G3516B 50Hz Generator Set Engine 7EZ00001-UP(SEBP2906 - 51) - Systems & Compo...

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Product: GEN SET ENGINE

Model: G3516B GEN SET ENGINE 7EZ
Configuration: G3516B 50Hz Generator Set Engine 7EZ00001-UP

Testing and Adjusting

G3500B Engines
Media Number -RENR2268-09 Publication Date -01/08/2012 Date Updated -20/08/2012

i03627524

Ignition Transformer
SMCS - 1561

The Electronic Control Module (ECM) provides extensive diagnostics for the ignition system. A
diagnostic code is generated if a problem with the primary circuit or the secondary circuit is detected.
For instructions on troubleshooting the electrical circuit, refer to the Troubleshooting Manual.

If an ignition transformer is suspect, use the following procedure to check the transformer:

Ignition systems can cause electrical shocks. Avoid contacting the

ignition system components and wiring.

Do not attempt to remove the valve covers when the engine is operating.
The transformers are grounded to the valve covers. Personal injury or
death may result and the ignition system will be damaged if the valve
covers are removed during engine operation. The engine will not
operate without the valve covers.

1. Turn the engine control switch to the OFF/RESET position. Switch the circuit breaker for the
engine OFF.

2. Remove the valve cover of the suspect cylinder.

NOTICE

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Pulling on the wiring harness may break the wires. Do not pull on the
wiring harness.

3. Disconnect the ignition harness from the transformer. Remove the transformer from the engine.

Illustration 1 g00715304

(1) Screw for the ground spring

(2) Ground spring

(3) Spacer

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(4) Terminal for the spark plug

(5) Extension

(6) O-ring seal

4. Inspect the body of the transformer and ground spring (2) for corrosion and/or damage. Verify
that screws (1) for the ground spring are secure.

Note: Punch through is caused by misfire in the engine that does not generate a diagnostic
code.

5. Check the extension near spacer (3) for signs of punch through (pin holes) and/or arcing.

6. Inspect O-ring seal (6) inside the extension for damage.

7. Remove O-ring seal (6). Inspect terminal (4) inside the extension for looseness, corrosion,
and/or damage. Insert an extra spark plug into the transformer and check for spring pressure of
terminal (4) .

NOTICE

The extension can be scratched and damaged with a wire brush. Do not
use a wire brush on the extension.

8. Clean any deposits from the inside of the extension. Use a 6V-7093 Brush with isopropyl
alcohol.

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Illustration 2 g00814314

(1) Screw for the ground spring

(4) Terminal for the spark plug

(7) + Terminal

(8) - Terminal

9. Measure the primary circuit by checking the voltage of the diode.

a. Set the multimeter to the diode scale. Connect the multimeter leads to terminals (7, 8) of
the 2-pin connector. The polarity of the leads is not important. Measure the voltage
between the terminals. Record the measurement.

b. Reverse the multimeter leads. Measure the voltage between the terminals again. Record
the measurement.

One of the voltage measurements is approximately 0.450 VDC. The other measurement
indicates an open circuit.

10. Measure the resistance of the secondary circuit.

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a. Set the multimeter to the 40,000 Ohm scale. Measure the resistance between screw (1) for
the ground spring and terminal (4) for the spark plug.

Note: The resistance of the secondary coil will vary with the temperature. Illustrations 3
and 4 demonstrate the relationship between the secondary coil's resistance and the
temperature. A reading that is within ± 1000 ohms is acceptable.

Illustration 3 is a graph for the resistance of the following transformers: 199-9011 and
229-9753

Illustration 4 is a graph for the resistance of the following transformers: 232-6350 and
259-2078

Illustration 3 g00863850

(Y) Resistance in ohms

(X) Temperature in degrees Celsius (degrees Fahrenheit)

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Illustration 4 g01170387

11. Switch the suspect transformer with a transformer from a different cylinder that is known to be
good. Install the transformers. Install the valve covers.

12. Switch the suspect transformer with a transformer that is known to be OK from a different
cylinder. Install the transformers. Install the valve covers.

13. Reset the control system. Clear any logged diagnostic codes.

14. Start the engine and operate the engine in order to generate a diagnostic code.

If the problem follows the transformer, replace the transformer. Make sure that you use the
correct transformer for the engine. Reset the control system. Clear any logged diagnostic
codes.

If the problem stays with the cylinder, there is a problem with the spark plug or the electrical
circuit for the transformer.

For troubleshooting of the electrical circuit, refer to the Troubleshooting Manual.

Spark Plug
If a diagnostic code is generated for the ignition transformer's secondary circuit, the spark plug may
need to be replaced. Misfire and a cold cylinder are other indications of a worn spark plug. Use Cat
ET to monitor the exhaust port temperatures in order to locate a cold cylinder.

The service life of the spark plugs is affected by fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also affected by voltage. Higher voltage is required by
higher inlet manifold air pressure, a higher compression ratio, or retardation of the timing. Higher
voltage reduces the service life of components such as spark plugs, wires, and transformers.

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To help predict the spark plug's service life, use Cat ET to monitor the secondary voltage. The value is
expressed as a percent of secondary voltage. The value increases as the spark plug gap wears over
time. A new spark plug is at 0 percent. A value over 90 percent may require maintenance. A spark
plug at 100 percent requires replacement. Maintaining a log of this voltage at a particular site will
help to determine the proper interval for replacement of the spark plugs.

For instructions on inspection and replacement of the spark plug, refer to the engine's Operation and
Maintenance Manual. For more information on the spark plug, refer to the engine's Specifications
manual.

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