Johnson Controls G77 Series Installation Sheets Manual page 15

Modifying All spark ignition controls have a spark transformer connected to a high
Existing Ignition
voltage cable. There are three types of connections for the high voltage
Cable
cable: Spike, Rajah, and 6.35 mm (1/4 in.) male spade (see Figure 9).
The replacement G77x has a Spike transformer. When replacing a control
that has a Rajah or male spade connection, the crimp-on connector must be
cut off and connected as follows.
1. Slide the rubber boot up the cable.
2. Cut the lead just above the connector (see Figure 10). Make a straight
3. Center the exposed wire on the end of the lead over the spike in the
4. Ensure the lead is inserted all the way into the spark transformer.
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cut perpendicular to the cable.
spark transformer and push the wire lead down firmly over the spike
(see Figure 11).
Slide the boot back down the cable and over the spark transformer.
Spike Connection
Figure 9: High Voltage Cable Connectors
High Voltage Cable
Figure 10: High Voltage Cable with Crimp-On Connector
Spike must be in
contact with the
center wires.
Figure 11: Spark Transformer Connection
GG77x Intermittent Pilot Ignition Controls Technical Bulletin
6.35 mm (1/4 in.)
Rajah Connection
Male Spade
Insulating Boot
Cut off connector here.
High Voltage Cable
Crimp-on
Connector
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