Usage:
3116 Marine;
3400 and 3500 Diesel Family of Engines
Necessary Parts
Installing the 6I1864 12 VDC, 6I1868 24 VDC, and 6I1908 32 VDC Relay Kit
Procedure to Determine the Quantity and Voltage Relays to be Replaced
1. Determine number of relays, to be replaced, by inspecting inside of junction box.
2. Determine voltage by voltage identification on old relay.
Refer to the Parts List chart.
3. Order 1 Relay Group for every existing relay to be replaced.
Installation
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When servicing or repairing electric power generation equipment, do the following:
When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Make sure the testing equipment is designed for and correctly operated for the high voltage and current tests being made. Improper test equipment may fail and present a high voltage shock hazard to its user. |
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1. Locate relays on rear panel of junction box.
2. Remove nuts from relay mounting studs.
If relay sub-panel is present, remove all relay bases and then discard sub-panel.
3. Isolate one of the relays, and locate wire identification codes on harness wire ends near 4W2217 Base.
4. Match up portion of circuit identification (ID) relevant to relay from existing relay base with circuit ID on new relay group:
* Existing wire with ESS3B-SR3-4 would match with new wire labeled SR-4 to SR-85.
NOTE: Since the new relay kits are suitable to replace any relay, their circuit ID is SR-1 instead of SR1-1 or SR2-1 etc.
NOTE: Refer to 3116 Marine Engine Identification (ID) Conversion.
5. Should any of the old relay wires remain unidentified, refer to the Relay Assemblies being replaced to confirm existing wire numbers.
6. After ensuring that all wires to existing relay bases have been identified and matched with corresponding wires on the new relays, remove existing terminals from 4W2217 bases:
- * Insert a narrow blade screwdriver inside the 3.0 mm (.12 in) slot adjacent the base terminal.
- * Press down until the screwdriver moves down approximately 4.0 mm (.16 in) and releases the retention tang on the side of the terminal.
- * Remove screwdriver.
The terminal can now be removed by:
- * Gently pulling or prying it from the bottom of the 4W2217 base.
- * Press down until the screwdriver moves down approximately 4.0 mm (.16 in) and releases the retention tang on the side of the terminal.
NOTE: If screwdriver is left in slot while trying to remove terminal it may cause terminal to bind and not come out. (Friction prevents terminal from sliding out.)
7. After removing all terminals from ONE and ONLY one relay base:
- * Slip one 30.0 mm (1.18 in) length of heat shrink tubing over each wire from the existing base .. and
- * Another 30.0 mm (1.18 in) length of heat shrink tubing over each wire on the new relay kit.
8. Assemble wires from existing base with corresponding wires on new relay base by plugging male spade into female flag terminal.
Slip one of the two pieces of heat shrink tubing over terminal connection and apply the recommended heat to insulate assembly.
The flag terminal has a sharp corner and may penetrate the heat shrink tubing:
* Overlap the second piece of heat shrink tubing from the other wire over the first insulated assembly and apply the recommended heat.
After cooling, inspect the assembly to ensure there are not cuts in the tubing or any exposed metal.
9. Cut existing cable ties as needed from wires connected to relays:
* Re-route wiring to feed from left or right into bottom of new relay bases.
10. Use the nut and spacer to install new relay base onto existing studs that were used to secure the original 4W2217 bases:
- * Place spacer on stud, then base on spacer.
- * Tighten nut CAREFULLY .. the plastic base can be damaged if the nut is over tightened.
Repeat Steps 1 - 10 for any additional relays to be replaced.
11. Install new cable ties to neatly secure wiring.
Excessively long wires should be coiled and secured with cable ties to adjacent clips and/or wiring.
12. Inspect relay circuits to ensure conformance with appropriate wiring diagrams.
3116 Marine Engine Identification (ID) Conversion
Reference Print(s) For Relay and Relay Base
12 VDC Relay:
Original Relay 9G1928
New Relay 3E9362
24 VDC Relay:
Original Relay 6T4007
New Relay 3E6477
32 VDC Relay:
Original Relay 6T4006
New Relay 3E6477
Relay Base:
Original Relay Base 4W2217
New Relay Base 7T6365
Reference Print(s) For Junction Box Wiring
3304, 3306, 3406, 3408, 3412, 3500 SI Family of Engines
3304/3306 SI 4W9602/9Y3804
3406 SI 4W8395/9Y8397 EC. 10 & EC. 02
3408/3412 SI 4W9602 or 2W8905 or 7W8005/2W8943
3500 SI 4P8968/7E8378
3500 SI 9Y8395/9Y8397 EC. 10 & EC. 02
3500 SI 4P8968/7E8378
3116 Marine Engine
3116 7E1330/5N9532
3400 and 3500 Diesel Family of Engines
3400 4W9607/4W9603
3400 4W9602/4W9604
3400 7W8003/4P0328 and 5N9560
3400 7W8079/7W8018
3400 7W8007/5N9562
3400 7W8007/5N9562
3500 7C2686/7C2925
3500 7C2687/7C5029
3500 7W6798/7C5030
3500 7W6799/7W3467
3500 7W9358/7W6795