prelub specification sheets - trysome

Prelub Specification Sheets

www.trysome.co.za | +27 (0)11 823 5650

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Applications: A pre-lubrication & evacuation system intended for engines of 2 to 6 ℓ displacement or sump capacities of 4 to 28 quarts. Models

available for 12 V systems.

Performance: 12 V system

23.89° C 15W-40 Oil: 3-3.5 gpm @ 25-30 A depending on available engine port sizes.

0° C 15W-40 Oil: 0.8-1.3 gpm @ 30-40 A depending on available engine port sizes.

Maximum Duty Cycle ................................................................................................................... 4 minutes ON and 30 minutes OFF

Ambient Temperature . .................................................................................................................. –40 to 125° C (-40 to 257° F)

System Connections:• Plumbing – Custom fittings will be supplied that thread directly into the engine. Oil will be drawn through an oil pan port and returned to a port ahead

of the existing engine filter.

» Oil pan suction fitting should have at least 7.11 mm ID (#6 STOR, 6.35 mm NPT, M14) if used with viscous oil (15W-40 below 4.4° C). If a large

port is not available, call for alternatives.

» Oil filterhead return port should have at least 4.57 mm ID (3.18 mm pipe, #4 STOR, M12)

» Install the pressure switch into the furthest downstream port in the engine’s pressurised oil system. Adapters are available to install the switch in

most port types and sizes.

• Electrical – Connect the motor to a source of power with the gauge of cables recommended on the next page. Install keyswitch and pressure switch

adapter harnesses. Plug the main wiring harness into the connectors at the keyswitch harness, magswitch, pressure switch harness and control

relay.

Components and Features: » Permanent Magnet DC motor: Insulated Ground – improves reliability vs. case grounded motor. High power rise better maintains flow rate at lower

fluid temperatures and higher pressures.

» Pump: High-strength aluminium housing with steel gears and a seal protection feature that, in conjunction with a circuit breaker, prevents motor

damage due to excessive pump pressure.

» Controller: Standard Prelub “No Delay” logic delivers fastest possible start.

» Wiring Harness: Circuit breaker prevents harness and motor damage due to excessive current.

» Motor Switch: Rated for 200 A carry current yet consumes minimal power for activation.

» Installation Instructions: Application-specific instructions supplied for most machines.

» Inlet Hose: Rated for 121.11° C oil and will not collapse under pump vacuum.

» Pressure Hose: Rated for 121.11° C oil and bursts at 3 times maximum pump output pressure.

» Check Valve: Prevents backflow of oil after engine start with minimal restriction and weight.

Recommended Hardware:

(Other Plumbing/ Electrical configurations are possible with RPM approval)

Maximum Suction Hose Length (For quick Prelub of typical engine sizes)

Maximum oil lift height is 914.4 mm.

Suction Hose ID Maximum Length

12.70 mm ID 0.91 m

15.88 mm ID 1.83 m

P1K Specification Sheet

3


Maximum Pressure Hose Length (Limits pressure or motor current)

Electrical Connections (Total Length = Battery Cable + Motor Cable + Ground Cable)

Motor/Pump Assembly Dimensions:Length (Excluding fittings) ............................................................................................................................................................... 175 mm

Height w/ mounting bracket ............................................................................................................................................................ 84 mm

Width w/ mounting bracket ............................................................................................................................................................. 89 mm

Motor/ Pump Assembly Weight ....................................................................................................................................................... 2.3 kg

Wire Size Maximum Length

12 gauge 5.49 m

10 gauge 8.53 m

Pressure Hose ID Maximum Length

12.70 mm ID 3.05 m

15.88 mm ID 6.10 m

MOTORØ

6.9[ 174.5 mm ]

5.7[ 145.5 mm ]

1.5[ 38.8 mm ]

3.0[ 76.2 mm ]

5.3[ 135.7 mm ]

1.1[ 29.0 mm ]

3.3[ 83.8 mm ]

2.0[ 50.6 mm ]

INLET -6 SAE STRAIGHTTHREAD PORTOUTLET -6 SAE STRAIGHTTHREAD PORT

OUTLET (NEAR SIDE) & INLET (FAR SIDE)-6 SAE STRAIGHT THREAD PORT

3.0[ 75.3 mm ]2 X Ø.257 HOLES FOR

1/4-20 UNC BOLTS

1.2[ 30.0 mm ]

3.5[ 88.9 mm ]

3.0[ 76.2 mm ]

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Applications: A pre-lubrication & evacuation system intended for engines of 10 ℓ displacement or with sump capacities of 10 gallons. Models

available for both 12 V and 24 V systems.

Performance: 12 & 24 V Systems

21.11° C 15W-40 Oil: 4-5 gpm @ 60-70 A (30-40 A) depending on available engine port sizes.

0° C 15W-40 Oil: 2-3 gpm @ 80-90 A (40-50 A) depending on available engine port sizes.

Maximum Duty Cycle ................................................................................................................... 4 minutes ON and 30 minutes OFF

Ambient Temperature . .................................................................................................................. –40 to 125° C (-40 to 257° F)



» Oil pan suction fitting should have at least 10.16 mm ID (19.05 mm ORB, 12.7 mm NPT, M22) if used with viscous oil (15W-40 below 4.4° C). If

a large port is not available, call for alternatives.

