- Engine:
- G399 (S/N: 49C1-UP)
Introduction
This Special Instruction describes the installation of the following conversion arrangements for G399 Engines:
Note: The 231-6572 Ignition Conversion Ar (Shielded) meets requirements of the Canadian Standards Accociation (CSA) for hazardous environments.
Both of the conversion arrangements include the 7C-0753 Magneto . The 7C-0753 Magneto replaces the former 7W-1479 Magneto that is no longer available.
Note: If your engine is equipped with the two original 1W-3714 Magnetos , refer to Special Instruction, SEHS8478, "Installation Of 7W-1479 Magneto " in order to modify the engine for an ignition system that uses one magneto.
The coils of the ignition transformers for the original magneto are not compatible with the 7C-0753 Magneto . For this reason, the conversion arrangements also include new ignition transformers and wiring.
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.
Installation of the 231-6569 Ignition Conversion Ar (Standard)
Required Parts
| 231-6569 Ignition Conversion Ar (Standard) | |
| Part | Qty |
| 2L-8066 Ring Terminal | 16 |
| 2L-8076 Ring Terminal | 17 |
| 2L-8078 Ring Terminal | 5 |
| 4L-2791 Markers | 1 |
| 4W-5439 Transformer | 16 |
| 5M-2894 Hard Washer | 2 |
| 5P-0658 Electrical Wire | 16.5 m (54.1 ft) |
| 5P-1476 Spade Terminal | 1 |
| 6B-0933 Spacer | 2 |
| 6L-1576 Chamber Gasket | 16 |
| 6L-7816 O-Ring Seal | 16 |
| 7C-0753 Magneto | 1 |
| 7C-4368 Wiring Harness | 1 |
| 8L-8413 Cable Strap | 40 |
| 8M-7145 Washer | 6 |
| 9Y-2289 Adapter | 16 |
| 9Y-5314 Plug Wire Assembly | 16 |
| 194-8518 Spark Plug | 16 |
Remove the Original Parts
- Disconnect wire assembly (1) from transformer (2) and from the spark plug. Remove the wire assembly.
 | |
| Illustration 1 | g00951575 |
(1) Wire assembly (2) Transformer (3) Spark plug (4) Adapter (5) Wiring harness (6) Magneto (7) Conduit (8) Ground strap | |
- Remove the spark plugs (3) and adapters (4) .
- Disconnect transformer (2) from wiring harness (5). Loosen the transformer's mounting bolts and remove the transformer.
The transformers' mounting bolts and the washers will be reused.
- Disconnect wiring harness (5) from the instrument panel (not shown) and from magneto (6). Loosen the mounting clips for the wiring harness.
The clips will be reused.
- Cut the cable straps from the wiring harness. Pull the wiring away from the engine through conduit (7) .
The conduit will be reused.
- Disconnect ground strap (8) from magneto (6) .
The magneto's ground strap will be reused.
- Remove magneto (6) .
The magneto's mounting bolts will be reused.
Installation of the Spark Plug Adapters and the Spark Plugs.
 | |
| Illustration 2 | g00951971 |
(1) 9Y-5314 Plug Wire Assembly (2) 6L-7816 O-Ring Seal (3) 9Y-2289 Adapter (4) 194-8518 Spark Plug (5) 6L-1576 Chamber Gasket | |
- Install O-ring seal (2) on the adapter.
- Install chamber gasket (5) on the adapter.
- Install the adapter (3) with a torque of 200 ± 13 N·m (145 ± 10 lb ft). Cover the seal groove and the seal with liquid soap before inserting the adapter into the cylinder head.
- Set the plug gap to .29 ± .04 mm (0.0114 ± 0.0016 inch).
- Install the spark plug (4) into the adapter with a torque of 48 ± 4 N·m (35 ± 3 lb ft).
Install the Transformers and the Wiring Harness.
