Installation of the Caterpillar Ignition System (CIS) on G3612 and G3616 Engines Caterpillar

Engine:

G3612 (S/N: 1YG1-123)

G3616 (S/N: 4CG1-81)

Introduction

This Special Instruction describes the installation of the Caterpillar Ignition System (CIS) on G3612 and G3616 Engines. The CIS replaces mechanical parts that are prone to wear. The CIS improves the ignition system's precision and reliability. The CIS also provides self-diagnostics and diagnostics for the ignition system.

The CIS was designed to operate with the Caterpillar Timing Control Module (TCM) in the Engine Supervisory System. The function of the TCM remains unchanged. No reprogramming is required.

For information on the operation of the CIS, refer to Systems Operation/Testing and Adjusting, RENR2255, "Ignition System".

A brief overview provides a summary of the installation procedure. The actual installation procedure provides more detailed identification of the parts.

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Reference: The following reference materials may be necessary for this procedure:

• Disassembly and Assembly, SENR5535, "G3612 and G3616 Engines"

• Operation and Maintenance Manual, SEBU6496, "G3612 and G3616 Engines"

• Systems Operation/Testing and Adjusting, RENR2255, "G3612 and G3616 Engines"

• Troubleshooting, SENR6510, "G3600 Engines"

• Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)"

• Special Instruction, SEHS9122, "Using the 7X-1400 Digital Diagnostic Tool (DDT) Group"

• For engines that were built before October 1998, refer to the 3E-9348 Wiring Diagram that was shipped in the engine mounted terminal box.

• For later engines, refer to the 128-3198 Wiring Diagram that was shipped in the engine mounted terminal box.

Overview

Illustration 1	g00905483
Typical example (in-line engine) (1) Magneto (2) Magneto interface box (3) Ignition harness

Magneto (1), magneto interface box (2), and the related wiring harnesses are removed. The original ignition harness (3) is removed.

Note: The oil mister pump is not necessary on G3600 Engines. For more information, refer to Engine News April, "Oil Mister Pump and Lines Group No Longer Used".

Illustration 2	g00905503
(4) Oil mister pump (5) Adapter

Oil mister pump (4), the oil lines, adapter (5), and the oil mister pump's drive are removed. A plate with a magnet for the camshaft position sensor is bolted to the camshaft in place of the pump drive's components.

Illustration 3	g00905488
Camshaft position sensor

A new adapter is installed over the camshaft and a camshaft position sensor is installed.

Illustration 4	g00905504
CIS Programming Control

The CIS Programming Control and a new ignition harness are installed. A wiring harness is routed from the camshaft position sensor to the programming control.

Illustration 5	g00905493
Terminal box

Wiring harnesses for the programming control's communication with the TCM and for the programming control's electrical power are connected to the engine's terminal box.

Illustration 6	g00905355
CIS Programming Display

The CIS Programming Display is connected to the programming control. The programming display provides an interface between the service technician and the CIS. The installation is tested for proper operation.

Required Parts

Table 1 includes parts that are required for installation of the CIS.

Remove the Original Ignition System's Components

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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

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Illustration 7	g00907774
Rear view (1) Ignition harness (2) Magneto/Interface harness (3) Magneto

1. Disconnect ignition harness (1) and magneto/interface harness (2) from magneto (3) .

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Illustration 8	g00903620
Section view of the magneto's drive coupling (3) Magneto

2. Remove magneto (3) from the rear housing. Do not remove the magneto's drive coupling. Keep the magneto's mounting bolts and washers for later use.

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Illustration 9	g00907785
Rear view (1) Ignition harness (4) 147-6549 Gasket (not shown) (5) 147-6548 Plate

3. Install gasket (4) and plate (5) in place of the magneto. Use the mounting bolts and washers that were removed from the magneto in Step 2.

4. Remove ignition harness (1) from the engine. If you remove bolts, washers, clips, and spacers, keep the parts for later use.

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Illustration 10	g00908262
Left side view (2) Magneto/Interface harness (6) Ground strap (7) Interface box (8) Interface harness

5. Remove the straps that tie magneto/interface harness (2) and interface harness (8) together. Disconnect the interface harness from interface box (7) .

6. Remove the mounting hardware in order to remove interface box (7) and magneto/interface harness (2) as a unit. Keep ground strap (6) for later use.

