Installation of the Cat Digital Ignition System for G3406 Engines{1550} Caterpillar

Engine:

G3406 (S/N: 4FD1-2140; 1RK1-99; 5NW1-UP)

Introduction

This Special Instruction describes the installation of the Cat Digital Ignition System on G3406 Engines. The digital ignition system replaces mechanical parts that are prone to wear. The magneto is removed. The system provides more precise control of ignition timing.

The digital ignition system includes a timing disc, a speed sensor (timing), a timing control, and wiring harnesses. The sensor monitors the rotation of the timing disc in order to sense a reference position of the crankshaft. The sensor sends a signal to the timing control. The timing control calculates the correct ignition timing. The timing control initiates the ignition by providing a pulse to the transformer of the proper cylinder.

There are two options for providing the electrical power for the timing control:

• The customer provides a source of 12 VDC or 24 VDC.

• An alternator enables self-powered ignition.

The optional alternator is installed onto the magneto drive. A wiring harness connects the alternator to a voltage regulator in order to provide the correct voltage to the digital ignition system. Voltage for the timing control is regulated to 27 ± 3 VDC.

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

Replacement of the Mechanical Parts

1. Before you remove any of the components, set the No. 1 cylinder to the top center position (compression stroke). Remove the plug from the flywheel housing and lock the flywheel into position with the 0S-1619 Bolt that is provided with the ignition kit. Follow the instructions in Testing and Adjusting, "Finding Top Center Compression Position For No. 1 Piston".

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Illustration 1	g00757809
(1) Magneto (2) Governor and magneto drive

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Illustration 2	g00757819
(1) Magneto (2) Governor and magneto drive (3) 7W-2074 Shaft As

Note: For CSA ignition systems, discard the ground strap for the magneto.

2. Disconnect the ground wire or the ground strap from magneto (1). Disconnect the ignition harness from the magneto. Remove the two bolts and washers that hold the magneto to the governor and magneto drive (2). Remove the magneto and shaft (3) from the governor and magneto drive.

   If the 163-6118 Alternator Gp will be used, keep the 7W-2074 Shaft As . The shaft will be reinstalled.

   If the 163-6118 Alternator Gp will not be used, discard the 7W-2074 Shaft As . A 191-9386 Shaft As will be installed in place of the original shaft.

3. The PSG governor or the EG3P actuator must be removed in order to complete the disassembly of the governor and the magneto drive. Remove the governor or the actuator.

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Illustration 3	g00757803
(4) Damper guard (5) Alternator (6) Cover

4. If damper guard (4) and/or alternator (5) (if equipped) are bolted to cover (6), remove the components from the front housing. Remove cover (6). Keep the nuts and the washers.

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Illustration 4	g00757851
(6) Cover (7) Full nut (8) Gear

5. Remove full nut (7) and gear (8) through the opening for cover (6). Discard the nut and the gear.

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Illustration 5	g00757883
(2) Governor and magneto drive (9) Oil lines

Note: Some engines have only one oil line for the governor and magneto drive (2) .

6. Disconnect the oil lines (9) from the governor and magneto drive (2) .

7. Attach a suitable strap and a lifting device to the governor and magneto drive. The governor and magneto drive weighs approximately 28 kg (62 lb).

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Illustration 6	g00757904
(2) Governor and magneto drive (10) Bolts (11) Nuts

8. Remove two bolts (10) and two nuts (11). Remove the governor and magneto drive (2). Keep the fasteners.

Note: When you separate the front housing of the governor and magneto drive from the rear housing, do not remove any of the gears.

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Illustration 7	g00757912
(12) Front housing of the governor and magneto drive (13) Rear housing of the governor and magneto drive (14) 7W-2083 Housing Gasket (15) 1B-3623 Bolt (16) 6F-4718 O-Ring Seal

9. Separate front housing (12) from rear housing (13). Keep the fasteners. Remove gasket (14), bolt (15) and O-ring seal (16). Dispose of the gasket, the bolt, and the O-ring seal.

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Illustration 8	g00757922
(12) Front housing (13) Rear housing (14) 7W-2083 Housing Gasket (16) 6F-4718 O-Ring Seal (17) 6V-9608 Bolt

10. Install new bolt (17) in place of bolt (15). Ensure that all of the gears are in the original position. Install new gasket (14). Reassemble front housing (12) and rear housing (13). Use the fasteners that were removed for Step 9. Install new O-ring seal (16) .

11. Attach a strap and a suitable lifting device to the governor drive. The governor drive weighs approximately 24 kg (53 lb). Lift the governor drive into position on the front housing. Install the governor drive onto the front housing. Use the original fasteners that were removed for Step 8.

Note: Some governor drives have only one oil line.

12. Reconnect the oil line to the governor drive.

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Illustration 9	g00757926
(17) 6V-9608 Bolt (18) 179-9541 Gear (19) 179-9540 Spacer (20) 179-9538 Timing Disc (21) 151-5520 Washer (22) 4K-0367 Nut

13. Install new gear (18) onto bolt (17) which extends through the engine front housing. Ensure that the counterbore of the gear is facing outward.

14. Install spacer (19) and timing disc (20). Ensure that the counterbore of the disc is facing inward.

15. Apply 4C-4030 Thread Lock Compound to the threads of nut (22). Orient the threaded hole of timing disc (20) to the 12 o'clock position. Install washer (21) and hand tighten nut (22) .

