DETROIT DIESEL © Installation Instructions a 18SP523—installation of Remote-Mounted PRELUB Kit on Series 4000 Construction, Industrial and Generator Engines Introduction Detroit Diesel® Series 4000™ construction, industrial Tris remote-mounted PRELUB* engine pre-lubrication and generator engine. The kit consists of the Items kit is intended for installation on a U.S.-manufactured sted in Table 1 Item No. | PartNumber | Qty. Description 23640380 1 | Kit, PRELUB System for Construction, Industrial, and Generator Set Engines [NOTE: A kit consists of the single dash () Items shown in its respective column.) 2 23640211 1_ [= Adaptor, #16 JIC (M)— #12 NPT (M) 3 23640213 1 [= Check Valve, 8/4 in, NPT 4 23540214 1_ [= Elbow, #12 STOR (M)— #12 NPT (Vp 7 23640216 1_[ = Seal Ring, Copper 8 23640215 1_ [= Adaptor, Engine Inlet 10 23640212 1 [= Adaptor, 45 Dag., #16 JIC (M) — #12 NPT (M) 1 23540206 1_ [= Pump Fitting, Straight #16 STOR (M) — #16 JIC (M) 14 23640217 1_[_ = Pressure Switch, M10 Base 16 23640181 1_[- Pump Asm., High Volume w/o Switch Timer 7 23640205 1_[- = Pump Fitting, Straight #20 STOR (M) ~ #24 JIC (M) 18 23640204 1_[_ = Pump Fitting Elbow, #20 STOR (M) ~ #24 JIC (M) 22 23640201 1_[_ = Screen Fitting, Elbow 16 NPT (M)— 24 JIC (M) 24 23640219 1_[_ = Fitting, Tee for Pressure Switch 18SP523 = Installation Instructions 23640184 1_ [= Switch/Timer 23640185 4 | —Bot 23640186 1_ [= Wiring Hamess, Main 23540187 1__[—Harness, Key Switch 23640188, 1_[ = Power Cable Assembly w/Fuse 23640192 1 [= Cable Assembly 23540670 1_ [= Adaptor, Wiring Harness 23640194 1_[_ = Windshield Sticker # Item numbers refer to kit parts shown on Figure 1. See Figure 1 Table 1. PRELUB System Kit 23540380 Components 18SP523 Page 1 of 16PRELUB System Operation ‘The PRELUB system is activated when the ignition key is tured to the start postion. However, before initiating an engine start, the PRELUB system first draws oil from the oll pan and pumps it through a check valve into the all fiter. The fitered oil then flows into the engine, filing the ol galleries up to the 4 psi (28 kPa) pressure switch setting. When this pressure setting is reached, the electronics within the PRELUB system energize the starting motor to crank the engine. Thus, the engine wil not start until critical bearing surfaces have a full charge of lubricating oll and a minimum oil system pressure of 4 psi (28 kPa). Installing the PRELUB System Install the remote-mounted PRELUB system as follows: Q caution: “To avoid injury trom accidental engine start-up while servicing the engine, disconnect/clsable the starting system, 1. With the engine at ambient temperature and cool to, the touch, disconnect/disable the electrical starting system to prevent accidental engine start-up. 2,.Using a suitable container, drain the lubricating oll from the engine and discard in an environmentally responsible manner, according to state and/or federal (EPA) recommendations. 8. Remove a suitable plug from the oll pan and attach the suction hose by using adaptors. The oil pan connection must be low enough to ensure oll can be pumped. See Figure 2 4, The suction hose assembly plumbs into the engine ll pan through a plug on the ol pan, See Figure 2. Determine which 1 in. NPT plug is the closest to the pump location, Replace this plug with suction screen fitting item 22 provided in the kt. See Figure 1 5. Mount the PRELUB pump in a place that allows the suction hose length to be 36 in. or less and no smaller than 1 in. 1D. The pump should be no more than 3 feet higher than the ol pan port selected. 5. Install suction hose and fittings as follows: Locally supplied hose (Aeroguip® 2661-24 RL or equivalent) should be obtained, Cut the hose to the appropriate length, if necessary, and assemble the fiings on the hose. NOTICE: Do not use a hose smaller than #24 for the suction side of the pump. This could cause pump matfunction or failure. 7. if the machine is equipped with an electric starting motor, mount the pump adjacent to the starter, if possible. This will make electrical connections easier. See Figure S for PRELUB pump installation dimensions. 8. Prime the suction side of the PRELUB pump. 9. Install the fitting (See Figure 1, tern 17 oF 18) in the suction port of the PRELUB pump. Connect one end of the hose assembly to the suction screen fitting (item 22) and the other end to the suction port fitting (tem 17 or 18) on the PRELUB pump. NOTICE: If the wrong plate location is used, the pump wil run continuously and the engine will not start. 