» Oil filterhead return port should have at least 7.62 mm ID (9.53 mm pipe, 14.29 mm ORB, M16)

» Install the pressure switch into any port in the engine’s pressurized oil system. Adapters are available to install the pressure switch in most port

types and sizes.



relay.

Components and Features: » Permanent Magnet DC motor. Insulated ground - improves reliability vs. case grounded motor. High power rise better maintains flow rate at lower


» Pump: Cast-iron housing with steel gears and a seal protection feature that, in conjunction with a fuse, prevents motor damage due to excessive

pump pressure.


» Wiring Harness: Fuse prevents wire and motor damage due to excessive current.


» Installation Instructions: Application-specific instructions supplied for most machines.

» Suction Hose: Rated for 148.89° C oil and will not collapse under any vacuum level.

» Pressure Hose: Rated for 148.89° C oil, and nearly 5 times maximum pump output pressure.


» Pump Relief Valve: Standard.





12.70 mm ID 0.61 m

15.88 mm ID 1.52 m

22.23 mm ID 4.88 m

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Maximum Pressure Hose Length (limits pressure or motor current)

IF Suction Hose Length is > ½ Maximum Length above,

Then Use Max Permitted Ratio of Pressure Hose Length: Suction Hose Length

If Suction Hose Length is < ½ Maximum Length above,

Then Use Max Permitted Pressure Hose Length

Electrical Connections (Total Length = Battery Cable + Motor Cable + Ground Cable)

Motor/Pump Assembly Dimensions:Length .......................................................................................................................................................................................... 259 mm

Height ............................................................................................................................................................................................ 91 mm

Width ............................................................................................................................................................................................ 104 mm

Motor/Pump Assembly Weight ......................................................................................................................................................... 5.7 kg

Suction Hose IDPressure Hose ID

9.52 mm ID 12.7 mm ID 15.88 mm ID

12.70 mm ID 5: 1 9: 1 20: 1

15.88 mm ID 2: 1 4: 1 10: 1

22.23 mm ID Not Allowed 2.5: 1 6: 1


9.52 mm ID 2.13 m

12.70 mm ID 3.05 m

15.88 mm ID 7.32 m

Wire SizeMaximum Length

12 V System 24 V System

8 Gauge 6.10 m 24.38 m

6 Gauge 9.14 m 36.58 m

91.44 mm

104.14 mm

96.52 mm

76.2 mm 30.48 mm

93.98 mm

259.08 mm

Ø.425 MTG HOLESØ.425 MTG HOLES

BATTERY TERMINAL M6TORQUE TO 3 FT-LBS

GROUND TERMINAL M6TORQUE TO 3 FT-LBS

OUTLET -8 SAE STRAIGHT THREAD PORT

INLET -8 SAE STRAIGHT THREAD PORT

INLET (NEAR SIDE) -8 SAE STRAIGHT THREAD PORTOUTLET (FAR SIDE) -8 SAE STRAIGHT THREAD PORT

38.10 mm

33.02 mm

81.28 mm

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Applications: A pre-lubrication & evacuation system intended for engines of 15 ℓ displacement or with sump capacities of 16 gallons. Models

available for both 12 V and 24 V systems.

Performance: 12 & 24 V Systems



Maximum Duty Cycle (Evac operation) ........................................................................................... 4 minutes ON and 30 minutes OFF

Ambient Temperature ................................................................................................................... –40 to 125° C (-40 to 257° F)



» Oil pan suction fitting should have at least 0.5” ID (22.23 mm ORB, 12.70 mm NPT, M22) if used with viscous oil (15W-40 below 4.4° C). If a

large port is not available, call for alternatives.

» Oil filterhead return port should have at least 7.62 mm ID. (9.53 mm pipe, 14.29 mm ORB, M16)

» Install the pressure switch into any port in the engine’s pressurized oil system. Adapters are available to install the pressure switch in most port

types and sizes.

• Electrical – Connect the motor to a source of power with the gauge of cables recommended on the next page and splice the supplied connector into

the key switch wire. Plug the main wiring harness into the connectors at the key switch, magswitch, pressure switch and control relay.

Components and Features: » Permanent Magnet DC motor. Insulated ground – improves reliability vs. case grounded motor. High power rise better maintains flow rate at lower


» Pump: Cast iron housing with steel gears and a seal protection feature that, in conjunction with a fuse, prevents motor damage due to excessive

pump pressure.


» Wiring Harness: Fuse prevents wire and motor damage due to excessive current.


» Installation Instructions: Application-specific instructions provided for most machines.

» Suction Hose: Rated for 148.89° C oil and will not collapse under any vacuum level.



» Pump Relief Valve: Standard.






