GEAR-SUN 7G5594 - Caterpillar

System Operation Description:Use this procedure to troubleshoot a suspected problem with an ignition transformer or use this procedure if one of the diagnostic codes in Table 1 or Table 2 are active or easily repeated.
Table 1
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
401-5 Ignition Transformer Secondary #1 : Current Below Normal
402-5 Ignition Transformer Secondary #2 : Current Below Normal
403-5 Ignition Transformer Secondary #3 : Current Below Normal
404-5 Ignition Transformer Secondary #4 : Current Below Normal
405-5 Ignition Transformer Secondary #5 : Current Below Normal
406-5 Ignition Transformer Secondary #6 : Current Below Normal
407-5 Ignition Transformer Secondary #7 : Current Below Normal
408-5 Ignition Transformer Secondary #8 : Current Below Normal
409-5 Ignition Transformer Secondary #9 : Current Below Normal
410-5 Ignition Transformer Secondary #10 : Current Below Normal
411-5 Ignition Transformer Secondary #11 : Current Below Normal
412-5 Ignition Transformer Secondary #12 : Current Below Normal
413-5 Ignition Transformer Secondary #13 : Current Below Normal
414-5 Ignition Transformer Secondary #14 : Current Below Normal
415-5 Ignition Transformer Secondary #15 : Current Below Normal
416-5 Ignition Transformer Secondary #16 : Current Below Normal While the engine is started, the Electronic Control Module (ECM) detects a low current flow in the secondary circuit for the ignition transformer. The code is logged.
The alarm output is activated.
Table 2
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
401-6 Ignition Transformer Secondary #1 : Current Above Normal
402-6 Ignition Transformer Secondary #2 : Current Above Normal
403-6 Ignition Transformer Secondary #3 : Current Above Normal
404-6 Ignition Transformer Secondary #4 : Current Above Normal
405-6 Ignition Transformer Secondary #5 : Current Above Normal
406-6 Ignition Transformer Secondary #6 : Current Above Normal
407-6 Ignition Transformer Secondary #7 : Current Above Normal
408-6 Ignition Transformer Secondary #8 : Current Above Normal
409-6 Ignition Transformer Secondary #9 : Current Above Normal
410-6 Ignition Transformer Secondary #10 : Current Above Normal
411-6 Ignition Transformer Secondary #11 : Current Above Normal
412-6 Ignition Transformer Secondary #12 : Current Above Normal
413-6 Ignition Transformer Secondary #13 : Current Above Normal
414-6 Ignition Transformer Secondary #14 : Current Above Normal
415-6 Ignition Transformer Secondary #15 : Current Above Normal
416-6 Ignition Transformer Secondary #16 : Current Above Normal While the engine is started, the ECM detects an excessive current flow in the primary circuit for the ignition transformer. The code is logged.
The alarm output is activated. The ignition transformers initiate combustion by providing high voltage to the spark plugs. The output from the secondary circuit of the transformer provides voltage to the terminals of the spark plug. The transformers are located underneath the valve covers. Each transformer is grounded to a valve cover via a ground spring.The secondary circuit of the transformer provides an initial 8,000 to 37,000 V to the spark plug. This voltage ionizes the air that is in the spark plug gap and generates a spark in the air gap. This voltage is then reduced to about 1,000 V. The total duration of the spark is approximately 400 microseconds.The ECM can diagnose the primary circuit of the ignition transforme