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Illustration 10	g00757933
(20) 179-9538 Timing Disc (22) 4K-0367 Nut (23) 2W-0459 Gasket (24) 179-9539 Cover (25) 4F-7226 Bolt

16. Use the original fasteners that were removed for Step 4 to install gasket (23) and cover (24). If the damper guard and/or the alternator (if equipped) were originally attached with the bolts, install the components at this time.

17. Install bolt (25) through the threaded hole in cover (24). Thread the bolt into timing disc (20) in order to hold the disc in place. If necessary, move the disc in order to install the bolt.

18. Tighten nut (22) to 215 ± 10 N·m (160 ± 7 lb ft). Remove bolt (25) .

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Illustration 11	g00757980
(24) 179-9539 Cover (26) 8T-6765 Pipe Plug (27) 6N-2508 Gasket (28) 6N-2509 Cover (29) 0S-1588 Bolt (30) 5M-2894 Hard Washer

19. Install the following parts onto cover (24) : pipe plug (26), gasket (27), cover (28), three bolts (29) and three hard washers (30) .

20. Remove the 0S-1619 Bolt from the flywheel housing. Install the original plug into the flywheel housing.

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Illustration 12	g00758070
(3) 7W-2074 Shaft As or 191-9386 Shaft As

21. Installation of shaft (3) depends on use of the 163-6118 Alternator Gp :

    If the 163-6118 Alternator Gp will be used, reinstall 7W-2074 Shaft As (3). Then proceed to Step 22.

    If the 163-6118 Alternator Gp will not be used, install new 191-9386 Shaft As (3). Then proceed to Step 23.

22. To install the alternator, perform the following steps:
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    Illustration 13	g00758758
    (13) Rear housing of the governor drive (31) 163-6118 Alternator Gp (32) 5M-2894 Hard Washer (33) 0L-2070 Bolt (34) 9S-8752 Full Nut (35) 8M-9024 Hard Washer (36) 0S-0509 Bolt (not shown)

    1. Clean the face of the rear housing of governor drive (13). Install a new 6V-1196 O-Ring Seal onto alternator (31) for the joint between the rear housing and the alternator. Lubricate the bore for the seal lightly with clean engine oil.

    2. Install the alternator. Orient the electrical connector to the six o'clock position. Attach one side of the alternator with hard washer (32), bolt (33), hard washer (35), and full nut (34). Attach the other side of the alternator with bolt (36) (not shown) and the other hard washer (32) (not shown).

       After the alternator is installed, proceed to Step 24.

23. To install cover (31), perform the following steps:

    Note: The cover must be installed and tightened within 10 minutes of the application of the sealant.

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    Illustration 14	g00758727
    Side view and rear view of the governor drive (13) Rear housing of the governor drive (31) 7W-1431 Magneto Drive Cover (32) Two 5M-2894 Hard Washers (33) 0L-2070 Bolt (34) 9S-8752 Full Nut (35) 8M-9024 Hard Washer (36) 0S-0509 Bolt

    1. Clean the face of the rear housing of the governor drive (13) with solvent. Apply 1U-8846 Gasket Sealant uniformly to the area of the joint between the rear housing and cover (31). Also apply the sealant to the areas around the bolt holes.

    2. Install the cover. Attach one side of the cover with hard washer (32), bolt (33), hard washer (35), and full nut (34). Attach the other side of the cover with bolt (36) and the other hard washer (32) .

24. Install the PSG governor or the EG3P actuator.

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Illustration 15	g00758912
(24) 179-9539 Cover (37) 116-6806 Speed Sensor (Timing) (38) Locknut (39) 4B-8407 Gasket

25. Install sensor (37) and gasket (39) into cover (24). Thread the sensor into the cover until the sensor contacts the timing disc. Unscrew the sensor for 1/2 ± 1/10 turn (180 ± 36 degrees) in order to obtain a clearance of 0.71 ± 0.14 mm (0.028 ± 0.006 inch) between the sensor and the timing disc. Hold the sensor in place and tighten locknut (38) to 45 ± 7 N·m (33 ± 5 lb ft).

26. Install the timing control and the wiring.

Installation of the Timing Control and the Wiring

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Illustration 16	g00758942
Dimensions of the 163-6164 Timing Control

Note: Do not install the timing control on the engine or the driven equipment.

1. Install the timing control. The control must be mounted within 20 feet of the engine. Typically, the control is installed near the control panel.

   Note: The control can withstand rain. However, the control will not tolerate a high-pressure wash.

   If the 163-6118 Alternator Gp is not used, proceed to ""Installation of the Harness for the Timing Control" ".

   If the 163-6118 Alternator Gp is used, proceed to Step 2.

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Illustration 17	g00759023
Dimensions of the 163-6119 Voltage Regulator Gp

Note: The voltage regulator is only for use with the 163-6118 Alternator Gp .

2. Install the voltage regulator in a location that does not exceed an ambient temperature of 66 °C (150 °F). To facilitate the wiring, install the voltage regulator near the timing control.

3. Install the harness for the timing control. Proceed to ""Installation of the Harness for the Timing Control" ".

Installation of the Harness for the Timing Control

Installation of the harness for the timing control depends on the harness that is used. The connections depend on the type of ignition system.

For Standard ignition systems, install the 183-2878 Wiring Harness . Proceed to ""Installation of the Harness for the Timing Control for Standard Ignition Systems" ".

