Usage:
3304 ( 2B1 ),
3304 ( 4B1 ),
3304 ( 5B1 ),
3306 ( 66D1 ),
3306 ( 67D1 ),
3306 ( 23C1 ): 2W6386;
3406 ( 90U1 ),
3406 ( 91U1 ),
3406 ( 75Z1 ),
3408 ( 99U1 ),
3408 ( 67U1 ),
3408 ( 78Z1 ),
3412 ( 60M1 ),
3412 ( 38S1 ),
3412 ( 81Z1)
This instruction is for use in installation of the new time delay relay conversion groups that are given above. The original oil pressure time delay system made use of a 5N3014 Oil Pressure Switch that must be removed and a new 7N5946 Pressure Switch installed as a replacement. It will also be necessary to change the wiring, according to the wiring diagrams given for each specific engine model. Be sure to use the correct installation procedure, wiring diagram, etc. for your engine. After installation is complete, do the TEST PROCEDURE FOR TIME DELAY RELAY CONVERSION GROUP, as given in the rear of this instruction.
| NOTICE |
|---|
Always shutdown the engine and disconnect the batteries from the electrical system, before installation of the conversion group. |
1 For 3306 Engines, remove bolts (1), (2) and (3) that fasten the oil cooler bonnets to the oil cooler core. For 3304 Engines remove bolts (2), (4) and (5) that fasten the oil cooler bonnets to the oil cooler core. See the specific Service Manual for necessary procedures.
2 For 3306 Engines, use 3B1915 Bolts (6), (7) and (8), each with 5M2894 Washer, to fasten the relay and bracket assembly in position as shown.
3 For 3304 Engines, use three 3B1915 Bolts (9), (10) and (11), each with a 5M2894 Washer, to fasten the relay and bracket assembly in position as shown.
4 Disconnect the wires from the original time delay switch shown at location (A). Put tape on the end of each of these wires because they will not be needed for the new switch. Remove the 5N3014 Time Delay Oil Pressure Switch.
5 Use the 4M5317 Reducing Bushing to install 7N5946 Pressure Switch at location (A) as the replacement for the 5N3014 Switch.
Installation of 2W6386 Time Delay Relay Conversion Group on 3406 Engine
The 2W6386 Time Delay Relay Conversion Group is normally installed on the right side of the engine, except when the starter motor for the engine is on the right side. For those engines that have a starter motor on the right side, the time delay conversion group must be installed on the engine left side.
NOTE: If the engine is equipped with an oil pressure contactor (right side of engine), and the time delay relay conversion group is to be installed on the right side, move the contactor forward and use bolts 8 and 9 from the right rear of the oil pan, to fasten the contactor in position.
1 Remove two oil pan bolts, number 3 and 5 from the rear, on the specific side of the engine where the conversion group is to be installed (see explanation above).
2 Use two S1591 Bolts (1) with 5M2894 Washers to fasten conversion group (2) in position on the oil pan. Disconnect wires (3) and remove the original 5N3014 Time Delay Oil Pressure Switch (4). Use a 4M5317 Bushing to install 7N5946 Pressure Switch as a replacement for switch (4) in the same location. Put tape on the wire ends for former wires (3) because these wires will not be used.
NOTE: If the engine has a 12V electrical system, remove 9F3099 Switch (A) and install a 302266 Switch in its place.
Installation of 2W6386 Time Delay Relay Conversion Group on 3408 Engine
1 For those engines that have a speed switch at the left front side of the engine oil pan, remove the bolts that fasten the speed switch bracket to the oil pan. For these engines, also remove one additional bolt, so that bolts 2, 3 and 4 have been removed from the left front of the engine oil pan.
2 For those engines that do not have a speed switch at this left front location of the oil pan, remove bolts 2 and 4 from the left front of the oil pan.
NOTE: Because of the two different conditions given above, the installation location for each one is different. See the information that follows.
3 If the engine does have a special switch at the left front of the engine oil pan, use one original bolt (1), two S1591 Bolts (2) and (3) and one 8M7145 Washer (4) to fasten 2W6386 Time Delay Conversion Group (5) and speed switch bracket (6) to the engine oil pan.
4 If the engine did not have the speed switch, use the necessary bolts and washers from the conversion group to fasten 2W6386 Time Delay Relay Conversion Group (5) to the oil pan. [On this specific installation, there will not be a speed switch bracket (6), spacer (4) or bolt (2)].
5 Remove the original time delay oil pressure switch group (7) from the engine. Use the 4M5317 Bushing and install 7N5946 Pressure Switch as a replacement for oil pressure switch (7).
NOTE: Put tape over the ends of wires (8) that were used for pressure switch (7).
