Basic Ops. of The Prelube Timer

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Product: MOTOR GRADER

Model: 120H MOTOR GRADER CAF
Configuration: 120H Motor Grader CAF00001-UP (MACHINE) POWERED BY
3126B Engine
Special Instruction
Caterpillar Prelub Diagnostics{1469}
Media Number -REHS0439-01 Publication Date -01/10/2002 Date Updated -20/10/2002
i01777531
Caterpillar Prelub Diagnostics{1469}

SMCS - 1469-038
Commercial and Truck Engines: All

Machine Engines: All
Earthmoving Compactor:
826G (S/N: 7LN1-UP)
836 (S/N: 7FR1-UP)
Wheel Loader:
980G (S/N: 2KR1-UP)
988F Series II (S/N: 2ZR1-UP)
990 Series II (S/N: 4FR1-UP)
Wheel Tractor:
834B (S/N: 7BR1-UP)
Introduction
This Special Instruction applies to all Caterpillar machines with engines that are equipped with
the Prelub Engine Prelubrication System.
The Caterpillar Prelub System uses the starter motor to run an oil pump. This oil pump primes the
engine oil system before starting the engine. This information applies to machines using the Caterpillar
Prelub system that are equipped with the 139-1585 140-3108 Timer Assemblies . There are other
prelubrication systems that are installed on machines that are made by Caterpillar. This Special
Instruction is not applicable to these other systems.
Normal Operation
1. Turn the key switch to the CRANK position and hold the key switch in the CRANK position.
2. The starter motor runs in Prelub Mode. The motor spins but the flywheel is not engaged. The
starter motor runs for 3 to 45 seconds until oil pressure reaches between 27 kPa (4 psi) and 48 kPa
(7 psi). The oil pressure is measured at the oil pressure switch.
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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEBP3... Page 2 of 16
3. The key switch is still held in the CRANK position. The starter is delayed for three seconds and
the spinning stops.
4. The starter then engages the flywheel and the engine is cranked normally.
Basic Operation Of The Prelub Timer
Illustration 1 g00557737
Basic Prelub Electrical Schematic
Illustration 2 g00557729
Circuitry Of The Timer
(1) Relay Control.
(2) Three-Second Delay Control.
Power from the keyswitch is supplied to Contact 1 of the timer when the keyswitch is in the CRANK
and RUN positions. Contact 1 supplies power to the electronic circuits that are inside the timer. Contact
2 connects through the wiring harness to the starter solenoid's ground terminal. When the Prelub oil
pressure switch detects pressure less than 27 kPa (4 psi), Contact 4 is connected to ground. Power from
Contact 3 (CRANK) then passes through the normally closed internal relay. The Prelub magnetic switch
is then energized. When the magnetic switch closes, current flows to the motor terminal on the starter
solenoid. The starter motor is allowed to run without engaging the starter drive.
When the starter motor runs, the Prelub pump will pressurize the oil system. The Prelub pump draws oil
from the engine oil pan. The oil is then pumped into the engine oil system through the oil hoses of the
Prelub system. The oil pressure is measured at the Prelub oil pressure switch. When the oil pressure
exceeds 27 kPa (4 psi) to 48 kPa (7 psi), the timer turns off the magnetic switch of the Prelub system.
The starter motor will stop turning. The timer will wait for three seconds. An internal relay in the timer
will then allow power from the key switch (Contact 3) to pass through Contact 5 on the timer. The
starter will now crank normally.
Note: After Prelub has been activated, Prelub will not activate again until the key switch has been in the
OFF position for a minimum of two minutes.
The timer is located on the electric circuit between the key switch and the transmission ECM. The timer
is also located on the electric circuit between the key switch and any other control that prevents
cranking.
Initial Troubleshooting Procedure
Table 1
Service Tools Required

