (> 30 liters) #16 hose with 7/8 " ID (< = 30 liters) HVP: #20 hose with 1 1/8" ID Maximum length: 50" (1.27m) Suction hose is plumbed in designated Prelub oil pan port Pressure side hose requirements Prelub: #12 hose with 5/8" ID (> 30 liters) #10 hose with 1/2" ID (< = 30 liters) HVP: #16 hose with 7/8" ID Pressure hose is plumbed before filters Recommended Hose Material to conform per Material Spec 23178. Maximum Hose length: Ratio of maximum pressure hose length to maximum suction hose length Suction Hose Size HVP #16, 7/8" ID #20, 1 1/8" ID #20, 1 1/8 ID Pressure Hose Size #10, 1/2" ID 2.5:1 1.5:1 N/A #12, 5/8" ID 4.5:1 2.5:1 N/A #16, 7/8" ID 10:1 7:1 4:1

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PRELUB APPLICATION
QSK45/60/78
These engines will offer the higher capacity HVP pump in order minimize engine pre-lubrication time. The Prelub HVP is a stand-alone pre-lube pump. Also included is a new timer solenoid, 2-terminal pressure switch, and 400 Amp fuse. Because the pre-lube pump is separate from the starter motor there is no need to delay engagement of the starter motor when the oil rifle pressure has reached the 2 psi trip point. Therefore, the HVP uses a .5 zero-second delay timer in place of the three-second delay used with the integral pre-lube pump. For the QSK45 engine, the Prelub HVP is available only as a remote off-engine installation due to space constraints. For the QSK60 engine, the Prelub HVP is available both on- and off-engine.

QST30
This engine will continue to use integral Prelub starter motors. Product improvements implemented include a more durable timer solenoid, a 300 Amp slow-burn fuse, and a 2-terminal 2.5 psi pressure switch. The pressure switch trip point has been reduced from 4 psi to 2.5 psi in order to ensure adequate startability.

Newly Available Options for 2001

HVP off-engine With LB starters ST6098 PL6731 HVP off-engine With RB starters ST6099 PL6731 HVP off-engine Remote LOFH w/ Eliminator ST6097 PL6726 HVP off-engine Remote Lube w/ Spin-on Filters ST6097 PL6730

Engine Model QSK45

QSK60

HVP on-engine With Spin-on Filters ST6095 PL6728

HVP off-engine With Eliminator ST6096 PL6729

QSK78

HVP on-engine With Eliminator ST6089 PL6724 no wiring harness PL6727 wiring harness

QST30

Standard Prelub PL5707

Deep Rear Sump PL5709

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Overview of Typical Prelub System Layout

Major Components of the Prelubrication System include: Prelub Pump Assembly (starter or remote mounted) Composed of a gear pump and an electric motor Pressurizes engine oil rifle

Timer Relay Composed of magnetic relay and timer logic module Controls the activation/deactivation of the Prelub system

Pressure Switch Normally closed oil pressure switch Identifies when specified pressure is achieved in the engine oil galleries

Plumbing Required plumbing includes suction side hose to oil pan, pressure side hose to engine, and check valve at the engine for the pressure side hose

Wiring and Harness with Fuse Integrates the electrical components of the Prelub system Connects the pressure switch, key switch, and starter relay to the timer solenoid and Prelub motor

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PRELUB SYSTEM ARRANGEMENTS

Integral Prelub Systems
Integral Prelub system can be applied where electric starters are used. The prelubrication starter/pump is substituted for the lower conventional starter. With the integral system most of the Prelub components will be installed on engine at the factory. The starter/pump, pressure switch, and plumbing will be installed at the factory. Only the timer relay and wire harness need to be installed by the OEM. The integral Prelub system is available for engine sizes 30 liters or less. The ST options in the engine sales handbook will detail the Integral Prelub mounting locations and arrangements. Integral System Assembly Starter and Pump Assembly (A) Timer Solenoid (B) Oil Pressure Switch (C) Plumbing: Suction Line (D), Outlet Line (E), and Check Valve (F) Wiring Harness