15.88 mm ID 0.61 m

22.23 mm ID 2.13 m

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If Suction Hose Length is > ½ Maximum Length above,

Then Use Max Permitted Ratio of Pressure Hose Length: Suction Hose Length

IF Suction Hose Length is < ½ Maximum Length above,

THEN Use Max Permitted Pressure Hose Length

Electrical Connections (Total Length = Power Cable + Motor Cable + Ground Cable)


Height ............................................................................................................................................................................................ 91 mm

Width ............................................................................................................................................................................................ 104 mm

Motor/Pump Assembly Weight ........................................................................................................................................................ 5.7 kg


12.70 mm ID 15.88 mm ID

15.88 mm ID 2.7: 1 7.5: 1

22.23 mm ID 1.5: 1 3.6: 1


12.70 mm ID 1.52 m

15.88 mm ID 3.66 m

Wire Size Total Length (24 V System)

8 Gauge 12.19 m

6 Gauge 18.29 m

BATTERY TERMINAL M6TORQUE TO 3 FT-LBS

GROUND TERMINAL M6TORQUE TO 3 FT-LBS

INLET (NEAR SIDE) -10 SAE STRAIGHT THREAD PORTOUTLET (FAR SIDE) -8 SAE STRAIGHT THREAD PORT

OUTLET -8 SAE STRAIGHT THREAD PORT

INLET -8 SAE STRAIGHT THREAD PORT

Ø.425 MTG HOLESØ.425 MTG HOLES

104.14 mm

96.52 mm

76.2 mm

91.44 mm

30.48 mm33.02 mm

93.98 mm

259.08 mm

38.10 mm

81.28 mm

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P4L-20 Specification Sheet

Applications: A pre-lubrication & evacuation system intended for engines of 10 to 40 ℓ displacement or with sump capacities of 10 to 180 gallons.

Performance: 24 V System

21° C 15W-40 Oil: 16-20 gpm @ 60-75 A depending on available engine port sizes.


Maximum Duty Cycle .................................................................................................................. 12 min ON & 80 min OFF @ <80 A


System Connections:• Plumbing – Custom fittings are available to connect to the engine or sump. With Prelub™ plumbing, oil is drawn through an oil pan port and

returned to a port before the existing engine filter.

» Sump suction fitting should have at least 15.24 mm ID (26.99 mm ORB, 19.05 mm NPT, M27) if used w/viscous oil (15W-40 below 4.4° C). If a


» Oil return port should have at least 10.16 mm ID (12.70 mm pipe, 19.05 mm ORB, M22)

» Install the pressure switch into the furthest downstream port in the engine’s pressurized oil system. Adapters available for most port types and

sizes.

• Electrical – Connect motor through the magnetic solenoid switch to a source of power with the gauge of cables recommended on the next page.

Connect the main harness to the key switch harness, magnetic solenoid switch, pressure switch harness and control relay.

Motor-Pump Components and Features: » Motor: Series-parallel wound DC motor. High efficiency reduces current draw at all conditions.

» Pump: High-strength, low-weight aluminium housing with steel gears & improved shaft support.

» Integral Relief Valve (120 psi) and seal protection feature prevent motor or pump damage due to excessive pump pressure.

System Components and Features: » Timer: Standard Prelub “No-Delay” relay timer delivers fastest possible start.

» Wiring: Cable size & fuse prevent harness and motor damage due to excessive current.


» Inlet Hose: Rated for 148.89° C oil. Will not collapse under any vacuum level.

» Pressure Hose: Rated for 148.89° C oil and 5 times maximum pump output pressure.






22.23 mm 1.2 m

28.58 mm 3 m

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P4L-20 Specification Sheet



Longer lengths are possible with larger cables.

Maximum resistance of all cabling is: 24 V System – 0.013 Ohm


Height ............................................................................................................................................................................................ 119 mm

Width (motor only, mounting feet 154.94 mm wide) ......................................................................................................................... 117 mm

Motor/Pump Assembly Weight ........................................................................................................................................................ 8.1 kg


15.88 mm 22.23 mm

22.23 mm 4.5: 1 10: 1

28.58 mm 2.5: 1 7: 1


8 ga [13.3 mm2] 6.1 m

4 ga [21.1 mm2] 12.2 m

185.42 mm

GROUND TERMINAL 5/16-18TORQUE TO 6 lb-ft/8 N-m

BATTERY/POSITIVE TERMINAL 5/16-18TORQUE TO 6 lb-ft/8 N-m

R 3.1

(PUMP FACES)

OUTLET -10 SAE O-RING BOSS

OUTLET -10 SAE O-RING BOSS (NEAR SIDE)INLET -12 SAE O-RING BOSS (FAR SIDE)

INLET -12 SAE O-RING BOSS

55.88 mm

116.84 mm

58.42 mm

27.94 mm27.94 mm

226.06 mm

15.24 mm

48°

26°

71.12 mm

10

P4K-40 Specification Sheet

Applications: A pre-lubrication & evacuation system intended for engines of 30 to 120 ℓ displacement or with sump capacities of 25 to 105

gallons. Models available for 24 V systems.

Performance: 21° C 15W-40 Oil: 16-20 gpm @ 60-75 A depending on available engine port sizes.




System Connections:• Plumbing – Custom fittings are available to connect to the engine. Oil will be drawn through an oil pan port and returned to a port ahead of the

existing engine filter

» Oil pan suction fitting should have at least 25.4 mm ID (41.28 mm ORB, 25.4 mm NPT, M42) if used with viscous oil (15W-40 below 4.4° C). If a


» Oil filterhead return port should have at least 15.24 mm ID. (19.05 mm pipe, 26.99 mm ORB, M27)

» Install the pressure switch into the furthest downstream port in the engine’s pressurised oil system. Adapters available for most port types and

sizes.



relay.