Description Part Number
A Digital Multimeter (DMM) with a DC Volts mode. If the testing will 9U-7330 Digital
be completed with only one person, a DMM with a "peak hold" or Multimeter
"record" mode is required. The Fluke 87 DMM is recommended.
A clamp-on DC current probe capable of measuring 400 amperes or 155-5176 AC/DC Current
more. Probe or 8T-0900
Ammeter
A connector probe. 7X-1708 Multimeter
Probe or 7X-1709
Multimeter Probe
Note: During Prelub Mode, the starter motor runs but the drive is disengaged from the engine. The
engine will not crank in this mode but the starter motor will spin. The battery disconnect switch must be
ON for all testing unless otherwise stated. Batteries must be fully charged.
The key must be in the OFF position for more than two minutes between tests that involve the Prelub
Mode.
If you are testing alone, use the "Peak Hold" feature on your DMM in order to record the voltage
readings from the tests below. Turn on the DMM. Turn on the DMM's "Peak Hold" or "Record" feature.
Refer to the DMM instructions when performing the following tests. The "Peak Hold" mode on the
DMM must be reset before each step. All connections must be made prior to entering "Peak Hold"
mode.
Note: This Special Instruction can be used for the 4Q-5450 Timer Switch Assembly if the following
changes are noted:
The 4Q-5450 Timer Switch Assembly does not have a "113" circuit (Contact 1). A yellow wire is
in Contact 1 of the connector but this wire is not used.
The negative wire to the Prelub magnetic switch is green. The Prelub magnetic switch is mounted
to the timer on this type.
Contact 5 on both systems goes to the starting circuit. The wire color on the 4Q-5450 Timer
Switch Assembly (Contact 5) is white and black rather than yellow on the other timers.
The delay of two minutes (key OFF) to inhibit Prelub Mode does not apply to the 4Q-5450 Timer
Switch Assembly .
Table 2
Symptom Go
To
The battery is not low but nothing happens when the key is switched to crank and held for Test
more than 5 seconds. 1
The starter does not run in Prelub mode before the delay of 3 seconds. The starter then cranks Test
the engine. 2
The starter runs in Prelub mode for more than 45 seconds but the starter stops when the key is Test
released from crank. 3
The starter motor runs in Prelub mode even after the key is released from the crank position. Test
4
The starter runs slowly in the Prelub mode. Test
5
The starter motor rapidly engages and disengages after the Prelub mode and the delay cycles. Test
6
The starter motor runs in Prelub mode. Then, the starter stops with the key still in the crank Test
position. The engine never cranks. 6
All Prelub and engine crank functions work normally but the system will enter Prelub mode Test
if the key is switched back to crank even before the 2 minute delay has elapsed. This function 7
applies to 140-3108 139-1585 Timer Assemblies only.
Test 1
1. Check Prelub Magnetic Switch.
a. Connect a DMM to the two small terminals on the Prelub magnetic switch. Connect the
negative lead of the DMM to the negative terminal on the Prelub magnetic switch. Connect
the positive lead of the DMM to the positive terminal on the Prelub magnetic switch. On
newer timers, the red/white wire is the negative side of the coil on the Prelub magnetic
switch. On all timers, the lead from the negative coil on the Prelub magnetic switch comes
out of the timer. The wire is next to the black wire (Contact 4).
b. Turn on the DMM. Set the DMM to "DC volts". Hold the key in the CRANK position for at
least five seconds.
Expected Result: The DMM reads at least 20 volts while the key is in the CRANK
position. The DMM should read 10 volts for 12 volt systems.
Results:
Yes - The Prelub timer is attempting to enter Prelub Mode. The oil pressure switch is
properly grounded and power is available to the timer. Go to Step 4.
No - The Prelub magnetic switch is not being energized. Go to Step 2.
2. Check Ground Circuit.
a. Insert a multimeter probe into the back of Contact 2 (ground). Insert the probe on the side of
the 6-pin connector that goes to the timer.
b. Connect the multimeter probe to the positive terminal on the DMM. Connect the negative
lead to a good ground.
c. Turn on the DMM and set the DMM to "DC Volts". Hold the key in the CRANK position
for at least 5 seconds.
Expected Result: The DMM reads at least 1 volt while the key is in the CRANK position.
The DMM should read .5 volts for 12 volt systems.
Results:
Yes - Ground circuit (200) has high resistance. Check the following items for
damage, corrosion, or poor connections: the ground wire from the Prelub 6-pin
connector (Contact 2), the ground terminal for the starter solenoid, the engine to
frame grounds and the negative battery post to engine ground. Make sure that the
main disconnect switch is turned ON. Make sure that the main disconnect switch is
working properly by checking continuity. Repair the problems with the circuit and
retest the system.
No - Go to Step 3
3. Check For Power From The Keyswitch.
a. Insert a multimeter probe into the back of Contact 3 (CRANK). Insert the probe on the side
of the 6-pin connector that goes to the timer.
lead to ground.
c. Turn on the DMM. Set the DMM to "DC Volts". Hold the key in the CRANK position for
at least 5 seconds.
position. The DMM should read at least 10 volts for 12 volt systems.
Results:
Yes - Go to Step 4.
No - There is no power from the key switch on Circuit 337 of the machine wiring.