6 Make the necessary electrical connections according to the specific instructions given in WIRING DIAGRAMS.
Installation of 2W6386 Time Delay Relay Conversion Group on 3412 Engine
1 For those engines that have a speed switch at the left front side of the engine oil pan, remove the bolts that fasten the speed switch bracket to the oil pan. For these engines, also remove one additional bolt, so that bolts 3, 4 and 5 have been removed from the left front of the engine oil pan.
2 For those engines that do not have a speed switch at this left front location of the oil pan, remove bolts 2 and 4 from the left front of the oil pan.
NOTE: Because of the two different conditions given above, the installation location for each one is different. See the information that follows.
3 If the engine is equipped with a speed switch, use some of the original bolts, and the necessary bolts and washers from the conversion group to fasten 2W6386 Time Delay Relay Group (1) to bolt holes 3 and 5 of the oil pan, and fasten the speed switch bracket to bolt holes 4 and 5 of the oil pan.
4 If the engine did not have the speed switch, use the necessary bolts and washers from the conversion group to fasten the 2W6386 Time Delay Relay Conversion Group (1) to the oil pan.
5 Remove the original 5N3014 Oil Pressure Switch Group (2) from the engine. Put tape on the ends of the wires (3) that were connected to the pressure switch.
6 Use the 4M5317 Bushing and install the 7N5946 Pressure Switch as a replacement for the original oil pressure switch group (2).
7 make the necessary electrical connections according to the specific instructions given in WIRING DIAGRAMS.
Wiring Diagrams (Marine, Industrial And Generator Set Engines)
All wiring needed to make the necessary connection during assembly, is sent with each group. (All wire is #14 AWG.) All that is necessary is to cut the wire to the correct lengths, install terminals as needed, and then make the connections according to the instructions and diagrams that follow. Be sure to use the correct wiring diagram and instructions for your engine model, to make the connections from the generator terminal strip to the components as shown.
NOTE: use the 9S9150 Crimping Tool for easier installation of the terminal connectors on the wires that are cut for use in the installation procedure.
3304 And/Or 3306 With Automatic Start/Stop Generator Set And Floor Standing Switchgear
1 - 5N2124 Relay (TDR)
2 - 6N8589 Circuit Breaker
3 - 7N5946 Pressure Switch
4 - Overspeed Switch (if so equipped)
REF. DRAWING 5N5400, SHEET 13 (REV. 2)
1 Connect wire (A) from terminal 3 of generator terminal strip to terminal 3 on relay (1).
2 Connect wire (B) from terminal 2 of the generator terminal strip to the open post of circuit breaker (2).
3 Connect wire (C) from terminal 1 of relay (1) to the NO terminal on 7N5946 Pressure Switch (3).
4 Connect wire (D) from COMMON terminal of 7N5946 Pressure Switch (3) to terminal 6 on relay (1).
5 Connect wire (E) from terminal 10 of generator terminal strip to terminal 7 on relay (1).
3304 And/Or 3306 With Automatic Start/Stop Package Generator Set And SR-4 Control Panel
1 - 5N2124 Relay (TDR)
2 - 6N8589 Circuit Breaker
3 - 7N5946 Pressure Switch
REF. DRAWING 3N5984, SHEET 3 (PRIOR TO REV. 12)
1 Connect wire (A) from terminal 3 of generator terminal strip to terminal 3 on relay (1).
2 Connect wire (B) from terminal 2 of the generator terminal strip to the open post of circuit breaker (2).
3 Connect wire (C) from terminal 1 of relay (1) to the NO terminal of 7N5946 Pressure Switch (3).
4 Connect wire (D) from COMMON terminal of 7N5946 Pressure Switch (3) to terminal 6 on relay (1).
5 Connect wire (E) from terminal 10 of generator terminal strip to terminal 7 on relay (1).
3304 And 3306 Industrial, Marine Or Generator Set Engines
1 - 5N2124 Relay (TDR)
2 - 6N8589 Circuit Breaker
3 - 7N5946 Pressure Switch
1 Connect wire (A) from battery negative to terminal 3 on relay (1).
2 Connect wire (B) from battery positive to open terminal on circuit breaker (2).
3 Connect wire (C) from NO contact of 7N5946 Pressure Switch (3) to terminal 1 of relay (1).
4 Connect wire (D) from the C contact of 7N5946 Pressure Switch (3) to terminal 6 on relay (1).
5 Connect wire (E) from terminal 7 on relay (1) to the common terminal on the water temperature contactor, or on a generator set, connect it to terminal 6 on the generator terminal strip.