Components and Features: » Motor: Series-wound DC motor. High efficiency reduces current draw at all conditions.

» Pump: High-strength aluminium housing with steel gears and a seal protection feature that, in conjunction with a fuse, prevents motor or pump

damage due to excessive pump pressure.

» Timer/Wiring: Standard Prelub “no-delay” relay timer delivers fastest possible start and harness fuse.

» Prevents harness and motor damage due to excessive current.

» Motor Switch: Rated for 300 A continuous yet consumes minimal power for activation.

» Inlet Hose: Rated for 91.44° C oil. Will not collapse under any vacuum level.

» Pressure Hose: Rated for 91.44° C oil and 5 times maximum pump output pressure.


» Standard Relief Valve (120 psi): Prevents pump damage.




*28.58 mm ID hose may be used only if viscous flow requirement is low.


28.58 mm* 1.22 m

34.93 mm 1.83 m

47.65 mm 3.66 m

11

P4K-40 Specification Sheet


*22.23 ID hose may only be used with 28.58 mm ID Suction hose.


Longer lengths are possible with larger cables.

Maximum resistance of all cabling is: 24 V System – 0.005 Ohm


Width (motor only, Bracket mounting feet 154.94 mm wide) ............................................................................................................. 122 mm

Height w/ magnetic switch mounted on motor (not shown) ............................................................................................................... 168 mm

Height of motor w/ remote-mount switch/timer (for use where space is limited) ................................................................................. 128 mm

Motor/ Pump Assembly Weight (bracket, motor, pump) ..................................................................................................................... 9.6 kg

Pressure Hose ID Maximum Length

22.23 mm ID* 2.44 m

28.58 mm ID 3.05 m

34.93 mm ID 7.62 m


4 gauge 6.10 m

2 gauge 9.14 m

GROUND TERMINAL M8x1.25TORQUE TO 6 lb-ft/8 N-m

(PUMP FACES)

OUTLET -16 STRAIGHT THREAD PORT

OUTLET (NEAR SIDE) -16 STRAIGHT THREAD PORTINLET (FAR SIDE) -20 STRAIGHT THREAD PORT

INLET (FAR SIDE) -20 STRAIGHT THREAD PORT

60°

30°R 3.2

121.92 mm

15.24 mm

58.42 mm

71.12 mm

50.8 mm

208.28 mm

279.40 mm

33.02 mm

60.96 mm

Ø 4.4

BATTERY/POSITIVE TERMINAL M8x1.25TORQUE TO 6 lb-ft/8 N-m

12

High-Volume Pump Specification Sheet

Applications: A pre-lubrication & evacuation system intended for engines of 40 to 140 ℓ displacement or with sump capacities of 25 to 140

gallons. Models available for 24 V systems.

Performance: 21.11° C 15W-40 Oil: 30-40 gpm @ 180-230 A depending on available engine port sizes.

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


Ambient Temperature .................................................................................................................... –40 to 125° C (-40 to 257°F)





» Oil filterhead return port should have at least 15.24 mm ID (19.05 mm pipe, 26.99 mm ORB, M22)

» Install the pressure switch into any 1/8” pipe thread port in the engine’s pressurised oil system. Adapters available for most port types and sizes.

• Electrical – Connect the motor to a source of power with the gauge of cables recommended on the next page and splice the supplied connector into

the key switch wire. Plug the wiring harness into the connectors at the keyswitch, pump and pressure switch.

Components and Features: » Motor: Series-parallel wound DC motor. High power rise better maintains flow rate at lower temperatures.

» Pump: High-strength aluminum housing with steel gears and a seal protection feature that, in conjunction with a fuse, prevents motor damage

due to excessive pump pressure.

» Timer/Wiring: Standard Prelub “no-delay” timer delivers fastest possible start and harness fuse prevents harness and motor damage due to

excessive current.

» Motor Switch: Rated for 600 A continuous yet consumes minimal power for activation.

» Inlet Hose: Rated for 91.44° C oil and will not collapse under any vacuum level.



» Relief Valve,150psi: OPTIONAL-Recommended for systems with Oil Evac oil drain feature.

Weights:Motor/Pump Assembly (Includes bracket, motor) .................................................................................................................... 21.8 kg

All other components (Plumbing & Electricals) ........................................................................................................................ 11.4 kg

Recommended Hardware:Suction Hose Length – Maximum recommended

» -24 size ....................................................................................................................... 1.2 m

» -32 size ....................................................................................................................... 3.7 m

» -20 size(may be used if viscous flow requirement is low) ................................................ 1.2 m

Note: Maximum oil lift height is 1.2 m

Pressure Hose Length – Maximum recommended

» -20 size ....................................................................................................................... 3.0 m

13

High-Volume Pump Specification Sheet

» -24 size ....................................................................................................................... 7.6 m

» -16 Size (w/-20 suction hose only) ................................................................................ 2.4 m

Motor Ground and Power Cables, Combined Length - Maximum w/24 V systems

» #2 gauge ..................................................................................................................... 6.0 m

» 0 gauge ....................................................................................................................... 9.2 m

Greater lengths are possible with larger cables. Max resistance of both cables is;

24 V system – 0.003 Ohm, 12 V system – Not available, 32 V system – Not available.

Motor/Pump Assembly Dimensions:Length ........................................................................................................................................................................ 410-430 mm

