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Special Instruction

Mounting Instructions For The CAT Digital Ignition System Controller For The G3406, G3408,
And The G3412 Engines{1550}
Media Number -REHS0486-02

Publication Date -01/02/2000

Date Updated -16/11/2001

i01263225

Mounting Instructions For The CAT Digital Ignition System

Controller For The G3406, G3408, And The G3412 Engines{1550}
SMCS - 1550

Engine:
G3406 (S/N: 4FD1-UP)
G3408 (S/N: 6NB1-UP)
G3408B (S/N: 6RJ1-UP)
G3412 (S/N: 7DB1-UP)

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

1. 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.

2. 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.

3. 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.

4. 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.
5. Mount the 163-6119 Voltage Regulator near the CDIS controller, which is off the engine. This
mounting location will ease the electrical connections.

6. 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.
7. 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
This is an Illustration of the Cat Digital Ignition Controller.

g00586963

(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.

1. 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.
2. 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.
3. 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".

4. 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 setting.
5. Start the engine and verify the ignition timing with a timing light. The timing switch may need to be
moved. This is a small adjustment of only one or two positions in either direction. These adjustments
will help to attain the correct timing ( 1/2 degree).
6. Install the switch covers and the thread lockwire through the holes in the cover. Secure these items
with a lockwire cap. This cap will prevent unauthorized tampering with the setting for the ignition
timing.

Illustration 2
This is an Illustration of the Caterpillar Digital Ignition Controller.

g00582974

(1) Application switch

(2) Timing switch

(3) Power and Timing sensor connection

(4) Ignition wiring connection
(A) 224.9 mm (9 inch)

(B) 196.3 mm (7.7 inch)

(C) 14.3 mm (0.5 inch)
(D) 181 mm (7 inch)

(E) 158.8 mm (6.3 inch)

(F) 11.1 mm (0.4 inch)

Table 1

APPLICATION SWITCH (1)

A = G3304
B = G3306/
G3406

WARNING: TO AVOID SHUTDOWN OR ENGINE DAMAGE, DO

NOT CHANGE SETTING WITH THE ENGINE RUNNING

C = G3408
D = G3304
E = G3306/
G3406
F = G3408

(1)

Application Switch Label (Typical Example)

Table 2

Quantity
1
1
1
1

Alternator And Voltage Regulator

Part Number

Description

163-6119

Voltage Regulator

163-6118
163-6120
169-6886

Alternator

Wiring Harness (Non-CSA)

Wiring Harness (CSA)

10 to 25
BTC
10 to 25
BTC
10 to 25
BTC
20 to 35
BTC
20 to 35
BTC
20 to 35
BTC

Troubleshooting
Normal Operation

Check the three LED indicators that are located on the face of the controller. The green "POWER" indicator
is ON when the power is applied. The red "PICKUP" and "APPLICATION" indicators are ON when there is
a fault.
Table 3

INDICATOR
POWER

POWER APPLIED ENGINE

STOPPED
ON

PICKUP

APPLICATION
(1)
(2)

POWER APPLIED ENGINE

ROTATING
ON

ON (1)

OFF

OFF

OFF (2)

No pickup signal is generated due to a lack of rotation.

This indicator will flash ON when engine rotation starts. The indicator will then flash OFF.

Troubleshooting
Check the three indicators that are located on the face of the controller. If the engine will not start or if the
engine will not run correctly, crank the engine with the fuel off. Then check the engine in accordance with
Table 4.
INDICATION AND CHECKS

Table 4

POWER Indicator OFF

Check the voltage to the positive lead and the negative lead of
the 6 pin pickup cable.
If the voltage is within the proper parameters, refer to the
remedy.

REMEDY
The voltage must be in the range of 10
VDC to 32 VDC.
Replace the CDIS controller.

PICKUP Indicator Is ON With The Engine Rotating

The gap between the pickup and the magnetic disk must be
1 .25 mm (0.040 0.0010 inch).

Correct the gap.

The pickup may be faulty.

Replace the pickup.

Check the cable between the pickup and the CDIS controller.

Connect or replace the cable.

If the previous steps are within the parameters, refer to the

remedy.

Replace the CDIS controller.

APPLICATION Indicator Is ON With The Engine Rotating

Correct the setting.

Check to be sure that the setting of the application switch

matches the application of the engine.

Check to be sure that the magnet pattern matches the application Correct the magnetic disc or the
of the engine.
pattern.
If the previous steps are within the parameters, refer to the
remedy.

Replace the CDIS controller.

Illustration 3
g00672029
2 Pin MS Customer Connection Harness for CSA Ignition. Use for grounding.

Illustration 4
This is an Illustration of the G3412 Engine Ignition Harness.

g00673388

Illustration 5
This is an Illustration of the G3408 Engine Ignition Harness.

g00673491

Illustration 6
This is an Illustration of the Standard Timing, Power, and Alarm Wiring Diagram.

g00647378

Illustration 7
This is an Illustration of the Optional Power Supply for Self-Powered Ignition.

g00647466

Illustration 8
This is an Illustration of the G3406 Engine Ignition Harness.

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