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Procedure for Installing the 296-0014 Prelubrication Oil Pump Gp on C175 Generator Sets{1307, 1319} Caterpillar


Procedure for Installing the 296-0014 Prelubrication Oil Pump Gp on C175 Generator Sets{1307, 1319}

Usage:

C175-16 WYB
Generator Set:
C175-16 (S/N: WYB1-UP)

Introduction

This Special Instruction is used to install the 296-0014 Prelubrication Oil Pump Gp on certain C175 Generator Sets. Do not perform any procedure that is outlined in this Special Instruction until you read and understand the information that is contained in this document.

1800 and 3000 Series Generators Required Parts List

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Table 1
Parts List for 1800 Series Generators    
Qty     Part Number     Part Description    
1     091-1442     Spacer    
2     112-6646     Locknut    
1     123-6574     Bushing    
2     132-5789     Clips    
1     148-0757     Magnetic Switch Gp    
4     168-2067     Mount As    
8     193-9723     Washer    
1     227-0066     Connector    
2     228-7094     O-Ring Seal    
3     228-7096     O-Ring Seal    
2     228-7108     O-Ring Seal    
1     250-1968     Wiring Diagram    
1     263-6735     Cable Fitting    
1     278-7292     Bracket As    
2     278-7339     Flexible Mount    
1     295-7548     Bracket As    
1     295-7549     Bracket    
1     295-7550     Bracket    
1     296-0014     Prelubrication Oil Pump Gp    
1     313-2647     Ball Valve    
1     313-9605     Elbow    
1     313-9606     Elbow    
1     318-3200     Hose As    
1     322-3434     Wiring Harness    
1     341-0113     Elbow As    
1     347-4445     Adapter    
1     348-8729     Check Valve    
1     378-8929     Hose As    
1     3W-9670     Boss    
1     4P-7429     Clip    
3     4P-7581     Clips    
9     4P-8134     Clip    
8     4P-8134     Clips    
8     5P-1076     Hard Washer    
2     5P-4115     Hard Washers    
1     5P-7470     Clip    
1     5P-7471     Clip    
1     5P-8182     Grommet    
1     5P-7815     O-Ring Seal    
2     6V-5100     O-Ring Seal    
2     6V-7357     Bolt    
2     6V-8400     O-Ring Seal    
1     6V-9006     Elbow    
1     6V-9513     Plug    
15     7K-1181     Cable Strap    
2     7X-2619     Bolts    
2     8C-3398     Lockwasher    
4     8T-3647     Bolts    
13     8T-4121     Hard Washers    
6     8T-4133     Nut    
1     8T-4139     Bolt    
1     8T-4191     Bolt    
1     8T-6466     Bolt    
2     8T-4136     Bolts    
10     8T-4184     Bolts    
4     8T-4186     Bolts    
12     8T-4223     Hard Washers    
8     8T-4224     Hard Washers    
9     8T-4244     Nuts    
4     8T-4908     Bolts    
5     8T-5005     Bolts    
1     9M-4494     Nut    
1     9S-6130     Plug    
4     9X-8256     Washers    

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Table 2
Parts List for 3000 Series Generators    
Qty     Part Number     Part Description    
1     2Y-5829     Nut    
1     3W-9670     Boss    
2     4P-7581     Clip    
11     5P-1076     Hard Washer    
2     5P-4115     Hard Washer    
1     5P-5846     O-Ring Seal    
1     5P-7470     Clip    
1     5P-7471     Clip    
1     5P-8182     Grommet    
1     6V-3822     Bolt    
2     6V-5100     O-Ring Seal    
6     6V-5839     Washer    
2     6V-7357     Bolt    
2     6V-8400     O-Ring Seal    
1     6V-9006     Elbow    
19     7K-1181     Cable Strap    
2     7X-2619     Bolt    
2     8C-3398     Lockwasher    
4     8T-3647     Bolt    
12     8T-4121     Hard Washer    
7     8T-4133     Nut    
2     8T-4136     Bolt    
1     8T-4139     Bolt    
11     8T-4184     Bolt    
1     8T-4185     Bolt    
4     8T-4186     Bolt    
7     8T-4223     Hard Washer    
8     8T-4224     Hard Washer    
7     8T-4244     Nut    
4     8T-4908     Bolt    
4     8T-5005     Bolt    
1     8T-6466     Bolt    
1     9M-4494     Nut    
4     9X-8256     Washer    
1     091-1442     Spacer    
2     112-6646     Locknut    
1     123-6574     Bushing    
7     132-5789     Clip    
1     148-0757     Magnetic Switch Gp    
4     168-2067     Mount As    
8     193-9723     Washer    
1     227-0066     Connector    
2     228-7094     O-Ring Seal    
3     228-7096     O-Ring Seal    
2     228-7108     O-Ring Seal    
1     263-6735     Cable Fitting    
1     278-7292     Bracket As    
2     278-7339     Flexible Mount    
1     296-0014     Prelubrication Oil Pump Gp    
1     297-1148     Bracket As    
2     297-1149     Bracket As    
1     297-2370     Bracket    
1     313-2647     Ball Valve    
1     313-9605     Elbow    
2     313-9606     Elbow    
1     318-3200     Hose As    
2     322-3434     Wiring Harness    
1     341-0113     Elbow As    
1     347-4445     Adapter    
1     348-8729     Check Valve    
1     378-8929     Hose As    