Width ................................................................................................................................................................................. 178 mm

Height w/ motor mounted switch/timer ................................................................................................................................. 235 mm

Height w/ remote-mount switch/timer (shown) ...................................................................................................................... 145 mm

4.875[123.82 mm]

4.875[123.82 mm]

5.726[145.44 mm]

16.223[412.06 mm]

BATTERY TERMINAL1/2-13 UNC-2ATORQUE TO 15-20 FT-LBS

GROUND TERMINAL1/2-13 UNC-2ATORQUE TO 15-20 FT-LBS

6.994[177.64 mm]

4.575[116.20 mm]

Ø.460 THRU HOLES

Ø.460 THRU HOLES

OUTLET PORT (NEAR SIDE) -16 SAE O-RING BOSS

INLET PORT (NEAR SIDE) -20 SAE O-RING BOSS

14

A.C. High-Volume Pump Specification Sheet

Applications: A pre-lubrication system intended for engines of 40 to 140 ℓ displacement or with sump capacities of 25 to 140 gallons. Ideally

suited for installation where high capacity batteries are unavailable for DC Prelub™ Systems such as air-start, power generation, and marine engines.

The AC-HVP pump is also suitable for the transfer of bulk fluids in both portable and stationary applications. Models available for 208 V, 230 V, and

460 V 60 Hz 3-Phase power supplies.

Performance: 460 V, 60 Hz, 3-Phase power (Current ~double on 208 V)

21.11° C 15W-40 Oil: 25-35 gpm @ 4-6.3 A depending on available engine port sizes.



Ambient Temperature .................................................................................................................... –40 to 125° C (-40 to 257°F)

*Pump can sustain extended duty when motor current < 12.6/6.3 Amps (warm oil, low pressure)

System Connections:• Plumbing – Custom fittings are available to mate directly into the engine. Oil will be drawn through an oil pan port and returned to a port ahead of the

existing engine filter.



» Oil filterhead return port should have at least 15.24 mm ID (19.05 mm pipe, 26.99 mm ORB, M22).

» Install the pressure switch into any port in the engine’s pressurized oil system. Adapters available for most port types and sizes.

• Electrical – Connect the Prelub™ Controller to a 3-phase power source and connect the AC Prelub™ Pump to the Controller in accordance with

all applicable electrical codes. Splice the supplied connector into the key switch wire. Plug the wiring harness into the connectors at the keyswitch,

controller and pressure switch.

Components and Features: » Motor: 5hp, IEEE 45 Certified, Totally Enclosed Fan-Cooled motor suitable for harsh environments.

» Pump: High-strength aluminium housing with steel gears and a seal protection feature that, in conjunction with customer supplied circuit

protection, prevents motor damage due to excessive pump pressure.

» System Controller: Standard Prelub “No-Delay” logic delivers fastest possible start.

» Design reduces extra electrical equipment needed for Code compliance when installing, saving the user installation time and money.

» Thermal-Overload, Phase-Loss, and Short-Circuit Protection for the Prelub™ Pump and control components.

» Rugged NEMA 12 Enclosure for installation in harsh environments.

» Inlet Hose: Rated for 91.44° C oil and will not collapse under any vacuum level.



» Pump Relief Valve: OPTIONAL-Recommended for applications that could dead-head pump.

15

10.75273mm

6.0152mm

8.1205mm

10.3262mm11.5292mm

8.3211mm

MOUNTING DIMENSIONS

CONTINUOUS HINGE

.317.8mm

(4 PLCS)

9.7247mm

AC-HVP CONTROLLER

A.C. High-Volume Pump Specification Sheet

A.C. PRELUB™ CONTROLLER SPECIFICATIONSD.C. Voltage Input 24 Vdc

Model Voltage 208 V 230 V 460 V

A.C. Voltage Input

208 V 190-230 Vac 3 Φ 60 Hz

230 V 208-255 Vac 3 Φ 60 Hz

460 V 415-505 Vac 3 Φ 60 Hz

InternalPower Supply

(AC) 24 Vac, 40 Va, Class 2, 2 Amp Fused Secondary

(DC) 24 Vdc, Full-Wave Rect., 2 Amp Fused

Horsepower Rating 3.73 kW

Enclosure NEMA 12 / IP54, Continuous Hinge

Dimensions 203 mm (w) x 254 mm (h) x 153 mm (d)

Weight 7.3 kg

Operating Temperature -5 to 55º C

Storage Temperature -40 to 65º C

Humidity 45 to 85% RH

Vibration 10 to 55 Hz 15 m/s2

Shock 50 m/s2

A.C. PRELUB™ PUMP SPECIFICATIONSPump Model AC-HVP

Flow Rate 35 GPM

Model Voltage 208 V 230 V 460 V

A.C. Voltage Input

208 V 190-230 Vac 3 Φ 60 Hz

230 V 208-255 Vac 3 Φ 60 Hz

460 V 415-505 Vac 3 Φ 60 Hz

Full Load Current 14 A 13 A 6.5 A

Inrush Current 90 A 90 A 45 A

Motor Rating 3.73 kW

Duty Cycle 30 Minute

Enclosure IEEE45 Rated, Tefc, Rigid Base

Dimensions 182 mm (w) x 232 mm (h) x 482 mm (l)

Weight 29.5 kg

Suction Port -20 SAE ORB (STOR)

Pressure Port -16 SAE ORB (STOR)

Max. Pressure 100 psi (w/PRV)

» Internal low-voltage supply for stand-alone operation where needed.

