Ignition Transformer...

G3520C and G3520E Generator Set

Engines Caterpillar
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 transformers 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 transformers are removed during engine operation.

1. Turn the engine control OFF. Switch the engine's circuit breaker OFF.
 Illustration 1

(1) Cover

(2) Connector

(3) Transformer

(4) Extension

(5) Spark plug

(6) Mounting flange for the transformer

2. Remove cover (1) .

3. Disconnect the ignition harness from connector (2) . Remove transformer (3) and extension (4)
from the engine.

4. Inspect the body of transformer (3) and extension (4) for corrosion and/or for damage.

5. The extension has an internal O-ring seal for spark plug (5) . Inspect the O-ring seal for damage.

6. The extension has an internal terminal for the spark plug. Inspect the terminal for looseness, for
corrosion, and/or for damage. Insert an extra spark plug into the transformer and check the
terminal for spring pressure.

NOTICE

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

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

Illustration 2
 Symbol for a diode

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

Illustration 3

Transformer's connector for the ignition harness

(A) Terminal

(B) Terminal
(C) Unused

i. Set the multimeter to the diode scale. Connect the multimeter leads to terminals (A)
and (B) on the transformer's connector for the ignition harness. The polarity of the
leads does not matter. Measure the voltage between the terminals and record the
measurement.
ii. Reverse the polarity of the probe and measure the voltage between the terminals
again.
One of the measurements is approximately 0.4 to 0.6 VDC. The other
measurement indicates an open circuit.
Voltage that is significantly outside of this range could indicate a problem with
the transformer.
9. Measure the resistance of the secondary circuit.
i. Set the multimeter to the 40000 Ohm scale. Measure the resistance between the
extension's internal terminal for the spark plug and mounting flange (6) for the
transformer.
 If the resistance between the terminal for the spark plug and the mounting
flange for the transformer is within the acceptable tolerance, proceed to Step
10.
Resistance that is significantly outside of this range could indicate a problem
with the transformer or with the extension.
Note: The resistance of the secondary coil will vary with the temperature. The
resistance depends on the transformer that is used. Illustration 4 shows the
connection for the former transformers. Illustration 5 is a graph for the resistance
of the former transformers. A reading that is within 1000 Ohms is acceptable.

Illustration 4

Former transformer
(2) Connector

(6) Mounting flange for the transformer

 Illustration 5

Resistance versus temperature

(Y) Resistance in ohms

(X) Temperature in degrees Celsius (degree Fahrenheit)

Note: The resistance of the secondary coil will vary with the temperature. The resistance
depends on the transformer that is used. Illustration 6 shows the connection for the new
transformers. Illustration 7 is a graph for the resistance of the new transformers. A reading
that is within 1000 Ohms is acceptable.
Illustration 6

New transformer

(2) Connector
(6) Mounting flange for the transformer
 Illustration 7

Resistance versus temperature

10. Switch the suspect transformer with a transformer from a different cylinder that is known to be good.
Install the transformers.
11. Reset the control system. Clear any logged diagnostic codes.
12. 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 with the
electrical circuit for the transformer.
For instructions on the electrical circuit, refer to the engine's 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 the
Caterpillar Electronic Technician (ET) to monitor the exhaust port temperatures in order to locate a
cold cylinder.
There is virtually no maintenance for the spark plug. The electrode gap is not adjustable. The
resistance cannot be measured. Unless the holes in the spark plug's precombustion chamber
become plugged, no cleaning is required.
For instructions on inspection and replacement of the spark plug, refer to the engine's Operation
and Maintenance Manual.
Illustration 8

Spark plug precombustion chamber

G3520C ignition transformer frequent failures

Try to adjust the extension stud to 22 mm of ignition transformer.
Check your earthling system.
Connection of earth strip cable form back of ECM box to engine body.
reuse the failure ignition transformer after 2 or 3 days.