Rework Instruction for Transformers for G3400C Engines with Tall Cylinder Heads{1409, 1550, 1561} Caterpillar

Engines:

G3408C (S/N: 3WR1-UP; 8YR1-UP; 6FW1-UP; BAZ1-UP)

G3412C (S/N: 6ZM1-UP; 9RR1-UP; 8LW1-UP)

Introduction

This Special Instruction provides the rework procedure for converting 165-1591 Ignition Transformer Gp into the 213-7443 Transformer .

Do not perform any procedure that is outlined in this Special Instruction until the entire Special Instruction has been read and understood.

Required Materials

A 214-6130 Ignition Conversion Gp contains the parts that are required to complete this rework procedure.

A 132-8263 Spanner Wrench is required in order to remove the terminal. The spanner wrench is also used to install the terminal.

Rework Procedure

Illustration 1	g00908154
165-1591 Ignition Transformer Gp (1) 9X-6477 Screw (2) 3L-8187 Lockwasher (3) 125-7038 Transformer Spring (4) 164-6474 Transformer (5) 135-2651 Seal (6) 128-0714 Spacer (7) 129-8803 Spark Plug Extension (8) 128-0716 Terminal (9) 119-9443 O-Ring Seal

Illustration 2	g00908276
213-7443 Transformer (1) 9X-6477 Screw (2) 3L-8187 Lockwasher (3) 125-7038 Transformer Spring (4) 164-6474 Transformer (5) 135-2651 Seal (6) 128-0714 Spacer (9) 119-9443 O-Ring Seal (10) 213-7445 Spark Plug Extension (11) 213-7447 Terminal

1. Remove terminal (8) with the 132-8263 Spanner Wrench .

2. Tighten spark plug extension (7) in the jaws of a bench vise.

3. Rotate transformer (4) back and forth in order to remove the transformer from the spark plug extension.

4. Remove spacer (6) from the spark plug extension. Discard the following components: spark plug extension (7), O-ring seal (9) and seal (5) .

5. Remove screws (1) and lockwashers (2) from transformer spring (3). Remove the transformer spring.

6. Assemble the spacer onto spark plug extension (10). Install new seal (5) that was provided in the kit.

7. Use a press to install the spark plug extension. Press the spark plug extension into the transformer until the spark plug extension is fully seated. The spacer should move freely after this operation is complete.

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Illustration 3	g00908004
Locating tab

8. Reinstall the transformer spring with the screws and the lockwashers. Ensure that the locating tab is located over the connector. Tighten the screws to 2.0 ± 0.5 N·m (18 ± 4 lb in).

9. Install terminal (11) with the spanner wrench. Press the terminal with the spanner wrench until an audible click is heard. The terminal is fully seated.

10. Install new O-ring (9) in the spark plug extension.