Procedure for Engine Idle Reduction System Upgrade on Certain 3512E Engines {1901, 1920} Caterpillar

Engine

3512E (S/N: SK31-UP; SK51-UP)

Pumper

SPF743 (S/N: SK71-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction describes the procedure for installing the new engine idle reduction system upgrade on certain 3512E engines.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

Required Parts

Table 1 shows all the available kits for this upgrade.

Table 2 contains the 561-8703 Battery Gp for the required battery kit.

Installation Procedure for the Engine Idle Reduction System Core Upgrade Kit (T4F)

Table 3 contains the 561-8696 Engine Conversion Kit used on all configurations.

Installation Procedure for the optional Low Profile Water Jacket Elbow Kit

Table 4 contains the 561-8695 Pipe Elbow and is used if you are using the jacket water port above the starter.

Table 4 provides clearance from the starter.

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Illustration 1	g06335210
(A) Cylinder Block (B) Starter (1) 7N-4945 Gasket

1. Line up gasket (1) with the bolt holes on cylinder block (A).
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   Illustration 2	g06334072
   (A) Cylinder Block (2) 8N-8550 Elbow (3) 0S-1594 Bolt (4) 165-3931 Bolt

2. Install elbow (2) onto cylinder block (A) with bolt (4) and 3 bolts (3).
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   Illustration 3	g06334084
   (B) Starter (2) 8N-8550 Elbow (5) 6B-9081 Reducer Bushing

3. Install reducer bushing (5) into elbow (2).
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   Illustration 4	g06334090
   (B) Starter (2) 8N-8550 Elbow (5) 6B-9081 Reducer Bushing (6) 001-6412 Connector

4. Install connector (6) into reducer bushing (5).

Installation Procedure for the 549-6376 Electric Starting Motor Gp

Note: Charge the batteries before starting the engine. Batteries with a low charge can damage the starter motor.

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Illustration 5	g06335985
(1) 349-6606 Electric Starting Motor Gp (2) 8S-2332 Bolt (3) 2S-5658 Hard Washer (4) 9Y-6089 Gasket (A) Flywheel Housing

1. Install starter motor (1) onto flywheel housing (A) with 3 bolts (2) and 3 washers (3).

Installation Procedure for the 545-9477 Electronic Mounting Gp

Note: The procedure below is for dynamic gas blending engines only.

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Illustration 6	g06353546
(A) Bracket (B) Ground Strap (1) 377-4710 Electronic Control Module (ECM) (2) 8T-8912 Bolt

1. Install ground strap (B) onto bolt (2).
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   Illustration 7	g06346644
   (A) Bracket (1) 377-4710 Electronic Control Module (ECM) (2) 8T-8911 Bolt (3) 198-4765 Hard Washer (4) 155-0576 Isolation Mount (5) 9N-0869 Hard Washer (6) 6I-1418 Spacer

   1. Install 4 bolts (2) with 4 hard washers (5), 4 spacers (6), and 4 isolation mounts (4) through ECM (1).

   2. On the backside of ECM (1) install 4 isolation mounts (4) and 4 hard washers (3) to bolts (2).

   3. Install ECM (1) onto bracket (A).

2. Install the 510-2494 Film and the 574-8876 Film onto ECM (1).
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   Illustration 8	g06356044
   (A) Bracket (1) 377-4710 Electronic Control Module (ECM) (7) 553-7139 Wiring Harness (8) 7K-1181 Cable Strap (9) 539-6415 Engine Harness As

3. Connect wiring harness (7) to ECM (1) and engine harness assembly (9).

   Note: Engines built before 2018 will not have engine harness assembly (11) and will need to install this assembly.

