Installation Procedure For The Caterpillar Ignition System (CIS) On The G3608 Engine{1550} Caterpillar

Engine:

G3608 (S/N: 4WF)

Introduction

This special instruction was written in order to give detailed instructions for the installation of the Caterpillar Ignition System. The following procedures should be read and understood before working on the engine.

The CIS has been designed in order to operate in conjunction with the Caterpillar Timing Control Module on natural gas engines. The system was designed in order to replace the Altronic III magneto and the Altronic Interface Box. The new features that have been included are the advanced spark energy control, the primary diagnostics, the spark diagnostics, the self-diagnostics, the pickup diagnostics and the serial communications. The function of the Caterpillar Timing Control Module remains unchanged. No reprogramming of the system is required. The ignition system consists of two main parts: an engine mounted Ignition System and an optional customer interface control module. The ignition system consists of a Ignition Module, and a Hall effect sensor.

Reference: For additional information, refer to the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)" and to the wiring diagram (in-line CIS).

Optional Display Module

The optional Display Module has an alphanumeric LCD display. The display shows the status of the engine, engine rpm, and energy level. Additional screens show setup and diagnostic information.

Reference: For additional information, refer to the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)".

Installation Of The Caterpillar Ignition System

Install the Rear Housing Cover

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Illustration 1	g00293709
This is an Illustration of the Magneto Drive. (1) 1W-8929 Coupling . (2) Magneto. (3) 130-7641 Housing Assembly

1. Remove the magneto (2). Leave the 1W-8929 Coupling (1) in the rear housing (3) .

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Illustration 2	g00293710
(4) 147-6548 Plate . (5) 147-6549 Gasket .

2. Install both the 147-6548 Plate (4) and the 147-6549 Gasket (5) over the old location of the magneto.

3. Remove the Altronics Interface Box. Save the ground strap.

Mount the 145-4919 CIS Electronic Control

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Illustration 3	g00293713
This is an Illustration of the 145-4919 CIS Electronic Control . (1) 145-8462 Plate . (2) 145-4919 CIS Electronic Control . (3) Ground Strap.

1. Install the 145-8462 Plate (1) onto the engine. See Illustration 1.

2. Mount the 145-4919 CIS Electronic Control (2) onto the 145-8462 Plate (1) .

3. Install the ground strap (3) that was saved from the Altronics Interface Box. Remove paint in order to ensure that a good ground connection is made.

Install the Oil Mist Pump and Lines

The 145-7982 Sensor Assembly senses a magnet. The magnet must be secured at the proper angular position. The leading edge of the sensor's signal represents the reset signal for the ignition in the manual timing position. In the electronic timing position, the sensor's signal is used in order to select the reset pulse from the Timing Control Module that occurs during the compression stroke. The Timing Control Module generates reset pulses during both the compression stroke and the exhaust stroke. The leading edge of the sensor's signal must occur at 12 degrees ahead of the most desired electronic timing. The falling edge of the sensor's signal must occur behind the most desired timing in the electronic mode.

1. The engine should be rotated until the piston for the number one cylinder is at the top center position.

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Illustration 4	g00293716
(1) 7C-1190 Metering Pump . (2) 7C-1165 Adapter .

2. Remove the 7C-1671 Tube , the 7C-1672 Tube , the 7C-1673 Tube , and the 7C-1674 Tube from the 7C-1190 Metering Pump (1) on the front of the engine.

3. Remove the 7C-1190 Metering Pump (1) from the front of the engine.

4. Remove the 7C-1165 Adapter (2) from the front of the engine.

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Illustration 5	g00293718
(3) 142-8608 Magnet Assembly . (4) 1W-2334 Gaskets . (5) 140-8359 Adapter Assembly . (6) 0S-1587 Bolt . (7) 5P-8245 Washer . (8) 142-2863 Plate . (9) 140-8360 Adapter . (10) 143-1270 Spacer .

5. Remove the 7C-1167 Adapter Assembly from the cam on the front of the engine.

6. Install the 140-8359 Adapter Assembly (5) onto the cam on the front of the engine. Install the 142-2863 Plate (8) onto the cam on the front of the engine. Use the 0S-1587 Bolts (6) and use the 5P-8245 Washers (7). The front of the plate must face away from the cam.

7. Apply 4C-4030 Thread Lock Compound to the threads of the 142-8608 Magnet Assembly (3). Assemble the 142-8608 Magnet Assembly (3) onto the 142-2863 Plate (8) .

8. Assemble both the 140-8360 Adapter (9) and the 143-1270 Spacer (10) onto the engine by using the eight 0L-1143 Bolts and the 1W-2334 Gaskets (4) .