Check the wiring from the key switch to the Prelub 6-pin connector. Check for wires
that are loose, corroded, or damaged. Check the key switch for proper operation.
Check related fuses and breakers. Repair the problems with the circuit. Retest the
system.
4. Check for Power to the Prelub Magnetic Switch.
a. Connect the negative lead of the DMM to ground.
b. Set the DMM to "DC Volts". Touch the DMM's positive lead to one of the large terminals
on the Prelub magnetic switch.
c. Read the DMM. Then touch the DMM's positive lead to the remaining large terminal on the
Prelub magnetic switch.
Expected Result: One of the terminals has system voltage.
Results:
Yes - Note this as the battery terminal on the Prelub magnetic switch. Continue to
Step 6.
No - There is no power to the Prelub magnetic switch. Go to Step 5.
5. Check Harness.
a. Connect the negative lead of the DMM to ground. Touch the positive lead of the DMM to
the starter solenoid's B+ terminal.
b. Turn on the DMM. Set the DMM to "DC Volts". Check for system voltage.
Expected Result: The terminal has system voltage.
Results:
Yes - There is an open circuit in the Prelub wiring between the battery terminal of the
starter solenoid and the Prelub magnetic switch (Circuit 101). Repair the wiring from
the starter solenoid to the Prelub magnetic switch. Retest the system.
No - Repair the open circuit in the battery to starter wiring. The open circuit could be
caused by one of the following problems: loose connections, broken wires, corroded
wires and faulty disconnect switch. Ensure that the main disconnect switch is working
properly. Ensure that the wiring from the battery to the frame and engine grounds is
good. See Starting System Diagnostic Procedures to continue.
6. Check Prelub Magnetic Switch.
a. Connect the positive lead of the DMM to the motor terminal on the Prelub magnetic switch.
The motor terminal is the large terminal opposite the battery terminal that was found in Step
4.
b. Turn on the DMM. Set the DMM to "DC Volts".
c. Hold the key in the CRANK position for 5 seconds.
Results:
Yes - There is an open circuit in the large wire from the Prelub magnetic switch to the
starter motor terminal (Circuit 301). Go to Step 7.
No - Replace the Prelub magnetic switch and retest the system.
7. Check Harness.
a. Connect the positive lead of the DMM to the motor terminal on the starter solenoid. The
motor terminal is the large terminal toward the motor. Connect the ground lead of the DMM
to ground.
c. Hold the key in the CRANK position for five seconds.
Results:
Yes - If the starter motor does not run, replace the starter motor and retest the system.
No - Repair or replace the Prelub wire (301) from the Prelub magnetic switch to the
motor terminal on the starter solenoid. Retest the system.
Test 2
1. Check Harness.
a. Insert a multimeter probe into the back of Contact 4 (oil pressure switch). Insert the probe
on the side of the 6-pin connector that goes to the timer.
lead to ground.
c. Turn on the DMM. Set the DMM to "DC Volts".
d. Hold the key in the CRANK position for at least 5 seconds.
The DMM should read at least .5 volts for 12 volt systems.
Results:
Yes - The oil pressure switch circuit is not grounded with the engine off. This
condition may be caused by one of the following problems: an open circuit in the
wiring, poor wiring connections and a faulty Prelub oil pressure switch. Go to Step 2.
No - Replace the timer and retest the system.
2. Check Oil Pressure Switch.
Leave the DMM connected as in Step 1 above.
a. Make sure that all of the electrical connections of the Prelub system are properly connected.
b. Disconnect the oil pressure switch. Connect a jumper wire between the two terminals in the
connector for the oil pressure switch.
c. Turn on the DMM. Set the DMM to "DC Volts".
d. Hold the key in the CRANK position for at least five seconds.
Note: If the starter motor now runs in Prelub Mode, replace the oil pressure switch.
Results:
Yes - The oil pressure switch wiring has an open circuit. Go to Step 3.
No - Make sure the terminals in the Prelub oil pressure switch connector are clean
and in good condition. Replace the Prelub oil pressure switch and retest the system.
3. Check Harness. Leave the DMM connected from the previous step.
a. Connect a jumper wire from the pink wire (circuit A447) at the Prelub oil pressure switch
connector to ground.
c. Hold the key in the CRANK position for at least five seconds.
Expected Result: The DMM reads at least 2 volts while the key is in the CRANK position.
Results:
Yes - Repair the open circuit wire (A447) between the Prelub timer and the Prelub oil
pressure switch connector. Check the connections for corrosion or damaged pins.
Repair the problems with the circuit and retest the system.
No - An open circuit exists between the Prelub oil pressure switch connector and the
120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEB... Page 10 of 16
starter solenoid ground (Circuit 200). Repair the problems with the circuit and retest
the system.
Test 3
1. Check for Prelub Oil Pressure Switch Operation.
a. Disconnect the connector for the Prelub oil pressure switch.
b. Turn the key to the CRANK position. Hold the key in the CRANK position for more than
10 seconds.
Expected Result: The starter cranks the engine after a three-second delay.
Results:
Yes - The Prelub oil pressure switch is not working properly or the Prelub oil
pressure switch never exceeds between 27 kPa (4 psi) and 48 kPa (7 psi). Go to Step