For CSA ignition systems, install the 183-2884 Wiring Harness . Proceed to ""Installation of the Harness for the Timing Control for CSA Ignition Systems" ".

Installation of the Harness for the Timing Control for Standard Ignition Systems

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Illustration 18	g00759016
(1) Magneto ground on the ignition harness (2) Magneto connector on the ignition harness

1. Remove the ring terminal from magneto ground (1) on the ignition harness.

2. Perform the following steps in order to install a 3E-3364 Receptacle onto the magneto ground:
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   Illustration 19	g00759072
   Assembly of the 3E-3364 Receptacle (1) Magneto ground on the ignition harness (3) 8T-8729 Connector Pin (4) 3E-3365 Receptacle Lock Wedge (5) 8T-8737 Seal Plug

   Note: You may need to use a 147-6456 Wedge Removal Tool to help remove the pin from the new receptacle. Then attach the ground wire.

   1. Use a 1U-5804 Crimp Tool to crimp wire (1) into pin (3) .

   2. Install the pin into terminal "1" of the receptacle. Secure the pin with wedge (4) .

   3. Install plug (5) into terminal "2" on the wire side of the receptacle.

3. To install the 183-2878 Wiring Harness , perform the following steps:
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   Illustration 20	g00759312
   Installation of the 183-2878 Wiring Harness (1) Magneto ground on the ignition harness (CP1) Magneto ground on the harness for the timing control (A) Connector for the timing control (2) Magneto connector on the ignition harness (B) Magneto connector on the harness for the timing control (T1) Ground terminal on the harness for the timing control (T2) Common ground terminal on the harness for the timing control (G) Common ground on the ignition harness

   1. Connect magneto ground (1) on the ignition harness to magneto ground (CP1) on the harness for the timing control.

   2. Connect timing connector (A) to the connector on the timing control.

   3. Connect magneto connector (2) on the ignition harness to magneto connector (B) on the harness for the timing control.

   4. Connect ground terminal (T1) to the ground screw on the top of the timing control.

   5. Connect common ground (T2) on the harness for the timing control to common ground (G) on the ignition harness and the engine block.

   6. If necessary, use 9X-6772 Cable Straps to secure common ground wire (T2) to the ignition harness.

   7. Proceed to ""Installation of the Harness for the Speed Sensor (Timing)" ".

Installation of the Harness for the Timing Control for CSA Ignition Systems

1. To install the 183-2884 Wiring Harness , perform the following steps:
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   Illustration 21	g00761141
   Installation of the 183-2884 Wiring Harness (1) Plug in the junction box for the ignition harness (T1) Common ground on the harness for the timing control (A) Connector for the timing control (2) Magneto connector on the ignition harness (B) Magneto connector on the harness for the timing control (3) Two 5P-1275 Lockwires (4) Two 8S-8158 Wire Seals

   1. Remove plug (1) from the junction box for the ignition harness. Attach common ground (T1) on the harness for the timing control to the common ground lug inside the junction box. Install the conduit for the ground wire onto the junction box. If necessary, use 9X-6772 Cable Straps to secure the conduit to the ignition harness.

   2. Connect timing connector (A) to the connector on the timing control. Use pliers to tighten the connection. Insert lockwire (3) through the hole in each connector. Secure the lockwire with wire seal (4) .

   3. Connect magneto connector (2) on the ignition harness to magneto connector (B) on the harness for the timing control. Use pliers to tighten the connection. Insert lockwire (3) through the hole in each connector. Secure the lockwire with wire seal (4) .

   4. Proceed to ""Installation of the Harness for the Speed Sensor (Timing)" ".

Installation of the Harness for the Speed Sensor (Timing)

Installation of the harness for the speed sensor (timing) depends on the harness that is used. The connections depend on the type of ignition system.

For Standard ignition systems, install the 163-6110 Wiring Harness . Proceed to ""Installation of the Harness for the Speed Sensor (Timing) for Standard Ignition Systems" ".

For CSA ignition systems, install the 163-8070 Wiring Harness . Proceed to ""Installation of the Harness for the Speed Sensor (Timing) for CSA Ignition Systems" ".

Installation of the Harness for the Speed Sensor (Timing) for Standard Ignition Systems

1. To install the 163-6110 Wiring Harness , perform the following steps:
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   Illustration 22	g00761023
   Installation of the 163-6110 Wiring Harness (1) Harness connector for the speed sensor (timing) (2) 116-6806 Speed Sensor (Timing) (3) Harness connector for the timing control (4) Black wire (5) Positive red wire (6) Negative white wire

   1. Connect harness connector (1) to sensor (2) .

   2. Connect harness connector (3) to the timing control.

   Note: The 24 AWG black wire (4) can be used for a relay. The relay is provided by the customer. Otherwise, the black wire will not be used.

   3. Cap black wire (4) .
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   Illustration 23	g00762199
   (5) Positive red wire (6) Negative white wire (7) Two 9G-2731 Fuse Holder As (8) Two 2S-6024 Fuses

   4. Crimp the end of positive red wire (5) into the end of fuse holder (7) .

   5. Crimp the end of negative white wire (6) into the end of the other fuse holder.

2. Connect the electrical power source.

   Connections for the electrical power depend on the source of the electrical power for the timing control.

   For installations with a source of power that is supplied by the customer, proceed to step 2.a.

