Usage:
NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3839" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3839" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
August 31, 1996Termination Date
February 28, 1997Problem
The G3500 Electronic Ignition System transformer has been redesigned to provide an improved spark plug electrical connection, an o-ring seal around the spark plug ceramic body, and an o-ring backed teflon seal at the spark plug well sealing bore in the cylinder head. An upgrade parts kit is now available to convert to the improved transformer design configuration.
Affected Product
Model & Identification Number
G3508 (9TG12-66 4WD12 )
G3512 (5JD12-21 7NJ12-130 )
G3516 (4EK12-593 8LD12-27 5PN29-34 )
Parts Needed
Dealers will need to order parts for this Program.
- 1 - 1250517 Kit-Transformer (per cylinder changed)
Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.
- (1-Owner Notification)
- (2-Rework Procedure)
Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
NOTE: The Ignition System Transformer will have to be removed from the engine to complete the change over to the new components. Caution should be taken if the engine has recently been running, the ignition system transformer and its components will be hot. Use care when handling.
The following procedure can be used to replace the bottom end components on the EIS Transformer.
1. Remove the transformer. For transformers with a standard Spark Plug Connection, remove the 6-32 Bolt inside the Teflon extender with a inch hex key wrench.
For transformers with the Volute Spring Spark Plug Connection, use the 1328263 Wrench to remove the terminal assembly inside the Teflon extender.
Once the spark plug connection has been removed, theTeflon extender can now be disassembled from the transformer body.
2. Remove the old Teflon extender from the transformer body. There will be a small amount of resistance, but, the Teflon extender should come out easily by hand. Twist the extender while pulling to aid in removal. The large metal spacer will be reused. Discard the old seal.
3. Install the o-ring/Teflon seal onto the transformer body. The o-ring should be trapped between the Teflon seal and transformer, per the included print. Install the metal spacer onto the transformer, then carefully press the extender into the transformer. Installation of the new Teflon extender will require a slightly larger force to press it into the transformer body. Insure that the extender remains aligned during installation. Press the extender until it bottoms. By design, the metal washer will be free to rotate.
NOTE: Misalignment of the Teflon extender during installation can cause damage. Insure that it remains properly aligned.
4. To ease assembly of the Volute spring terminal assembly, first place it onto the 1328263 wrench, pointing upward. The tool should fit the terminal assembly without interference. If the starting point of the larger diameter end of the spring is aligned in a slot, rotate the spring to hide the end within the terminal assembly bore. Hold the transformer with the spark plug end pointing down. Guide the terminal assembly upward into the Teflon extender and finger tighten the terminal assembly. Tighten the terminal assembly to a torque of 2.70 ± 0.25 N·M (24.0 ± 2.2 in. lb.).
5. Prior to installation of the upgraded transformer, insure that the cylinder head bore is cleaned to eliminate any deposits that could damage the Teflon seal during installation. Any cleaning of the bore should not affect the original surface finish.
NOTE: Any damage to the Teflon seal will reduce its sealing capability. Use care when handling individual parts and when installing the transformer assembly into the cylinder head bore.