- Use the original mounting bolts and washers to install transformers (1) .
 | |
| Illustration 3 | g00951577 |
(1) 4W-5439 Transformer (2) 9Y-5314 Plug Wire Assembly (3) 7C-4368 Wiring Harness (4) Ground wire (5) Original conduit (G) Ignition shutoff's wire | |
- Connect wire assemblies (2) to the transformers and to the spark plugs.
- Install wiring harness (3) .
- Use the 5P-0658 Electrical Wire to fabricate a wire (4) that is long enough to run between the magneto case and the mounting bolt for the transformer for cylinder 1.
- Compare each wire on the wiring harness (3) to each terminal on the harness connector. Refer to ""Wiring Diagrams for the 231-6569 Ignition Conversion Ar (Standard) " " for the correct correlation between the connector pins to engine cylinders. Use the 4L-2791 Markers to identify each wire for each cylinder's transformer.
- Route the wiring harness through the original conduit (5) toward the appropriate transformers. Include the wire that was fabricated in Step 3.a. Use a 8L-8413 Cable Strap at every 7.5 to 10 cm (3 to 4 inches) of wiring. Use the original clips to secure the wires.
Route the wire from terminal "G" to the instrument panel.
- Crimp a 2L-8076 Ring Terminal onto the wires for each transformer. Connect these terminals to the positive "+" post on the appropriate transformer. Route the wires over the bent portion of the mounting brackets for the transformers. Make sure that the wiring does not contact the mounting brackets or any sharp edges.
- Crimp a 2L-8078 Ring Terminal to one end of the wire that was fabricated in Step 3.a. Attach this terminal to the mounting bolt for the number 1 cylinder's transformer. Crimp a 2L-8076 Ring Terminal to the other end of the wire. Attach this wire to the cover bolt on the magneto housing.
- Crimp the 5P-1476 Spade Terminal to the wire for terminal "G". Connect this terminal to terminal "M1" on the magnetic switch in the instrument panel.
Show/hide table
Illustration 4 g00951579
Typical magnetic switch
(M1) Switch's terminal for the wire from the magneto's terminal "G"
- Use the 5P-0658 Electrical Wire to fabricate the ground wiring for the transformers. Assemble the ground wiring according to Illustration 5.
 | |
| Illustration 5 | g00951580 |
Schematic for the ground wiring (5) 2L-8066 Ring Terminal (eight places) (6) 2L-8078 Ring Terminal (7) 2L-8076 Ring Terminal | |
Wiring Diagrams for the 231-6569 Ignition Conversion Ar (Standard)
Note: The front end of the engine is opposite the flywheel end. The left and right sides of the engine are determined by the flywheel end. The number 1 cylinder is the right front cylinder. Refer to Illustration 6 for the locations of the cylinders.
 | |
| Illustration 6 | g00951581 |
Cylinder position | |
The wiring from the magneto's connector to the ignition transformers is determined by the direction of the engine crankshaft's rotation. The direction of rotation is determined from viewing the flywheel end.
Illustration 7 is a wiring diagram for engines with standard rotation: when the engine is viewed from the flywheel end, the crankshaft rotates in the counterclockwise direction.
Illustration 8 is a wiring diagram for engines with opposite rotation: when the engine is viewed from the flywheel end, the crankshaft rotates in the clockwise direction.