   1. Secure the harness with 8 cable straps (8).

Installation Procedure for the 560-1407 Sensor and Mounting Gp

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Illustration 9	g06334165
(1) 555-9030 Bracket As (2) 550-4761 Current Sensor Gp (3) 6V-8801 Nut (4) 8T-4896 Hard Washer (5) 4L-6454 Bolt (6) 9X-6016 Hex Socket Screw (7) 096-6166 Hard Washer (8) 557-0261 Sensor Harness As

1. Install the 560-1407 Sensor and Mounting Gp on the ground cable for each of the battery packs.

2. Ensure that the battery is properly clipped to avoid rubbing on the sensors.

3. To protect the sensors and cables, securely fasten the batteries to prevent movement in any direction.

Installation Procedure for the Engine Idle Reduction System Diesel Electronic Control Module Kit

Table 5 contains the 561-8697 Engine Electronics Kit for the diesel engines configuration.

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Illustration 10	g06335038
(A) Bracket (B) Cover (1) 558-9997 Bracket (2) 7X-0291 Bolt (3) 8T-4896 Hard Washer (4) 132-5789 Clip (5) 7K-1181 Cable Strap (6) 7X-6315 Ground Strap (7) 5K-0906 Bolt (8) 8T-4224 Hard Washer

Note: Bracket (A) and cover (B) are existing components on the engine.

1. Install bracket (1) onto bracket (A) with 2 bolts (2) and 2 hard washers (3).

   1. Install 2 bolts (2), 2 hard washers (3), and clip (4) to cover (B).

   2. Secure the harness with cable strap (5).

   3. Install ground strap (6) onto bracket (A) with bolt (7) and washer (8).
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   Illustration 11	g06335071
   (1) 558-9997 Bracket (6) 7X-6315 Ground Strap (9) 8T-8911 Bolt (10) 9N-0869 Hard Washer (11) 8T-9655 Isolation Mount (12) 7X-0613 Hard Washer (13) 563-0624 Plate As (14) 101-0852 Screw (15) 4B-4863 Washer

2. Install plate assembly (13) onto bracket (1).

   1. Install 4 bolts (9) with 4 washers (10) and 4 isolation mounts (11) through the plate assembly.

   2. Install 4 isolation mounts and 4 hard washers (12) on the backside of the plate and attach the assembly to the bracket.

   3. Secure ground strap (6) onto the plate assembly with screw (14) and washer (15).
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   Illustration 12	g06335102
   (1) 558-9997 Bracket (13) 563-0624 Plate As (16) 377-4710 Electronic Control Module Screw (17) 7X-6315 Ground Strap (18) 377-4710 Electronic Control Module (ECM) (19) 5P-2955 Bolt (20) 9N-0869 Hard Washer (21) 155-0576 Isolation Mount (22) 347-1083 Spacer

3. Install ECM (18) onto plate assembly (13).

   1. Install bolt (19) through the loose end of ground strap (17) with washer (20) and isolation mount (21) through the ECM.

   2. Install 2 bolts (19) with 2 washers (20) and 2 isolation mounts through the ECM.

   3. On the backside of the ECM install 3 isolation mounts, and 3 spacers (22), to bolts (19), and attach to the plate assembly.
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   Illustration 13	g06333713
   (13) 563-0624 Plate As (18) 377-4710 Electronic Control Module (ECM) (19) 5P-2955 Bolt (20) 9N-0869 Hard Washer (21) 155-0576 Isolation Mount (22) 347-1083 Spacer (23) 7X-0274 Bolt (24) 9M-1974 Hard Washer (25) 183-4274 Bracket

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   Illustration 14	g06333602
   (13) 563-0624 Plate As (18) 377-4710 Electronic Control Module (20) 9N-0869 Hard Washer (21) 155-0576 Isolation Mount (22) 347-1083 Spacer (23) 7X-0274 Bolt (24) 9M-1974 Hard Washer (25) 183-4274 Bracket

4. For the bottom right of ECM (18), install bolt (25) with washer (26), bracket (27), washer (22), and mount (23) through the ECM.