» The controller incorporates a Door Interlock and Pad-lockable

» System Operator for safety compliance.

» Front Panel Indicator and Operator keep the user informed of system status.

» Optional Functional Features available – contact RPM for details.

» Powerful 5hp motor provides quick and reliable Prelub™ function.

» Other pump configurations are possible – contact RPM for details.

9.15232mm

7.16182mm

4.9124mm

3.0076mm

7.74197mm

9.49241mm

18.98 [482mm] w/ STD. LID19.73 [501] w/ RELIEF VALVE LID

.348.6mm x 4 PLCS.

2.872mm

OUTLET PORT (near side): -16 SAE O-RING BOSSINLET PORT (far side): -20 SAE O-RING BOSS

JUNCTION BOX MAY BE ROTATED 180º

AC-HVP PUMP

Recommended Hardware:Suction Hose Length – Maximum recommended

» -24 size ....................................................................................................................... 1.2 m

» -32 size ....................................................................................................................... 3.7 m

» -20 size (may be used if viscous flow requirement is low) ............................................... 1.2 m

Note: Maximum oil lift height is 1.2m.

Pressure Hose Length – Maximum recommended

» -20 size ....................................................................................................................... 3.0 m

» -24 size ....................................................................................................................... 7.6 m

» -16 Size (w/ -20 suction hose only) ............................................................................... 2.4 m

Electrical Cable Length (Motor Ground and Power Cables)

» #8 AWG ....................................................................................................................... < 21 m*

» #6 AWG ....................................................................................................................... < 34 m*

*Greater lengths are possible with larger cables. Minimum ground wire is #10 AWG per NEC 250.122

Ø

.31[7.8 mm] (4 PLCS)

6.0[152 mm]

10.75[273 mm]

8.1[205 mm]

10.3[262 mm]

7.16[182 mm]

4.9[124 mm]

9.15[232 mm]

2.8[72 mm]

18.98 [482 mm] w/STD. LID19.73 [501 mm] W/RELIEF VALVE LID

JUNCTION BOX MAY BE ROTATED 180°

.34[8.6 mm] 3.00

[76 mm]

7.74[197 mm]

9.49[241 mm]

4.9[124 mm] x 4 PLCS.

OUTLET PORT (near side): - 16 SAE O-RING BOSSINLET PORT (far side): - 20 SAE O-RING BOSS

8.3[211 mm]

9.7[247 mm]

11.5[292 mm]

MOUNTING DIMENSIONSAC-HVP CONTROLLER

AC-HVP CONTROLLER

CONTINUOUS HINGE

16

Self-Contained Evac Tool™ Specification Sheet

Applications: A remotely-powered, handheld, transfer pump for lubricating oils. Models available for 12 Vdc and 24 Vdc.

Performance: #10 Machine Upfit Kit (16 mm ID Suction Hose)

Current @ 24 Vdc ½ of Current @ 12Vdc

3.5 gpm: 60º C 15W-40 Oil @ 12-14 A & 12 Vdc

2.00 gpm: 23.88º C 15W-40 Oil @ 16-18 A & 12 Vdc

1.25 gpm: 10º C 15W-40 Oil @ 20-22 A & 12 Vdc

Maximum Duty Cycle .................................................................................................................... 50% (4 minute Max. ON Time)

Ambient Temperature Rating* ...................................................................................................... 0º F to 150º F (-18º C to 65º C)

Target Evac Duration ................................................................................................... 90 seconds (depends on machine upfit kit)

Maximum Oil Viscosity ..............................................................................................700 cSt (2700 SUS) 50º F 15W-40 or thinner

*Be sure fluids are adequately heated if using with ambient temperature below 23.88° C. Most efficient evac occurs with oil temperatures greater

than 23.88º C because engine manufacturers recommend that oil be drained warm so that contaminants are suspended in oil and drained rather than

settling and being left in the pan to re-circulate.

Tool is not rated for transfer of combustibles or coolants (e.g. gasoline, kerosene, antifreeze, etc.) modification of tool or machine upfit kit without

specific RPM approval will void warranty.

Components and Features: » Efficient, high-torque, permanent magnet DC motor.

» Built-in, automatic, reset circuit breaker to protect against motor abuse.

» Tool housing is a rugged, impact-modified, reinforced polymer.

» High-amperage, capable motor switch with silver contacts for long life.

» Remote Activation Switch (with 2.44 m lead) assembly available.

» Shoulder strap available for ease of transport or securing tool to machine.

» Polyethylene carrying case available to organise tool & accessories.

» SCET™ is supplied with an 457.2 mm long suction hose and 1.22 m long pressure hose.

» Various Tool Plumbing configurations are available.

Machine Upfit Kits: » Kits are machine-specific & contain all necessary hardware.

» Detailed installation instructions, including application photographs, are included.

» Plumbing and Electrical connectors are mounted on an easily accessible Evac Bracket.

» Plumbing connects sump drain to a no-spill Flush Face Quick Disconnect.

