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GAS ENGINE ACCESSORIES

P/N 01.00.001-EN

GAS REGULATION

REV. 03/2013

SENSOR SYSTEMS

GAS ENGINE MANAGEMENT

SPARK PLUGS

IGNITION SYSTEMS

PRODUCT GUIDE 2013

1


COPYRIGHT The copyright for any material used in the MOTORTECH publications is reserved. Any duplication or use of objects such as pictures or texts in other electronics or printed publications is not permitted without MOTORTECH's agreement. TRADEMARK INFORMATION MOTORTECH is not a part of nor affiliated with ALTRONIC速, CATERPILLAR速, CUMMINS速, WAUKESHA速. All OEM names and part numbers shown are for reference purpose only. All trademarks, logos, and symbols used or shown in the MOTORTECH publications are exclusive objects to the right of their owners and are used for reference purpose only.


98

TOOLS AND TEST EQUIPMENT

28

IGNITION COILS

30 NEW MOTORTECH Style 31 MOTORTECH Style 31 ALTRONIC® Style 32 CATERPILLAR® Style 33 Conversion Kits 34 Accessories 36 Flange Versions 38 Externally Mounted 39 Integral Standard Versions 40 Integral High Energy Versions

100 SparkView 101 SparkScan1 102 Ignition Coil Tester 104 Ignition Pickup Simulator 105 ScopeLite 106 Tools and Workshop Equipment

108

SPARK PLUGS AND ACCESSORIES

42

TRIGGERING

110 MOTORTECH XT-Plugs 112 MOTORTECH XTL-Plugs 116 MOTORTECH MPC Spark Plugs 116 MOTORTECH ICP Spark Plugs 117 DENSO® Spark Plugs 124 Accessories and Tools

44 Pickups 47 Pickup Leads 48 Trigger Devices 50 Trigger Discs 52 Accessories

128

GAS ENGINE MANAGEMENT

130 ALL-IN-ONE 134 DetCon20 137 PowerView3 138 MOTORTECH AlphaRail − Wiring Rail System

54

HIGH TENSION LEADS AND ACCESSORIES

56 High Tension Leads – PolyMotTM Style 60 High Tension Leads 61 Unshielded Safety Leads for Shielded Spark Plugs 63 Unshielded Safety Leads for Conventional Spark Plugs 64 Accessories 68 MOT-Blues – Shielded High Tension Leads 69 Conventional Shielded High Tension Leads 70 Terminal Kits

140

SENSOR SYSTEMS

142 MOTORTECH AlphaRail − Wiring Rail System 144 Sensor Harnesses 147 Oxygen Sensors 148 MAP/MAT Sensors 149 Thermocouples

150

GAS REGULATION

152 VariFuel2 158 VariStep 159 EmCon5 162 Throttles 164 DUNGS® Gas Trains

166

GAS ENGINE ACCESSORIES

168 LLC – Liquid Level Controller 170 Coolant Filters 172 Lube Oil Filters 174 Cleaning Station

176

INDEX

76

PRIMARY LEADS

78 Shielded Primary Leads − for MOTORTECH AlphaRail 80 Conventional Shielded Primary Leads

82

EXTENSIONS

84 86 87 87 87

Spark Plug Extension – PolyMotTM Style Repair Kits for CATERPILLAR® Ignition Coils Teflon Extensions for CATERPILLAR® Ignition Coils Shielded Integral Ignition Coil Adaptor Shielded Spark Plug Extensions

SPARK PLUGS

90 MOTORTECH AlphaRail − Wiring Rail System 92 Wiring Rail Kits 94 Ignition Kits

GAS ENGINE MANAGEMENT

WIRING RAIL SYSTEM

SENSOR SYSTEMS

88

12 MIC5 Series 14 MIC4 Series 18 MICT 19 PowerView3 20 MIC850 Series 24 MIC500 Series

GAS REGULATION

IGNITION CONTROLLERS

GAS ENGINE ACCESSORIES

10

IGNITION SYSTEMS

TABLE OF CONTENTS

3


WELCOME TO MOTORTECH

Welcome!

MOTORTECH − WE UPGRADE GAS ENGINES 4

For those who fail to advance from what they have already achieved are quickly overtaken by the ever-changing demands of the market. This is why it pays to be innovative. At MOTORTECH we have been working hard to meet the needs of our customers for almost 25 years. We always strive to be one decisive step ahead of the rest! This is how we have proven ourselves worthy of being your qualified partner for stationary gas engines. Therefore, it should come as no surprise that MOTORTECH places high value in innovation, in research and in development. With over 200 employees, more than 20% are now active in this dynamic area! The continuous new and further developments of our product line for ignitions, controls and monitoring of the combustion process, ensure maximum availability and efficiency of your gas engines. With greater efficiency comes fewer emissions which is good for our environment. An example of our innovative strength is our new line of performance ignition coils. They were developed along with the new production technology used for manufacturing at MOTORTECH. If you have any questions or concern, please feel free to contact us. We guarantee you a solution for your gas engine.

Florian Virchow Managing Director


BENEFITS

• Equipment for all kinds of stationary gas engines • Development of hardware and software solutions • Design and production of innovative system solutions and individual solutions • Delivery and maintenance of ignition and control systems • Extensive test procedures to assure highest levels of product safety • Comprehensive technical support • From problem analysis to new design • Fastest possible delivery of gas engine accessories and replacement parts of all kinds • Specialists in electronic controls and for gas engines used for CHP and compressor drives • Installation and on-site repair – in emergencies and around the world, around the clock

MOTORTECH – WORKING FOR YOU EVERYWHERE ALL THE TIME!

Take advantage of our benefits

5


INNOVATIVE DESIGN AND PRODUCTS

Innovative Design

TAKE ADVANTAGE OF 25 YEARS OF EXPERIENCE! 6

We develop innovative hardware and software solutions for engine management that will keep your gas engine state-of-the-art for years to come. Our microprocessor-controlled ignition, anti-knock control, temperature monitoring and CHP control (Combined Heat and Power) for gas engines exceed the most stringent future requirements. This includes interactive functions for all devices – like the integration of TFT touch screens via CAN BUS interfaces that enable fast data exchange and visualization of important engine parameters. On the mechanical side MOTORTECH is developing gas mixers and throttles for various engine sizes and gas qualities using computer-supported development and analysis tools like 3D-CAD. This means your gas engine will always deliver maximum performance from nearly any type of gas. Mechanical Products Six high-tech CNC machining centers and other precision machines for processing metal and plastic parts are available for the production of mechanical products. To achieve the greatest reliability, we use state-of-the-art laser technology to weld and mark parts. We often develop and build our own manufacturing equipment. There are often no optimal production machines on the market to produce our special system components that meet our rigorous standards. This means that we can produce exactly those products our customers need. Electronic Products Our base modules are produced with state-of-the- art technology in small volume production runs in Germany and are marketed worldwide. These conditions make it possible to individually adapt the electronics to every engine type and set of requirements. Just plug it in and the engine runs. Replacement parts and components undergo extensive automatic test procedures and durability tests at MOTORTECH prior to their application. Even the smallest system component must satisfy the high quality requirements of our “Zero Failure Strategy”.