7. Remove interface harness (2). If you remove washers, bolts, and clips, keep the parts for later use.

   The interface harness wires must be disconnected from the terminal strip in the engine mounted terminal box. The terminals for engines that were built before October 1998 are identified differently than the terminals for later engines.

   Disconnect the wires from the terminals that are identified in Table 2.

   Tape the disconnected wires in order to isolate the unused wires.

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   Table 2

   Identification of the Terminals for the Interface Harness
   Before October 1998	October 1998 and Later	Function
   Terminal
   141	794	Pulses
   142	795	Manual override
   143	792	Clock
   144	793	Reset
   145	796	Timing ground
   146	797	Shield
   Terminal box's ground lug		Black wire

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Illustration 11	g00908696
(9) Actuator (10) Mounting bracket

8. Remove actuator (9) in order to remove mounting bracket (10). Keep the nuts, bolts, and washers for later use.

   Note: The original mounting bracket can be reused with the CIS programming control. However, the vertical portion of the bracket must be cut off in order to avoid interference with the control's mounting hardware. Also, new mounting holes for the control must be drilled through the vertical portion of the bracket.

Remove the Oil Mister Pump

1. Operate the prelube pump and the barring device in order to put the number 1 cylinder in the Top Center position on the compression stroke. Pin the camshaft. For instructions, refer to Systems Operation/Testing and Adjusting, RENR2255, "Finding the Top Center Compression Position for No. 1 Cylinder".

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Illustration 12	g00907786
Front view (1) Oil mister pump (2) Oil supply tube

2. Disconnect oil supply tube (2) from oil mister pump (1). Remove the oil supply tube and the tube's fitting from the oil supply port.

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Illustration 13	g00907787
Front view (3) 3J-1907 O-Ring Seal (4) 9S-4191 Plug

3. Install O-ring seal (3) and plug (4) into the oil supply port.

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Illustration 14	g00907789
Left side view of the oil lines (5) 8L-2786 O-Ring Seal (6) 9S-4185 Plug

4. Disconnect the remaining oil lines from the oil mister pump. Remove the retaining bolts, washers, nuts, and clamps for the oil lines. Remove the oil lines and fittings from the engine.

5. Install O-ring seals (5) and plugs (6) into the ports for the oil lines' fittings.

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Illustration 15	g00905053
Section view of the oil mister pump and pump drive (1) Oil mister pump (7) Adapter (8) Bolt (9) Washer (10) Shaft

Note: Shaft (10) is held in place by a thrust washer that is bolted into adapter (7). Be careful not to drop the shaft when you remove the adapter.

6. Remove bolts (8) and washers (9) that hold adapter (7) onto the front housing. Remove the adapter, the oil mister pump, and shaft (10) as a unit.

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Illustration 16	g00905105
Section view of the oil mister pump's drive adapter (11) Bolt (12) Adapter (13) Camshaft

7. Remove bolts (11) and remove adapter (12) from camshaft (13) .

Install the New Mechanical Parts and the Camshaft Position Sensor

Note: One side of plate (2) is marked "FRONT". The front of the plate must face away from the camshaft.

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Illustration 17	g00905122
Section view (1) 142-8608 Magnet As (2) 175-1495 Plate (G3612 Engine) (2) 175-1496 Plate (G3616 Engine) (3) 5P-8245 Hard Washer (4) 0S-1587 Bolt (5) Camshaft

1. Coat the threads of magnet assembly (1) with 4C-4030 Thread Lock Compound . Install the magnet assembly into the side of plate (2) that is marked "FRONT".

2. Coat the threads of bolts (4) with 4C-4030 Thread Lock Compound . Place plate (2) into position on camshaft (5). Make sure that the side of the plate that is marked "FRONT" is facing you. Use washers (3) and bolts (4) to install the plate onto the camshaft.

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Illustration 18	g00908723
Section view and front view (6) 1W-2334 Gasket (7) 140-8360 Adapter (8) 0L-1571 Bolt (9) 5P-9658 O-Ring Seal (10) 162-9237 Cover (11) 6V-7699 Hard Washer (12) 3L-2540 Bolt (13) Hole for the camshaft position sensor

3. Place gasket (6) and adapter (7) into position on the front housing. Use bolts (8) to install the parts onto the front housing.