   1. Install bolt (23) through isolation mount (21) and spacer (22). Attach the bolt to plate (13).
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   Illustration 15	g06333565
   (18) 377-4710 Electronic Control Module (ECM) (26) 260-3718 Bracket (27) 260-3939 Screw

5. Attach bracket (26) to ECM (18) with screw (27).
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   Illustration 16	g06333532
   (18) 377-4710 Electronic Control Module (ECM) (25) 183-4274 Bracket (26) 260-3718 Bracket (28) 560-3076 Engine Harness As (29) 7K-1181 Cable Strap (30) 3S-2093 Cable Strap

6. Connect engine harness assembly (28) to ECM (18).

   1. Secure the harness with cable straps (30) and 2 cable straps (29) to bracket (26) and bracket (25).
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   Illustration 17	g06333545
   (28) 560-3076 Engine Harness As (31) 539-6415 Engine Harness As (32) 7K-1181 Cable Strap (33) Clip

7. Connect engine harness assembly (28) to engine harness assembly (31).

   1. Secure engine harness assembly (28) with 2 cable straps (32).
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   Illustration 18	g06333558
   (28) 560-3076 Engine Harness As (32) 7K-1181 Cable Strap (34) 533-2928 Wire As (35) 9X-6772 Cable Strap

8. Secure engine harness assembly (28) with cable straps (32) and (35) and plug in wire assembly (34).

Installation Procedure for the Alternator Upgrade Kit

Table 6 contains the 561-8702 Alternator Kit to upgrade to the required 150 amp alternator.

Note: This kit is only required if the engine does not already have a 150 amp alternator.

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Illustration 19	g06327217
(A) Bracket (B) Bracket (1) 5F-4899 Bolt (2) 5M-2894 Hard Washer (3) 0S-1608 Bolt (4) 272-1889 Charging Alternator Gp

1. Install alternator (4) to bracket (B) using 2 bolts (1) with 2 washers (2).

   1. Attach the alternator to bracket (A) using 2 bolts (3) with 2 hard washers (2).
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   Illustration 20	g06344723
   (B) Bracket (4) 272-1889 Charging Alternator Gp (5) 468-2775 Pulley (6) Nut (7) Washer

2. Install pulley (5) with nut (6) and washer (7) onto alternator (4).

3. Tighten nut (6) to 127 ± 10 N·m (94 ± 7 lb ft).
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   Illustration 21	g06327212
   (4) 272-1889 Charging Alternator Gp (8) 468-2811 Serpentine Belt

4. Install serpentine belt (8) as shown in the illustration above.
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   Illustration 22	g06327208
   (B) Bracket (9) 447-8626 Guard As (10) 1A-2029 Bolt (11) 198-4766 Hard Washer (12) 0S-1618 Bolt (13) 198-4765 Hard Washer

5. Install guard (9) onto bracket (B) using 5 bolts (10) with 5 hard washers (11), 3 bolts (12), and 3 hard washers (13) in the locations shown in the illustration above.

Installation Procedure for the 548-7155 Engine Oil Cooler Cover Gp

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Illustration 23	g06344495
(A) 164-4020 Hub (1) 3P-0653 O-Ring Seal (2) 459-1810 Plate (3) 0S-1591 Bolt (4) 9X-6458 Hard Washer

1. Install plate (2) and o-ring seal (1) with 4 bolts (3) and 4 washers (4) onto hub (A).
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   Illustration 24	g06328936
   (2) 459-1810 Plate (5) 352-7222 Check Valve Gp

2. Install check valve (5) into plate (2).
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   Illustration 25	g06328943
   (5) 352-7222 Check Valve Gp (6) 5K-9090 O-Ring Seal

3. Install o-ring seal (6) into check valve (5).

Installation Procedure for the 541-4953 Prelube Pump Mounting Gp

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Illustration 26	g06330552
(A) Accessory Drive Housing (1) 528-5226 Bracket As (2) 7X-0732 Hard Washer (3) 8T-8912 Bolt (4) 265-9596 Hard Washer (5) 8T-9389 Bolt

1. Install bracket assembly (1) onto accessory drive housing (A) using 2 bolts (3) with 2 hard washers (2) and bolt (5) with hard washer (4).
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   Illustration 27	g06327626
   (1) 528-5226 Bracket As (6) 295-7549 Bracket (7) 8T-9377 Bolt (8) 8T-4226 Plated Washer

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   Illustration 28	g06327625
   (1) 528-5226 Bracket As (6) 295-7549 Bracket (7) 8T-9377 Bolt (8) 8T-4226 Plated Washer (9) 121-3307 Resilient Mount Assembly

   Note: The pink nuts in the illustration above are part of bracket assembly (1).