10, Remove the metric plug ‘tom the water distribution housing (see Figure 5) and replace it with the metric male-to-female STOR adaptor (tem 8) and washer (item 7) provided. Then connect the male NPT elbow (item 4) into the STOR adaptor already installed. Assemble the check valve (tem 8) using the fittings provided. NOTE: For proper check valve operation, make sure the arrow ‘on the valve points toward the fiter adaptor. 11. Locally supplied hose (Aeroquip FC350-16 or equivalent) should be obtained, Cut the hose to the appropriate length, if necessary, and assemble the fittings on the hose. NOTICE: Do not use a hose smaller than #16 for the pressure side of the pump. This could cause pump matfunction or faire. 12, Install the fiting (tem 2 or 10) in the check valve (item 8). Install the pressure-sice hose to this fiting (tem 2 or 10} and to fitting item 11} on the outlet side of the PRELUB pump. 18SP523 Page 2 of 1613. Remove the M10 plug on the side of the oll fiter housing (see Figure 6) and instal the tee (tem 24) with the O-ring seal provided. 14, Install the PRELUB pressure switch (tem 14) in the M10 port of the tee. 15. Secure all hoses with clamps or tie-straps to prevent vibration damage. Refll the engine with the required lubricating oil Wiring the PRELUB System Using the components supplied in the kit, wire the PRELUB system as folows: 1. Mount the PRELUB switch/timer assembly onto the: high volume pump. See Figure 7. 2, Plug the PRELUB main wiring harness into the ‘connector on the PRELUB switchvtimer assembly, See Figure 9. 4, Plug the small PRELUB wiring harness into the main PRELUB hamess. Secure harness with ties to prevent chafing or vibration damage. 5, Connect the pink wire (447 PK) of the PRELUB main harness to the "NC" terminal on the pressure switch (tem 14) located in the cil fiter housing Connect the black wire (200 BK) to the “C” terminal. NoTici ‘To avoid possible electrical system damage, use a multimeter set for VOC to verify engine crank/start terminal on the key switch before attaching the white wire (837 WH) to the switch, 6. Locate the ignition “Start” wire connection at the ‘Start’ or “ST" terminal of the main key switch Remove this wire from the terminal and use the connector provided to splice it to the orange wire (G07 OR) of the small PRELUB harness. 7.Conneet the white wire (387 WH) of the small harness to the “Start” or “ST” terminal of the key switch. Connect the second orange wire (113 OR) of the small harness to the "Ru terminal of the key switch. 8. Locate the end of the main PRELUB hamess with ‘two large cables (103 RD and 801 OR) and one small, black wire (200 BK). Connect the red (103 RD) cable to the field stud on the PRELUB remote unit. Connect the orange cable (801 OR) to the battery positive (+) terminal 9, Connect the small black wire (200 BK) and the black ground cable included in the kit to the Ground” terminal on the back of the PRELUB remote unit, Connect the other end of the ground cable to the battery ground/negative terminal 10. Check to make sure all connections are tight and cables are properly supported, then reinstall all standard machine connections and terminal covers 11. Attach PRELUB starting system windshield sticker to the windshield or to a convenient location on the dashboard, gage panel or control bridge. 12. Start the engine and check for proper PRELUB system operation PRELUB System Troubleshooting Flow Chart If the PRELUB system does not function properly after instalation, refer to the flowchart for troubleshooting the system, See Figure 11 18SP523 Page 3 of 16anaa1s3ul4 Figure 1. PRELUB System Plumbing Components (C & I, Generator and Marine) (NOTE: Not all items shown are for C&l or Generator applications.) ‘48SP523 Page 4 of 16IF PLUMBING THE SUCTION HOSE TO THE FRONT OF THE OIL PAN, REMOVE THE PLUG SHOWN BY THE ARROW AND REPLACE IT WITH THE SCREENED FITTINGS (ITEM 19) SUPPLIED IN THE PLUMBING KIT. OIL PAN FITTING - REAR OF ENGINE OIL PAN FITTING - FRONT OF ENGINE IF PLUMBING THE SUCTION HOSE TO THE REAR OF THE OIL PAN, REMOVE THE CENTER PLUG ARROW AND REPLACE IT WITH THE SCREENED FITTINGS, (ITEM 19) SUPPLIED IN THE PLUMBING KIT. THE CENTER FITTING IS THE RECOMMENDED LOCATION, BUT THE OUTER BLOCKS MAY BE. USED IF THE THREAD SIZE IS 1 INCH NPT. 2682007] Figure 2. Installation of Remote-Mounted PRELUB Kit on Series 4000 Engine 18SP523 Page 5 of 16dl 21684008 Figure 3. PRELUB Pump Installation Dimensions REMOVE THIS PLATE AND REPLACE WITH PLATE PROVIDED IN | KIT, LONGER BOLTS ARE PROVIDED TO SECURE THE THICKER PLATE, 2188008 Figure 4, PRELUB System Plumbing Connection Point on Series 4000 C&l and Generator Engine 48SP523 Page 6 of 16