G3304 and G3306 Engines Caterpillar

Magneto - Assemble

Usage:

Assembly Procedure

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Table 1
Required Tools
Tooling	Part Number	Description	Qty
A	1P-1855	Retaining Ring Pliers	1
B	1P-0510	Driver	1
C	1P-1857	Retaining Ring Pliers	1

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00997130

If you replace the bearings in bearing support (2) you must replace the bearings and bearing support as a unit.
Use a press in order to install the distributor gear and shaft assembly (1) in bearing support (2).
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Illustration 2 g00997131
Use Tooling (A) in order to install snap ring (3) that holds the distributor gear and shaft assembly (1) in position.
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Illustration 3 g00997132
Place an identification mark on the tooth by mark (4) on assembly (5).
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Illustration 4 g00997133
Align mark (6) on assembly (5) with the Letter "A" on the distributor gear and shaft assembly (1).
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Illustration 5 g00997134
Use a press in order to install assembly (5) in bearing support (2).
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Illustration 6 g00997135

Note: Install the open end of vent cap (7) in the DOWN position.
Install two screens and vent cap (7) on each side of housing (8).
Use Tooling (B) in order to install the bearing in housing (8).
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Illustration 7 g00997136
Use Tooling (C) in order to install snap ring (9).
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Illustration 8 g00997137
Place coil (12) in position with wire (11), as shown. Install wedges (10). Fasten wire (11) under wedge (10).
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Illustration 9 g00997138
Place bearing support (2) and assembly (5) in position in housing (8). Use a press and 3/16 inch diameter rod (13) that is 1 3/4 inches long in order to install the assembly (5) in housing (8).
Install the three screws that hold bearing support (2) and clip (14) in position.
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Illustration 10 g00997139
Use Tooling (A) in order to install snap ring (15).
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Illustration 11 g00997140
Install seal (16) with the lip of the seal away from the housing.
Install pin (17). Use the left hole for counterclockwise rotation, as shown.
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Illustration 12 g00997142
Install plate (18) on bearing support (2).
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Illustration 13 g00997144
Install key (19) on the distributor shaft.
Note: Cam (20) has two slots, one slot for each direction of magneto rotation. Each slot has an arrow for each direction of rotation.
Make an alignment of the key in the distributor shaft and the slot by the counterclockwise arrow on cam (20). Place cam (20) in position on the shaft.
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Illustration 14 g00997145
Install nut (22) that holds the cam in position.
Install condenser (23) and contact points (12).
Note: Do not use additional lubricant.
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Illustration 15 g00997147
Turn cam (20) until the high point of the cam is against arm (24) of the contact points. Adjust the gap for the contact points to 0.43 mm (0.017 inch).
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Illustration 16 g00997148
Adjust the magneto edge gap by rotating assembly (5) until the keyway is in an UP position, then turn the shaft approximately 15° in the direction of the magneto, as shown.
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Illustration 17 g00997151
Loosen screws (25).
Install a 2.39 mm (0.094 inch) diameter rod (27) in timing hole (26) until the rod makes contact with the rotor shaft. Timing hole (26) is used for magnetos with counterclockwise rotation. Turn the rotor shaft clockwise, the direction opposite normal rotation, until rod (27) locks between the rotor pole shoe and the housing field.
With the rotor shaft in position, move the plate to the right or left until the contact points start to open. Tighten screws (25).
Note: Use a timing light in order to find the point when the contacts open.
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Illustration 18 g00997152
Place distributor disc (28) in position on shaft (1). Install the screw and the lockwasher for distributor disc (28).
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Illustration 19 g00997155
Install key (30) and place hub assembly (29) in position on the rotor shaft.
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Illustration 20 g00997173

Note: The coil of spring (33) must be in the correct direction for magneto rotation. For counterclockwise rotation, the coil of the spring must be in a clockwise direction from end (32).
Place spring (33) in position in coupling shell (31).
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Illustration 21 g00997784
Place spring end (32) in position in the groove .
Turn shell (31) counterclockwise one turn, as shown. Push the shell and the hub assembly together. Install the washer and the nut that hold the shell in position.
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Illustration 22 g00997177

Note: Install the open portion of the vent cap in the DOWN position when you install the magneto on the engine.
Install two screens (35) and vent cap (34) on each side of end cap (36).
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Illustration 23 g00997178
Connect grounding wires (37) to end cap (36).
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Illustration 24 g00997180
Place the gasket and end cap (36) in position and connect grounding wire (37), coil wire (38), and the wire for the condenser to the contact points.
Fasten end cap (36) to the housing with four lockwashers and the screws.
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Illustration 25 g00997181
Install brush and spring assemblies (40) in block assembly (39). The brushes must move freely in the block.
Place grommets (41) in position in cover (42).
Install block assembly (39) on cover (42) with the ground terminal in the DOWN position, as shown.
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Illustration 26 g00997183
Place the gasket and cover (42) in position and connect grounding wire (37) to the terminal on block (39). Fasten cap (42) to the end with four lockwashers and the screws.
Remove the nut from end cap (36).
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Illustration 27 g00997184
Check the adjustment of the brush spring by measuring the clearance between block (39) and the distributor disc with drill rod (43). The minimum clearance is 4.76 ± 0.80 mm (0.187 ± 0.032 inch). Add gaskets under end cap (42) in order to increase the clearance. Use "Number 10" washers between block (39) and end cap (42). This will decrease the clearance.
Test the performance of the magneto on a test bench.