2. Install bracket (6) onto bracket assembly (1) using 4 bolts (7) with 8 plated washers (8) and 8 resilient mount assemblies (9).

   1. Tighten bolts (7) to 19 ± 3 N·m (14 ± 2 lb ft).
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   Illustration 29	g06327616
   (8) 295-7549 Bracket (10) 474-2426 Prelubrication Oil Pump Gp (11) 2K-4973 Locknut (12) 7X-0632 Hard Washer (13) 037-1295 U-Bolt (14) 528-5227 Plate

3. Install 2 u-bolts (13) around prelubrication oil pump (10).

   1. Install the u-bolts through plate (14) and bracket (8).

   2. Install 4 hard washers (12) with 4 locknuts (11).

   3. Tighten locknuts (11) to 20 ± 5 N·m (15 ± 4 lb ft).
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   Illustration 30	g06327803
   (10) 474-2426 Prelubrication Oil Pump Gp (15) 9S-8010 Plug (16) 228-7096 O-Ring Seal

4. Install plug (15) with o-ring seal (16) into prelubrication oil pump (10).

5. Tighten plug (15) to 175 ± 26 N·m (129 ± 19 lb ft).
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   Illustration 31	g06327812
   (10) 474-2426 Prelubrication Oil Pump Gp (17) 9S-9334 Plug (18) 238-5084 O-Ring Seal

6. Install plug (17) with o-ring seal (18) into prelubrication oil pump (10).

7. Tighten plug (17) to 150 ± 22 N·m (111 ± 16 lb ft).
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   Illustration 32	g06327620
   (10) 474-2426 Prelubrication Oil Pump Gp (19) 238-5084 O-Ring Seal (20) 228-7096 O-Ring Seal

8. Install o-ring seal (19) and o-ring seal (20) into prelubrication oil pump (10).

Installation Procedure for the Engine Mounted Prelube Upgrade Kit 250 Hour Oil Pan

Table 7 contains the 561-8699 Prelube KT-UPG for the 250-hour oil pan configuration.

Note: This procedure is only for engines equipped with the 250-hour oil pan.

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Illustration 33	g06329845
(1) 474-2426 Prelubrication Oil Pump Gp (2) 152-9840 Elbow (3) 539-1359 Hose As (4) 562-7033 Hose As (5) 6V-9009 Elbow

1. Install elbow (2) into prelubrication oil pump (1). Attach hose assembly (3) to the elbow.

2. Tighten elbow 2 to 175 ± 26 N·m (129 ± 19 lb ft)

3. Install elbow (5) into prelubrication oil pump (1). Attach hose assembly (4) to the elbow.

4. Tighten elbow (5) to 200 ± 30 N·m (148 ± 22 lb ft)
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   Illustration 34	g06335229
   (6) 562-7235 Bracket (7) 5P-1076 Hard Washer (8) 7X-7470 Bolt

5. Install bracket (6) using bolt (8) with washer (7).
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   Illustration 35	g06335245
   (3) 539-1359 Hose As (4) 562-7033 Hose As (6) 562-7235 Bracket (9) 269-8249 Clip (10) 269-8251 Clip (11) 8T-2502 Bolt (12) 5P-1075 Hard Washer (13) 8T-2525 Grommet (14) 5P-7468 Clip (15) 5P-7469 Clip

6. Secure hose assembly (4) to bracket (6).

   1. Install clips (9) and (10) around grommet (13).

   2. Install bolt (11) and hard washer (12) through the clips and attach to bracket (6).

7. Secure hose assembly (3) to bracket (6).

   1. Install clips (14) and (15) around grommet (13).

   2. Install bolt (11) and hard washer (12) through the clips and attach to bracket (6).
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   Illustration 36	g06345419
   (16) 548-6973 Fitting (17) 228-7094 O-Ring Seal