QUALITY

At MOTORTECH special emphasis is put on quality and safety, because neither you nor we can afford defects. That is why our entire company is DIN ISO 9001 certified. Additionally, MOTORTECH has passed the certification audit of the strictest automotive standard ISO TS 16949/2002 (similar to QS 9000) in 2004. In conjunction with ISO 9001, this certificate specifies Quality Management System requirements for development, production and any applicable assembly and maintenance of the specific products. Safety Management System "We live quality!" − That is also reflected in our high work safety standards. Thanks to our comprehensive Safety Management System, there have been no work-related accidents whatsoever at MOTORTECH in the last 20 years! Sales Partner All MOTORTECH subsidiaries and distributors are trained on a regular basis by experienced personnel to enable us to keep our comprehensive quality promise to even our most distant customers. MOTORTECH does not simply satisfy industry standards and requirements − we exceed them!

QUALITY IS WHEN THE CUSTOMER RETURNS, NOT THE PRODUCT!

Certified Quality

7


MAINTENANCE, REPAIR, ON-SITE SERVICE

Service Team

WHEN THINGS GET HOT OUR SERVICE TEAM IS AT YOUR SITE QUICKLY! 8

Take advantage of MOTORTECH’s many years of technical expertise in maintenance, repair and service. Our team participates in an ongoing training program and is familiar with the technical and maintenance procedures of all commonly used systems. Our technicians will perform know how repairs using the latest test instruments and tools, either at your company site or at our own workshops, even on products that we did not produce. Furthermore, to assure you with the best possible delivery anywhere in the world, MOTORTECH maintains an extensive inventory of parts and finished goods. Always At Your Site Regardless of which part of the globe we need to travel to, we know that the stakes are high, and therefore we also outperform the others. That is because we want everything to run smoothly at your site, everywhere and at anytime. This is entirely in keeping with our motto: Let us drop everything and work on your problem!


COMPLETE SERVICE

MOTORTECH’s customer-focused know-how can provide support and consultation for your new developments, project planning, and problem analyses. Moreover, we are ready to assist you with advice and service at anytime. Just give us a call! You can be sure that our team will find an optimal solution for your particular problem area. Warehousing To assure you the best possible delivery anywhere in the world, MOTORTECH maintains an extensive inventory of parts and finished goods. Optimized orderprocessing and select global logistics partners deliver even the smallest of parts via a direct route to where they are needed. Customer Training Shared knowledge is multiplied knowledge. Our extensive training program is specifically made for your technical and service employees. We can teach them about new developments in gas engine technology, and we invite all interested persons to discuss their experiences, either at our classrooms in Celle (Germany), New Orleans (USA) or at in-house training events at your company facilities.

MOTORTECH – WORKING FOR YOU, EVERYWHERE ALL THE TIME!

Consultation

9


10


IGNITION CONTROLLERS Years ago, MOTORTECH has made the decision to become a key player in design and manufacturing of ignition controls for the Global Industrial Gas Engine Business. A large engineering staff develops hard and software platforms. Test facilities were put in place to stress our hardware by temperature, heat and vibration. Cooperation with engine manufacturers, packagers and end users have led to specific designs and arrangements that will ensure the best performance of the rotating equipment. The new engine regulations and the growing biogas market, the developing mine gas industry and all other kinds of alternative fuel applications have raised strong demands for high energy, extended spark duration and very precised timing. Coupled to the demand for lean burn strategies, efficiency and equipment availability MOTORTECH was forced to look at high technology for the future.

11


IGNITION CONTROLLERS

NEW

MIC5

MOTORTECH IGNITION CONTROLLER

MIC5 Series Ignition Controllers The latest MOTORTECH development convinces with a future oriented electronical concept for more power and a significantly higher degree of efficiency. High ignition energy, accurate spark timing and diversified online diagnostics help to improve engine efficiency, spark plug life and availability of the equipment under the strictest emission regulations. The controller is fully customer configurable via Laptop. ∙ 20 ignition output channels ∙ Constant spark intensity via adjusted duration ∙ 500 mJ primary energy ∙ Ignition diagnostics (primary and secondary) ∙ Fault memory with trend data ∙ Integrated CANopen and Modbus RTU interface ∙ Easy access per USB port

MOST

MOTORTECH OUTPUT STAGE TECHNOLOGY

∙ Adjustable spark duration and intensity ∙ Constant spark intensity via adjusted duration

Technical Data & Features

• 1 Auxiliary Synchronization Output (ASO) which can support a detonation control system

• CAN Bus 2.0b interface (CANopen protocol J1939)

• 20 ignition outputs

(e.g. DetCon) or fuel injection pump controllers

• RS485 interface (Modbus RTU)

• 250 VDC primary voltage

• Ignition release input

• 500 mJ primary energy

• Go/NoGo output

• 0.1° crankshaft accuracy

• Overspeed shutdown function

• Triggered by 1, 2 or 3 pickups

• Access controlled

(magnetic, hall effect or inductive / configurable) • Multiple timing control via

Ignition Diagnostic

- Potentiometer

• Run time data

- Speed curve

• Alarm and error messages

- 0-20 mA analog input

• Data logging

- 0-10 V analog input

• Primary and secondary misfire detection

• Multiple energy control via MOST

• Cylinder individual high voltage calculation (kV)

(MOTORTECH Output Stage Technology) • Programmable firing order • 1 multipurpose output (GPO)

12

Interfaces

• 18 to 32 VDC supply voltage

• 6 LEDs provide a quick system state overview

• USB 1.1 interface Configuration • Fully configurable via Laptop with MICT software (see page 18)


D A

CAN

1

CAN

PowerView3

MOTORTECH ENGINE INFORMATION MONITOR

DetCon20

MOTORTECH DETONATION CONTROL SYSTEM

0-5V / 4-20 mA

6

C IGNITION SYSTEMS

8

3

4

X V

5

W

2

Y 7

B

Required Accessories

Accessories

1 MIC5 ignition controller

B Junction box

2 Output harness*

C AlphaRail – Wiring rail

3 Pickups* 4 Trigger pins & magnets

MOTORTECH IGNITION RAIL SYSTEM

* For detailed information about these products please contact your local distributor.

System Enhancement A DetCon20 – Detonation controller

alternative

D PowerView3 – HMI module

5 Trigger discs alternative

Z

AlphaRail

Description

- Trigger device

V Camshaft

6 Pickup leads*

W Crankshaft

7 1 ignition coil per cylinder*

X Engine

8 1 primary lead/high tension lead

Y Cylinder

per ignition coil*

Z Harness to connect ignition rail and junction box

Pickup Arrangements 3-pickup arrangement for 4-stroke engines

1-pickup arrangement for 4-stroke engines

2-pickup arrangement for 2-stroke engines

1) Reset

1) Camshaft

1) Reset

Magnetic pickup (holes, pins, teeth, screws)

Hall-Effect pickup (disc with magnets)

Magnetic pickup (holes, pins, teeth, screws)

2) Speed

2) Speed

Magnetic pickup (holes, pins, teeth, screws)

1) Camshaft

3) Camshaft

Inductive pickup (disc with pins, screws,

Hall-Effect pickup (magnets)

alternative

Magnetic pickup (holes, pins, teeth, screws)

slots / trigger device)

alternative

3) Camshaft Inductive pickup (pins, screws, slots)

13


IGNITION CONTROLLERS

MIC4

MOTORTECH IGNITION CONTROLLER

MIC4 Series Ignition Controllers The new economically attractive MOTORTECH development convinces with a future oriented electronical concept for more power and a significantly higher degree of efficiency. High ignition energy, accurate spark timing and diversified online diagnostics help to improve engine efficiency, spark plug life and availability of the equipment under the strictest emission regulations. The controller is fully customer configurable via Laptop. ∙ 16 ignition output channels ∙ Constant spark intensity via adjusted duration ∙ 300 mJ primary energy ∙ Ignition diagnostics (primary and secondary) ∙ Fault memory with trend data ∙ Integrated CANopen and Modbus RTU interface ∙ Easy access per USB port