   For installations with the 163-6118 Alternator Gp , proceed to ""Installation of the Harness for the Alternator" ".

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   NOTICE
   The timing control is sensitive to polarity. If the wiring for the electrical power is connected improperly, the timing control will be damaged.

   Note: The wiring for the electrical power supply is provided by the customer. Use a wire size of 16 AWG.

   1. Crimp the positive lead of the electrical power source to the end of fuse holder (7) for positive red wire (5) .

      Note: An optional shutdown switch can be installed between the fuse for the negative white wire (6) and the customer wiring. The switch is not included in the 183-2881 Ignition Kit .

   2. Crimp the negative lead of the electrical power source to the end of the fuse holder for negative white wire (6) .

   3. Install fuses (8) into the fuse holders.

   4. Protect the wire splices with the 8T-6342 Tube . Extend the heat shrink tubing for approximately 10 mm (0.4 inch) past the end of each splice.

3. Set the timing. Proceed to ""Setting the Timing" ".

Installation of the Harness for the Speed Sensor (Timing) for CSA Ignition Systems

1. To install the 163-8070 Wiring Harness , perform the following steps:
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   Illustration 24	g00761159
   installation of the 163-8070 Wiring Harness (1) 116-6806 Speed Sensor (Timing) (CR3) Harness connector for the speed sensor (timing) (CR5) Harness connector for the timing control (CP4) 9X-3406 Receptacle As for the power input

   1. Connect harness connector (CR3) to sensor (1) .

   2. Connect harness connector (CR5) to the connector on the timing control.

   Note: A 24 AWG wire inside the body of the conduit can be used for a relay. The relay is provided by the customer. Otherwise, the wire will not be used.

   3. Connect the electrical power source.

      Connections for the electrical power depend on the source of the electrical power for the timing control.

      For installations with a source of power that is supplied by the customer, proceed to Step 1.d.

      For installations with the 163-6118 Alternator Gp , proceed to ""Installation of the Harness for the Alternator" ".

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   NOTICE
   The timing control is sensitive to polarity. If the wiring for the electrical power is connected improperly, the timing control will be damaged.

   Note: The wiring for the electrical power supply is provided by the customer. Use a wire size of 16 AWG.

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   Illustration 25	g00762245
   (2) 3E-6488 Connector Plug (3) Two 9G-2731 Fuse Holder As (4) Two 2S-6024 Fuses

   4. Crimp the positive lead of the electrical power source to the end of fuse holder (3). Crimp another wire into the other end of the fuse holder. Install fuse (4) into the fuse holder. Solder the wire into socket "A" of plug (2) .

   Note: An optional shutdown switch can be installed on the negative lead of the customer wiring. The switch is not included in the 183-2885 Ignition Kit .

   5. Crimp the negative lead of the electrical power source to the end of the other fuse holder (3). Crimp another wire into the other end of the fuse holder. Install fuse (4) into the fuse holder. Solder the wire into socket "B" of plug (2) .

   6. Protect the wire splices with the 8T-6342 Tube . Extend the heat shrink tubing for approximately 10 mm (0.4 inch) past the end of each splice.
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   Illustration 26	g00761204
   (CP4) 9X-3406 Receptacle As (2) 3E-6488 Connector Plug (5) 5P-1275 Lockwire (6) 8S-8158 Wire Seal

   7. Connect plug (2) to receptacle (CP4). Use pliers to tighten the connection. Insert lockwire (5) through the holes in the connectors. Secure the lockwire with wire seal (6) .

2. Set the timing. Proceed to ""Setting the Timing" ".

Installation of the Harness for the Alternator

Installation of the harness for the alternator depends on the harness that is used. The connections depend on the type of ignition system.

For Standard ignition systems, install the 163-6110 Wiring Harness . Proceed to ""Installation of the Harness for the Alternator for Standard Ignition Systems" ".

For CSA ignition systems, install the 163-8070 Wiring Harness . Proceed to ""Installation of the Harness for the Alternator for CSA Ignition Systems" ".

Installation of the Harness for the Alternator for Standard Ignition Systems

1. To install the 163-6120 Wiring Harness , perform the following steps:
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   Illustration 27	g00761069
   Installation of the 163-6120 Wiring Harness (CR6) Harness connector for the alternator (CR7) Harness connector for the voltage regulator (1) Positive red wire (2) Negative white wire (A) Lead for the +24 VDC (B) Lead for the ground

   1. Connect harness connector (CR6) to the alternator.

   2. Connect harness connector (CR7) to the voltage regulator.

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   NOTICE
   The timing control is sensitive to polarity. If the wiring for the electrical power is connected improperly, the timing control will be damaged.

   3. Crimp the positive lead (A) into the end of the fuse holder for positive red wire (1) .

      Note: An optional shutdown switch can be installed between the fuse for the negative white wire (2) and the lead for the ground (B). The switch is not included in the 183-2881 Ignition Kit .

   4. Crimp the lead for the ground (B) into the end of the fuse holder for negative white wire (2) .

   5. Install the fuses into the fuse holders.

   6. Protect the wire splices with the 8T-6342 Tube . Extend the heat shrink tubing for approximately 10 mm (0.4 inch) past the end of each splice.