8. Install fitting (16) into the oil pan.

   1. Tighten fitting (16) to 60 ± 9 N·m (44 ± 7 lb ft).

   2. Install o-ring seal (17) into fitting (16).
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   Illustration 37	g06345417
   (16) 548-6973 Fitting (17) 228-7094 O-Ring Seal (18) 7X-3168 Adapter (19) 228-7096 O-Ring Seal

9. Install adapter (18) onto fitting (16).

   1. Install o-ring seal (19) into adapter (18).
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   Illustration 38	g06345415
   (16) 548-6973 Fitting (18) 7X-3168 Adapter (20) 313-2647 Ball Valve (21) 228-7096 O-Ring Seal (22) 8T-3611 Connector (23) 228-7094 O-Ring Seal

10. Install ball valve (20) onto adapter (18).

    1. Install connector (22) with o-ring seal (21) onto ball valve (20).

    2. Install o-ring seal (23) into connector (22).
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    Illustration 39	g06345411
    (4) 562-7033 Hose As (16) 548-6973 Fitting (18) 7X-3168 Adapter (20) 313-2647 Ball Valve (22) 8T-3611 Connector

11. Attach hose assembly (4) to connector (22).
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    Illustration 40	g06335495
    (A) Oil Pan (B) Oil Pan Gasket (3) 539-1359 Hose As (4) 562-7033 Hose As (23) 539-1361 Oil Tube As (24) 329-0780 Stud (25) 6V-8801 Nut (26) 7X-7729 Washer (27) 5P-7469 Clip (28) 5P-7468 Clip (29) 6V-1874 Grommet

12. Secure oil tube assembly (23) to oil pan (A).

    1. Install clip (27) and clip (28) around grommet (29) and the oil tube assembly.

    2. Install stud (24) through oil pan (A), oil pan gasket (B), and both clips.

    3. Install nut (25) and washer (26) on each end of the stud.
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    Illustration 41	g06329779
    (3) 539-1359 Hose As (23) 539-1361 Oil Tube As (30) 6V-8727 Connector

13. Connect oil tube assembly (23) to hose assembly (3) with connector (30).
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    Illustration 42	g06335534
    (23) 539-1361 Oil Tube As (31) 239-5032 Connector

14. Connect oil tube assembly (23) to connector (31).

15. Ensure that the ball valve is in the open position.

Installation Procedure for the Engine Mounted Prelube Upgrade Kit 500 Hour Oil Pan

Table 8 contains the 561-8700 Prelube KT-UPG for the 500-hour oil pan configuration.

Note: This procedure is only for engines equipped with the 500 hour oil pan.

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Illustration 43	g06332848
(1) 474-2426 Prelubrication Oil Pump Gp (2) 6V-9009 Elbow

1. Install elbow (2) onto prelubrication oil pump (1).

2. Tighten elbow (2) to 200 ± 30 N·m (148 ± 22 lb ft).
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   Illustration 44	g06332844
   (2) 6V-9009 Elbow (3) 228-7094 O-Ring Seal (4) 562-7034 Hose As

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   Illustration 45	g06332839
   (2) 6V-9009 Elbow (4) 562-7034 Hose As

3. Install o-ring seal (3) into elbow (2). Install hose assembly (4) onto elbow (3).
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   Illustration 46	g06332875
   (1) 474-2426 Prelubrication Oil Pump Gp (5) 152-9840 Elbow

4. Install elbow (5) into prelubrication oil pump (1).

5. Tighten elbow (5) to 175 ± 26 N·m (129 ± 19 lb ft).
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   Illustration 47	g06332873
   (1) 474-2426 Prelubrication Oil Pump Gp (5) 152-9840 Elbow (6) 550-9195 Hose As (7) 228-7094 O-Ring Seal

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   Illustration 48	g06332870
   (1) 474-2426 Prelubrication Oil Pump Gp (5) 152-9840 Elbow (6) 550-9195 Hose As