Installation Procedure

Installation of Pump Group and Mounting Brackets

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Illustration 1g03318439

View of mounting brackets for 1800 series generator

(1) 295-7550 Bracket

(2) 8T-4184 Bolts

(3) 8T-4223 Washers

(4) 295-7548 Bracket As

(5) 8T-5005 Bolt

(6) 8T-4226 Plated Washer

(7) 168-2067 Mount As

(8) 295-7549 Bracket

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Illustration 2g03318787

View of mounting brackets for 3000 series generator

(5) 8T-5005 Bolt

(6) 8T-4226 Plated Washer

(7) 168-2067 Mount As

(9) 297-2370 Bracket

(10) 297-1149 Bracket As

(11) 8T-4184 Bolt

(12) 5P-1076 Hard Washer

(13) 297-1148 Bracket As

  1. Use the following Steps in order to assemble the pump mounting brackets.

    1. For 1800 series generators, install bracket (1) onto the end of bracket (4) using two bolts (2) and washers (3). Install four mounts (7) into bracket (8). Fasten bracket (8) to bracket (4) using four bolts (5). Install washer (6) on the top of the four mounts (7) and on the bottom of the four mounts. Refer to Illustration 1:

    1. For 3000 series generators, install brackets (10) on either end of bracket (13). Use bolts (11) with washer (12) to secure the brackets. Install four mounts (7) into bracket (8). Fasten bracket (8) to bracket (4) using four bolts (5). Install washer (6) on the top of the four mounts (7) and on the bottom of the four mounts. Refer to Illustration 2.
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    Illustration 3g03318496

    Typical example

    (14) 296-0014 Prelubrication Oil Pump Gp

    (15) 8T-4186 Bolt

    (16) 8T-4121 Hard Washer

    (17) 8T-4133 Nuts

  1. Install pump (14) onto the bracket using four bolts (15), eight washers (16) , and four nuts (17) at the top of the bracket and the bottom of the bracket.
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    Illustration 4g03318518

    (18) 8T-4908 Bolts

    (19) 8T-4224 Hard Washers

    (20) 313-9606 Elbow

    (21) 8T-3647 Bolts

  1. Clean the surfaces of the flange on both sides of the pump before the fittings are installed.

  1. Lubricate the 6V-5100 O-Ring Seal using 1U-6396 O-Ring Assembly Compound . Install o-ring seals onto elbow (20). Install elbow (20) .

  1. Install elbow (20) onto the pump using bolts (18) and (21) and washers (19) as shown in Illustration 4.
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    Illustration 5g03318543

    Typical example

    (18) 8T-4908 Bolts

    (19) 8T-4224 Hard Washers

    (20) 313-9606 Elbow

    (21) 8T-3647 Bolts

    (22) 341-0113 Elbow As

    (23) 313-9606 Elbow

  1. Lubricate the 6V-5100 O-Ring Seal and the 228-7108 O-Ring Seal , with 1U-6396 O-Ring Assembly Compound . Install o-ring seals onto the elbows (22) and (23) .

  1. Install elbows (22), and (23) into elbow (20) .
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    Illustration 6g03318936

    (24) Cover

    (25) End nuts

    (26) Cable fitting

  1. Remove the two end nuts (25) from cover (24) on the pump motor.

  1. Install the cable fitting (26) onto the motor cover (24) and secure the cable fitting with a 9M-4494 Nut .

  1. Install a 123-6574 Bushing onto Cable Fitting (26) .

  1. Reinstall the motor cover onto the pump motor. Leave the nuts loose on the motor cover. The cover will be removed for installation of the wiring harness.
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    Illustration 7g03318960

    (27) 347-4445 Adapter

    (28) 313-2647 Ball Valve

    (29) 6V-9006 Elbow

  1. Drain engine oil to a level that is below the prelube hose connection port.

  1. Remove the oil pan plug.

  1. Lubricate a 228-7108 O-Ring Seal using 1U-6396 O-Ring Assembly Compound and install onto adapter (27) .

  1. Install adapter (27) onto the oil pan.

  1. Lubricate a 228-7096 O-Ring Seal using 1U-6396 O-Ring Assembly Compound and install onto ball valve (28) .

  1. Install ball valve (28) onto adapter (27) and position the valve at the 12 o'clock position.

  1. Lubricate a 228-7096 O-Ring Seal using 1U-6396 O-Ring Assembly Compound and install onto elbow (29) .

  1. Install elbow (29) onto ball valve (28). Position the elbow as shown in illustration 7.

Installation of Prelube Pump onto the Base Rails

  1. Set the pump mounting bracket onto the base frame rails.
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    Illustration 8g03318969

    Side-by-side view of 1800 and 3000 series generator mounting brackets with hardware

    (2) 8T-4184 Bolt

    (3) 8T-4223 Hard Washer

    (11) 5P-1076 Hard Washer

    (30) 8T-4244 Nut

  1. Secure the mounting bracket to the base frame using bolts (2) with washer (11) are installed on the bottom. Install nut (30) with washer (3) onto the bottom side of the bracket.
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    Illustration 9g02207596

  1. On a 1800 series, install 4P-8134 Clip in the locations shown in Illustration 9. The clips will be used to secure the wiring harness.
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    Illustration 10g03318984

  1. On a 3000 series, install 4P-8134 Clips in the locations shown in Illustration 10. The clips will secure the wiring harness with 7K-1181 Cable Straps . The 132-5789 Clip on the left bracket will be secured with a 2Y-5829 Nut , 6V-5839 Washer and 6V-3822 Bolt .