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Non-Integral Prelub System

The non-integral Prelub System is similar to the integral system. In this system a dedicated Delco motor is used to drive the Prelub pump. The pump is not integrated with the starter motor. The non-integral Prelub systems offer the OEM flexibility in mounting the Prelub system on the chassis or the engine. The OEM is responsible for installing and mounting the pump, plumbing, timer relay and wire harness. Non-Integral Prelub Assembly Motor and Pump (A) Timer Relay (B) Oil Pressure switch (C) Suction Line (D), Outlet Line (E), and Check Valve (F) Remote Mounting Bracket (G)

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Prelub HVP Systems

For engines of 45 liters and larger, RPM has developed the Prelub HVP system. The Prelub High Volume Pump (HVP) provides higher oil flows into the engine. The increased flow is required for the larger engines to quickly pressurize the engine oil rifle. Due to the pump design, the Prelub HVP system cannot be integrated with the engine starter motor. Consequently, the HVP Prelub system is available mounted on the engine or on the chassis. The engine mounted version of the Prelub HVP system is mounted to the engine via bracket. An example is shown below. Refer to the engine sales handbook for mounting arrangement details. Engine mounted Prelub HVP system is installed on the engine at the factory. The pump, hoses, and pressure switch are mounted at the factory. The OEM will install only the wire harness and timer relay.

The chassis mounted Prelub HVP uses the same motor and pump as the engine mounted system. A bracket for the HVP motor/pump assembly is provided with the engine in kit. The OEM is responsible for mounting the pump on the chassis. The OEM is also responsible for installing the plumbing, wire harness, and timer relay. The HVP engine mounted bracket is in the appendix for reference.

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INSTALLATION REQUIREMENTS Pump and Motor

For engine mounted Prelub and Prelub HVP systems, the location for the Prelub motor is selectable via the starter motor application option (ST option). The Prelub pump/motor, hose and pressure switch are mounted at the factory. Chassis mounted Prelub and HVP systems require a bracket for mounting the Prelub motor. A bracket is supplied in a kit with the engine. Drawings of the Prelub HVP brackets are included in the appendix. The pump mounting location on the chassis must be no higher than 1 foot above the engine crankshaft. The location must also be no further than 1270 mm [50 in] from the suction port in the oil pan. There is no limitation on the orientation of the installed pump. The wiring to the Prelub motor is documented in the appendix. HVP pump maximum duty cycle is 4 minutes ON and 30 minutes OFF. The ambient temperature range is from 40 to 125C (-40 to 257F).

Prelub Plumbing
Suction Side Hose The suction side hose will connect the oil pan sump to the Prelub pump. The suction hose will be installed at the factory for engine mounted Prelub systems. For optimum performance, the length of the suction side hose should be minimized. The OEM is responsible for installing the suction hose for chassis mounted systems. For standard Prelub system, engines larger than 30 liters should use a #20 with 1 1/8 ID for the suction side hose. A #16 with 7/8 ID hose should be used for engine sizes 30 liters and less. The HVP system will use a #20 with 1 1/8 ID. HVP system oil pan suction fitting should have at least 1 ID (1 5/8 ORB, 1 NPT, M42). The suction hose length is not to exceed 1270 mm [50 in] in length. The OEM should cut the hose to fit the installation. The oil supply port location varies by engine model. Refer to the oil pan option in the sales handbook for the designated Prelub port. The oil drain ports must not be used. Clips for the hose need to be used to avoid rubbing or excessive vibration. The clips are OEM supplied. Pressure Side Hose The pressure side hose will connect the Prelub pump to the engine. The pressure hose will be installed at the factory for engine mounted Prelub systems. For chassis mounted Prelub systems, a #10 hose with ID is supplied in the Prelub kit with the engine. HVP Prelub systems will be supplied with a #16 hose with 7/8 ID. The kit pressure side hose should be cut to fit the OEM application. HVP system oil return port should have at least 0.6 ID (3/4 pipe, 1 1/16 ORB, M22). The length of the pressure side hose is limited by diameters of the pressure and suction hoses as well as the length of the suction side hose. The table below provides the maximum pressure hose length to suction hose length ratios. Installations should use only high quality SAE connections and fittings for oil lines. Maximum Hose length: Ratio of maximum pressure hose length to maximum suction hose length Suction Hose Size #16, 7/8" ID #20, 1 1/8" ID HVP - #20 Pressure Hose Size #10, 1/2" ID 2.5:1 1.5:1 N/A #12, 5/8" ID 4.5:1 2.5:1 N/A #16, 7/8" ID 10:1 7:1 4:1