2.
No - The wire from the Prelub timer connector is shorted to ground or the timer is
faulty. Go to Step 7.
2. Check Oil Pressure.
a. Remove the oil pressure switch from the engine.
b. Connect an oil pressure gauge to the engine's oil pressure switch port.
c. Connect a jumper wire between the terminals in the connector of the Prelub oil pressure
switch.
d. Turn the key to the CRANK position and observe the oil pressure. Hold the key in the
CRANK position until one of the following events occurs: the oil pressure is 48 kPa (7 psi),
or 45 seconds pass.
Expected Result: The oil pressure exceeds 48 kPa (7 psi).
Results:
Yes - Replace the Prelub oil pressure switch and retest the system.
No - Go to Step 3.
3. Check Oil In The Engine.
Check that the engine oil pan is filled to the proper level with clean oil.
Expected Result: The oil is good.
Results:
Yes - Go to Step 4.
No - Fill to proper level with good oil or change oil as needed. Retest the system. If the oil
is contaminated, determine the root cause in order to prevent a recurrence.
4. Check Prelub Pump Output.
a. Remove the pressure hose (outlet) from the pump.
b. Connect a hose from the pressure port to a suitable container. Ensure that the hose remains
in the container.
c. Turn the key to the CRANK position until one of the following events occurs: the oil
pressure is 48 kPa (7 psi), or 45 seconds pass.
Expected Result: Oil flows from the hose.
Results:
Yes - Go to Step 6.
No - Go to Step 5.
5. Check Oil Suction Tube.
Check the suction hose for air leaks and restrictions. Make sure that the end of the suction tube is
immersed in oil.
Expected Result: There are air leaks or restrictions.
Results:
Yes - Repair leaks or restrictions and retest the system.
No - Replace the Prelub starter motor.
6. Check Pressure Hose and Check Valve.
Check that the Prelub oil check valve is properly installed. The arrow must be pointing in the
direction of oil flow. Check the pressure hose for restrictions.
Expected Result: The check valve was installed properly and the hoses are free of restrictions.
Results:
Yes - The oil system in the engine has a large internal leak, blocked oil passages, or
excessive engine bearing wear. Repair the system and retest the system.
No - Install the check valve properly and/or repair pressure hose restrictions as needed.
Retest the system.
7. Check Harness To Prelub Oil Pressure Switch.
a. Remove Pin 4 (black wire) from the Prelub 6-pin connector.
b. Reconnect the connector and hold the key in the CRANK position for at least ten seconds.
If the engine cranks after a delay, release the key.
Expected Result: The starter has a delay. After the delay, the starter cranks the engine.
Results:
Yes - Repair the short to ground in the wire (circuit A447) from Contact 4 to the
Prelub oil pressure switch and retest the system. Remember to reinstall Pin 4 in the 6-
pin connector.
No - Replace the Prelub timer and retest the system. Remember to reinstall Pin 4 in
the 6-pin connector.
Test 4
Note: Tapping on the Prelub magnetic switch may temporarily break the weld that is causing the contact
disk to stick in the Prelub magnetic switch. Normal operation would be temporarily restored. If this
occurs, replace the Prelub magnetic switch. Caterpillar does not recommend this action due to the
possibility of breaking the component. Similarly, tapping on the starter solenoid may temporarily break
the weld that is causing the contact disk to stick inside the starter solenoid. Normal operation would be
temporarily restored. If this occurs, replace the starter solenoid. Caterpillar does not recommend this
action due to the possibility of breaking the component.
1. Check Harness.
Make sure that the batteries are fully charged and make sure that the batteries are in good
condition. Low cranking voltage may contribute to welding of the contact disk.
a. Turn OFF the main disconnect switch.
b. Disconnect one of the large wires from the Prelub magnetic switch.
c. Turn ON the disconnect switch.
Expected Result: The starter motor still runs.
Results:
Yes - Turn OFF the disconnect switch. The Prelub magnetic switch or the Prelub
wiring is shorted. Go to Step 2.
No - Replace the Prelub magnetic switch and retest the system.
2. Check Harness.
a. Disconnect the Prelub wire from the motor terminal on the starter solenoid.
b. Turn ON the disconnect switch.
Expected Result: The starter motor still runs.
Results:
Yes - The contact disk inside the starter solenoid is stuck. Replace the starter solenoid
and retest the system. If the starter motor shows signs of damage, also replace the
starter motor.
No - The wiring from the Prelub magnetic switch and the starter motor is shorted.
Repair the problems with the circuit and retest the system.
Test 5
1. Check for Excessive Starter Current.
a. Connect a current probe (DC) around either of the large wires that are connected to the
Prelub magnetic switch. Use a 155-5176 Current Probe .
b. Turn the key to the CRANK position. Observe the current after the starter motor has run for
more than two seconds in Prelub Mode.
Note: Do not use "Peak Hold" or "Record Mode" on the DMM for this test.
Expected Result: The DMM reads at least 300 amperes while the key is in the CRANK
position. The DMM should read at least 400 amperes for 12 volt systems.
Results:
Yes - The starter current is excessive. Go to Step 2.
No - Service batteries and charge batteries as needed. Check Prelub wiring