2. Set the timing. Proceed to ""Setting the Timing" ".

Installation of the Harness for the Alternator for CSA Ignition Systems

1. To install the 169-6886 Wiring Harness , perform the following steps:
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   Illustration 28	g00761330
   Installation of the 169-6886 Wiring Harness (CP4) Connector for the power input (CR4) Harness connector for the power input (CR6) Harness connector for the alternator (CR7) Harness connector for the voltage regulator

   1. Connect harness connector (CR6) to the alternator.

   2. Connect harness connector (CR7) to the voltage regulator.

   3. Connect harness connector (CR4) to connector (CP4) .

2. Set the timing. Proceed to ""Setting the Timing" ".

Setting The Timing

Illustration 29	g00761355
Front view and side view of the 163-6164 Timing Control (1) "TIMING SWITCH" (2) "APPLICatION SWITCH"

The timing control has a "TIMING SWITCH" (1) and an "APPLICatION SWITCH" (2). The "APPLICatION SWITCH" must be set to the engine model that is controlled. The switch must also be set to the timing range that is appropriate for the fuel that is consumed. The "TIMING SWITCH" is used to fine-tune the ignition timing. Use the following procedure to set the ignition timing.

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NOTICE
Do not change the setting of the "APPLICatION" switch during engine operation. An engine shutdown can occur and/or the engine can be damaged. Always shut the engine OFF before you change the setting of the "APPLICatION" switch.

1. Obtain a fuel analysis of the gas.

2. Enter the data from the fuel analysis into the Caterpillar Software Program, LEKQ6378, "Methane Number Program".

3. Refer to the Engine Performance, "Fuel Usage Guide" or consult with your local Caterpillar dealer in order to determine the desired ignition timing.

4. Use the label for the "APPLICatION SWITCH" to choose the correct position for the switch. Set the switch at the lowest possible range for the desired timing.

   Table 1 is an example of the settings that are listed on the label for the "APPLICatION SWITCH".

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   Table 1

   Settings of the Application Switch
   A = G3304	10 to 25 degrees BTC
   B = G3306/ G3406	10 to 25 degrees BTC
   C = G3408	10 to 25 degrees BTC
   D = G3304	20 to 35 degrees BTC
   E = G3306/ G3406	20 to 35 degrees BTC
   F = G3408	20 to 35 degrees BTC

   Recommendations for setting the "APPLICatION SWITCH"

   For G3406 Engines, the "APPLICatION SWITCH" must be set to "B" or "E".

   For a G3406 Engine with a desired ignition timing of 19 degrees BTC or less, the switch must be set to "B".

   A G3406 Engine may have a desired ignition timing between 20 to 25 degrees BTC. The "APPLICatION SWITCH" could be set to "B" or "E". However, setting the switch to the lowest possible range for the desired timing is recommended. In this case, set the switch to "B".

   For a G3406 Engine with a desired ignition timing of 26 degrees BTC or more, the switch must be set to "E".

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NOTICE
The "TIMING SWITCH" can be damaged if the switch is turned directly between the "0" position and the "15" position. Do not turn the "TIMING SWITCH" between these positions in either direction.

Note: The "TIMING SWITCH" is graduated in increments from "0" to "15". The switch is fully advanced at "15". The timing is retarded by one degree per each mark as the switch is moved toward zero.

5. Set the timing switch to 15. Then move the switch to the setting that corresponds with the desired timing.

   Examples for setting the "TIMING SWITCH"

   A G3406 Engine has a desired ignition timing of 19 degrees BTC. The "APPLICatION SWITCH" is set to "B" (10 to 25 degrees BTC). A "TIMING SWITCH" setting of "15" corresponds to a desired timing of 25 degrees BTC. Move the "TIMING SWITCH" for six positions toward "0" to the "9" position. This setting corresponds with a desired timing of 19 degrees BTC.

   A G3406 Engine has a desired ignition timing of 23 degrees BTC. The "APPLICatION SWITCH" is set to "B" (10 to 25 degrees BTC). A "TIMING SWITCH" setting of "15" corresponds to a desired timing of 25 degrees BTC. Move the "TIMING SWITCH" for 2 positions toward "0" to the "13" position. This setting corresponds with a desired timing of 23 degrees BTC.

   A G3406 Engine has a desired ignition timing of 26 degrees BTC. The "APPLICatION SWITCH" is set to "E" (20 to 35 degrees BTC). A "TIMING SWITCH" setting of "15" corresponds to a desired timing of 35 degrees BTC. Move the "TIMING SWITCH" for nine positions toward "0" to the "6" position. This setting corresponds with a desired timing of 26 degrees BTC.

Note: Do not check the timing at low idle speed.

6. Start the engine. Operate the engine at rated speed. Verify the ignition timing with a timing light.

   Adjust the "TIMING SWITCH", if necessary. Make a small adjustment of only one or two positions in either direction. Adjust the switch in order to maintain the correct timing within 1/2 degree.

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Illustration 30	g00762284
(3) Two 176-7375 Switch Caps (4) 5P-1275 Lockwire (5) 8S-8158 Wire Seal

7. Install caps (3) for the switches. Thread lockwire (4) through the holes in both caps. Secure the lockwires with wire seal (5) .

   The lockwire will help prevent unauthorized tampering of the setting for the ignition timing.

Indications of Normal Operation and Indications of Abnormal Conditions

Illustration 31	g00764934
Indicators on the timing control (1) "POWER" (2) "PICKUP" (3) "APP." (application)

Indications of Normal Operation

"POWER" indicator - The green "POWER" indicator is always on when the system has power.