MOST

MOTORTECH OUTPUT STAGE TECHNOLOGY

∙ Adjustable spark duration and intensity ∙ Constant spark intensity via adjusted duration

Technical Data & Features

• 1 Auxiliary Synchronization Output (ASO) which can support a detonation control system

• CAN Bus 2.0b interface (CANopen protocol J1939)

• 8 / 16 ignition outputs

(e.g. DetCon) or fuel injection pump controllers

• RS485 interface (Modbus RTU)

• 250 VDC primary voltage

• Ignition release input

• 300 mJ primary energy

• Go/NoGo output

• 0.1° crankshaft accuracy

• Overspeed shutdown function

• Triggered by 1, 2 or 3 pickups

• Access controlled

(magnetic, hall effect or inductive / configurable) • Multiple timing control via

Ignition Diagnostic

- Potentiometer

• Run time data

- Speed curve

• Alarm and error messages

- 0-20 mA analog input

• Data logging

- 0-10 V analog input

• Primary and secondary misfire detection

• Multiple energy control via MOST

• Cylinder individual high voltage calculation (kV)

(MOTORTECH Output Stage Technology) • Programmable firing order • 1 multipurpose output (GPO)

14

Interfaces

• 10 to 32 VDC supply voltage

• 6 LEDs provide a quick system state overview

• USB 1.1 interface Configuration • Fully configurable via Laptop with MICT software (see page 18) Hardware • Different housing styles available • Coil driver board equipped with 8 or 16 ignition outputs


D A

CAN

1

CAN

PowerView3

MOTORTECH ENGINE INFORMATION MONITOR

DetCon20

MOTORTECH DETONATION CONTROL SYSTEM

0-5V / 4-20 mA

6

C IGNITION SYSTEMS

8

3

4

X V

5

W

2

Y 7

B

Required Accessories

Accessories

1 MIC4 ignition controller

B Junction box

2 Output harness*

C AlphaRail – Wiring rail

3 Pickups* 4 Trigger pins & magnets

MOTORTECH IGNITION RAIL SYSTEM

* For detailed information about these products please contact your local distributor.

System Enhancement A DetCon20 – Detonation controller

alternative

D PowerView3 – HMI module

5 Trigger discs alternative

Z

AlphaRail

Description

- Trigger device

V Camshaft

6 Pickup leads*

W Crankshaft

7 1 ignition coil per cylinder*

X Engine

8 1 primary lead/high tension lead

Y Cylinder

per ignition coil*

Z Harness to connect ignition rail and junction box

Pickup Arrangements 3-pickup arrangement for 4-stroke engines

1-pickup arrangement for 4-stroke engines

2-pickup arrangement for 2-stroke engines

1) Reset

1) Camshaft

1) Reset

Magnetic pickup (holes, pins, teeth, screws)

Hall-Effect pickup (disc with magnets)

Magnetic pickup (holes, pins, teeth, screws)

2) Speed

2) Speed

Magnetic pickup (holes, pins, teeth, screws)

1) Camshaft

3) Camshaft

Inductive pickup (disc with pins, screws,

Hall-Effect pickup (magnets)

alternative

Magnetic pickup (holes, pins, teeth, screws)

slots / trigger device)

alternative

3) Camshaft Inductive pickup (pins, screws, slots)

15


IGNITION CONTROLLERS CONTROLLER Housing Style “LD” (Light Duty)

1

Standard configuration for applications in direct vicinity of gas engines in protected environment. The electronic system is integrated in a solid aluminum housing. • 17 pole military style connector (socket) for 8 and 16 ignition outputs • Plug connectors for input wiring • For ambient temperatures from -40°C to +60°C (-40°F to +140°F) • Protection rating IP54 • 10,43 in. x 9,45 in. x 3,74 in. / 265 x 240 x 95 mm (L x W x H) Housing Style “PM” (Panel Mount)

2

Device configuration for assembly in control panels. Equipped with plug connectors for simple integration into the wiring system. • Plug connectors for input and output wiring (8 and 16 ignition outputs) • For ambient temperatures from -20°C to +50°C (-4°F to +122°F) • Protection rating IP20 • 11,10 in. x 7,87 in. x 2,64 in. / 282 x 200 x 67 mm (L x W x H)

Housing Style “HD” (Heavy Duty)

3

When it‘s time to really get down to business. The Heavy Duty housing is 100 % reliable whether in hot desert sand or perpetual ice! • 17 pole military style connector (socket) for 8 and 16 ignition outputs • Plug connectors for input wiring • For ambient temperatures from -40°C to +70°C (-40°F to +158°F) • Integrated cooling element for optimal heat dissapation • Protection rating IP65 • 10,43 in. x 10,39 in. x 4,84 in. / 265 x 264 x 123 mm (L x W x H) back

MIC4 Series Ignition Controllers – Standard Versions – Light Duty – MIL Style Connectors

1

MOST

Connector

P/N

max. Outputs

Connector

66.00.410-8

8

66.00.410-16

16

Input

Analog Input

Output

Pickup Voltage

ASC

MIL Style

17 pole socket

programmable via MICT

not applicable

MIL Style

17 pole socket

programmable via MICT

not applicable

Equivalent to

MIC4 Series Ignition Controllers – Standard Versions – Panel Mount – Plug Connector Style

2

MOST

Connector

P/N

max. Outputs

Connector

66.00.400-8

8

Plug connector

Input

Analog Input

Output

Plug connector programmable via MICT

Pickup Voltage

ASC not applicable

66.00.400-16

16

Plug connector

Plug connector programmable via MICT

not applicable

Equivalent to

MIC4 Series Ignition Controllers – Standard Versions – Heavy Duty – MIL Style Connectors

3

16

MOST

Connector

P/N

max. Outputs

Connector

66.00.440-8

8

66.00.440-16

16

Input

Analog Input

Output

Pickup Voltage

ASC

MIL Style

17 pole socket

programmable via MICT

not applicable

MIL Style

17 pole socket

programmable via MICT

not applicable

Equivalent to


MIC4 Series Ignition Controllers – Shielded Output Harnesses1) for Light Duty and Heavy Duty Ignition Controllers P/N

Description

Connector

Length

95.40.217-L

Output harness for MIC4 Light Duty and Heavy Duty ignition controllers

17 pole pin, 180°

"L"= 15/25/50 ft.

1)

Equivalent to

Customer has to supply flex conduit.