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The port location for the oil pressure hose will vary by engine model. Acceptable port locations are documented on the engine installation diagrams. For every installation, the pressure side hose must be connected before the engine lubrication filters. The check valve is to be installed where the pressure side hose is attached to the engine. Flow through the valve is to be toward the engine. The valve will prevent reverse flow after the engine is started. If the check valve is installed incorrectly, Prelub motor failure may result.

Pressure Switch
A pressure switch (normally closed) is included. This switch must be located to sense oil pressure after the oil has passed through the full flow oil filters. Switch has a 2.5 +/-0.5 psi pressure setting and a 2-terminal Packard connection which will improve assembly of the wiring harness to the switch. The recommended location is at the main oil rifle at the rear of the block or flywheel housing. See the appendix for pressure switch performance and terminal specifications.

Timer Relay
The timer relay must be mounted off the engine. The mounting technique should protect the unit from shock & vibration, excessive temperatures and direct high-pressure sprays. The relay must be mounted to minimize the shock and vibrations along the axis of the relay canister. For most wheeled applications, the timer relay canister should be mounted with the canister horizontal and axis of the canister at 90 to the crankshaft centerline. Mounting the canister horizontally will minimize the chance of the switch being actuated because of vertical shock loading. Mounting the canister at 90 to the direction of travel will minimize the chance of the switch being activated due to shock loading from the vehicle.

The relay must also be mounted to avoid heat sources such as mufflers and exhaust manifolds. The relay should not be exposed to ambient temperatures over 185 F (85 C). The relay should be protected from direct contact of a high pressure wash. Moisture may enter the canister and damage functionality. Refer to the appendix for the timer relays terminal specifications and bracket mounting details.

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Torque Recommendations
Switch Timer Connections: 3628971 and 3675123PL Coil Leads 25 in-lb 2.8 N-m Power Leads 45-50 in-lb 5-5.6 N-m 3633715 and 4065468 Heavy duty Coil Leads 20 in-lb 2.25 N-m Power Leads 90-110 in-lb 11.3-12.4 N-m 50MT Starter Connections: 3084198, 3628997, 3628757, 3629866, 3171100, 3410641, 3093137, 3603868PL, 3604658PL, 3604645PL, 3603866PL, 3675199PL Battery Positive Stud 20-25 ft-lb 27-34 N-m Motor Terminal 20-25 ft-lb 27-34 N-m Ground Stud 20-25 ft-lb 27-34 N-m S Terminal 16-30 in-lb 1.8-3.4 N-m 42 MT Starter Connections: 3094371, 3094393, 3604321PL, 3604484PL, 3604322PL Battery Positive Stud 20-25 ft-lb 27-34 N-m Motor Terminal 20-25 ft-lb 27-34 N-m Ground Stud 20-25 ft-lb 27-34 N-m S Terminal 16-30 in-lb 1.8-3.4 N-m 41RM Connections: 3628965, 3630004, 3675250PL Battery Positive Term 85 in-lb 9.5 N-m Ground Stud 20-25 ft-lb 27-34 N-m 40RM Connections: 3652546PL Battery Positive Stud 20-25 ft-lb 27-34 N-m Ground Stud 20-25 ft-lb 27-34 N-m Pressure Switches: 3629867, 3084200, 3628750, 3652554PL, 3652721PL Installation Torque Hand Tight and 1.5 turns when using thread sealer. Hand Tight and 2 turns when no thread sealer. Screw Terminals 12-15 in-lb 1.3-1.7 N-m 3094392, 3171350 Installation Torque 19-23 ft-lb 25-30 N-m Screw Terminals 12-15 ft-lb 1.3-1.7 N-m 3347747 Installation Torque 23-24 ft-lb 32-33 N-m Screw Terminals 15-20 in-lb 1.3-1.7 N-m Check Valves 3804202, 3628751, 3633246, 3675124PL, 4007201, 4065979 Installation Torque Hand Tight plus 1.5 turns 3094401 Installation Torque 55-70 ft-lb 75-95 N-m

