Installation of Improved Relays for the Power Distribution Panel Used on Certain 3500 Marine Engines{4493, 7451, 7490} Caterpillar

Introduction

This Special Instruction provides the procedure in order to install the improved relays for the power distribution panel on 3500 Marine Engines. Refer to following Table 1 for the power distribution panel relay part numbers.

Parts Needed

Installation of the 448-4867 Relay Kit

Illustration 1	g03476549
Typical DIN rail (1) 9X-9675 End Bracket (2) 204-5594 Relay (STE) (3) 204-5594 Relay (STOP 1) (4) 204-5594 Relay (STOP 2)

Illustration 2	g03476550
(5) Bridge bar

1. Remove all wires connected to relays (3) and (4). Refer to Illustration 1 for the correct wires.

2. Remove and discard bridge bar (5) from the relays on the DIN rail. Refer to Illustration 2 for the location of the bridge bar.

3. Remove end bracket (1) from the DIN rail.

4. Remove and discard relays (3) and (4) from the DIN rail.

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Illustration 3	g03476553
(6) 448-4867 Relay Kit

5. Install relay kit (6) onto the DIN rail where relays (3) and (4) had been located. Slide all the relays together, so there are no gaps.

6. Install end bracket (1) onto the DIN rail.

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Illustration 4	g03476552
(7) 110-8714 Wire End (8) 109-3038 Wire End (9) 125-7875 Heat Shrink Tube (10) 5P-5677 Wire

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Illustration 5	g03476639
(11) Wire daisy chain

7. Cut wire (10) into seven pieces 150 mm (6 inch) long.

8. Strip both ends of all wire (10) approximately 10 mm (0.394 inch) long.

9. Cut heat-shrink tube (9) into seven pieces 25 mm (1 inch) long.

10. Remove the "C150-G86" wire from relay STE (2) A1 terminal. Refer to Illustration 1 for the correct wire.

11. Attach the "C150-G86" wire to one of the wires (10) cut in Step 7 with wire end (8) .

12. Install heat-shrink tube (9) over wire end (8), the "C150-G86" wire, and wire (10) .

13. Attach two wires (10) at a time with wire end (8) .

14. Install heat-shrink tube (9) over wire end (8) and wires (10) .

15. Repeat until all wires (10) are connected.

16. Crimp wire end (7) onto the end of the last wire (10) .

17. Connect the daisy chain wire (11) to the relays A1 terminal beginning with STE, RESET 1, RUN 1, STOP 1, STPE, RESET 2, RUN 2, STOP 2. Refer to Illustration 5 for the daisy chain.

    Note: For marine propulsion engines use the "C150-G86" wire, one wire end (7), five wire ends (8), five heat-shrink tubes (9), and five wires (10) .

18. Reconnect the wires removed in Step 1 to the appropriate relay terminals.

    The effective serial numbers are listed in Table 2.

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    Table 2

    Effective Serial Numbers
    S/N:S2B00847-UP
    S/N:S2D00275-UP
    S/N:S2E00853-UP
    S/N:TTB00579-UP
    S/N:S2H00657-UP
    S/N:S2J00795-UP
    S/N:S2L00991-UP
    S/N:S2N00132-UP
    S/N:E3W00379-UP
    S/N:TTC00645-UP
    S/N:TTF00607-UP
    S/N:MKH00289-UP
    S/N:S2R00817-UP
    S/N:S2S00495-UP
    S/N:S2X01699-UP
    S/N:TTD00424-UP
    S/N:PAG00483-UP