MIC4 Series Ignition Controllers – Junction Box P/N

Description

06.05.067

Junction box

MIC4 Series Ignition Controllers – Special Version – Light Duty – MIL Style Connectors P/N

max. Outputs Connector

Pickup Voltage

ASC

Equivalent to

66.00.411-8

8

MIL Style

10 pole pin

10 pole socket

programmable via MICT

not applicable

MIC500 P/N 06.00.520

66.00.412-16

12

MIL Style

10 pole pin

14 pole socket

programmable via MICT

not applicable

MIC500 P/N 06.00.525

66.00.413-16

16

MIL Style

10 pole pin

19 pole socket

programmable via MICT

not applicable

MIC500 P/N 06.00.525

66.00.414-161)

16

MIL Style

35 pole socket

programmable via MICT

not applicable

MIC850 P/N 66.00.855-24/-24-D

not applicable

CAT® G3300 / G3400 series P/N 163-6164 / ALTRONIC® DISN P/N 791808-x / MIC500 P/N 06.00.513

not applicable

CAT® G3412 P/N 1636108 / ALTRONIC® DISN P/N 791812-x / 791816-x / MIC500 P/N 06.00.514

not applicable

WAUKESHA® CEC VGF & VHP series 6 & 8 cyl.2) / MIC500 P/N 06.00.515-6/-8

66.00.415-8

66.00.416-16

66.00.417-8

8

16

8

MIL Style

MIL Style

MIL Style

Input

6 pole pin

Analog Input

10 pole socket

6 pole pin

10 pole pin

7 pole pin

10 pole socket

Output

10 pole pin

19 pole pin

10 pole pin

programmable via MICT

programmable via MICT

programmable via MICT

19 pole pin

programmable via MICT

not applicable

WAUKESHA® CEC VGF & VHP series 12 & 16 Cyl.2) / MIC500 P/N 06.00.516/517

MIL Style

14/17 pole socket

programmable via MICT

not applicable

WOODWARD® IC9xx / MIC850 P/N 66.00.851-24/-24-D

12

MIL Style

14 pole socket

programmable via MICT

not applicable

MIC850 P/N 66.00.855-12/-12-D

66.00.421-16

16

MIL Style

6 pole socket

10 pole socket

19 pole socket

programmable via MICT

not applicable

MIC500 P/N 06.00.510

66.00.422-16

16

MIL Style

10 pole socket

-

19 pole socket

programmable via MICT

not applicable

MIC500 P/N 06.00.511

66.00.418-16

16

MIL Style

66.00.419-161)

16

66.00.420-16

1) 2)

7 pole pin

10 pole pin

IGNITION SYSTEMS

MOST

Connector

Maximum of 16 outputs available for this model. When replacing CEC controller by MIC4 use of DSM control is not possible.

MIC4 Series Ignition Controllers – PowerView3 HMI Module P/N

Description

06.05.085

PowerView3 HMI module

06.05.086-F

PowerView3 activation code for visualization of MIC4/MIC5 data1)

06.05.086-U

PowerView3 activation code for visualization of MIC4/MIC5 data2)

1) 2)

Activation code has to be ordered separately with each PowerView3 HMI module. Only available for upgrade of existing PowerView3 HMI module in the field.

17


IGNITION CONTROLLERS CONTROLLER

MICT

MOTORTECH INTEGRATED CONFIGURATION TOOL

MICT – Motortech Integrated Configuration Tool The MICT is the graphical user interface for all controllers of the MIC4 and MIC5 series. With a Laptop all configurations can be done and run time data of the engine can be checked and adjusted. • Language selectable • Microsoft Windows XP / Vista / 7 compatible • Included Data base offers engine information such as firing order, firing sequence, number of ignition coils per cylinder and typical number of teeth on flywheel for easy engine configuration • Print function of a given moment in the operation can be used for external problem analysis, etc. • Context sensitive online help • Different access levels to avoid accidental misconfigurations

Parameter Set The MIC4 offers two sets of parameters for the necessary inputs in order to calculate the engine ignition timing, which e.g. can be used for a two gas quality operation. Furthermore the parameter sets can be visualized graphically.

Sample Screens – Configuration

Parameter Set – Configuration Visualisation The graphic display of the parameter set A and B offers a fast, visual control of the configured values.

18

Sample Screen – Runtime Data

Parameter Set – Energy Settings For start phase and normal operation of the engine, durations at different high voltage levels and ignition spark intensity can be adjusted with the advanced energy settings.

Breakdown Voltage The MICT offers a lot of real time and detailed information about the status of each individual ignition output. Important data will be visually prepared, so that any irregularities will stand out easily. For example, secondary voltage will be displayed as bar graph, and the type of misfiring carries a warning light as symbol.


PowerView3

NEW

MOTORTECH ENGINE INFORMATION MONITOR

PowerView3 – HMI Module The operating data of MIC4 and MIC5 series ignition controllers will be completely visualized via HMI module (Human Machine Interface). The overview sheet shows the relevant information as engine speed, ignition timing and status of pickups, ignition outputs or active parameter set.

IGNITION SYSTEMS

The PowerView3 also allows justification of various ignition parameters such as ignition timing and energy. Functions as the selftest for error diagnostics can also be executed via HMI module. The control keys guarantee simple navigation through different display pages and menus. All in all the PowerView3 HMI module is also able to provide error diagnostics on-site without requiring a laptop! The PowerView3 is also available for data visualization of: • Detonation control (DetCon) • Temperature monitoring (available soon) Sample Screens

MIC Overview Screen shows the most important operating data of the connected ignition controller.

Ignition Misfiring and estimated secondary voltage of each individual cylinder will be shown.

Secondary Voltages Recording Visualization of secondary voltage trend data.

PowerView3 – HMI Module P/N

Description

06.05.085

PowerView3 – HMI module

06.05.086-F

PowerView3 – activation code for visualization of MIC4/MIC5 data1)

06.05.086-U

PowerView3 – activation code for visualization of MIC4/MIC5 data2)

1) 2)

Activation code has to be ordered separately with each PowerView3 HMI module. Only available for upgrade of existing PowerView3 HMI module in the field.

19


IGNITION CONTROLLERS

MIC850

MOTORTECH IGNITION CONTROLLER

MIC850 Series – Ignition Controllers High ignition energy, accurate spark timing and diversified online diagnostics help to improve engine efficiency, spark plug life and availability of the equipment under the strictest emission regulations. The controller is fully customer configurable via PC. Further fine tuning can be made by using the built in keyboard. Firmware updates can easily be made via implementing a SD-Card. An optional built in graphical display offers the customer an access to approx. 20 screens with online data. This includes the access to specific information as the cylinder individual high voltage (kV) reading and the primary and secondary misfire detection.

Technical data and features

Diagnostic

Hardware

• 24 ignition outputs

• Run time data

• Ignition controller can be equipped with one

• 18 to 30 VDC supply voltage

• Ignition timing and mapping

• 300 VDC primary voltage

• Alarm and error messages

• 180 mJ of primary energy • 0.1° crankshaft accuracy • Triggered by 1, 2 or 3 pickups (configurable) • Will fire accurately as low as 20 RPM (slow start application)

• Data logging • Pickup voltage • Input supply voltage • Timers

• Standard military style connectors • 14 pole (socket) for 12 outputs • 35 pole (socket) for 24 outputs • Optional: graphical display and keyboard built into front cover • No separate wiring required!

• Multiple timing control via

• Circuit board temperatures

- Potentiometer

• Primary and secondary misfiring detection

- Speed curve

• Cylinder individual high voltage reading (kV)

MICT – MOTORTECH Ignition Configuration Tool

- 4-20mA analog input

• etc.

• Language selectable

- 0-5V analog input • Multiple energy control via - Manual setting - Spark plug run time

• Windows PC based Interfaces

• Graphical user interface

• CAN Bus interface (CANOpen protocol)

• Easy engine configuration by library based

- Automatic control of spark duration (ASC)

• USB port

• 3 Multi purpose Outputs (GPO)

• SD-Card slot for firmware updates

• 2 Auxiliary Synchronization Outputs (ASO) which can support the DetCon20 detonation control system and fuel injection pump controllers • Overspeed shutdown function • Large built in LC-Display with keyboard (optional) in selectable languages • Access controlled

20

(12 outputs) or two (24 outputs) coil driver boards

preprogrammed information • programmed parameters are evaluated during input • 24 configurable alarms • Programmed timing and energy curves can be monitored • Print function of a given moment in the operation can be used for external problem analysis via E-Mail or any other data communication


MIC850 Series Ignition Controllers – HMI Module (optional)

Auto Spark Control Display and adjustment options of the requested spark plug firing duration directly at the HMImodule.

the selftest for error diagnostics via HMI module can also be executed. 8 control keys guarantee simple navigation through different display pages and menus. All in all, the MIC850 HMI module is also able to provide error diagnostics on-site without requiring a mobile PC!