6. Install o-ring seal (7) into elbow (5). Install hose assembly (6) onto elbow (5).
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   Illustration 49	g06335602
   (4) 562-7034 Hose As (6) 550-9195 Hose As (8) 5P-7468 Clip (9) 5P-7469 Clip (10) 8T-2525 Grommet (11) 296-6980 Spacer (12) 8T-9377 Bolt (13) 5P-1075 Hard Washer (14) 218-0054 Spacer (15) 7X-0296 Bolt

7. Install clip (8) and clip (9) around grommet (10) and hose assembly (4).

   1. Insert bolt (12) with hard washer (13) through the clips and spacer (11) and attach to the oil pan.

   2. Tighten bolt (12) to 23 ± 4 N·m (17 ± 3 lb ft).

8. Install clips (8) and (9) around grommet (10) and hose assembly (6).

   1. Install bolt (15) with hard washer (13) through the clips, spacer (14), the cover assembly, and attach to the oil pan.

   2. Tighten bolt (15) to 23 ± 4 N·m (17 ± 3 lb ft).
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   Illustration 50	g06335617
   (16) 170-6541 Elbow (17) 228-7094 O-Ring Seal (18) 548-6973 Fitting

9. Install fitting (18) into the oil pan.

   1. Tighten fitting (18) to 60 ± 9 N·m (44 ± 7 lb ft).

   2. Install o-ring seal (17) into fitting (18).

10. Install elbow (16) onto fitting (18).
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    Illustration 51	g06333298
    (16) 170-6541 Elbow (18) 548-6973 Fitting (19) 228-7096 O-Ring Seal

11. Install o-ring seal (19) onto elbow (16).
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    Illustration 52	g06333295
    (16) 170-6541 Elbow (18) 548-6973 Fitting (20) 313-2647 Ball Valve

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    Illustration 53	g06333304
    (18) 548-6973 Fitting (16) 170-6541 Elbow (20) 313-2647 Ball Valve (21) 228-7096 O-Ring Seal

12. Install ball valve (20) onto elbow (16).

    1. Install o-ring seal (21) into the ball valve.
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    Illustration 54	g06333287
    (18) 548-6973 Fitting (16) 170-6541 Elbow (20) 313-2647 Ball Valve (22) 6V-9006 Elbow

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    Illustration 55	g06333312
    (18) 548-6973 Fitting (16) 170-6541 Elbow (20) 313-2647 Ball Valve (22) 6V-9006 Elbow (23) 228-7096 O-Ring Seal

13. Install elbow (22) onto ball valve (20).

    1. Install o-ring seal (23) into elbow (22).
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    Illustration 56	g06333264
    (4) 562-7034 Hose As (18) 548-6973 Fitting (16) 170-6541 Elbow (20) 313-2647 Ball Valve (22) 6V-9006 Elbow

14. Install hose assembly (4) onto elbow (22).
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    Illustration 57	g06335648
    (23) 352-7222 Check Valve Gp (24) 239-5032 Connector (25) 228-7094 O-Ring Seal (26) 539-1361 Oil Tube As

15. Install connector (24) onto check valve (23).

    1. Install o-ring seal (25) into connector (24).

16. Install oil tube assembly (26) onto connector (24).
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    Illustration 58	g06387994
    (A) Oil Pan Gasket (B) Oil Pan (4) 562-7034 Hose As (26) 539-1361 Oil Tube As (27) 6V-8801 Nut (28) 7X-7729 Washer (29) 8T-7934 Hard Washer (30) 5P-7468 Clip (31) 5P-7469 Clip (32) 8T-9101 Bolt (33) 228-7094 O-Ring Seal (34) 6V-1874 Grommet

17. Install clip (30) and clip (31) around oil tube assembly (26) and grommet (34).

    1. Install bolt (32) with washer (28) through the clips.

    2. Install hard washer (29) on the backside of the clips.

    3. Install the bolts through oil pan (B) and oil pan gasket (A).

    4. Secure oil tube assembly (26) with nut (27) and washer (28).

18. Install o-ring seal (33) into oil tube assembly (26).
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    Illustration 59	g06332899
    (6) 550-9195 Hose As (26) 539-1361 Oil Tube As

