PLUG 9W7783 - Caterpillar

Assembly Procedure
Table 1
Required Tools
Tooling Part Number Description Qty
A 1P-1855 Retaining Ring Pliers 1
B 1P-0510 Driver 1
C 1P-1857 Retaining Ring Pliers 1 Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
Illustration 1 g00997130
If you replace the bearings in bearing support (2) you must replace the bearings and bearing support as a unit.
Use a press in order to install the distributor gear and shaft assembly (1) in bearing support (2).
Illustration 2 g00997131
Use Tooling (A) in order to install snap ring (3) that holds the distributor gear and shaft assembly (1) in position.
Illustration 3 g00997132
Place an identification mark on the tooth by mark (4) on assembly (5).
Illustration 4 g00997133
Align mark (6) on assembly (5) with the Letter "A" on the distributor gear and shaft assembly (1).
Illustration 5 g00997134
Use a press in order to install assembly (5) in bearing support (2).
Illustration 6 g00997135Note: Install the open end of vent cap (7) in the DOWN position.
Install two screens and vent cap (7) on each side of housing (8).
Use Tooling (B) in order to install the bearing in housing (8).
Illustration 7 g00997136
Use Tooling (C) in order to install snap ring (9).
Illustration 8 g00997137
Place coil (12) in position with wire (11), as shown. Install wedges (10). Fasten wire (11) under wedge (10).
Illustration 9 g00997138
Place bearing support (2) and assembly (5) in position in housing (8). Use a press and 3/16 inch diameter rod (13) that is 1 3/4 inches long in order to install the assembly (5) in housing (8).
Install the three screws that hold bearing support (2) and clip (14) in position.
Illustration 10 g00997139
Use Tooling (A) in order to install snap ring (15).
Illustration 11 g00997140
Install seal (16) with the lip of the seal away from the housing.
Install pin (17). Use the left hole for counterclockwise rotation, as shown.
Illustration 12 g00997142
Install plate (18) on bearing support (2).
Illustration 13 g00997144
Install key (19) on the distributor shaft. Note: Cam (20) has two slots, one slot for each direction of magneto rotation. Each slot has an arrow for each direction of rotation.
Make an alignment of the key in the distributor shaft and the slot by the counterclockwise arrow on cam (20). Place cam (20) in position on the shaft.
Illustration 14 g00997145
Install nut (22) that holds the cam in position.
Install condenser (23) and contact points (12). Note: Do not use additional lubricant.
Illustration 15 g00997147
Turn cam (20) until the high point of the cam is against arm (24) of the contact points. Adjust the gap for the contact points to 0.43 mm (0.017 inch).
Illustration 16 g00997148
Adjust the magneto edge gap by rotating assembly (5) until the keyway is in an UP position, then turn the shaft approximately 15° in the direction of the magneto, as shown.
Illustration 17 g00997151
Loosen screws (25).
Install a 2.39 mm (0.094 inch) diameter rod (27) in timing hole (26)