0332419 JOHNSON LWR MT BRKT

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.This document provides details regarding the general operation and troubleshooting process for the ignition control module installed on the 14.2L engine configuration as utilized on Generator Sets.Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Accidental engine starting can cause injury or death to personnel working on the equipment.To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Problem
Caterpillar gas engines may malfunction due to misalignment between timing Magnetic Pickup Unit (MPU) and zero degree flywheel hole.Solution
Caterpillar is aware of this problem and as an interim action, perform the below service instructions for engine ignition module.Important Emission Information
Certain 14.2L engines are equipped from the factory with a catalytic converter and as such, are certified to meet U.S. Environmental Protection Agency (EPA) emission standards for stationary emergency engines. The service information described herein must be followed exactly to ensure that the resulting configuration is certified to EPA standards and meets all applicable requirements. Failure to follow these instructions correctly and completely may be a violation of EPA regulations subject to fines or other penalties as described in the Clean Air Act. Adjusting the engine ignition timing to a non-specified value is prohibited. Compliance with the service instructions provided is required to maintain the EPA emissions certification.Reimbursement
Use of this document does not authorize any reimbursement through standard Caterpillar warranty, ESC warranty, or goodwill. Implementation of this document is at the discretion of a dealership.Prerequisites
The below prerequisites need to be followed before performing the calibration procedure:
Isolate the genset before commencing any work on the unit.
Open the genset breaker.
Activate emergency stop.
Turn off fuel supply to the genset and disconnect battery cables.Note: Only qualified service personnel should service this equipment.The engine ignition is controlled by a Altronic CD1 ignition system which consists of four basic components:
CD1 Unit.
Magnetic pick up sensor for timing input
Wire interface harness.
Individual coils (one per cylinder) or a Multi-Tower coil module.The ignition system requires a suitable power supply, 12VDC or 24VDC. The CD1 unit steps up the power supply voltage to charge an energy storage capacitor then, uses a microcircuit logic with Silicon Controlled Rectifier (SCR) switching devices to release the stored energy to the appropriate ignition coil in a programmed, timed sequence according to the application.The CD1 unit can operate as a "Single-Firing" or "Double-Firing / Waste Spark" ignition system.The CD1 ignition module uses a "coded" flywheel which, the reluctance timing MPU sensor uses to sense the angular rotation of the engine crankshaft. The outside diameter of the flywheel is "drilled" with holes positioned with a specific angular spacing. The angular spacing of these holes, provide the basic timing accuracy of the ignition system.With engine "cylinder 1" set to its most advanced timing position, the corresponding engine flywheel timing hole which is aligned with the MPU Timing Sensor is referenced as, zero degree. Since the 12.9L, 13.3L, and 14.2L engines have six-cylinders, there will be three additional flywheel timing holes spaced at 120 degrees, 240 degrees, and 260 degrees, as referenced from the zero degree hole.
Illustration 1 g06304518
Misalignment between timing MPU and zero degree flywheel hole
Illustration 2 g06304519
Proper alignment between timing MPU and zero degree flywheel hole