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Introduction
This Special Instruction describes the procedure for mounting the CAT Digital Ignition System (CDIS) Controller on G3406, G3408, and G3412 engines. Do not perform any procedure in this Special Instruction until you have read this information and you have understood this information.Controller Mounting
Mount the 163-6108 Timing Control (G3412) or mount the 163-6164 Timing Control (G3406 and G3408). Mount these controls to a distance that is within 6 m (20 ft) of the front of the engine. Refer to Illustration 1. DO NOT mount the Timing Control on the engine or driven equipment.Note: The timing control is rainproof but the control will not tolerate washing with pressurized water.
The installation of the parts depend on the engine model:
For the G3412 Engine, connect the 163-6110 Wiring Harness to the 163-6108 Timing Control .
For G3408 and G3406 Engines, connect the 163-6110 Wiring Harness to the 163-6164 Timing Control .Attach the ground wire ring terminal of the ignition harness to one of the timing control mounting bolts.
For G3412 Engines, connect the Ignition 163-6109 Wiring Harness to the controller.
For G3408 Engines, connect the Ignition 163-6165 Wiring Harness to the controller.
For G3406 Engines, connect the Ignition 163-2447 Wiring Harness to the controller.Use straps in order to attach the harnesses to the existing clips down the left side of the engine.Note: The CSA acronym refers to the Canadian Standards Association.Route the harnesses with the CSA certification down the right side of the engine.
For G3412 Engines, connect the 163-8070 Wiring Harness to the 163-6108 Timing Control . Then connect the 163-6149 Wiring Harness to the Timing Control.
For the G3408 Engines, connect the 163-6171 Ignition Harness to the 163-6164 Timing Control . Then connect the 163-8070 Wiring Harness to the Timing Control.
For the G3406 Engines, connect the 183-2448 Ignition Harness to the 163-6164 Timing Control . Then connect the 163-8070 Wiring Harness to the Timing Control.
The customer will supply 12 V power or 24 V power. The following components are provided for both the positive input and the negative input: two 10 amp fuses, holders and heat shrink tubing for splicing. An optional shutdown switch (minimum 10 amp) can be installed on the positive lead. This switch is not included in the kit. The fuse holders and the fuses are installed in the wiring harness on the CSA ignition system.Note: The controller is sensitive to polarity. For the 163-6110 Wiring Harness , the red wire must be connected to the positive lead. The white wire must be connected to the negative lead. The black wire is not needed. The black wire should be folded back and the black wire should be taped.An alternator and a voltage regulator are available for installations that do not have a 12 V power supply or a 24 V power supply for the Cat Digital Ignition System. This alternator can only supply power for the CDIS controller. The alternator can not power any other equipment.Refer to table 2.
Install the 163-6118 Alternator in the normal place for the magneto. The 2W-8711 Magneto Drive Shaft is used in order to drive the alternator. Fasten the alternator in place with two 8T-2502 Bolts and two 5P-1075 Hard Washers . The orientation of the washer should have the MS connector in the six o'clock position.
Mount the 163-6119 Voltage Regulator near the CDIS controller, which is off the engine. This mounting location will ease the electrical connections.
Install the 163-6120 Wiring Harness , which is not CSA, between the alternator and the voltage regulator. However, you may install the 169-6886 Wiring Harness (CSA) instead of the other harness between the alternator and the voltage regulator. Route the wiring harness for the alternator along the same path as the ignition harness. Strap the two harnesses together.
For the Ignition Systems that are not CSA, the fuses and holders are not attached when the unit is shipped. These components need to be installed on the positive lead and on the negative lead. These leads go to the 163-6110 Wiring Harness .
Illustration 1 g00586963
This is an Illustration of the Cat Digital Ignition Controller. (A) 224.9 mm (9 inch) (B) 14.3 mm (0.5 inch) (C) 196.3 mm (7.7 inch) (D) 94 mm (3.7 inch) (E) 12.7 mm (0.5 inch) (F) 181 mm (7 inch) (G) 158.8 mm (6.3 inch) (H) 11.1 mm (0.44 inch) (I) 7.94 mm (0.31 inch)Setting The Timing
The 163-6164 Timing Control has an application switch and a timing switch. These switches are located on the right side of the box. The 163-6108 Timing Control also has these switches in the same location. The application switch is on the top. This 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. The following steps describe the procedure that is used to set the ignition timing.
Determine the engine model that will be controlled. One example of an engine model is the G3408. Another example of an engine model is the G3412.
Perform an analysis of the fuel in order to determine the methane number. Refer to the Engine Performance Book or consult with your local Caterpillar dealer in order to determine the desired ignition timing.
Set the application switch to the appropriate model and the appropriate timing range.Note: Choose the appropriate setting of the application switch. The desired timing should be in the upper end of the lowest timing range.
Example: G3408, desired ignition timing 23° BTC. Switch setting should be "C".
The timing switch is fully advanced at location 15, and the switch retards one degree for each mark as the switch is moved to zero. Use the same example that was used in Step 3. Set the timing switch to 15. Set the switch to a setting that is two positions toward the zero position. This movement will place the timing close to the correct