Standard Counterclockwise Rotation
 | |
| Illustration 7 | g00951799 |
Wiring diagram for standard counterclockwise rotation | |
Opposite Clockwise Rotation
 | |
| Illustration 8 | g00951801 |
Wiring diagram for standard clockwise rotation | |
Installation of the 231-6572 Ignition Conversion Ar (Shielded)
Required Parts
| 231-6572 Ignition Conversion Ar (Shielded) | |
| Part | Qty |
| 0S-1571 Bolt | 4 |
| 0S-1588 Bolt | 3 |
| 0S-1594 Bolt | 6 |
| 1A-2029 Bolt | 1 |
| 1C-0569 Bolt | 7 |
| 1H-5167 Wire Clip | 6 |
| 1L-6023 Terminal Strip | 3 |
| 1L-9899 Markers | 1 |
| 1N-3735 Harness | 1 |
| 1N-3736 Harness | 2 |
| 1N-3738 Harness | 2 |
| 1N-3739 Harness | 1 |
| 1N-3740 Harness | 1 |
| 1N-3741 Harness | 1 |
| 1S-0996 Clip | 2 |
| 1S-9593 Cable Strap | 32 |
| 2M-0849 Hard Washer | 4 |
| 3B-4501 Lockwasher | 21 |
| 3H-3627 Screw | 12 |
| 3J-5389 Plug | 3 |
| 3K-8667 Jumper | 10 |
| 3M-7045 Plug | 2 |
| 3S-2093 Cable Strap | 3 |
| 4J-3814 Clip | 4 |
| 4L-2791 Markers | 1 |
| 4W-5470 Junction Box As | 1 |
| 4W-6090 Bracket | 1 |
| 4W-6091 Conduit | 1 |
| 4W-6733 Plate | 1 |
| 4W-6742 Harness | 3 |
| 4W-6743 Harness | 1 |
| 4W-6744 Harness | 1 |
| 4W-6745 Harness | 1 |
| 4W-6746 Harness | 1 |
| 4W-6747 Harness | 1 |
| 5F-7207 Spacer | 2 |
| 5J-0299 Clip | 5 |
| 5M-2894 Hard Washer | 15 |
| 5N-1759 Bracket | 2 |
| 5P-1475 Spade Terminal | 2 |
| 5P-1476 Spade Terminal | 53 |
| 5P-4508 Electrical Wire | 2.5 m (8.2 ft) |
| 5P-7995 Electrical Wire | 2.4 m (7.9 ft) |
| 6V-8801 Nut | 10 |
| 7C-0753 Magneto | 1 |
| 7C-4462 Harness | 1 |
| 8C-8514 Screw | 1 |
| 8L-8413 Cable Strap | 35 |
| 8M-2770 Clip | 7 |
| 9L-3560 Elbow | 1 |
| 9M-1974 Hard Washer | 7 |
| 9S-1366 Bolt | 2 |
| 9Y-3985 Spark Plug | 16 |
| 9Y-3987 Spark Plug Cover | 16 |
| 107-2400 Transformer | 16 |
Remove the Existing Ignition System
- Disconnect the wiring harnesses from the magneto.
- Disconnect the ground strap between the magneto and the engine at the magneto. Leave the ground strap attached to the engine. The ground strap will be reused.
- Remove the magneto from the engine. Save the following items that were used to mount the existing magneto: mounting bolts, washers and nut.
- Open the door of the instrument panel. Disconnect the ground wire and the wire from M1 to the transformers.
- Remove the conduit and wiring going to the engine cylinders from the instrument panel. Remove the conduit and wiring from the magneto to the cylinders. Remove the following items from each cylinder: transformers and spark plugs. The existing spark plug adapters will be used for the new spark plugs and for the new transformers.
Assemble the Junction Box
- The correct orientation for the junction box is shown in Illustration 9.
When the junction box is installed, the top of the junction box has the two 3/4-14 holes for plugs (9) .
 | |
| Illustration 9 | g00951397 |
Junction box (1) 4W-5470 Junction Box As (2) 1L-6023 Terminal Strip (3) 3H-3627 Screw (4) 3B-4501 Lockwasher (5) 8C-8514 Screw (6) 5P-1475 Spade Terminal (7) 5P-4508 Electrical Wire (8) 3K-8667 Jumper (9) 3M-7045 Plug (10) 3J-5389 Plug (11) 9L-3560 Elbow | |
- Install terminal strips (2) into junction box (1) .
- For the two outer terminal strips, use four screws (3). Place one lockwasher (4) under each screw head. Refer to view "A-A" in Illustration 9.
- For the middle terminal strip, use four screws (3) and twelve lockwashers (4). For each screw, place two lockwashers between the terminal strip and the junction box. Place one lockwasher under each screw head. Refer to view "B-B" in Illustration 9.
- Install ground screw (5). Place one lockwasher (4) under the screw head.