Timing In this window you can adjust the reset position with the engine running. This is meant to compare the ignition timing of the display with the one measured by timing light.

Schedule A Overview of the ignition timing adjustment of configuration A. Here you can directly see whether ignition timing adjustment takes place via an analog input or via speed curve. The current ignition timing will be displayed under „Global Timing“.

IGNITION SYSTEMS

The operating data of MIC850 ignition control devices will be completely visualised via HMI module (Human-Machine Interface). The overview sheet shows the relevant information. The MIC850 HMI module allows justification of various ignition parameters such as ignition timing and energy. Functions as

MICT – MOTORTECH Integrated Calibration Tool Individual parameterization of those devices is explicitly described on various program pages. The parameters will already be evaluated during data input and errors will be optically emphasized.Complex parameter coherences are graphically displayed in order to avoid any errors and for easier understanding. A context depending support explains the individual parameters and their correlation. MICT operating time data

Engine Parameter The MICT refreshable engine library stores the engine data such as various manufacturers, series and types. It facilitates the system configuration and helps to avoid mistakes. Should you not find a certain engine in the list or the stated parameters do not correspond with your expectation, configuration can be set up as you like.

display reflects any operating time parameter and is perfectly qualified for diagnostic purposes and error correction. Printing function for a given moment of time of the running period does support problem analysis. The backed up connection-oriented communication protocol between MICT and ignition guarantees an accurate data transfer even under difficult conditions on-site.

Parameter Set The MIC850 offers two sets of parameters for the necessary inputs in order to calculate the engine ignition timing, which e.g. can be used for a two gas quality operation. A basic value is pre-defined and specified for each parameter set, stating whether and how the potentiometer adjustment and the pending analog input signals (4-20 mA and 0-5V) must be taken into consideration.

Pickups The MIC850 renders support for systems with 1-3 active or passive pickups. Pickup configuration can either be set up by manual input or via selection of preprogrammed data sets.

21


IGNITION CONTROLLERS

1

A

DetCon20

MOTORTECH DETONATION CONTROL SYSTEM

0-5V / 4-20 mA

6

C 8

3

4

X V

5

W

2

Y 7

B Z

AlphaRail

Required Accessories

Accessories

1 MIC850 ignition controller

B Junction box

2 Output harness*

C AlphaRail – Wiring rail

MOTORTECH IGNITION RAIL SYSTEM

* For detailed information about these products please contact your local distributor.

3 Pickups* 4 Trigger pins & magnets

System Enhancement A DetCon20 – Detonation controller

alternative

5 Trigger discs alternative

Description V Camshaft

- Trigger device 6 Pickup leads*

W Crankshaft

7 1 ignition coil per cylinder*

X Engine Y Cylinder

8 1 primary lead/high tension lead

Z Harness to connect ignition rail and junction box

per ignition coil*

Pickup Arrangements 3-pickup arrangement for 4-stroke engines

1-pickup arrangement for 4-stroke engines

2-pickup arrangement for 2-stroke engines

1) Reset

1) Camshaft

1) Reset

Magnetic pickup (holes, pins, teeth, screws)

Hall-Effect pickup (disc with magnets)

Magnetic pickup (holes, pins, teeth, screws)

2) Speed

2) Speed

Magnetic pickup (holes, pins, teeth, screws)

1) Camshaft

3) Camshaft

Inductive pickup (disc with pins, screws,

Hall-Effect pickup (magnets)

alternative

3) Camshaft Inductive pickup (pins, screws, slots)

22

alternative

slots / trigger device)

Magnetic pickup (holes, pins, teeth, screws)


MIC850 Series Ignition Controllers – Standard Versions – MIL Style Connectors P/N

max. Outputs

Connector

Output Connector

Pickup Voltage

66.00.855-12

12

MIL Style

14 pole socket

24 VDC

66.00.855-12-D

12

MIL Style

14 pole socket

24 VDC

66.00.855-24

24

MIL Style

35 pole socket

24 VDC

66.00.855-24-D

24

MIL Style

35 pole socket

24 VDC

HMI

MOST

Equivalent to

not applicable x

not applicable not applicable

x

not applicable

MIC850 Series Ignition Controllers – Shielded Output Harnesses1) for Ignition Controllers P/N 66.00.855-12/-12-D / 66.00.855-24/-24-D Description

Connector

Length

95.40.414-L

Output harness for P/N 66.00.855-12/-12-D

14 pole pin, 90°

"L"= 15/25/50 ft.

95.40.435-L

Output harness for P/N 66.00.855-24/-24-D

35 pole pin, 90°

"L"= 15/25/50 ft.

1)

Equivalent to

IGNITION SYSTEMS

P/N

Customer has to supply flex conduit.

MIC850 Series Ignition Controllers – Special Versions – MIL Style Connectors P/N

max. Outputs

Connector

Output Connector

Pickup Voltage

66.00.851-24

24

MIL Style

14/17 pole socket 24 VDC

66.00.851-24-D

24

MIL Style

14/17 pole socket 24 VDC

HMI

x

MOST

Equivalent to

not applicable

WOODWARD® IC9xx

not applicable

WOODWARD® IC9xx

MIC850 Series Ignition Controllers – Shielded Output Harnesses1) for Ignition Controllers P/N 66.00.851-24/-24-D P/N

Description

Connector

Length

95.40.414-L

Output harness for P/N 66.00.851-24/-24-D

14 pole pin, 90°

"L"= 15/25/50 ft.

95.40.417-L

Output harness for P/N 66.00.851-24/-24-D

17 pole pin, 90°

"L"= 15/25/50 ft.

1)

Equivalent to

Customer has to supply flex conduit.

MIC850 Series Ignition Controllers – Junction Box P/N

Description

06.05.067

Junction box

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

23


IGNITION CONTROLLERS

MIC500

MOTORTECH IGNITION CONTROLLER

MIC500 − The price attractive Ignition System The MIC500 is a 16 Bit microprocessor controlled ignition unit for small and midsize engines from 2 to 16 cylinders. The cost effective control unit is fully programmable by the operator via PC or handheld programming tool. The single pickup system is triggered off a camshaft disc (4-stroke engine) or a crankshaft mounted disc (2-stroke engine). Ignition timing accuracy is approx. 0.25 degrees crankshaft. The MIC500 is available in special versions to replace the • WAUKESHA® CEC® ignition box on the VGF and VHP series engines • CATERPILLAR® ignition box for G3300 and G3400 series engines • ALTRONIC® DISN® The unit is a physical drop in and only needs to be programmed for the application. For the advanced features see table below.

Technical data and features

Programming features

Display

• 10 to 30 VDC

• Overspeed shut off

A small external display can be ordered optionally.

• 300 VDC primary voltage

• Ignition timing via

Linked to RS232 port it will display the following

• 180 mJ ignition energy

- potentiometer

information:

• 2 to 16 ignition outputs

- 4-20 mA analog input

• Ignition timing

- Speed curve

• Engine speed

Interface

• Ignition energy

• RS232

• Analog input current • Alarm and error messages

24


RS232

1

A D

DetCon20

MOTORTECH DETONATION CONTROL SYSTEM

4-20 mA

3

C 8

IGNITION SYSTEMS

6

4

X 5

V

2

Y 7

B

AlphaRail

Required Accessories

Accessories

1 MIC500 ignition controller

B Junction box

2 Output harness*

C AlphaRail − Wiring rail

3 Pickup* 4 Trigger pins & magnets alternative

5 Trigger discs alternative

Trigger device

MOTORTECH IGNITION RAIL SYSTEM

* For detailed information about these products please contact your local distributor.