» Many specialty oil pan drain fittings available; custom fittings are possible.

» Harness connects machine battery to Deutsch connector (3.05 m of 12 ga. SXL wire supplied).

» Various Evac Bracket assemblies available for installation flexibility.

17

Self-Contained Evac Tool™ Specification Sheet

Physical Characteristics:Tool Weight (w/ plumbing)........................................................................................................................................................ 15 kg

Tool Dimensions (no plumbing) .......................................................................................................................... 338 x 193 x 104 mm

Tool Suction Hose .......................................................................................................................................... 460 mm (l) x 16 mm ID

Tool Pressure Hose ...................................................................................................................................... 1220 mm (l) x 16 mm ID

D-RINGS FOR OPTIONAL SHOULDER STRAP

POWER RECEPTACLE

INLET PORT-10 37° FLARE

4.1 mm337.82 mm

7.6

OUTLET PORT-10 37° FLARE

18

Prelub Pump Installation

Unpack and inspect the pump for damage.

Survey the machine for a location to mount the pump. The pump should be

mounted horizontally away from sources of high heat with enough clearance

around the pump to allow connection of power cables and hoses. Mount the pump

bracket securely to the machine using nuts and bolts or welding.

The pump may be removed from the bracket to make mounting easier. During

reassembly of the pump into the bracket, make sure the B+ stud on the motor

is not touching the mounting bracket.

Squirt some engine oil in the pump ports to lubricate the gears prior to hose

connection.

Plumbing Installation

Suction Hose InstallationRefer to figure 3 for hose and fitting layout.

NOTE: DO NOT USE A SMALLER DIAMETER SUCTION HOSE THAN PROVIDED

The suction hose plumbs into the engine through the oil drain port located on the

bottom of the engine oil pan.

Remove the drain valve from the oil pan. Put the oring(103382) supplied in the

kit into the groove of the oil pan suction plate. Place the Oil pan suction plate

(103281) between the oil pan and the oil pan drain valve. Secure the assembly

with longer bolts. Longer bolts are NOT supplied with kit due to differences in

thread type and size. Install the screened elbow into the suction plate using pipe

dope or thread tape on the pipe threads.

Plan the suction hose routing to keep hose away from sources of high heat, sharp

bends and places where the hose may chafe. Cut the hose to length and use the

appropriate hose fittings to connect the hose to the suction port on the pump and the

elbow that is installed in the suction plate.

Upfit Kit Installation Instructions for Komatsu SA6D140

Photo 1 pump mounting example.

Your application may be different.

19

Figure 2. Pressure Fitting and Check Valve Installation

Pressure Fitting InstallationRemove the plug from the end of the oil cooler as shown in figure 2. Thread the adapter (104429) into the oil cooler. Assemble the fittings as follows:

Elbow (100855) into Adapter (104429). Next install the check valve (101328) into the elbow. The 1/2” NPT - #10 JIC adapter (100607) is last. All pipe

threads should be sealed with thread tape or pipe dope.

NOTE: When installing check valve, tighten to 1 1/2 turns. Overtightening check valve will cause damage to the valve and render it

inoperable.

Pressure Hose InstallationPlan pressure hose routing to give the least length but away from sources of high heat, sharp bends and places where the hose may chafe. Install

the necessary hose fittings as required to connect to the pressure port on the pump and the check valve assembly as shown in figure 3. Secure the

pressure hose with clamps and tie-wraps to prevent damage to the hose and surrounding engine components.

Pressure Switch InstallationInstall the pressure switch into the main oil rifle on the engine or a pressure port that is on the downstream side of the filter. Adapters may need to be

acquired to install the pressure switch. Seal pressure switch threads with thread tape or pipe dope to prevent leaks.


104429

100855

101328

100607

20


104429

103584

101311

101310

101312

101796

103281 103382

100855

101328

100607

101313

101315

101314

101688

100774

Pressure Side LayoutPrelub Pump

Suction Side Layout

Figure 3

21


1. Insert the relay mounting bracket (103547) into the relay (103546).

2. Mount the Prelub mag switch to the machine. Use Photograph 2 as an

example. Mount the switch horizontal and across the direction of travel

of the machine. Secure the relay to one of the bolts through the mag

switch bracket.

3. Plug Prelub main wiring harness (103634) into the connector of the

relay. Attach (101RD) Red and (301PU) Purple leads to large copper

terminals on switch.

4. Place the two white plugs into the open terminals on the 4-pin

connector of the main harness and install the wedge.

5. Locate the “START” wire at the machine key switch. Disconnect the

start wire from the key switch and connect the 337WH wire from

the Prelub™ key switch harness (102683). Cut the terminal from

the start wire that you removed from the key switch and attach the

Deutsch socket and connector from the bag attached to the key

switch harness. Plug this wire into the 307OR wire from the Prelub™

key switch harness as shown in the diagram below. Make sure all

connectors are secured and none of the pins have backed out. Use

extension harness (103211) as necessary and connect key switch

harness to the main harness (103634).

6. Using extension harness (103211) as necessary plug the pressure

switch into the main harness.

7. Connect the opened end of the 101RD cable to the B+ stud on the

starter using the terminal, heat shrink and boot supplied.