"PICKUP" indicator - The red "PICKUP" indicator is illuminated when the system is powered and the engine is stopped. When the engine is stopped, the speed sensor (timing) does not generate a signal. The indicator is extinguished when engine rotation is detected.

"APP." indicator - The red "APP." indicator flashes momentarily when engine rotation starts. The indicator is extinguished during normal operation.

Indications of Abnormal Conditions

"POWER" indicator - There is a problem if power is applied to the system and the green "POWER" indicator does not illuminate.

"PICKUP" indicator - There is a problem if the red "PICKUP" indicator is illuminated during engine rotation.

"APP." indicator - If the red "APP." indicator illuminates continuously during cranking or during engine operation, the ignition ceases. The engine will not start until the condition is resolved.

For the probable causes of the abnormal conditions and for suggested repairs, see ""Troubleshooting" ".

Troubleshooting

The Green "POWER" Indicator Does Not Illuminate

This condition indicates that the timing control is not receiving power. Troubleshooting for this condition depends on the source of power.

For installations with power that is supplied by the customer, see ""Customer Supplied Power" ".

For installations with the 163-6118 Alternator Gp , see ""Power from the Alternator" ".

Customer Supplied Power

Probable Causes

• A fuse is blown.

• There is a problem with the connectors or wiring.

• The system voltage is not correct.

• There is a problem with the timing control.

Recommended Repairs

1. Check the fuses at the connection of the customer supplied power and the harness for the timing control.

   Expected Result

   The fuses are in good condition.

   Results

   OK - The fuses are in good condition. Proceed to Step 2.

   Not OK - One of the fuses is blown. Replace the fuse. Determine the cause of the blown fuse. Make repairs, as needed.

2. Inspect the harness connectors, the pins, and the sockets for proper connections. Inspect the connectors and the wiring for corrosion, abrasion, and pinch points.

   Expected Result

   The harness connectors, pins, and sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points.

   Results

   OK - The harness connectors, pins, and sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Proceed to step 3.

   Not OK - The harness connectors, pins, and sockets are not properly connected. Corrosion, abrasion, and pinch points are found. Make repairs, as needed.

3. Check the voltage to the timing control.
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   Illustration 32	g00764970
   Six-pin connector for power to the timing control (A) Sensor connector (B) Sensor connector (C) Sensor connector (D) Output for alarm (if equipped) (E) +Battery side (F) -Battery side

   1. Turn OFF the power supply for the timing control. Disconnect the six-pin connector from the timing control.

   2. Turn ON the power supply for the timing control. Measure the voltage between socket (E) and socket (F) of the six-pin connector. Then turn OFF the power supply for the timing control.

      Expected Result

      The voltage is approximately 10 to 32 VDC.

      Results

      OK - The voltage is approximately 10 to 32 VDC. There is a problem with the timing control. Replace the timing control.

      Not OK - The voltage is not approximately 10 to 32 VDC. Proceed to step 4.

4. Measure the power supply from the customer supplied power source. Measure the voltage between the positive lead and the negative lead.

   Expected Result

   The voltage is approximately 10 to 32 VDC.

   Results

   OK - The voltage is approximately 10 to 32 VDC. There is a problem with the harness to the timing control.

   If the connectors and wiring appear to be OK, check the continuity of the wires. A reading of less than five ohms indicates that the wire is OK. An infinite reading indicates a break in the wire. Replace the wiring, as needed.

   Not OK - The voltage is not approximately 10 to 32 VDC. The wiring is probably OK. There is a problem with the power source. Correct the power source, as needed.

Power from the Alternator

Probable Causes

• A fuse is blown.

• There is a problem with the connectors or wiring.

• There is a problem with the alternator.

• There is a problem with the voltage regulator.

• There is a problem with the timing control.

Recommended Repairs

1. Check the fuses at the connection of the harness from the voltage regulator and the harness for the timing control.

   Expected Result

   The fuses are in good condition.

   Results

   OK - The fuses are in good condition. Proceed to Step 2.

   Not OK - One of the fuses is blown. Replace the fuse. Determine the cause of the blown fuse. Make repairs, as needed.

2. Inspect the harness connectors, the pins, and the sockets for proper connections. Inspect the connectors and the wiring for corrosion, abrasion, and pinch points.

   Expected Result

   The harness connectors, pins, and sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points.

   Results

   OK - The harness connectors, the pins, and the sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Proceed to step 3.

   Not OK - The harness connectors, the pins, and the sockets are not properly connected. Corrosion, abrasion, and pinch points are found. Make repairs, as needed.

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Illustration 33	g00765923
(AA) Connector for the voltage regulator (A) +24 VDC (B) Ground (C) Unused (D) Unused (E) Alternator output (F) Alternator output

3. Measure the resistance of the alternator stator at the connector for the voltage regulator. Disconnect the six-pin connector for the voltage regulator. Measure the resistance between terminals "E" and "F" on the connector. Use the R × 1 scale.

   Expected Result

   The resistance between terminals "E" and "F" on the six-pin connector for the voltage regulator is approximately 18 to 22 ohms.

   Results

   OK - The resistance between terminals "E" and "F" on the six-pin connector for the timing control is approximately 18 to 22 ohms. The alternator and the harness from the alternator to the voltage regulator are OK. Proceed to Step 4.