- Use two spade terminals (6) and some wire (7) to fabricate a jumper wire. Install the jumper wire between ground screw (5) and the right terminal strip's upper left terminal.
- Install ten jumpers (8) in order to provide a ground path between the right terminal strip's right terminals. Refer to view "C-C" in Illustration 9.
- Label the appropriate terminals for identification. Refer to ""Wiring Diagrams for the 231-6572 Ignition Conversion Ar (Shielded) "
".
The 1L-9899 Markers can be used to label several of the terminals. Otherwise, use a permanent marker.
- Install plugs (9) and (10) .
- Install elbow (11) into the rear hole on the bottom of the junction box.
Installation of the Spark Plugs, Transformers and the Spark Plug Covers.
 | |
| Illustration 10 | g00948607 |
(1) 107-2400 Transformer (2) 9Y-3987 Spark Plug Cover (3) 7L-0918 Plug Adapter (4) 9Y-3985 Spark Plug | |
- The plug adapter (3) should be left from the previous ignition system.
- Set the plug gap on the spark plug to .37 ± .04 mm (0.0146 ± 0.0016 inch).
- Install the spark plug into the plug adapter.
Torque ... 38 ± 3 N·m (28 ± 2 lb ft)
- Thread the transformer (1) onto spark plug (4). Tighten the transformer onto the spark plug finger tight. Turn the transformer for an additional 45° in the clockwise direction.
- Slide cover (2) onto the transformer. Make sure that the cover fits snugly over the spark plug adapter.
Installation of the Junction Box
 | |
| Illustration 11 | g00950310 |
Mounted junction box (1) 0S-1588 Bolt (2) 5M-2894 Hard Washer (3) 6V-8801 Nut (4) 4W-6090 Bracket (5) 0S-1594 Bolt (6) 2M-0849 Washer (7) 0S-1571 Bolt (8) 4W-6733 Plate (9) 9S-1366 Bolt (10) 5F-7207 Spacer | |
- Install the junction box's lower bracket (8). Refer to Illustration 11 as a reference.
- Remove the top bolt from the flange for the intake manifold for cylinder 1 and for cylinder 3.
- Use the following items for each fastener in order to install the lower bracket for the junction box: bolt (9), washer (6) and spacer (10) .
- Install the bolts into the top holes of the flanges for the intake manifold of cylinder 1 and of cylinder 3.
- Install the junction box's upper bracket (4). Refer to Illustration 11 as a reference.
- Remove the bolts from the flange of the exhaust elbow for cylinder 1.
- Use the following items for each fastener in order to install the upper bracket for the junction box: bolt (5), hard washer (2) and washer (6). Align the front of the upper bracket with the lower bracket at installation.
- Use the following items for each fastener in order to bolt the upper bracket and the lower bracket together: bolt (1), hard washer (2) and nut (3) .
- Install the junction box onto the assembled brackets. Use the following items for each fastener in order to bolt the junction box to the brackets: bolt (7), hard washer (2) and nut (3)
- Tighten all bolts securely.
Install the Conduit and Wiring between the Instrument Panel and the Junction Box
- Install the 4W-6091 Conduit between the instrument panel and the junction box. The conduit consists of a piece of conduit and two connectors.
- The conduit will connect to the left side of the instrument panel in the hole left from the old conduit. The conduit should be routed around the front of the engine to the junction box. The conduit will then connect to the 9L-3560 Elbow that was installed in the bottom of the junction box.
- Run two wires from the instrument panel to the junction box through the conduit that was just installed. Use the 5P-4508 Electrical Wire and the 5P-7995 Electrical Wire that was provided in the conversion kit.
- Install a 5P-1476 Spade Terminal on either end of the 5P-7995 Electrical Wire . Connect the wire between terminal M1 in the junction box and terminal M1 on the magnetic switch in the instrument panel.
- Install a 5P-1476 Spade Terminal on either end of the 5P-4508 Electrical Wire . Connect the wire between the lower right terminal block that has the label N in the junction box and the ground terminal in the instrument panel. Refer to Illustration 16 as a reference.