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Wire Harness
A wire harness for the Prelub system is provided in a kit with the engine. The provided wire harness will connect the pressure switch and the Prelub motor to the timer relay. The OEM is responsible for providing system voltage to the B+ terminal on the Prelub starter motor or the B+ terminal of the chassis mounted Prelub harness. The OEM is also responsible for providing a ground wire from the Prelub motor back to the batteries. The wiring for the Prelub system and cranking motor must meet Cummins wiring requirements. See AEB 111.15 for wiring requirements. The harness will also include a fuse to protect the Prelub circuit. In accordance with Cummins AEB 111.15 all circuits (except cranking) must be protected by a fuse. The nominal, steady state, current draw during a Prelub cycle is approximately 200amp, and maximum current draw is approximately 270amp. Consequently, the Prelub harness is sized smaller than a cranking motor harness. However, if the motor fails during the Prelub cycle, the motor is capable to pull much higher currents. The smaller Prelub harness is more susceptible to damage when compared to the larger cranking harness. The fuse will protect the Prelub harness from progressive damage. It is recommended that the wire harness included with the Prelub system is used in the engine installation. However, if the OEM is unable to use the standard harness, the OEM may accept design responsibility and develop a custom harness. If a custom harness is developed, refer to AEB 111.15 design guidelines. Additional recommendations unique to the Prelub system include: Minimum wire size Prelub: #4 gage Prelub HVP: #0 gage Maximum resistance of main power circuit 0.004 ohm (24 volt standard system)\ 0.003 ohm (HVP system) Wire installation temperature capability o 120 C Wire installation material Thermoset plastic Fuse Prelub: 300 amp maximum Prelub HVP: 400 amp maximum The OEM is responsible for wiring from the battery to the B+ terminal on the Prelub motor and for the wiring from the ignition switch to the timer logic module or the RPM harness. Refer to Cummins AEB 111.15 for wiring recommendations. The wire diagrams of the standard RPM harness are in the appendix.

Instructions to aid Installation of the HVP onto QSK60 engines with Spin-on Filters
1) Installation of Bracket - Pump bracket p/n 4066169 is to be fitted to the set of 4 mounting holes on the cylinder block (2 M12 on oil pan rail and 2 M10 on cylinder block side face) that are closest to the oil filter head. The M12 capscrews (p/n 3910495) are torqued to 80Nm, and the M10 capscrews (p/n 3089016) are torqued to 45Nm. 2) Installation of Fittings into HVP - Lightly lubricate the O rings of all straight thread O ring connections using 15W40 oil. Install elbow p/n 3393258 into the upper supply port of the HVP Prelub. Position the elbow facing forward and tighten to 78Nm. Install elbow p/n 4065714 into the lower suction port of the HVP Prelub. Position the elbow so that it is facing forwards and into the cylinder block at an angle of approx. 45 degrees and tighten to 101Nm. See Photo HVP (4).