3406, 3408 Or 3412 With Automatic Start/Stop Generator Set And Floor Standing Switchgear
1 - 5N2124 Relay (TDR)
2 - 6N9349 Circuit Breaker
3 - 7N5946 Pressure Switch
4 - Overspeed Switch (if so equipped)
5 - Wire to air shutoff (if so equipped)
6, 7 - Relay (SR1)
REF. DRAWING 5N5400, SHEET 13 (REV 2)
1 Connect wire (A) from terminal 3 of generator terminal strip to terminal 3 on relay (1).
2 Connect wire (B) from terminal 2 of generator terminal strip to the open post of circuit breaker (2).
3 Connect wire (C) from terminal 1 of relay (1) to the NO terminal on 7N5946 Pressure Switch (3).
4 Connect wire (D) from COMMON terminal of 7N5946 Pressure Switch (3) to terminal 6 on relay (1).
5 Connect wire (E) from terminal 10 of generator terminal strip to terminal 7 on relay (1).
6 Connect wire (F) from the open coil terminal of SR1 (6) to terminal strip contact 6.
7 Connect wire (G) from the open contact terminal of SR1 (7) to the shutoff solenoid.
3406, 3408 Or 3412 With Automatic Start/Stop Package Generator Set And SR-4 Control Panel
1 - 5N2124 Relay (TDR)
2 - 6N9349 Circuit Breaker
3 - 7N5946 Pressure Switch
4, 5 - Shutdown relay (SR1)
REF. DRAWING 3N5984, SHEET 3 (PRIOR TO CHG. 12)
1 Connect wire (A) from terminal 3 of generator terminal strip to terminal 3 on relay (1).
2 Connect wire (B) from terminal 2 of generator terminal strip to the open post of circuit breaker (2).
3 Connect wire (C) from terminal 1 of relay (1) to NO terminal on 7N5946 Pressure Switch (3).
4 Connect wire (D) from COMMON terminal of 7N5946 Pressure Switch (3) to terminal 6 on relay (1).
5 Connect wire (E) from terminal 10 of generator terminal strip to terminal 7 on relay (1).
6 Connect wire (F) from the open coil terminal of SR1 (4) to terminal strip contact 6.
7 Connect wire (G) from the open contact terminal of SR1 (5) to the shutoff solenoid.
3406, 3408 Or 3412 Industrial, Marine Or Generator Set Engines
1 - 5N2124 Relay (TDR)
2 - 6N9349 Circuit Breaker
3 - 7N5946 Pressure Switch
4 - SR1 Relay
1 Connect wire (A) from terminal 3 of relay (1) to battery negative.
2 Connect wire (B) from the open terminal of circuit breaker (2) to battery positive.
3 Connect wire (C) from terminal 1 of relay (1) to the NO contact of 7N5946 Pressure Switch (3).
4 Connect wire (D) from the COMMON terminal of 7N5946 Pressure Switch (3) to terminal 6 of relay (1).
5 Connect wire (E) from terminal 7 of relay (1) to the common contact of the water temperature contactor.
6 Connect wire (F) from the open contact terminal of SR1 Relay (4) to the shut-off solenoid.
7 Connect a wire (G) from the open coil terminal of SR1 Relay (4) to the normally open contact of the water temperature contactor.
Test Procedure For Time Delay Relay Conversion Group
After the installation procedure for the conversion group is complete, do the test procedure given here to be sure that installation and system operation are correct.
1 Connect the batteries to the engine electrical system.
2 Start the engine and use any one, or all of the test procedures that follow, to test the operation of the electrical protection system for the engine.
A. To give an indication of engine low oil pressure, use a piece of #14 electrical wire as a jumper across the C to NC terminals of the low oil pressure switch (NOT 7N5946 SWITCH). The engine must either shut down, or activate the low oil pressure alarm system. The conversion group will still be energized (activated) for approximately 70 seconds. Remove the jumper wire and reset the control. Start the engine.
B. To give an indication of high water temperature, use a piece of #14 electrical wire as a jumper across the C to NO terminals of the high water temperature contactor. The engine must either shut down, or activate the high water temperature alarm system. The conversion group will still be energized for approximately 70 seconds. Remove the jumper wire and reset the control. Start the engine.
C. To give an indication of an engine overspeed, run the engine at rated speed, then push IN the 75% verify push button on the electronic speed switch. The engine must shut down. The conversion group will still be energized for approximately 70 seconds. Push the reset button on the speed switch. Start the engine.
3 In test procedures A, B and C electrical power to the engine shut-off solenoid is automatically disconnected in approximately 70 seconds after an engine shut down. This time delay is to make sure of a shut down before electrical current to the solenoid is disconnected. Use a test light or a voltmeter to test for correct operation of the system.