4. Make sure that O-ring seal (9) is installed in the adapter's bore for cover (10). Place the cover into position on the adapter and install the cover with washers (11) and bolts (12) .

Note: When the camshaft is pinned, approximately 75 percent of magnet assembly (1) is visible through hole (13) .

5. Make sure that magnet assembly (1) is visible directly through hole (13) in the adapter.

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Illustration 19	g00907792
Left side view (broken view) (1) 142-8608 Magnet As (14) 145-7982 Sensor (Camshaft)

6. Thread sensor (14) into hole (13) until the sensor contacts the face of magnet assembly (1). Then unscrew the sensor for 3/4 of a turn (270 degrees) in order to obtain a clearance of approximately 1.06 mm (0.042 inch). Tighten the sensor's locknut to a torque of 45 ± 7 N·m (33 ± 5 lb ft).

7. Remove the timing pin from the camshaft and return the timing pin to the storage location.

Install the CIS Programming Control and the Wiring Harnesses

1. Service the spark plugs. Replace the spark plugs, if necessary. For instructions, refer to Operation and Maintenance Manual, SEBU6496, "Ignition System Spark Plugs - Check/Adjust".

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Illustration 20	g00907804
(1) 122-3360 Bracket (2) Actuator

2. Install mounting bracket (1) and actuator (2). Use the bolts, washers, and nuts that were removed in Step 8 of the ""Remove the Original ignition System's Components" " procedure.

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Illustration 21	g00907793
(3) 145-8462 Plate (4) 0S-1588 Bolt (5) 3V-3308 Hard Washer (6) 9S-8752 Full Nut (7) 172-0062 CIS Programming Control (G3612 Engine) (7) 172-0063 CIS Programming Control (G3616 Engine) (8) 7H-3937 Lockwasher

3. Install mounting plate (3) onto mounting bracket (1) with bolts (4), washers (5), and nuts (6) .

4. Install programming control (7) onto plate (3). Use the mounting hardware that is supplied with the programming control.

   When you install the programming control, also install the ground strap that was removed in Step 6 of the ""Remove the Original Ignition System's Components" " procedure. If necessary, remove paint in order to ensure a good ground connection. Place lockwasher (8) between the ground lug and the programming control. Tighten the ground strap's fasteners to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

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Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

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Illustration 22	g00907794
(9) 146-1802 Wiring Harness (G3612 Engine) (9) 146-1803 Wiring Harness (G3616 Engine) (10) Lockwire (11) Wire seal

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Illustration 23	g00908854
(9) 146-1802 Wiring Harness (G3612 Engine) (9) 146-1803 Wiring Harness (G3616 Engine) (10) Lockwire (11) Wire seal

5. Install ignition harness (9). Attach the conduit to the engine with the clips, spacers, washers, and bolts that were removed in Step 4 of the ""Remove the Original Ignition System's Components" " procedure.

6. Secure the ignition harness' connectors with lockwires (10) and wire seals (11) .

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Illustration 24	g00908855
(12) 146-1810 Harness (G3612 Engine) (12) 146-1813 Harness (G3616 Engine) (13) 146-18012 Harness (14) 146-1811 Harness

Note: Harness (12) is for the camshaft position sensor. Harness (13) provides electrical power to the programming control. Harness (14) is for the CIS signal wires.

7. Connect harnesses (12), (13), and (14) to the programming control. Fasten the harnesses to the engine with any washers, bolts, and clips that were removed in Step 7 of the ""Remove the Original Ignition System's Components" " procedure.

   Use 7K-1181 Cable Straps and 6K-0806 Cable Straps to further secure the harnesses.

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Illustration 25	g00907795
Left side view (12) 146-1810 Harness (G3612 Engine) (12) 146-1813 Harness (G3616 Engine)

8. Route harness (12) to the camshaft position sensor and connect the harness.

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Illustration 26	g00907802
Rear view (13) 146-18012 Harness (14) 146-1811 Harness

9. Route harnesses (13) and (14) around the rear of the engine to the terminal box on the right side of the engine.

10. Cut two holes in the bottom of the terminal box in order to accommodate harnesses (13) and (14) .

11. Connect the wires from harness (14) to the proper terminals in the terminal box.

    The terminals for engines that were built before October 1998 are identified differently than the terminals for later engines. The terminals are identified in Table 3.