AEB 44.01 Page 13 of 26

3) Installation of the HVP Prelub to the Bracket - Locate the HVP Prelub unit (p/n 4065469) into the two U saddles on the bracket, centralise and then fit the U shaped pump brackets 2 with p/n 4066180. These brackets are secured with 4 M10 capscrews (p/n 3902460). A small amount of Loctite 641 should be applied to the capscrew threads, and the capscrews tightened down evenly to a torque of 30Nm. 4) Installation of Supply Hose - Elbow p/n 4065496 is installed into the M33 port at the front of the lub oil filter head to a torque of 60Nm. The elbow is positioned to point to the rear of the engine and slightly outboard. The check valve assembly (p/n 4065979) is fitted onto the elbow with a torque of 47Nm. A thin coat of Loctite 641 should be applied to the elbow thread prior to check valve assembly. The supply hose p/n 4066164 is installed between the check valve assembly and the upper HVP elbow with the hose elbow end at the HVP connection. Hose nut torque to be 190Nm. See Photos HVP 2 & 4. The hose is secured using 1 spacer p/n 3629762, 1 capscrew p/n 3904446 and 1 clip p/n 67950 which is installed onto the lower number 4 RB handhole cover. The check valve assembly is secured using 1 spacer p/n 3629762, 1 capscrew p/n 3904446 and 1 clip p/n 68189 which is installed onto the lower number 3 RB handhole cover. 5) Installation of Suction Hose - Elbow p/n 3410392 is installed into the M42 port on the right bank of the oil pan adapter nearest the rear of the engine. The suction hose p/n 4066166 is installed between the HVP lower connection and the oil pan adapter elbow. The hose is supported via a bracket p/n 109895 which is mounted onto the underside of the oil pan adapter in a location on the 2nd capscrew rearwards from the central weep hole boss. A hose clip p/n 68189 is secured around the hose and connected to the bracket using 1 capscrew p/n 3903990 and 1 nut p/n 3093828. Torque to 45Nm.

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Instructions to aid conversion of QSK60 engines from Integral Prelub to HVP Prelub
1) If engine in equipped with Eliminator, see photo below for connection locations of plumbing from HVP to the engine.

Pressure Connection Supply Connection (Elbow 3410392)

HVP Pump (off-engine)

View looking to the rear

2) Parts and Plugs needed for conversion from Integral Prelub to HVP Prelub: Plugs required for removal of Integral Prelub: Engine sump supply connection: 42mm ORB (P/N 3089023) Eliminator pressure connection: 22mm ORB (P/N 3089238) Integral Prelub motor pump housing (not required if Integral Prelub starter is replaced with standard 50MT starter, P/N 3171099): Supply: 7/8-14 ORB Pressure: -16 ORB

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Parts required for installation of HVP: Timer Relay (P/N 4065468) Pressure Switch (P/N 4065465) Wire Harness Kit (P/N 4065275) Parts as shown per diagram below: HVP 4065469 Elbow 3393258 Elbow 4065714

Hose 4065573

Hose 4065571

Union 4007207 Check Valve 4007204

To M42 sump port Elbow 3410392

To bottom port on Eliminator Elbow 4065549 Union 4065547

3) Upfit Procedure: Remove Integral Prelub pump gears, (replace gasket) } Note: These 2 steps not required if standard Install (2) plugs in Integral Prelub pump housing } 50MT starter is upfitted in lieu of Integral starter Install (2) plugs in engine previous Integral Prelub connection Remove Integral Prelub hoses Remove Integral Prelub harness Original 1-terminal pressure switch in flywheel housing must be replaced with new pressure switch, P/N 4065465. Install remote HVP wiring harness kit, P/N 4065275 Install timer relay, P/N 4065468.