19. Attach hose assembly (6) onto oil tube assembly (26).
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    Illustration 60	g06333201
    (4) 562-7034 Hose As (26) 539-1361 Oil Tube As (30) 5P-7468 Clip (31) 5P-7469 Clip (34) 6V-1874 Grommet (35) 4L-9337 Bolt (36) 5P-1075 Hard Washer (37) 6V-8801 Nut (38) 8T-2525 Grommet

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    Illustration 61	g06333195
    (4) 562-7034 Hose As (30) 5P-7468 Clip (31) 5P-7469 Clip (34) 6V-1874 Grommet (35) 4L-9337 Bolt (36) 5P-1075 Hard Washer (37) 6V-8801 Nut (38) 8T-2525 Grommet

20. Install clip (30) and clip (31) around grommet (34) and oil tube assembly (26).

    1. Install clip (30) and clip (31) around grommet (38) and hose assembly (4).

    2. Install bolt (35) with hard washer (36) through the clips and secure the assembly with nut (37) and hard washer (36).

21. Ensure that the ball valve is in the open position.

Installation Procedure for the Engine Mounted Prelube Kit 750 Hour Oil Pan

Table 9 contains the 561-8701 Prelube KT-UPG for the 750-hour oil pan configuration.

Note: This procedure is only for engines equipped with the 750 hour oil pan.

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Illustration 62	g06332729
(1) 474-2426 Prelubrication Oil Pump Gp (2) 8T-3611 Connector (3) 228-7094 O-Ring Seal (4) 562-7035 Hose As

1. Install connector (2) into oil pump (1).

   1. Tighten connector (2) to 200 ± 30 N·m (148 ± 22 lb ft).

   2. Install o-ring seal (3) into connector (2).
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   Illustration 63	g06332732
   (1) 474-2426 Prelubrication Oil Pump Gp (2) 8T-3611 Connector (4) 562-7035 Hose As

2. Install hose assembly (4) onto connector (2).
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   Illustration 64	g06387988
   (1) 474-2426 Prelubrication Oil Pump Gp (4) 562-7035 Hose As (5) 8T-7927 Connector (6) 228-7094 O-Ring Seal (7) 6V-9855 Elbow (8) 549-0729 Hose As

3. Install connector (5) into prelubrication pump (1).

   1. Tighten connector (5) to 175 ± 26 N·m (129 ± 19 lb ft).

   2. Install o-ring seal (6) into connector (5).

   3. Install elbow (7) onto connector (5).

   4. Install o-ring seal (6) onto elbow (7).

4. Install hose assembly (8) onto elbow (7).
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   Illustration 65	g06335726
   (1) 474-2426 Prelubrication Oil Pump Gp (8) 549-0729 Hose As (9) 5P-7468 Clip (10) 5P-7469 Clip (11) 8T-2525 Grommet (12) 5S-7383 Bolt (13) 5P-1075 Hard Washer (14) 128-8678 Spacer

5. Install clip (9) and clip (10) around grommet (11) and hose assembly (8).

   1. Install bolt (12) with hard washer (13) through the clips and spacer (14) to attach the assembly to the oil pan.
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   Illustration 66	g06335732
   (8) 549-0729 Hose As (15) 352-7222 Check Valve Gp (16) 239-5032 Connector (17) 228-7094 O-Ring Seal

6. Install connector (16) onto check valve (15).

   1. Install o-ring seal (17) onto connector (16).

7. Install hose assembly (8) onto connector (16).
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   Illustration 67	g06335739
   (1) 474-2426 Prelubrication Oil Pump Gp (18) 548-6973 Fitting (19) 228-7094 O-Ring Seal (20) 170-6541 Elbow (21) 228-7096 O-Ring Seal

8. Install fitting (18) into the oil pan.

   1. Tighten fitting (18) to 60 ± 9 N·m (44 ± 7 lb ft).

   2. Install o-ring seal (19) into fitting (18).

9. Install elbow (20) onto fitting (18).

   1. Install o-ring seal (21) onto elbow (20)
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   Illustration 68	g06332786
   ( 20) 170-6541 Elbow (22) 313-2647 Ball Valve