System Enhancement A DetCon20 − Detonation controller D RS232 Ignition display

Description V Camshaft

6 Pickup lead*

W Crankshaft

7 1 ignition coil per cylinder*

X Engine

8 1 primary lead/high tension lead

Y Cylinder

Z Harness to connect ignition rail and junction box

per ignition coil*

Z

Pickup Arrangements 1- pickup arrangement for 4-stroke engines

1- pickup arrangement for 2-stroke engines

1) Camshaft

1) Reset

Hall-Effect pickup (disc with magnets)

Magnetic pickup (holes, pins, teeth, screws)

alternative

Inductive pickup (disc with pins, screws, slots)

25


IGNITION CONTROLLERS MIC500 Series Ignition Controllers – Standard Versions – MIL Style Connectors Connector P/N

max. Outputs

Connector

Input

MOST

ASC

06.00.520

8

MIL Style

10 pole pin

Analog Input

10 pole socket 24 VDC

Output

Pickup Voltage

not applicable

not applicable

Equivalent to

06.00.525

12

MIL Style

10 pole pin

14 pole socket 24 VDC

not applicable

not applicable

06.00.530

16

MIL Style

10 pole pin

19 pole socket 24 VDC

not applicable

not applicable

MIC500 Series Ignition Controllers – Non-Shielded Input Harnesses for Ignition Controllers P/N 06.00.520/525/530 P/N

Description

Connector

Length

Pickup

06.02.501-160

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

inductive

06.02.505-160

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

magnetic

06.02.510-160

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

hall-effect

MIC500 Series Ignition Controllers – Non-Shielded Output Harnesses for Ignition Controllers P/N 06.00.520/525/530 P/N

Description

Connector

Length

Outputs

06.02.608-240

Output harness for P/N 06.00.520

10 pole pin, 180°

240 in.

8

06.02.612-240

Output harness for P/N 06.00.525

14 pole pin, 180°

240 in.

12

06.02.616-240

Output harness for P/N 06.00.530

19 pole pin, 180°

240 in.

16

MIC500 Series Ignition Controllers – Shielded Input Harnesses for Ignition Controllers P/N 06.00.520/525/530 P/N

Description

Connector

Wire Length

Conduit Length

Pickup

95.30.501-80

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

80 in.

inductive

95.30.505-80

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

80 in.

magnetic

95.30.510-80

Input harness for P/N 06.00.520/525/530

10 pole socket, 180°

160 in.

80 in.

hall-effect

MIC500 Series Ignition Controllers – Shielded Output Harnesses for Ignition Controllers P/N 06.00.520/525/530 P/N

Description

Connector

Wire Length

Conduit Length

Outputs

95.30.608-80

Output harness for P/N 06.00.520

10 pole pin, 180°

160 in.

80 in.

8

95.30.608-160

Output harness for P/N 06.00.520

10 pole pin, 180°

240 in.

160 in.

8

95.30.608-300

Output harness for P/N 06.00.520

10 pole pin, 180°

380 in.

300 in.

8

95.30.612-80

Output harness for P/N 06.00.525

14 pole pin, 180°

160 in.

80 in.

12

95.30.612-160

Output harness for P/N 06.00.525

14 pole pin, 180°

240 in.

160 in.

12

95.30.612-300

Output harness for P/N 06.00.525

14 pole pin, 180°

380 in.

300 in.

12

95.30.616-80

Output harness for P/N 06.00.530

19 pole pin, 180°

160 in.

80 in.

16

95.30.616-160

Output harness for P/N 06.00.530

19 pole pin, 180°

240 in.

160 in.

16

95.30.616-300

Output harness for P/N 06.00.530

19 pole pin, 180°

380 in.

300 in.

16

MIC500 Series Ignition Controllers – Special Versions – AMP Style Connectors Connector P/N

max. Outputs

Connector

06.00.508

8

AMP Style 23 pole pin

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

26

Input

Analog Input

Output

combined with input

combined with input

Pickup Voltage

MOST

ASC

Equivalent to

24 VDC

not applicable

not applicable

WOODWARD® IC100


MIC500 Series Ignition Controllers – Non-Shielded Input and Output Harnesses for Ignition Controller P/N 06.00.508 P/N

Description

Connector

Length

Pickup

06.01.001-160

Input and output harness for P/N 06.00.508

23 pole socket, 180°

160 in.

inductive

06.01.101-160

Input and output harness for P/N 06.00.508

23 pole socket, 180°

160 in.

magnetic

06.01.301-160

Input and output harness for P/N 06.00.508

23 pole socket, 180°

160 in.

hall-effect

MIC500 Series Ignition Controllers – Special Versions – MIL Style Connectors P/N

max. Outputs Connector

06.00.513

8

MIL Style

6 pole pin

10 pole socket

06.00.514

16

MIL Style

6 pole pin

06.00.515-61)

8

MIL Style

06.00.515-81)

8

06.00.5161) 06.00.5171) 1) 2)

Input

Analog Input

Output

Pickup Voltage

MOST

ASC

Equivalent to

10 pole pin

8 VDC

not applicable

not applicable

CAT® G3300 / G3400 series P/N 163-6164 / ALTRONIC® DISN P/N 791808-x

10 pole pin

19 pole pin

8 VDC

not applicable

not applicable

CAT® G3412 P/N 163-6108 ALTRONIC® DISN P/N 791812-x / 791816-x

7 pole pin

10 pole socket

10 pole pin

8 VDC

not applicable

not applicable

WAUKESHA® CEC VGF & VHP series 6 cyl.2)

MIL Style

7 pole pin

10 pole socket

10 pole pin

8 VDC

not applicable

not applicable

WAUKESHA® CEC VGF series 8 cyl.2)

16

MIL Style

7 pole pin

10 pole pin

19 pole pin

8 VDC

not applicable

not applicable

WAUKESHA® CEC VGF & VHP series 12 Cyl.2)

16

MIL Style

7 pole pin

10 pole pin

19 pole pin

8 VDC

not applicable

not applicable

WAUKESHA® CEC VGF & VHP series 16 Cyl.2)

IGNITION SYSTEMS

Connector

Ignition controller comes preprogrammed. When replacing CEC-controller by MIC500 use of DSM control is not possible.

MIC500 Series Ignition Controllers – Non-Shielded Input Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517 P/N

Description

Connector

Length

Pickup

06.02.011-80

Input harness for P/N 06.00.513/514

6 pole socket, 180°

80 in.

hall-effect

06.31.034-80

Input harness for P/N 06.00.515-6/515-8/516/517

7 pole socket, 180°

80 in.

hall-effect

MIC500 Series Ignition Controllers – Non-Shielded Analog Input Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517 P/N

Description

Connector

Length

06.71.047

Analog input harness for P/N 06.00.513/515-6/515-8

10 pole pin, 180°

160 in.

06.02.022-160

Analog input harness for P/N 06.00.514/516/517

10 pole socket, 180°

160 in.

MIC500 Series Ignition Controllers – Non-Shielded Output Harnesses for Ignition Controllers P/N 06.00.513/514/515-6/515-8/516/517 P/N

Description

Connector

Length

Outputs

06.31.035-160

Output harness for P/N 06.00.513/515-6/515-8

10 pole socket, 180°

160 in.

