5032999 JOHNSON PLUG

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
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".
Illustration 1 g00757809
(1) Magneto (2) Governor and magneto drive
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.
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.
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.
Illustration 3 g00757803
(4) Damper guard (5) Alternator (6) Cover
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.
Illustration 4 g00757851
(6) Cover (7) Full nut (8) Gear
Remove full nut (7) and gear (8) through the opening for cover (6). Discard the nut and the gear.
Illustration 5 g00757883
(2) Governor and magneto drive (9) Oil linesNote: Some engines have only one oil line for the governor and magneto drive (2) .
Disconnect the oil lines (9) from the governor and magneto drive (2) .
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).
Illustration 6 g00757904
(2) Governor and magneto drive (10) Bolts (11) Nuts
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.
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
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.