Installation of New Mounting Hardware for Caterpillar Ignition System (CIS) Modules{1550, 1550} Caterpillar

Engine:

G3612 (S/N: 1YG1-UP)

G3616 (S/N: 4CG1-UP)

Introduction

This Special Instruction provides removal and installation instructions for new mounting hardware for Caterpillar Ignition System (CIS) modules. This new hardware will help reduce vibration on the CIS modules. There is a procedure for engines with Hydrax actuators and for engines with Heinzmann actuators.

Reference: See Disassembly and Assembly, SENR5535.

Hydrax Actuators

Removal

Illustration 1	g00952324
(1) CIS mounting plate (2) Shock mount (3) CIS module (4) 145-8462 Plate (5) 122-3360 Support Bracket

1. Shut down the engine. Disconnect all of the harnesses from the CIS module (3). Remove the following components as a unit from plate (4) : CIS mounting plate (1), shock mounts (2) and CIS module (3) .

2. Remove the existing shock mounts (2) from CIS mounting plate (1) .

3. Remove the plate (4) from the support bracket (5) .

4. Remove the bolts, washers, and nuts from the two holes in the 145-0039 Bracket (6) that are closest to the rear of the engine. Refer to Illustration 2.

Installation

Illustration 2	g00952325
(5) 122-3360 Support Bracket (6) 145-0039 Bracket (7) 226-3810 Bracket

1. Install bracket (7) on the back side of support bracket (5). Use two 0S-1588 Bolts , four 3V-3308 Hard Washers and two 9S-8752 Full Nuts . This hardware is provided in the 227-5969 Mounting Kit .

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Illustration 3	g00952327
(6) 145-0039 Bracket (7) 226-3810 Bracket (8) 226-3811 Bracket

2. Install two new brackets. Connect 226-3811 Bracket (8) to 226-3810 Bracket (7) with the following components: one 0S-1588 Bolt , two 3V-3308 Hard Washers and one 9S-8752 Full Nut . This hardware is provided in the 227-5969 Mounting Kit .

3. Repeat Step 2 in order to install the second 226-3811 Bracket (8) to bracket (7) .

4. Connect the two 226-3811 Brackets (8) to the 145-0039 Bracket (6) with the following components: two 2A-4639 Bolts , four 3V-3308 Hard Washers and two 9S-8752 Full Nuts . This hardware is provided in the 227-5969 Mounting Kit .

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Illustration 4	g00952330
(9) 7C-6121 Shock Mount

5. Install the new 7C-6121 Shock Mounts (9) onto the CIS mounting plate (1). Secure the shock mounts with four 6V-8185 Nuts and four 8T-4204 Washers . This hardware is provided in the 227-5969 Mounting Kit . Torque the nuts to 12 ± 3 N·m (9 ± 2 lb ft). Do not overtighten the nuts. Ensure that the shock mounts are not twisted.

6. Install the CIS module (3), CIS mounting plate (1), and the new shock mounts (9) as an assembly onto the 226-3810 Bracket (7). Secure this assembly with four 6V-8185 Nuts and four 8T-4204 Washers . This hardware is provided in the 227-5969 Mounting Kit . Torque the nuts to 12 ± 3 N·m (9 ± 2 lb ft). Do not overtighten the nuts.

7. Reconnect the harnesses to the CIS module.

8. Return power to the CIS module. Start the engine and verify that the engine is operating properly.

Heinzmann Actuators

Removal

Illustration 5	g00952332
(1) CIS mounting plate (2) Shock mount (3) CIS module (4) 145-8462 Plate (5) 101-0131 Mounting Bracket

1. Shut down the engine. Disconnect all of the harnesses from the CIS module (3). Remove the following components as a unit from plate (4) : CIS mounting plate (1), shock mounts (2) and CIS module (3) .

2. Remove the existing shock mounts (2) from CIS mounting plate (1) .

3. Remove plate (4) from the mounting bracket (5) .

4. Remove the bolts, washers, and nuts from the two holes in the 101-0128 Bracket (6) that are closest to the rear of the engine. Refer to Illustration 6.

Installation

Illustration 6	g00952333
(5) 101-0131 Mounting Bracket (6) 101-0128 Bracket (7) 226-3810 Bracket

1. Install bracket (7) onto mounting bracket (5). Use two 0S-1588 Bolts , four 3V-3308 Hard Washers and two 9S-8752 Nuts . This hardware is provided in the 227-5970 Mounting Kit .

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Illustration 7	g00952334
(5) 101-0131 Mounting Bracket (6) 101-0128 Bracket (7) 226-3810 Bracket (8) 228-9902 Bracket (9) 228-9903 Bracket (10) 5V-9221 Spacer (11) 9X-8874 Bolt (12) 9S-1366 Bolt

2. Install two new brackets. Connect 228-9902 Bracket (8) to 226-3810 Bracket (7) with the following components: one 0S-1588 Bolt , two 3V-3308 Hard Washers and one 9S-8752 Full Nut . This hardware is provided in the 227-5970 Mounting Kit .

3. Connect 228-9903 Bracket (9) to 226-3810 Bracket (7) with the following components: one 0S-1588 Bolt , two 3V-3308 Hard Washers and one 9S-8752 Full Nut . This hardware is provided in the 227-5970 Mounting Kit .

   Note: In order for the new brackets to fit properly, new holes may need to be drilled or the existing holes may need to be slotted in the 101-0131 Mounting Bracket (5) .

4. Connect bracket (8) to 101-0128 Bracket (6) with the following components: one 9S-1366 Bolt (12), two 5P-8245 Hard Washers and one 1F-7958 Full Nut . This hardware is provided in the 227-5970 Mounting Kit .

5. Connect bracket (9) to 101-0128 Bracket (6) with the following components: one 9X-8874 Bolt (11), two 5P-8245 Hard Washers , one 5V-9221 Spacer (10) and one 1F-7958 Full Nut . This hardware is provided in the 227-5970 Mounting Kit .

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Illustration 8	g00952335
(13) 188-3288 Shock Mount

6. Install the new 188-3288 Shock Mounts (13) onto the CIS mounting plate (1) with the following components: four 8T-5391 Bolts and four 8T-4224 Hard Washers . This hardware is provided in the 227-5970 Mounting Kit . Torque the bolts to 26 ± 6 N·m (19 ± 4 lb ft). Do not overtighten the bolts.

7. Install the CIS module (3), CIS mounting plate (1), and new shock mounts (13) as an assembly onto the 226-3810 Bracket (7). Use four 6V-8189 Nuts and four 8T-4224 Hard Washers to fasten the assembly to the bracket (7). This hardware is provided in the 227-5970 Mounting Kit . Torque the nuts to 26 ± 6 N·m (19 ± 4 lb ft). Do not overtighten the nuts.

8. Reconnect the harnesses to the CIS module.

9. Return power to the CIS module. Start the engine and verify that the engine is operating properly.