Installation of Piping from the Engine to the Prelube Pump

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    Illustration 11g03319029

    (16) 8T-4121 Hard Washers

    (31) 313-9605 Elbow

    (32) 8T-4136 Bolts

    (33) 348-8729 Check Valve

    (34) 6V-8400 O-Ring Seal

    (35) 378-8929 Hose As

  1. Lubricate the seal of the elbow (31) using 1U-6396 O-Ring Assembly Compound . Install the elbow onto the oil pump outlet housing.

  1. Secure elbow (31) with bolts (32) and washers (16) .

  1. Lubricate the bore of the elbow (31) with 1U-6396 O-Ring Assembly Compound .

  1. Install check valve (33) into elbow (31). Secure hose (35) to the end of the check valve (33) .
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    Illustration 12g02731755

    Typical side view

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    Illustration 13g03319059

    (5) 8T-5005 Bolt

    (16) 8T-4121 Hard Washers

    (17) 8T-4133 Nut

    (36) 3W-9670 Boss

    (37) 5P-7470 Clip

    (38) 5P-7471 Clip

    (39) 5P-8182 Grommet

  1. Install grommet (39), clips (37), (38) and spacer (36) as shown in Illustration 13. Secure the clips and spacers to the base with bolt (5) with washer (16), and nut (17) .
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    Illustration 14g03319077

    (35) 378-8929 Hose As

    (40) 341-0113 Elbow As

  1. Lubricate a 228-7094 O-Ring Seals with 1U-6396 O-Ring Assembly Compound and install onto hose (3) .

  1. Secure hose (35) onto the elbow (40) shown in Illustration 14.
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    Illustration 15g03319082

    (41) 318-3200 Hose As

  1. Lubricate a 228-7094 O-Ring Seal using 1U-6396 O-Ring Assembly Compound and install onto hose (41) .

  1. Install hose (41) between the oil pan and the prelube pump.

Installation Procedure for Wiring Group

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    Illustration 16g02733296

    (1) Harness

    (2) 4P-7429 Clip

    (3) 8T-4139 Bolt

    (4) 8T-4223 Hard Washers

    (5) 8T-4244 Nut

  1. Secure the clip (2) onto the frame rail with bolt (3) washer (4), and nut (5) .

  1. Route the (1) harness along the 378-8929 Hose As and secure the harness with (6) 7K-1181 Cable Straps . Refer to Illustration 16.
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    Illustration 17g03319463

    278-7293 Solenoid Mounting Gp

    Refer to print 278-7293 Solenoid Mounting Gp for detailed information.

    (7) 5P-4115 Hard Washer

    (8) 7X-2619 Bolt

    (9) 8C-3398 Lockwasher

    (10) 278-7339 Flexible Mount

    (11) 9X-8256 Washer

    (12) 112-6646 Locknut

    (13) 148-0757 Magnetic Switch Gp

    (14) 278-7292 Bracket As

    (15) 8T-4121 Hard Washer

    (16) 8T-4191 Bolt

    (17) 4P-7581 Clip

    (18) 7K-1181 Cable Strap

  1. Assemble 278-7293 Solenoid Mounting Gp as shown in Illustration 17.
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    Illustration 18g03319488

    (19) 278-7293 Solenoid Mounting Gp

  1. Install solenoid (19) to the prelube pump mounting base as shown in Illustration 18.

  1. Connect the wiring harness to the solenoid.

  1. Route the wiring harness to the prelube pump motor. Secure the harness to the installed 4P-8134 Clips using 7K-1181 Cable Straps .

  1. Remove the cover to the prelube pump motor and install the harness cable into the 263-6735 Cable Fitting .
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    Illustration 19g02210773

    Prelube pump electrical terminals

  1. Install the harness leads onto the prelube pump motor. Connect the red lead to the positive terminal. Connect the other lead to the negative terminal. Refer to Illustration 19.

  1. Reinstall prelube pump motor cover.
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    Illustration 20g02224176

  1. Install the 4P-8134 Clips to the crankshaft side covers.

  1. Secure the harness to the engine using 7K-1181 Cable Straps .
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    Illustration 21g02223556

  1. Connect the opposite end of the harness to the circuit panel. Connect the connector receptacle.
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    Illustration 22g03319492

    (20) Ground stud

  1. Connect the ground connector to ground stud (20) .
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    Illustration 23g03319494

    (21) Prelube breaker

  1. Connect the power connector to prelube breaker (21) .

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