8. Connect the opened end of 301PU to the Torx bolt on top of the motor

frame of the Prelub™ pump using the terminal, heat shrink and boot

provided. The ground cable (103427) connects to the ground stud on

the side of the motor frame and a good vehicle ground.

Photograph 2

10788FOR TECHNICAL ASSISTANCE CALL 1-800-255-2250

PRELUB is a trademark of RPM Industries, Inc.

PRELUB™ Upfit Kit Installation InstructionsFor Komatsu SA6D140

PRESSURESWITCH

MACHINESTARTER

RELAYTO BATTERY "+"

TO STARTER

307 OR337 WT

PHOTOGRAPH 2

Page 4 of 5

TO BATTERY "+"

FUSE

301PU

101RD

1. Insert the relay mounting bracket (103547) intothe relay (103546).

2. Mount the Prelub mag switch to the machine.Use Photograph 2 as an example. Mount theswitch horizontal and across the direction of travelof the machine. Secure the relay to one of thebolts through the magswitch bracket.

3. Plug Prelub main wiring harness (103634) intothe connector of the relay. Attach (101RD) Redand (301PU) Purple leads to large copperterminals on switch.

103547

103546

103546

103211

102683

103211

103584

103429

MACHINE KEYSWITCH

B+

RUN

START

103428

103427

4.Place the two white plugs into the open terminals on the 4 pinconnector of the main harness and install the wedge.

5. Locate the "START" wire at the machine key switch.Disconnect the start wire from the key switch and connect the337WH wire from the Prelub™ key switch harness(102683). Cutthe terminal from the start wire that you removed from the keyswitch and attach the Deutsch socket and connector from thebag attached to the key switch harness. Plug this wire into the307OR wire from the Prelub™ key switch harness as shown inthe diagram below. Make sure all connectors are secured andnone of the pins have backed out. Use extensionharness(103211) as necessary and connect key switch harnessto the main harness(103634).

6. Using extension harness(103211) as necessary plug thepressure switch into the main harness.

7. Connect the opened end of the 101RD cable to the B+ studon the starter using the terminal, heat shrink and boot supplied.

8. Connect the opened end of 301PU to the Torx bolt on top ofthe motor frame of the Prelub™ pump using the terminal, heatshrink and boot provided. The ground cable(103427) connects tothe ground stud on the side of the motor frame and a goodvehicle ground.

Plug themain wiring harness (103634) into the connector on themagnetic switch. Attach the free end of the ground wire frommagnetic switch to a confirmed good ground.

RD

WT

BK103634

104005

SWITCHGROUNDCABLE

� � � � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � �

� � � � � � � �

� � � � � �

� � � � � � � � � � � � � �

� � � � �

7/27/06

3

21 Trysome Auto Electrical - www.trysome.cc - [email protected]

22


Star

ter R

elay

Conv

entio

nal

Star

ter

Prel

ubM

otor

(301

PU)

Fuse

(448

RD)(2

00BK

)

(307

0R)

(337

WH)

Mac

hine

Key

SW

R R

CS

B

Syst

emCo

ntro

lRe

lay

Pres

sure

Sw

itch

Clos

ed a

t 4 P

SI(447

PK)

(337

WH)

(307

OR)

(337

WH)

86 30 87 87A

85

Perlu

b M

ag S

W

SG MTR

BAT

Neut

ral S

W o

r Com

pute

rBa

tt +

Batt

+

Batt

+

Schematic Diagram

23

KOMATSU SAA6D125E-5 QuickEvac™ Installation Instructions

Komatsu SAA6D125E-5 Engine

Tool Requirements:• Loctite 592 or equivalent

• Drill w/bits up to 12.70 mm dia.

• Wrenches up to 381 mm

• Standard & Metric Socket Sets

• Standard Allen Key Set to 19.05 mm

• Deutsch Crimper

• Wire Crimper/ Cutter

• Heat Gun

24


103139

103138

103584

103067

102537 102366

104037 104203

101310

101311

101583

101312

102723 100777If Needed

103703

104036

101582100774If Needed

101328

100607

104036

103703

104036

SP

Pressure Side Layout

Suction Side Layout

Figure 1

Plumbing Diagram

25


MotorGround

PRELUB

RPMI ndustries,I nc.

301OR

101RD

START

RELAYBAT

C

Figure 2

OIL E-VAC BRACKET ASSEMBLY

103546Relay

SwitchGround Cable

102973

(+) Terminal

(-) Terminal

104373Magnetic switch 103567

102974 TO BATTERY “+”104392Adapter Harbess

103634Main Harness

103585 or 103211Extension Harness

103584Pressure Switch

102683Keyswitch Harness

103585 or 103211Extension Harness

103546Relay

103547Relay Bracket

MACHINEIGNITIONSWITCH

337WT 3070R

MACHINE STARTINGSYSTEM

FUSE101RD

3010R

Electrical Diagram

26

Cummins B Series 5.9 l Bus QuickEvac™ Installation Instructions

Figure 1

103584

103961

103101

103258

103438

100830or

101582

102327

102366

101313or

101314

101313or

101314

101313or

101314101313

or 101314

101313or

101314

101313or

101314

102327

101498

101328

100607

102327

101582

100774If Needed

100774If Needed

102040 102164OR

102537

Suction SideLayout

Pressure SideLayout

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