   Note: 75 percent of the 142-8608 Magnet Assembly (3) is visible through the hole in the 140-8360 Adapter (9) when the number one cylinder is at the top center position.

9. Reassemble the 7C-1190 Metering Pump to the 140-8360 Adapter (9) .

10. Install the 146-0845 Tube , the 146-0846 Tube , the 146-0847 Tube , and the 146-0848 Tube .

    Reference: Consult the Service Manual, SENR4259.

11. Assemble the 145-7982 Sensor Assembly onto the 140-8360 Adapter (9). Turn the sensor assembly until the sensor assembly contacts the 142-8608 Magnet Assembly (3). Then back out 3/4 turn.

Install the Engine Wiring

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Illustration 6	g00293947

1. Install the following harnesses onto the 145-4919 CIS Electronic Control :
   • 146-1807 Harness (1)

   • 146-1808 Harness (2)

   • 146-1809 Harness (3)

2. Route the lines to the appropriate locations. Tie-wrap the lines into position.

   1. Punch two 22 mm (0.8 inch) holes in the bottom of the junction box.

   2. Route the 146-1808 Harness and the 146-1809 Harness to the engine mounted junction box. Install the harnesses.

   3. Route the 146-1807 Harness to the front cover of the cam.

3. The following wires in the engine mounted junction box should be removed:
   • Terminal 141 (white wire)

   • Terminal 142 (blue wire)

   • Terminal 143 (green wire)

   • Terminal 144 (orange wire)

   • Terminal 145 (black wire)

   • Terminal 146 (shielded wire)

4. Remove the black wire that is connected to the ground lug in the bottom of the junction box.

5. Install the following wires of the 146-1809 Harness in the engine mounted junction box in the following manner:
   • Terminal 141 (white wire with a yellow stripe)

   • Terminal 142 (white wire with an orange stripe)

   • Terminal 143 (white wire with a blue stripe)

   • Terminal 144 (white wire with a green stripe)

   • Terminal 145 (black wire that is marked "S851")

   • Terminal 146 (shielded wire in a harness)

6. Install the 146-1808 Harness in the engine mounted junction box.

   1. The red wire should be connected to the battery positive terminal.

   2. The black wire should be connected to the battery negative terminal.

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Illustration 7	g00293952
This Illustration shows the connection from the 146-1807 Harness to 145-7982 Sensor Assembly .

7. Install the 146-1807 Harness onto the 145-7982 Sensor Assembly .

8. Remove the old ignition harness.

Install the 146-1801 Wiring Harness Assembly

1. Ensure that the ground connections on the front of the 146-1801 Wiring Harness Assembly are connected to the engine block. Remove paint in order to ensure that a good ground connection is made.

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Illustration 8	g00295492
This Illustration shows the connection for the 146-1801 Wiring Harness Assembly into the 145-4919 CIS Electronic Control .

2. Install the 146-1801 Wiring Harness Assembly on the 145-4919 CIS Electronic Control .

Test the System

1. Clean the spark plugs. If necessary, replace the spark plugs.

2. Connect the 149-4235 CIS Programming Display to the 145-4919 CIS Electronic Control by using the 152-0890 Wiring Harness Assembly .

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Illustration 9	g00293914
This is an Illustration of the control panel of the Engine Supervisory System. (1) LED Display. (2) Timing Control Module. (3) Engine Control Module. (4) Mode Control Switch. (5) Sensor Wires To The Engine.

3. Apply power to the control panel of the Engine Supervisory System.

4. Observe the LED indicators that are inside of the 145-4919 CIS Electronic Control .

   1. The power should be on.

   2. The fault should be off.

   3. The sensor can be on or off.

   4. The communication should be flashing when the CIS Operator Interface is connected.

5. Review the fault codes on the 149-4235 CIS Programming Display . No fault codes should be present.

   Reference: In order to correct any problems, consult the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)".

6. Shut off the fuel flow to the engine.

7. Crank the engine without fuel.

8. Observe that the sensor assembly's LED flashes at a rate that is half the speed of the engine rpm.

9. Observe the status of the Fault LED.

10. Observe any fault codes that appear on the Customer Interface Module.

    Reference: In order to correct any problems, consult the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)".

11. Stop the engine.

12. Open the fuel flow to the engine.

Start The Engine

1. Place the engine into Magneto Calibration Mode by using the Digital Diagnostic Tool.

2. Use the 149-4235 CIS Programming Display in order to preset the 145-4919 CIS Electronic Control . Follow the instructions that are given in the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)".

3. Start the engine.

4. The timing should be set at 28 degrees when the engine is operating above 550 rpm. In order to adjust the timing, follow the instructions that are given in the Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)".

5. Remove the engine from the Magneto Calibration Mode by using the Digital Diagnostic Tool.

6. Verify that the Engine Performance is correct.