connections from the starter solenoid to the Prelub magnetic switch for looseness,
corrosion, or hot spots. Make sure that the ground connections are good. Repair the
problems with the circuit and retest the system.
2. Check for Oil Leakage.
Check for oil inside the starter motor.
Expected Result: Oil is present inside the starter motor.
Results:
Yes - This could be accompanied by a Prelub pump lid gasket failure, which is an indication
of a Prelub Check Valve failure, or excessive restrictions in the Pressure hose of the Prelub
system. Go to Step 3.
No - Replace the starter motor and retest the system.
3. Pinpoint Oil Leak.
The oil could be entering from the starter nose housing or the oil could be entering from the
Prelub pump. Remove the starter and inspect the nose housing.
Results:
Oil appears to be coming from the nose housing. Replace the starter and retest the system.
Oil appears to be coming from the Prelub pump. Replace the starter. Replace the Prelub
check valve. Repair any restrictions in the pressure hose. Retest the system.
Test 6
Test 6 can be made much quicker and easier by making a Prelub bypass connector. To make the Prelub
bypass connector, perform the following procedure.
Procedure to Build a Prelub Bypass Connector
Table 3
Parts Needed
Part Number Description Quantity
102-8805 Receptacle Kit 1
9W-0852 Connector Pin 1
N/A 14 AWG wire

