TEE AS 1649904 - Caterpillar

1. Remove the four screws from the magneto cover and remove cover (2). 2. Remove the two screws (3) from the top of the distribution board. Put a screwdriver between the heat sink section and the pulser coil housing. Pull the screwdriver to remove the heat sink and end cap section. It may be necessary to lightly hit the end cap section with a soft hammer to break the sections loose. 3. Remove four screws (4) from plate (5). Remove the plate. 4. Remove nut (6) and the washer which fasten the pulser to the shaft. Remove pulser (7).
Use extra care when removing nut (6). Do not use the drive coupling to keep the pulser shaft from turning. Damage to the fiber gear may result. Put a large nut over a pick-up on the pulser coil. Turn the drive coupling until the pulser comes in contact with the nut. Remove nut (6).
5. Remove two screws (8) from the center of pulser coil (9). Disconnect the two white and the two gray wires from terminals (B-1), (B-2), (B-3) and (B-4). Remove the nylon strap that holds the wires. Remove the two screws from the lower edge of the pulser coil. Remove the pulser coil. The electronic section of the magneto can be removed at this time. 6. Remove four screws (10) which hold pulser coil housing (11) to the drive end of the magneto. Remove housing (11). 7. Remove three screws (12) from bearing support assembly (13). 8. Remove nut (14) which fastens drive coupling (15) to the shaft. Remove the drive coupling from the shaft. Remove the key from the shaft. 9. Remove washer (16), seal (17) and washer (16) from the shaft. Remove the snap ring from the shaft.10. Remove the drive assembly from housing (18). 11. Remove the two screws that fasten wedges (19) to the housing. Remove the wedges. Remove coil (20) from the housing. Install the new coil.12. Install bearing support assembly (13) in the housing. Be sure the bearing support assembly is in the center of the housing when tightening the screws. 13. Install the snap ring on the shaft. 14. Install a washer (16), seal (17) and washer (16) on the shaft. Install the key to the shaft. 15. Install the drive coupling (21) on the magneto drive shaft (22). Install the nut that fastens the drive coupling to the shaft. 16. Install the four screws (10) that fastens the pulser coil housing (11) to the drive end of the magneto. 17. Install pulser coil (9) in the pulser coil housing. Install the two screws in the center of the pulser coil. Install the two screws in the lower edge of the pulser coil. 18. Install pulser rotor on the shaft (for magnetos that operate in the clockwise direction, the mark C on the pulser rotor must be facing out, the mark A is for counterclockwise magnetos). Install the spacer then the washer and the nut that hold the pulser to the