15/10/21 20:51 SIS 2.

2005/08/25 Ignition Transformer (SENR6412)

SMCS - 1561 i02355430

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
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
(2) Ground spring
(3) Spacer
(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.
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15/10/21 20:51 SIS 2.0

Note: Punch through causes 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 a 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.

Illustration 2 g00814314
(1) Screw
(4) Terminal connector
(7) + pin
(8) - pin

9. Measure the voltage of the diode for the primary circuit.

Illustration 3 g00754013
Symbol for a diode

a. Set the multimeter to the diode scale. Measure the voltage between positive pin (7) and negative pin (8).

b. Reverse the polarity of the probe and measure the voltage between the pins again.
For the diode of the primary circuit, the correct voltage between the positive pin and the negative pin is approximately 0.450 VDC. When
the polarity is reversed, there is no reading.

10. Measure the resistance of the secondary circuit.

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 4 and 5 demonstrate the relationship between the
secondary coil's resistance and the temperature. A reading that is within ± 1000 ohms is acceptable.

Illustration 4 is a graph for the resistance of the following transformers: 165-1589 and 165-1590

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Illustration 5 is a graph for the resistance of the following transformers: 232-6346 and 232-6347

Illustration 4 g00863850
(Y) Resistance in ohms
(X) Temperature in degrees Celsius (degrees Fahrenheit)

Illustration 5 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. Reset the control system. Clear any logged diagnostic codes.

13. 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 Electronic Troubleshooting, SENR6413, "G3500 Engines".

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

2TJ1-UP, 4EK1-UP, 4WD1-UP, 5JD1-UP, 5ZZ1-UP, 6JW1-UP, 7NJ1-UP, 7SZ1-UP, 8BZ1-UP, 8JZ1-UP, 8LD1-UP, 8PW1-UP, 9TG1-UP, CPG1-UP,
CPJ1-UP, CPS1-UP, CPY1-UP, CRN1-UP, CSP1-UP, CSZ1-UP, CTL1-UP, CTM1-UP, CTN1-UP, E2C1-UP, E621-UP, E6N1-UP, E6R1-UP, E6W1-
UP, E6Y1-UP, E8A1-UP, L6A1-UP, L6E1-UP, L6F1-UP, L6G1-UP, NG21-UP, TJ21-UP, TJ41-UP, TJ71-UP, WC21-UP, WC31-UP, WC61-UP, WC71-
UP, WC81-UP, ZAZ1-UP, ZBA1-UP

PIP-10659899
2021/10/15
23:51:33-03:00
i01555678
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