152.4 mm (6 inches)
1. Using the proper crimp tool, install 9W-0852 Connector Pins on each end of the 14 AWG wire.
2. Insert one end of the 14 AWG wire (with 9W-0852 Connector Pin installed) into Location 3 of the
102-8805 Receptacle Kit . Insert the remaining end of the 14 AWG wire (with 9W-0852
Connector Pin installed) into Location 5 of the 102-8805 Receptacle Kit .
3. The Prelub bypass connector can now be plugged into the Prelub wiring harness in place of the
timer. This will restore normal operation of the starter with no Prelub function. If the starter now
works normally (less the Prelub mode and delay) replace the Prelub timer. If the starter still
chatters or does not engage, begin with Step 2 below.
The batteries must be fully charged and the battery cables must be clean and tight before continuing.
1. Test For Prelub Timer Fault.
Note: The Prelub Mode and delay will not function during this test.
a. Disconnect the Prelub timer.
b. Connect a jumper wire from Contact 3 to Contact 5. Be careful not to short to any other
wires in the connector. Do not damage the Prelub harness connector.
Expected Result: The engine cranks normally.
Results:
Yes - Replace the Prelub timer. Retest the system.
No - The wiring, starter relay, or starter solenoid is at fault. Go to Step 2.
2. Check Current from Keyswitch.
Leave the jumper wire or bypass connector (from above) in place for this test.
a. Insert a connector probe into Contact 5 of the Prelub harness connector (on the harness
side).
c. Hold the key in the CRANK position for three seconds.
Results:
Yes - The key switch and wiring to the Prelub timer is OK. Go to Step 3.
No - There is insufficient current from the key switch. The key switch, related wiring,
or connections need repair. Repair the problems with the circuit and retest the system.
3. Check Harness.
Leave the jumper wire or bypass connector (from above) in place for this test.
a. Connect the positive lead from the DMM to the positive terminal on the starter relay coil.
b. Connect the negative lead to the ground terminal on the starter solenoid.
c. Hold the key in the CRANK position for three seconds.
Results:
Yes - The Prelub system and wiring are good. The starter relay, starter solenoid, or
related wiring/connections are at fault. Pinpoint the fault and repair as needed.
No - The circuit from the Prelub timer has excessive voltage drop. The circuit (307)
goes through the following components: Contact 5 in the Prelub connector, the
transmission control, any other starter lockout system and the starter relay coil. Check
all related connections for corrosion and proper connection. Check the related wiring
for damage. Verify the integrity of all starter lockout devices such as the transmission
control. Repair the problems with the circuit and retest the system.
Test 7
1. Check Key ON Circuit from Keyswitch.
a. Connect the positive DMM probe to the backside of Contact 1 (Circuit 113) in the Prelub
timer connector.
b. Connect the negative DMM probe to ground.
c. Turn on the DMM. Set the DM to "DC Volts".
d. Turn the key to the RUN position.
Results:
Yes - Replace the Prelub timer and retest the system.
No - The key ON circuit (113) from the key switch to the Prelub timer has a fault
(high resistance or open circuit). Repair the problems with the circuit and retest the
system.
Copyright 1993 - 2010 Caterpillar Inc. Thu Aug 12 10:27:16 UTC+0900 2010
All Rights Reserved.
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Basic Ops. of The Prelube Timer