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    Table 3

    Identification of the Terminals and the Wires for the CIS Programming Control
    Before October 1998	October 1998 and Later	Connector Terminal, Function, and Wire Color
    Terminal
    141	794	A Pulses White with yellow stripe
    142	795	C Manual override White with orange stripe
    143	792	E Clock White with blue stripe
    144	793	G Reset White with green stripe
    145	796	H Timing ground Black marked "S851"
    146	797	- Shield
    Terminal box's ground lug		B Black marked S852

12. If necessary, open a new hole in the terminal box for harness (13). Connect the red wire to the +Battery terminal. Connect the black wire to the -Battery terminal.

Test the System

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Illustration 27	g00293914
Engine Supervisory System (ESS) (1) Gauge panel (2) TCM (3) Electronic Control Module (ECM) (4) Mode control switch (5) Connector

1. Make sure that the electrical power to the control panel is OFF. Make sure that the mode control switch on the ESS is in the OFF/RESET position.

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NOTICE
Connection of the programming display to an active electrical power source can damage the programming display. Always make sure that the system's electrical power is OFF before you connect the programming display.

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Illustration 28	g00907803
(6) 152-0890 Wiring Harness (7) 149-4235 CIS Programming Display

2. Connect harness (6) to the programming control. Connect the other end of the harness to programming display (7) .

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Illustration 29	g00904665
Retarder switch and LED display inside the programming control (8) Retarder switch (9) "POWER" (10) "TX" (11) "RX" (12) "ALARM" (13) "HE P/U"

3. Remove the cover from the programming control.

   The features are defined below:

   Retarder switch - This switch is used to adjust the timing when the TCM is operating in the magneto calibration mode.

   "POWER" - This indicator is illuminated continuously when the programming control has electrical power. If this indicator flashes, there is a problem with the electrical power.

   "TX" - This indicator flashes when the programming control is transmitting information on the RS-485 serial link.

   "RX" - This indicator is illuminated when the programming control receives information on the RS-485 serial link.

   "ALARM" - This indicator flashes if the programming control detects an abnormal operating condition.

   "HE P/U" - This indicator illuminates when the magnetic field affects the camshaft position sensor.

4. Turn the mode control switch on the ESS to the STOP position.

5. Observe the LED indicators inside the programming control. Verify the following conditions:
   • The "POWER" indicator is illuminated.

   • The "ALARM" indicator is not illuminated.

   • If the magnetic field is near the camshaft position sensor, the "HE P/U" indicator is illuminated. Otherwise, this indicator is not illuminated.

   • The "TX" and "RX" indicators are flashing because the programming display is connected to the programming control via the RS-485 serial link.

6. Observe the programming display in order to verify that no warnings and/or faults are active.

   If a warning or a fault is active on the programming display, or if the "ALARM" indicator in the programming control is flashing, refer to the following publications:

   • Systems Operation/Testing and Adjusting, RENR2255, "G3612 and G3616 Engines"

   • Troubleshooting, SENR6510, "G3600 Engines"

   • Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)"

7. Turn OFF the engine's fuel supply so that the engine will not start. Crank the engine.

8. Observe the "HE P/U" indicator in the programming control.

   Because the camshaft rotates twice for each crankshaft rotation, the "HE P/U" indicator will flash at one-half of the rate of the cranking speed. Ensure that the "HE P/U" indicator is flashing.

9. Make sure that the "ALARM" indicator in the programming control is not flashing and that no warnings or faults are active on the programming display.

10. Stop cranking the engine.

11. Turn ON the engine's fuel supply.

12. Use the Digital Diagnostic Tool (DDT) to place the TCM into the magneto calibration mode.

    For information on using the DDT, refer to Special Instruction, SEHS9122, "Using the 7X-1400 Digital Diagnostic Tool (DDT) Group".

13. Start the engine. When the engine speed is greater than 550 rpm, turn the retarder switch in the programming control in order to obtain a timing of 28 degrees BTC.

14. Use the the DDT to place the TCM into the automatic timing mode.

15. Verify that the engine operation is normal:
    • No alarms are active.

    • There is no misfire.

    • The engine speed is stable.

    • No problems occur when the engine is loaded.