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Reference Documents:
AEB 111.15 -- Cummins Branded Electric's Service Bulletin 3666091 -- Prelub Installation AEB 40.12 Cummins Prelub for K19, K38/50, and V28 Construction Engines

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APPENDIX
HVP Pump Integral Prelub Pump Motor Cut Away Electrical Components and Sensors Timer Relay: All Systems 300 Amp Fuse: Standard Prelub Systems 400 Amp Fuse: High Volume Pump Systems Prelub Pressure Switch Chassis Mounted Brackets Pump/Motor Bracket: Chassis and HVP Systems Wire Diagrams Integral Prelub with Single Starter Integral Prelub with Dual Starters Chassis Mounted Prelub High Volume Pump Prelub System

AEB 44.01 Page 18 of 26

High Volume Pump (HVP) Prelub (P/N 4065469 with brackets, P/N 4007201 without brackets (QSK78)) Pump has -13 terminal studs 5.250 1 4.964

6.250

Motor/Pump Dimensions: Length: Height w/ mounting bracket (not shown): Width with mounting bracket (not shown): Performance:

15 inch (381 mm) 9 inch (229 mm) 6 inch (152 mm)

70 F 15W-40 Oil: 30-40 gpm @ 180-230A depending on available engine port sizes. 0 F 15W-40 Oil: 20-30 gpm @ 300-350A depending on available engine port sizes.

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Integral Prelub Pump/Motor Diagram

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Timer Relay: QST30 Engine (3-sec delay) (P/N 3633715)

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Timer Relay: QSK45/60/78 Engines (P/N 4065468)

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300 AMP Fuse: Integral Prelub System (P/N 3633716)

400 AMP Fuse: High Volume Pump (HVP only) Prelub Systems (P/N 4007418)

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Pressure Switch for QST30, QSK45/60/78 Prelub systems (P/N 4065465)

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QSKV Pump/Motor Bracket Chassis Mounted Prelub and HVP (Supplier RPM P/N 102707)

Bracket for Engine-Mounted HVP Prelub Pump (1 bracket P/N 4066169, 2 brackets P/N 4066180)

2 x 4066180 Brackets

4066169 Bracket

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Integral Prelub System - Single Starter

MACHINE IGNITION SWITCH Existing Ignition "Start"Wire
START

TO BATTERY "+"

337 WH 307 OR
MACHINE STARTER RELAY

200 BK SWITCH / TIMER 447 PK 301 PUR PRESSURE SWITCH

F U S E 200 BK

MOTOR

G S

STARTER CRANK SOLENOID

BATTERY 101 RD
TO BATTERY "+"
PRELUB is a trademark of RPM Industries, Inc.

Integral Prelub System - Dual Starter

MACHINE STARTER RELAYS TO BATTERY "+"
ST (START)

Existing Ignition "Start" Wire

337 W 307 OR

MACHINE IGNITION SWITCH

200 BK 447 PK 301 PUR PRESSURE SWITCH

SWITCH / TIMER

F U S E

MOTOR

MOTOR

200 BK

STARTER CRANK SOLENOID

CONVENTIONAL STARTER CRANK SOLENOID

BATTERY

BATTERY

101 RD
TO BATTERY "+"
PRELUB is a trademark of RPM Industries, Inc.

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Chassis Mounted Standard Prelub

MACHINE IGNITION SWITCH Existing Ignition "Start"Wire
START

TO BATTERY "+"

337 WH 307 OR

MACHINE STARTER RELAY TO STARTER "S" TERMINAL

SWITCH / TIMER ASSEMBLY

200 BK

447 PK

PRESSURE SWITCH

101 RD F U S E

200 BK 301 OR

TO BATTERY "+"

PRELUB is a trademark of RPM Industries, Inc.

HVP Prelub System

MACHINE IGNITION SWITCH
ST RELAY (START) (RUN)

TO BATTERY "+"

307 OR

SPLICE

EXISTING IGNITION WIRE

TO AIR OR ELECTRIC STARTER

337 WH

MACHINE STARTER RELAY

SWITCH/TIMER PRESSURE SWITCH 200 BL FUSE BATTERY +

HVP UNIT

PRELUB is a trademark of RPM Industries, Inc.