3H6-02305-0 Tohatsu GASKET, EXHAUST PLATE

Introduction
This Special Instruction describes the installation of the Caterpillar Ignition System (CIS) on G3606 and G3608 Engines. The CIS replaces mechanical parts that are prone to wear. The CIS improves the ignition system's precision and reliability. The CIS also provides self-diagnostics and diagnostics for the ignition system.The CIS was designed to operate with the Caterpillar Timing Control Module (TCM) in the Engine Supervisory System. The function of the TCM remains unchanged. No reprogramming is required.For information on the operation of the CIS, refer to Systems Operation/Testing and Adjusting, RENR2254, "Ignition System".A brief overview provides a summary of the installation procedure. Photographs in the overview help identify the major components.Line drawings that include more detailed identification of the parts are used to describe the actual installation procedure.Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Reference: The following reference materials may be necessary for this procedure:
Disassembly and Assembly, SENR4259, "G3606 and G3608 Engines"
Operation and Maintenance Manual, SEBU6278, "G3606 and G3608 Engines"
Systems Operation/Testing and Adjusting, RENR2254, "G3606 and G3608 Engines"
Troubleshooting, SENR6510, "G3600 Engines"
Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)"
Special Instruction, SEHS9122, "Using the 7X-1400 Digital Diagnostic Tool (DDT) Group"
For engines that were built before October 1998, refer to the 3E-9347 Wiring Diagram that was shipped in the engine mounted terminal box.
For later engines, refer to the 128-2508 Wiring Diagram that was shipped in the engine mounted terminal box.Overview
Illustration 1 g00905483
(1) Magneto (2) Magneto interface box (3) Ignition harnessMagneto (1), magneto interface box (2), and the related wiring harnesses are removed. The original ignition harness (3) is removed.Note: The oil mister pump is not necessary on G3600 Engines. For more information, refer to Engine News April, "Oil Mister Pump and Lines Group No Longer Used".
Illustration 2 g00905503
(4) Oil mister pump (5) AdapterOil mister pump (4), the oil lines, adapter (5), and the oil mister pump's drive are removed. A plate with a magnet for the camshaft position sensor is bolted to the camshaft in place of the pump drive's components.
Illustration 3 g00905488
Camshaft position sensorA new adapter is installed over the camshaft and a camshaft position sensor is installed.
Illustration 4 g00905504
CIS Programming ControlThe CIS Programming Control and a new ignition harness are installed. A wiring harness is routed from the camshaft position sensor to the programming control.
Illustration 5 g00905493
Terminal boxWiring harnesses for the programming control's communication with the TCM and for the programming control's electrical power are connected to the engine's terminal box.
Illustration 6 g00905355
CIS Programming DisplayThe CIS Programming Display is connected to the programming control. The programming display provides an interface between the service technician and the CIS. The installation is tested for proper operation.Required Parts
Table 1 includes parts that are required for installation of the CIS.
Table 1
Required Parts for the CIS    
Pt. No.    Description    Qty    Function    
G3606 Engine    G3608 Engine    G3606 Engine G3608 Engine    
172-0060     172-0061     CIS Programming Control     1     Control and mounting plate    
145-8462     Plate     1    
146-1800     146-1801     Wiring Harness     1     Ignition harness    
175-1494     Plate     1     The plate holds the magnet assembly and the plate is bolted to the camshaft.    
0S-1587     Bolt     3    
5P-8245     Hard Washer     3    
4C-4030     Thread Lock Compound     1    
142-8608     Magnet As     1    
145-7982     Sensor (Camshaft)     1     Camshaft posit