8

06.02.010-160

Output harness for P/N 06.00.514/516/517

19 pole socket, 180°

160 in.

16

MIC500 Series Ignition Controllers – RS232 Ignition Display P/N

Description

06.05.040A

RS232 ignition display for use with MIC500 series ignition controllers

MIC500 Series Ignition Controllers – Junction Box P/N

Description

06.05.067

Junction box

27


28


IGNITION COILS The demand for more specialized ignition coils has forced MOTORTECH to design and manufacture its own ignition coil product lines. From standard EPOXY molded ignition coils to shell type high energy coils and very special shielded and CSA certified versions, there is a wide variety of coils “Made in Europe“ available through the global product distribution network. Lean burn gas engines, high voltage measuring (MOST – MOTORTECH Output stage technology and ASC – Auto Spark Control) or indicating systems (spark reference system) – all require very special coil characteristics. Not only the design but also the manufacturing processes are important. MOTORTECH ignition coils today are manufactured in a semi automated process under vacuum and together with modern high speed winding equipment it is ensured that one coil is like the other. Designed for the toughest applications and built to last.

29


IGNITION COILS

MotCoils

MOTORTECH IGNITION COILS

Non CSA Certified Ignition Coils Standard Versions – New MOTORTECH Style Ignition coils are becoming more and more important in modern, state of the art ignition systems. MOTORTECH made it its profession to develop a series of new high performance ignition coils produced in the European facilities and specially designed for use with newest technologies of MOTORTECH ignitions controllers: • Applicable for MOST – MOTORTECH Output Stage Technology of MOTORTECH MIC4 and MIC5 ignition controllers • Applicable for ASC – Automatic Spark Control of MOTORTECH MIC850 ignition controllers • Ideally suited for ignition of alternative fuels such as biogas Non CSA Certified Ignition Coils – Standard Versions – New MOTORTECH Style P/N

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

06.50.100

Supersedes

red

#10-32 UNF studs

M6

(-) ground

x

x

06.50.102

red

#10-32 UNF studs

female

(-) ground

x

x

06.50.104

blue

#10-32 UNF studs

M6

(-) ground

not applicable

x

06.50.105

blue

#10-32 UNF studs

female

(-) ground

not applicable

x

MOST

Equivalent to

100

MOST CDI

∙ Adjustable spark duration and intensity

variable

50 variable

MIC4/MIC5 with MOST *  – MOTORTECH Output Stage Technology

Secondary Current [mA]

MOTORTECH OUTPUT STAGE TECHNOLOGY

∙ Constant spark intensity via adjusted duration * Patent pending

100

200

300

400

500

spark duration

30

600

700

800


Non CSA Certified Ignition Coils – Standard Versions – MOTORTECH Style A large amount of different EPOXY ignition coils with different ignition characteristics are available for non-shielded applications. A variety of short and long duration coils with female, male (SAE) or even screw type vspark plug lead termination allows the operator to pick the best for his application. MOTORTECH ignition coils are made to the highest quality standards. A constant improvement of the manufacturing process has led to a product line that is unique when it comes to life time and repeatability of high voltage pattern and performance.

P/N

Supersedes

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.001

consult factory

black

#10-32 UNF studs

female

(-) ground

not applicable

not applicable

PPT2477P

06.50.002

06.50.001

black

#10-32 UNF studs

female

(-) ground

not applicable

not applicable

PPT2477L

06.50.003

06.50.007

black

#10-32 UNF studs

M6

(-) ground

x

not applicable

black

#10-32 UNF studs

M6

(-) ground

not applicable

not applicable

06.50.060

IGNITION SYSTEMS

Non CSA Certified Ignition Coils – Standard Versions – MOTORTECH Style

Non CSA Certified Ignition Coils – Standard Versions – ALTRONIC® Style For existing installations with ALTRONIC® ignition coils, MOTORTECH offers a series of replacement products. The ignition coils are designed to have the same characteristics in regards of standard and extended duration as well as the electrical characteristics to function with the ALTRONIC® patented “Spark Reference“ high voltage indication system. See chart below for cross reference numbers. Non CSA Certified Ignition Coils – Standard Versions – ALTRONIC® Style P/N

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.053

Supersedes

black

#10-32 UNF studs

female

(+) ground

not applicable

not applicable

291001

06.50.054

red

#10-32 UNF studs

female

(-) ground

not applicable

not applicable

591010

06.50.055

blue

#10-32 UNF studs

female

(-) ground

not applicable

not applicable

501061

Non CSA Certified Ignition Coils – Standard Versions – ALTRONIC® Style Thousands of smaller gas engines (including CUMMINS®) are equipped with a low cost ignition coil that is very limited to its high voltage output capability. MOTORTECH has taken up the customer complaints from the field and designed a new ignition coil that is nearly the same in physical dimensions, but eliminates all the weak aspects of the competitor‘s design. Non CSA Certified Ignition Coils – Standard Versions – ALTRONIC® Style P/N 06.50.103

Supersedes

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

black

#10-32 UNF studs

male

(-) ground

not applicable

not applicable

591040

31


IGNITION COILS

MotCoils

MOTORTECH IGNITION COILS

The rising demand for specialized ignition coils has led MOTORTECH to the decision to design a new series of ignition coils, specially made for use with CATERPILLAR® gas engines. • Compatible with original ignition coils • Support CATERPILLAR® ignition systems • Made in Europe Non CSA Certified Ignition Coils – Standard Versions – For CATERPILLAR® G3400 & G3500 Series Gas Engines (Non CSA Applications) P/N

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.141

white

DEUTSCH® connector

female

(-) ground

not applicable

not applicable

232-6348, 165-1591, 131-3277, 129-8802, 108-0615

06.50.1451)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

232-6348, 165-1591, 131-3277, 129-8802, 108-0615

06.50.143

white

DEUTSCH® connector

female

(-) ground

not applicable

not applicable

232-6352, 213-7443

06.50.147

white

DEUTSCH connector

female

(-) ground

not applicable

x

232-6352, 213-7443

06.50.151

white

DEUTSCH® connector

female

(-) ground

not applicable

not applicable

232-6346, 165-1589, 124-0749

06.50.155

white

DEUTSCH connector

female

(-) ground

not applicable

x

232-6346, 165-1589, 124-0749

06.50.153

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

232-6350

06.50.1571)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

232-6350

1)

1)

1)

®

® ®

Ignition coils only for use with MIC4 and MIC5 ignition controllers.

Non CSA Certified Ignition Coils – Standard Versions – For CATERPILLAR® G3400 & G3500 Series Gas Engines (CSA Applications) P/N

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.142

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

232-6349, 165-1592, 122-8070

06.50.1461)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

232-6349, 165-1592, 122-8070

06.50.144

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

232-6353, 213-7444

06.50.1481)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

232-6353, 213-7444

06.50.152

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

232-6347, 165-1590

06.50.1561)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

232-6347, 165-1590

06.50.154

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

259-2078

06.50.1581)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

259-2078

1)

32

®

®

®

®

Ignition coils only for use with MIC4 and MIC5 ignition controllers.


Non CSA Certified Ignition Coils Standard Versions – For CATERPILLAR® G3520C & G3600 Series & Perkins 4016-E61TRS Gas Engines P/N

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.161

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

310-3180

06.50.1621)

white

DEUTSCH® connector

female

(-) ground

not applicable

x

310-3180

06.50.111

white

DEUTSCH connector

female

(-) ground

not applicable

not applicable

837/9, 10000-06176

®

Ignition coils only for use with MIC4 and MIC5 ignition controllers.