   Not OK - The resistance between terminals "E" and "F" on the six-pin connector for the voltage regulator is not within 18 to 22 ohms. There is a problem with the alternator or the harness. Proceed to Step 5.

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Illustration 34	g00765942
Connector on the voltage regulator (A) +24 VDC (B) Return (C) Unused (D) Unused (E) Alternator output (F) Alternator output

4. Measure the resistance on the voltage regulator connector between terminals "C" and "A". Use the R × 100 scale.

   Expected Result

   The resistance is approximately 12 ohms or less than 12 ohms.

   Results

   OK - The resistance is approximately 12 ohms or less than 12 ohms. The voltage regulator is OK. Proceed to Step 6.

   OK - The resistance is not approximately 12 ohms or less than 12 ohms. There is a problem with the voltage regulator. Replace the voltage regulator.

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Illustration 35	g00765953
Alternator connector (A) Alternator output (B) Alternator output (C) Unused

5. Disconnect the connector from the alternator. Measure the resistance of the alternator stator between terminals "A" and "B" of the alternator connector. Use the R × 1 scale. Then measure the resistance between terminals "A" and "B" and the alternator housing. Use the R × 10,000 scale.

   Expected Result

   The resistance between terminals "A" and "B" on the alternator connector is approximately 18 to 22 ohms. The resistance between terminals "A" and "B" and the alternator housing is infinite.

   Results

   OK - The resistance between terminals "A" and "B" on the alternator connector is approximately 18 to 22 ohms. The resistance between terminals "A" and "B" and the alternator housing is infinite. The alternator is OK. There is a problem in the harness. Repair the harness or replace the harness.

   Not OK - The resistance between terminals "A" and "B" on the alternator connector is not approximately 18 to 22 ohms. The resistance between terminals "A" and "B" and the alternator housing is not infinite. There is a problem with the alternator. Replace the alternator.

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Illustration 36	g00766022
(AA) Connector for the voltage regulator (BB) Connector for the timing control (AA-A) +24 VDC (AA-B) Return (BB-E) +24 VDC (BB-F) Return

6. Disconnect the six-pin connector from the timing control. Measure the continuity of the wiring harness. Measure the continuity between terminal "E" on the connector for the timing control and terminal "A" on the connector for the voltage regulator. Measure the continuity between terminal "F" on the connector for the timing control and terminal "B" on the connector for the voltage regulator.

   Expected Result

   The readings are less than five ohms.

   Results

   OK - The readings are less than five ohms. The harness is OK. There is a problem with the timing control. Replace the timing control.

   Not OK - At least one of the readings is not less than five ohms. There is a problem in the harness between the voltage regulator and the timing control. Repair the harness or replace the harness.

The "PICKUP" Indicator is Illuminated During Engine Operation

This condition indicates a problem with the signal from the speed sensor (timing).

Probable Causes

• The clearance between the sensor and the timing disc is not correct.

• There is a problem with the sensor.

• There is a problem with the harness or the connectors for the sensor and the timing control.

• There is a problem with the timing control.

Recommended Repairs

1. Make sure that the sensor is installed according to the instructions in ""Replacement of the Mechanical Parts" ".

   Expected Result

   The sensor is installed according to the instructions.

   Results

   OK - The sensor is installed according to the instructions. Proceed to step 2.

   Not OK - The sensor is not installed correctly. Reinstall the sensor. Start the engine and verify that the operation is normal.

2. Remove the sensor. Install a sensor that is known to be good. Start the engine and observe the "PICKUP" indicator on the timing control.

   Expected Result

   The "PICKUP" indicator is not illuminated. Operation appears to be normal.

   Results

   OK - The "PICKUP" indicator is not illuminated. Operation appears to be normal.

   Not OK - The "PICKUP" indicator is illuminated. Proceed to step 3.

3. Inspect the harness connectors, the pins, and the sockets for proper connections. Inspect the connectors and the wiring for corrosion, abrasion, and pinch points.

   Expected Result

   The harness connectors, pins, and sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points.

   Results

   OK - The harness connectors, the pins, and the sockets are properly connected. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Proceed to step 4.

   Not OK - The harness connectors, the pins, and the sockets are not properly connected. Corrosion, abrasion, and pinch points are found. Make repairs, as needed.

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Illustration 37	g00765026
Connectors for the wiring of the sensor to the timing control

4. Measure the continuity of the wiring for the sensor.

   1. Measure the continuity between terminal (A) of the connector for the sensor and terminal (A) of the six-pin connector for the timing control.

   2. Measure the continuity between terminal (B) of the connector for the sensor and terminal (B) of the six-pin connector for the timing control.

   3. Measure the continuity between terminal (C) of the connector for the sensor and terminal (C) of the six-pin connector for the timing control.

      Expected Result

      The readings are less than five ohms.

      Results

      OK - The readings are less than five ohms. The wiring is OK. There is a problem with the timing control. Replace the timing control.

      Not OK - The reading for at least one of the wires is infinite. There is a problem with the wiring. Repair the wiring or replace the wiring.

The "APP." Indicator is Illuminated During Cranking or During Engine Operation

Probable Causes

• The setting of the "APPLICatION" switch is not correct.

• There is a problem with the timing disc.

• There is a problem with the timing control.

• The clearance between the speed sensor (timing) and the timing disc is not within specifications.

• There is an intermittent loss of continuity in the connector or the harness for the speed sensor (timing).