Install the Harnesses between the Junction Box and the Cylinders
 | |
| Illustration 12 | g00948603 |
Example of locations for straps (1) 9M-1974 Hard Washer (2) 1C-0569 Bolt (3) 8M-2770 Clip (4) 1H-5167 Wire Clip (5) 5J-0299 Clip (6) 1S-0996 Clip (7) 5M-2894 Hard Washer (8) 6V-8801 Nut (9) 0S-1594 Bolt (10) 4J-3814 Clip (11) 5N-1759 Bracket | |
| Cylinder | Part |
| 1 | 4W-6742 Harness |
| 2 | 1N-3736 Harness |
| 3 | 4W-6742 Harness |
| 4 | 1N-3738 Harness |
| 5 | 4W-6742 Harness |
| 6 | 1N-3739 Harness |
| 7 | 4W-6743 Harness |
| 8 | 1N-3740 Harness |
| 9 | 4W-6744 Harness |
| 10 | 1N-3741 Harness |
| 11 | 1N-3735 Harness |
| 12 | 4W-6745 Harness |
| 13 | 1N-3736 Harness |
| 14 | 4W-6746 Harness |
| 16 | 4W-6747 Harness |
 | |
| Illustration 13 | g00950477 |
Locations of the harnesses | |
- Install the harnesses for the cylinders. Refer to Table 3 and Illustration 13 for the correct harness and the correct location for each harness.
- Screw one end of the harness into the appropriate opening in the junction box. Plug one end of the harness onto the transformer and screw the connector onto the transformer. Perform this step for all harnesses.
- After the harnesses have been installed, crimp one 5P-1476 Spade Terminal onto each harness wire.
- Use the 4L-2791 Markers in order to label the harness wires in the junction box. For example, use the 2 markers of number 1 to label the two wires from the harness of cylinder 1. Label all of the harness wires with the appropriate numbered marker. Refer to Illustration 16 as a reference.
- Use the supplied straps and clips to secure the harnesses to the engine. Ensure that the harnesses are not contacting any sharp edges. Refer to Illustration 12.
- Install the harness wires on the appropriate terminal. Refer to Illustration 16 if Clockwise rotation is desired. Refer to Illustration 15 for CCW rotation.
Install the Harness between the Junction Box and the Magneto.
- Install the 7C-4462 Harness into the front left hole in the bottom of the junction box. Install the end of the harness with the 17 wires that are marked with letters. Tighten the harness connector onto the junction box.
- Run the other end of the harness to the magneto.
- After the harness has been installed, crimp one 5P-1476 Spade Terminal onto each harness wire.
- Install the harness wires on the appropriate terminal. Refer to Illustration 16 if Clockwise rotation is desired. Refer to Illustration 15 if CCW rotation is desired.
Wiring Diagrams for the 231-6572 Ignition Conversion Ar (Shielded)
Note: The front end of the engine is opposite the flywheel end. The left and right sides of the engine are determined by the flywheel end. The number 1 cylinder is the right front cylinder. Refer to Illustration 14 for the locations of the cylinders.
 | |
| Illustration 14 | g00951392 |
Cylinder positions | |
The wiring from the magneto's connector to the ignition transformers is determined by the direction of the engine crankshaft's rotation. The direction of rotation is determined from viewing the flywheel end.
Illustration 15 is a wiring diagram for engines with standard rotation: when the engine is viewed from the flywheel end, the crankshaft rotates in the counterclockwise direction.
Illustration 16 is a wiring diagram for engines with opposite rotation: when the engine is viewed from the flywheel end, the crankshaft rotates in the clockwise direction.
Shielded Standard Counterclockwise Rotation
 | |
| Illustration 15 | g00949790 |
Wiring diagram for shielded standard counterclockwise rotation | |
Shielded Opposite Clockwise Rotation
 | |
| Illustration 16 | g00949739 |
Wiring diagram for shielded opposite clockwise rotation | |
Install the Magneto
- Remove the cover from the flywheel housing in order to observe the timing marks on the flywheel.
