NUT 2011919 - Caterpillar

3304, 3306, 3406, 3408, 3412, 3500 SI Family of Engines;
3116 Marine;
3400 and 3500 Diesel Family of EnginesNecessary 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
When servicing or repairing electric power generation equipment, do the following:a. Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged "DO NOT OPERATE".b. Make sure the generator engine is stopped.c. Make sure all batteries are disconnected.d. Make sure all capacitors are discharged.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.
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. 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. 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. 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