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   Illustration 69	g06332779
   (20) 170-6541 Elbow (22) 313-2647 Ball Valve (23) 228-7096 O-Ring Seal

10. Install ball valve (22) onto elbow (20).

    1. Install o-ring seal (23) into ball valve (22).
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    Illustration 70	g06332774
    (22) 313-2647 Ball Valve (24) 6V-9006 Elbow

11. Install elbow (24) onto ball valve (22).
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    Illustration 71	g06332765
    (22) 313-2647 Ball Valve (24) 6V-9006 Elbow (25) 228-7094 O-Ring Seal

12. Install o-ring seal (25) into elbow (24).
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    Illustration 72	g06335750
    (1) 474-2426 Prelubrication Oil Pump Gp (4) 562-7035 Hose As (24) 6V-9006 Elbow

13. Install hose assembly (4) onto elbow (24).

14. Ensure that the ball valve is in the open position.

Installation Procedure for the Off Engine Pre-lube Upgrade Kit

Table 10 contains the 561-8698 Prelube KT-UPG for the off-engine pre-lube configuration.

Note: This procedure is only for engines using off engine mounted pre-lube pump.

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Illustration 73	g06344910
(1) 295-7549 Bracket

1. Install bracket (1) on to the machine/tractor.
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   Illustration 74	g06344906
   (1) 295-7549 Bracket (2) 295-7549 Bracket (3) 4L-6459 Bolt (4) 8T-4226 Plated Washer (5) 121-3307 Resilient Mount Assembly (6) 6V-8801 Nut

2. Install 4 bolts (3) with 4 washers (4) and 4 mount assemblies (5) through bracket (2).

   1. Install 4 washers (4) and 4 mount assemblies (5) on the end of each bolt (3).

   2. Attach bracket (2) to bracket (1) with 4 nuts (6) and 4 washers (4).

   3. Tighten bolts (3) to 19 ± 3 N·m (14 ± 2 lb ft).
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   Illustration 75	g06344899
   (1) 295-7549 Bracket (2) 295-7549 Bracket (7) 474-2426 Prelubrication Oil Pump Gp (8) 037-1295 U-Bolt (9) 2K-4973 Locknut (10) 7X-0632 Hard Washer (11) 528-5227 Plate

3. Install 2 u-bolts (8) around prelubrication oil pump (7) through plate (11) and bracket (2).

   1. Install 4 hard washers (10) with 4 locknuts (9).

   2. Tighten locknuts (9) to 20 ± 5 N·m (15 ± 4 lb ft).
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   Illustration 76	g06344891
   (7) 474-2426 Prelubrication Oil Pump Gp (12) 228-7096 O-Ring Seal (13) 9S-8010 Plug

4. Install plug (13) with o-ring seal (12) into prelubrication oil pump (7)

   1. Tighten plug (13) to 175 ± 26 N·m (129 ± 19 lb ft).
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   Illustration 77	g06344894
   (7) 474-2426 Prelubrication Oil Pump Gp (14) 9S-9334 Plug (15) 238-5084 O-Ring Seal

5. Install plug (14) with o-ring seal (15) into prelubrication oil pump (7)

   1. Tighten plug (14) to 150 ± 22 N·m (111 ± 16 lb ft).

Commissioning Procedure

1. Connect to Cat ^® Electronic Technician (Cat ET) Service Tool.

   Note: Cat ET 2019A or newer is recommended.

2. Take the Product Status Report (PSR) for all Caterpillar ^® ECMs.

3. Install the 573-4642 Software available in SIS web for the EIRS ECM.

   Note: The new software is available in the form of a flashfile through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS Web only displays the latest available flashfile.

4. Complete the EIRS commissioning audit checklist found in the publication listed below.

   Refer to Application and Installation Guide, LEBW0065 , "3512 Pressure Pumping Engine Idle Reduction System (EIRS)" at the following website:

   https://emc.cat.com/QuickSearch.aspx
   

   Note: Enabling the EIRS upgrade will automatically initiate the Software Enabled Attachment (SEA) process. This process will require an internet connection to obtain a factory password.