- Refer to Table 4 in order to determine the initial ignition timing.
Show/hide table
Table 4 Recommendations for Initial Ignition Timing Compression Ratio Aspiration Aftercooler's Rating Fuel Degrees Before Top Center 10:1 Natural aspiration - Dry, processed natural gas 30 10:1 Turbocharged aftercooled
32 °C (90 °F)20 10:1 Turbocharged aftercooled - Propane 10 10:1 Natural aspiration - Propane 15 7:1 Dry, processed natural gas 30 7:1 Turbocharged aftercooled
54 °C (130 °F)7:1 Natural aspiration - Unprocessed field gas 20 Butane 7:1 Turbocharged aftercooled - Propane Scrubbed field gas
- Turn the crankshaft in the direction of engine rotation until the number 1 piston is coming up on the compression stroke. Place that piston in the position that was determined from Table 4. Observe the timing marks on the flywheel and turn the crankshaft until the desired timing mark on the flywheel is directly under the pointer for the timing marks on the flywheel.
The number 1 cylinder is the first piston in the firing order for clockwise rotation and for CCW rotation.
Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston". Also observe the direction that the pointer on the magneto moves.
 | |
| Illustration 17 | g00735090 |
Flywheel timing marks | |
- Rotate the magneto's coupling and observe the pointer on the magneto. Align the pointer on the magneto with the appropriate mark for the direction of rotation.
For engines with standard rotation, align the pointer with the "CCW" mark.
For engines with opposite rotation, align the pointer with the "CW" mark.
When the desired timing mark on the flywheel is obtained, the pointer on the magneto must be aligned with the appropriate mark.
Note: The magneto has two marks that indicate the rotation of the magneto ("CW" and "CCW"). The magneto also has a pointer that moves clockwise or counterclockwise when the magneto's coupling is rotated. When you time the magneto to the engine, the pointer must indicate the correct timing mark.
 | |
| Illustration 18 | g00743172 |
Marks for the direction of rotation and pointer on the magneto | |
- Verify that lugs (1) on the magneto's coupling are approximately at the 12 o'clock and 6 o'clock positions. Observe the corresponding positions of the slots in the magneto drive's shaft (2). If the slots do not align with the lugs, pull the shaft away from the magneto drive in order to rotate the shaft to the correct orientation. Push the shaft back into the magneto drive.
 | |
| Illustration 19 | g00951126 |
(1) Lugs on the magneto's coupling (2) Magneto drive's shaft (3) Original mounting bolt (4) 5M-2894 Hard Washer (5) 7C-4462 Harness | |
- Keep the pointer on the magneto aligned with the appropriate mark and install the 7C-0753 Magneto . Use the original mounting bolts (3) with the new washers (4). Use the nut from the previous installation on the upper bolt. Connect wiring harness (5) to the magneto.
- Reconnect the ground strap from the engine to the magneto that was removed in Step 2. Reconnect the ground strap to a bolt on the housing of the magneto.
- Attach a timing light to the secondary lead for the spark plug of the number 1 cylinder.
- Start the engine. Operate the engine at high idle speed.
- Use the timing light to observe the timing marks on the flywheel. If necessary, slightly loosen the magneto's mounting bolts and rotate the magneto in order to gain the desired timing. When the timing is correct, tighten the magneto's mounting bolts.
Note: Do not adjust the timing at low idle because of the timing advance in the magneto.
- Apply a load to the engine. Ramp the load and operate the engine at the rated load.
- Slightly loosen the magneto's mounting bolts and rotate the magneto in order to advance the timing. Slowly advance the timing until mild detonation occurs. Slowly rotate the magneto in order to retard the timing by six degrees. Tighten the mounting bolts for the magneto.
This will provide a six degree margin for detonation.
Note: Detonation produces a pinging noise and/or a sharp metallic knocking.
- Stop the engine.
- Remove the timing light.
- Install the cover for the flywheel housing.