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Special Instruction
Installation Instructions for the Electric Fuel Priming Pump on Caterpillar Equipment With
the 24 Volt System{1258}
Media Number -REHS1037-04 Publication Date -31/01/2007 Date Updated -05/02/2007

i02696915

Installation Instructions for the Electric Fuel Priming Pump on

Caterpillar Equipment With the 24 Volt System{1258}
SMCS - 1258

Articulated Truck: All

Asphalt Paver: All
Challenger: All
Cold Planer: All
Combine: All
Commercial Engines and Truck Engines: All
Earthmoving Compactor: All
Excavator: All 300B Family Excavators All C-Series Wheeled Excavators All 300C Family Excavators
Forest Products: All
Motor Grader: All
Off-Highway Truck/Tractor: All
Pipelayer: All
Road Reclaimer/Soil Stabilizer: All
Soil Compactor: All
Track-Type Loader: All
Track-Type Skidder: All
Track-Type Tractor: All
Wheel Dozer: All
Wheel Loader: All

Introduction
The Special Instruction outlines the installation of the fuel priming pump.

Advantages of the Fuel Priming Pump

The fuel priming pump reduces the time that is needed in order to prime the fuel system. The fuel priming
pump will help eliminate contamination of the fuel supply.

Installation of 206-5756 Fuel Priming Pump Gp

Use the parts in Table 1 to install the fuel priming pump.

Necessary Parts for Installation

Table 1
Parts List For The 206-5756 Water Separator and Fuel Priming Pump Kit
Part Number Description Qty
190-8970 Base Assembly 1
1R-0770 Water Separator and Fuel Filter 1
173-7126 Bowl 1
8T-9655 Mount 6
8H-8769 Bolt 2
9N-0869 Washer 9
1D-4538 Bolt 1
191-1782 Spacer 1
191-1783 Spacer 2
180-8071 Hex Socket Plug 2
9G-0011 Toggle Switch 1
2S-6024 Fuse 1
031-5637 Fuse Holder 1
136-7227 O-Ring Seal 2
6V-8189 Nut 3

Table 2
Recommended Parts That are Not Supplied in the Kit
Part Number Description Qty
6A-3361 Electrical Wire 6
5P-0653 Electrical Wire 2
- Fuel Hose (300 PSI) -

The following procedure should be used in order to install the fuel priming pump on Caterpillar equipment.
Accidental machine starting can cause injury or death to personnel
working on the machine.

To avoid accidental machine starting, turn the battery disconnect

switch to the OFF position and remove the key. If the machine is not
equipped with a battery disconnect switch, disconnect the battery cables
from the battery and tape the battery clamps.

Place a do not operate tag at the battery disconnect switch location to

inform personnel that the machine is being worked on.

Fuel leaked or spilled onto hot surfaces or electrical components can

cause a fire.

Turn the disconnect switch OFF when draining and/or removing any
fuel system components.

NOTICE

Do not allow dirt to enter the fuel system. Thoroughly clean the area
around a fuel system component that will be disconnected. Fit a
suitable cover over disconnected fuel system component.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
 Dispose of all fluids according to local regulations and mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00784950

(1) Bolt

(2) 8T-9655 Mount

(3) Spacer

(4) 190-8970 Base As

(5) Mounting surface

(6) 9N-0869 Hard Washer

(7) 6V-8189 Nut

Determine an appropriate location in order to mount the pump. Refer to Illustration 1. A template is provided
for the mounting holes. The template is located at the end of this instruction. Use a 9 mm (0.354 inch) drill
bit for the mounting holes. Use the bolts, nuts, spacers and mounts that are provided to attach the filter base
to the machine.

The mounting location for the fuel priming pump will be determined by the application. Ensure that the fuel
priming pump is located in an area that can be serviced easily. Ensure that you have access to the 6V-8189
Nut when the 190-8970 Base As is attached to the machine. Ensure that the fuel priming pump is located
away from electrical components. Ensure that the fuel priming pump is located away from debris and all hot
surfaces.

The electrical circuit for the fuel priming pump must have an in-line 5 amp fuse. The electrical circuit for the
fuel priming pump must have a spring loaded activation switch. The spring loaded activation switch must
have a factory default setting to the OFF position. Route the wires for the fuel priming pump away from
rubbing or chafing surfaces. The activation switch should be mounted within reach of the ignition switch.
The activation switch should be disabled when the ignition switch is in the OFF position.

The diameter of the fuel hose will be determined by the application. The size of the fuel fittings will be
determined by the application. The fuel hose should be capable of a minimum rating of 2068.5 kPa (300 psi).
The fuel hose must be routed away from electrical components and away from hot surfaces. The fuel hose
must be routed away from rubbing and away from chafing surfaces.

Typical Electrical Diagram

Illustration 2 g00781973

(1) Base assembly

(2) Electrical connector

(3) Activation switch for priming pump

(4) Fuse holder (5 amp)

(5) Ignition switch

(6) 24 volt battery

Use Illustration 2 as a reference in order to install the wiring.

Typical Diagram for the Plumbing

Illustration 3 g00924871

This illustration is effective with all of the engine models that are below the 3500 Engines.

(1) Injector

(2) Fuel pressure regulator

(3) Fuel tank

(4) Primary fuel filter

(5) Fuel pump

(6) Fuel priming pump

(7) Secondary fuel filter

(8) Fuel supply rail

Illustration 4 g00782023

This illustration is effective with all of the 3500 Engines and up.

(1) Injector

(2) Fuel pressure regulator

(3) Fuel tank

(4) Primary fuel filter

(5) Fuel pump

(6) Fuel priming pump

(7) Secondary fuel filter

(8) Fuel supply rail

Hose Installation
Illustration 5 g00783289

Left side view

(A) Fuel outlet

(B) Fuel inlet

Illustration 6 g00783314

Right side view

(A) Fuel outlet

(B) Fuel inlet

Two inlet connections and two outlet connections are located on the base of the pump. Refer to Illustration 5
and Illustration 6. The arrows on the filter base indicate the direction of fuel flow through the pump. Use the
180-8071 Hex Socket Plug and the 136-7227 O-Ring Seal to plug the unused ports prior to activating the
pump.

Electrical Connection

Turn the battery disconnect switch to the OFF position. Refer to Illustration 2. Use 16 gauge wire to connect
the fuel priming pump to the electrical system. Route the wire in a manner that will avoid chafing and
scraping. If necessary, use rubber grommets.

Test for the Electric Priming Pump

After the electrical connections are completed, and the connections for the fuel line are completed, turn the
battery disconnect switch to the ON position. Turn the ignition switch to the ON position. Hold the
activation switch for the priming pump in the ON position. The electric priming pump should run when the
switch is held in the ON position.
Template for the Mounting Holes
Illustration 7 g00925147
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