Recommended Repairs

1. Verify that the "APPLICatION" switch is set according to the instructions in ""Setting The Timing" ".

   Expected Result

   the "APPLICatION" switch is set according to the instructions in ""Setting The Timing" ".

   Results

   OK - The "APPLICatION" switch is set according to the instructions in ""Setting The Timing" ". Proceed to Step 2.

   Not OK - the "APPLICatION" switch is not set according to the instructions in ""Setting The Timing" ". Set the "APPLICatION" switch according to the instructions in ""Setting The Timing" ".

2. Inspect the magnets around the edge of the timing disc.

   Expected Result

   Seven magnets are installed into the edge of the 179-9538 Timing Disc . The seven magnets are in place.

   Results

   OK - The seven magnets are in place. Proceed to Step 3.

   Not OK - There are not seven magnets around the edge of the timing disc. Install a new 179-9538 Timing Disc .

3. Make sure that the speed sensor (timing) is installed according to the instructions in ""Replacement of the Mechanical Parts" ".

   Expected Result

   The sensor is installed according to the instructions. Proceed to Step 4.

   Results

   OK - The sensor is installed according to the instructions. There may be an intermittent problem with the sensor or the harness for the sensor. Proceed to step 2.

   Not OK - The sensor is not installed correctly. Reinstall the sensor. Start the engine and verify that the operation is normal.

4. Remove the speed sensor (timing) and the harness for the sensor. Install a sensor that is known to be good. Install a harness that is known to be good. Start the engine and verify that the operation is normal.

   Expected Result

   The engine operates normally.

   Results

   OK - The engine operates normally.

   Not OK - The engine does not operate normally. There is a problem with the timing control. Replace the timing control.

163-6111 Wiring Diagram

Illustrations 38, 39, and 40 are from the two-page 163-6111 Wiring Diagram .

Illustration 38	g00761468
G3406 Engine ignition harness

Illustration 39	g00761586
Standard wiring for timing control, power, and alarm

Illustration 40	g00761645
Optional power supply

Parts

Table 2

Alternator and Voltage Regulator
Qty	Pt. No.	Description
1	163-6118	Alternator  (1)
1	163-6119	Voltage Regulator
1	163-6120	Wiring Harness  (2)
1	169-6886	Wiring Harness  (3)

( 1 )	A 6V-1196 O-Ring Seal is needed for installation of the alternator.
( 2 )	This harness is for Standard ignition systems.
( 3 )	This harness is for CSA ignition systems.

Table 3

183-2881 Ignition Kit for Standard Ignition Systems
Qty	Pt. No.	Description
1	3E-3364	Receptacle As
1	3E-3365	Receptacle Lock Wedge
1	8T-8729	Connector Pin
1	8T-8737	Seal Plug
1	183-2878	Wiring Harness
1	4B-8407	Gasket
1	116-6806	Speed Sensor (Timing)
1	163-6110	Wiring Harness
2	2S-6024	Fuse
8	8T-6342	Tube
2	9G-2731	Fuse Holder As
1	0L-2070	Bolt
1	0S-0509	Bolt
2	5M-2894	Hard Washer
1	7W-1431	Magneto Drive Cover
1	8M-9024	Hard Washer
1	9S-8752	Full Nut
7	9X-6772	Cable Strap
3	0S-1588	Bolt
1	0S-1619	Bolt
1	2W-0459	Gasket
1	4F-7226	Bolt
1	4K-0367	Full Nut
3	5M-2894	Hard Washer
1	6F-4718	O-Ring Seal
1	6N-2508	Gasket
1	6N-2509	Cover
1	6V-9608	Bolt
1	7W-2083	Housing Gasket
1	8T-6765	Pipe Plug
1	151-5520	Washer
1	179-9538	Timing Disc
1	179-9539	Cover
1	179-9540	Spacer
1	179-9541	Gear
1	5P-1275	Lockwire
1	8S-8158	Wire Seal
1	163-6164	Timing Control
1	191-9386	Shaft As

Table 4

183-2885 Ignition Kit for CSA Ignition Systems
Qty	Pt. No.	Description
1	183-2884	Wiring Harness
1	4B-8407	Gasket
1	116-6806	Speed Sensor (Timing)
1	163-8070	Wiring Harness
2	2S-6024	Fuse
1	3E-6488	Connector Plug
8	8T-6342	Tube
2	9G-2731	Fuse Holder As
1	0L-2070	Bolt
1	0S-0509	Bolt
2	5M-2894	Hard Washer
1	7W-1431	Magneto Drive Cover
1	8M-9024	Hard Washer
1	9S-8752	Full Nut
7	9X-6772	Cable Strap
3	0S-1588	Bolt
1	0S-1619	Bolt
1	2W-0459	Gasket
1	4F-7226	Bolt
1	4K-0367	Full Nut
3	5M-2894	Hard Washer
1	6F-4718	O-Ring Seal
1	6N-2508	Gasket
1	6N-2509	Cover
1	6V-9608	Bolt
1	7W-2083	Housing Gasket
1	8T-6765	Pipe Plug
1	151-5520	Washer
1	179-9538	Timing Disc
1	179-9539	Cover
1	179-9540	Spacer
1	179-9541	Gear
6	5P-1275	Lockwire
6	8S-8158	Wire Seal
1	163-6164	Timing Control
1	191-9386	Shaft As