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120H Motor Grader CAF00001-UP (MACHINE) POWERED BY 3126B Engine(SEBP3...

Product: MOTOR GRADER

Caterpillar Prelub Diagnostics{1469}

Commercial and Truck Engines: All

Basic Operation Of The Prelub Timer

(1) Relay Control.

(2) Three-Second Delay Control.

Initial Troubleshooting Procedure

Service Tools Required

No - The Prelub magnetic switch is not being energized. Go to Step 2.

2. Check Ground Circuit.

3. Check For Power From The Keyswitch.

4. Check for Power to the Prelub Magnetic Switch.

a. Connect the negative lead of the DMM to ground.

Expected Result: One of the terminals has system voltage.

No - There is no power to the Prelub magnetic switch. Go to Step 5.

Expected Result: The terminal has system voltage.

6. Check Prelub Magnetic Switch.

b. Turn on the DMM. Set the DMM to "DC Volts".

c. Hold the key in the CRANK position for 5 seconds.

No - Replace the Prelub magnetic switch and retest the system.

b. Turn on the DMM. Set the DMM to "DC Volts".

c. Hold the key in the CRANK position for five seconds.

c. Turn on the DMM. Set the DMM to "DC Volts".

d. Hold the key in the CRANK position for at least 5 seconds.

No - Replace the timer and retest the system.

2. Check Oil Pressure Switch.

Leave the DMM connected as in Step 1 above.

c. Turn on the DMM. Set the DMM to "DC Volts".

b. Turn on the DMM. Set the DMM to "DC Volts".

a. Disconnect the connector for the Prelub oil pressure switch.

2. Check Oil Pressure.

a. Remove the oil pressure switch from the engine.

Expected Result: The oil pressure exceeds 48 kPa (7 psi).

3. Check Oil In The Engine.

Expected Result: The oil is good.

4. Check Prelub Pump Output.

a. Remove the pressure hose (outlet) from the pump.

Expected Result: Oil flows from the hose.

5. Check Oil Suction Tube.

Expected Result: There are air leaks or restrictions.

Yes - Repair leaks or restrictions and retest the system.

No - Replace the Prelub starter motor.

6. Check Pressure Hose and Check Valve.

7. Check Harness To Prelub Oil Pressure Switch.

a. Remove Pin 4 (black wire) from the Prelub 6-pin connector.

a. Turn OFF the main disconnect switch.

c. Turn ON the disconnect switch.

Expected Result: The starter motor still runs.

No - Replace the Prelub magnetic switch and retest the system.

b. Turn ON the disconnect switch.

Expected Result: The starter motor still runs.

Yes - The starter current is excessive. Go to Step 2.

No - Service batteries and charge batteries as needed. Check Prelub wiring

2. Check for Oil Leakage.

Check for oil inside the starter motor.

Expected Result: Oil is present inside the starter motor.

No - Replace the starter motor and retest the system.

3. Pinpoint Oil Leak.

Procedure to Build a Prelub Bypass Connector

N/A 14 AWG wire

chatters or does not engage, begin with Step 2 below.