IGNITION SYSTEMS

1)

®

Non CSA Certified Ignition Coils – Accessories – Repair Kits for MOTORTECH Ignition Coils1) – For CATERPILLAR® G3400 and G3500 Series Gas Engines P/N

Description

Fits Ignition Coil P/N

Extension Length

Extension Diameter

06.80.741

Ignition coil repair kit

06.50.141/06.50.145

95 mm

30 mm

06.80.742

Ignition coil repair kit

06.50.142/06.50.146

97 mm

30 mm

06.80.743

Ignition coil repair kit

06.50.143/06.50.147

107 mm

30 mm

06.80.744

Ignition coil repair kit

06.50.144/06.50.148

109 mm

30 mm

06.80.751

Ignition coil repair kit

06.50.151/06.50.155

118 mm

30 mm

06.80.752

Ignition coil repair kit

06.50.152/06.50.156

105 mm

30 mm

06.80.753

Ignition coil repair kit

06.50.153/06.50.157

112 mm

30 mm

06.80.754

Ignition coil repair kit

06.50.154/06.50.158

105 mm

30 mm

1)

For suitable repair kits for CATERPILLAR® ignition coils, please refer to page 87.

Non CSA Certified Ignition Coils – Accessories – Spark Plug Extension for MOTORTECH/CATERPILLAR® Ignition Coil – For CATERPILLAR® G3520C and G3600 Series Gas Engines1) P/N

Description

Resistance

Fits Ignition Coil P/N

Extension Length

Extension Diameter

Equivalent to

06.80.459H

Spark plug extension

0 kΩ

06.50.161/06.50.162

248 mm

26 mm

283-5271, 308-1380

1)

Supersedes spark plug extensions P/N 06.80.375H and 06.80.446H.

Non CSA Certified Ignition Coils Ignition Coil Conversion Kits for CUMMINS® Gas Engines P/N

Description

75.30.143

Ignition coil conversion kit for CUMMINS® QSK60G Includes flange ignition coil with diagnostic interface, adaptor flange with fastening material, spark plug extension

75.30.144

Ignition coil conversion kit for CUMMINS® QSV81G/QSV91G Includes flange ignition coil with diagnostic interface, adaptor flange with fastening material, spark plug extension

1)

For primary lead options, please refer to page 79, 81.

NEW 33


IGNITION COILS Non CSA Certified Ignition Coils – Accessories Different ignition coil styles require different boots to seal the primary or secondary terminals. MOTORTECH boots are all made from highest grade of silicone (482 °F / 250 °C).

The boots will remain soft and flexible over a long time and protect the operator from touching any low or high voltage terminations. The boots also ensure that the critical areas stay clean and dry even in the worst environment.

Non CSA Certified Ignition Coils – Accessories – Boots for MOTORTECH Ignition Coils Ignition Coil Side P/N

Outlet

Primary

06.80.037

1

x

x

06.84.082

2

x

x

06.84.021

3

x

x

06.80.005

4

x

06.84.083

5

x

06.80.006

6

x

x

06.84.006

7

x

x

1)

Secondary

90 °

Ignition Coil 06.50. ...

Figure

180 °

003

053

054

055

060

x

x

x

x

x

102

x

x

103

104

105

x

x

x

1)

x

x

x

x

x

x

x

x x

x

x x

x

x

x

x

6

7

Two boots needed for each ignition coil.

1

4

3

2

5

Non CSA Certified Ignition Coils – Accessories – Boots for ALTRONIC® Ignition Coils Outlet P/N

Figure

Description

06.80.037

1

Boot, primary side

06.80.036

2

Boot, primary side

90 °

180 °

x

Ignition Coil 291001 / 591010 / 501061

x

1

34

100

291001 / 591010 / 501061

2


Non CSA Certified Ignition Coils – Accessories – Secondary Connections Ignition Coil 06.50. ... Figure

Description

003

053

054

055

x

x

x

060

06.80.030

1

Coil terminal, 180°, 1 kΩ resistor, requires P/N 06.80.126

06.80.091

2

Coil terminal, 180°, requires P/N 06.80.126

06.80.108

3

Crimp terminal base

x

x

06.80.116

4

Crimp terminal, 90°, requires P/N 06.80.108

x

x

06.80.116-180

5

Crimp terminal, 180°, requires P/N 06.80.108

06.80.126

6

Crimp terminal base

06.84.024

7

Coil terminal, 90°, including terminal P/N 02.85.920

06.84.025

8

Coil terminal, 180°, including terminal P/N 02.85.920

22.80.009

9

Coil terminal, 90°, 1 kΩ resistor, requires P/N 06.80.126

1)

100

102

103

104

x

x1)

x

x

x1) x

x

x x

x

x

105

x

x1)

x

x

x1)

x

x x x

x

IGNITION SYSTEMS

P/N

When using SAE contact pin P/N 06.51.223.

1

3

2

4

6

5

7

8

9

Non CSA Certified Ignition Coils – Accessories Ignition Coil 06.50. ... P/N

Figure

Description

003

053

054

055

060

100

06.51.223

1

SAE contact pin

x

06.90.2641)

2

Accessory kit incl. fastening screws and nuts

x

02.85.1004

3

SAE spreading adaptor

1)

x

x

x

102

103

104

105

x x

x

x

x x

Comes with each New MOTORTECH Style ignition coil.

1

2

3

35


IGNITION COILS

CSA Certified Ignition Coils – Flange Versions MOTORTECH makes available the BLUE and RED flanged ignition coil as a replacement for the existing products sold by the engine manufacturers.

CSA Certified Ignition Coils – Flange Versions P/N

36

Supersedes

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

Equivalent to

06.50.034

red

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

591012/ 69694F

06.50.035

blue

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

591018/ (A)69694G

95.09.100

silver

MIL Style 3 pole pin

female

(-) ground

x

x

95.09.133

silver

MIL Style 3 pole pin

female

(+) ground

not applicable

not applicable

95.09.134

silver

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

591012/ 69694F

95.09.135

silver

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

591018/ (A)69694G


NEW CSA Certified Ignition Coils – Flange Versions with Diagnostic Interface MOTORTECH flanged ignition coils with diagnostic interface are designed for operators who want to monitor their high voltage traces in a simple way. Measuring high voltage peak (kV) and spark duration (μsec) of all cylinders of an engine with flange coils regularly, will allow easy maintenance of the equipment. With a Scope Meter or the new MOTORTECH SparkView the operator can receive real time data.

CSA Certified Ignition Coils – Flange Versions with Diagnostic Interface Color

Primary Termination

HV Termination

Polarity

ASC

MOST

95.09.150

silver

MIL Style 3 pole pin

female

(-) ground

x

x

95.09.153

silver

MIL Style 3 pole pin

female

(+) ground

not applicable

not applicable

95.09.1541)

silver

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

95.09.1552)

silver

MIL Style 3 pole pin

female

(-) ground

not applicable

not applicable

95.09.1563)

silver

MIL Style 3 pole pin

female

(-) ground

x

x

1) 2) 3)

Supersedes

Equivalent to

IGNITION SYSTEMS

P/N

Same coil winding as P/N 06.50.034 / 95.09.134, but with diagnostic interface. Thus also equivalent to P/N 591012 and 69694F. Same coil winding as P/N 06.50.035 / 95.09.135, but with diagnostic interface. Thus also equivalent to P/N 591018 and 69694G / A69694G. Use of ignition coil only possible, if conversion kits P/N 75.30.143 or 75.30.144 previously were used.

Additional BNC connector for high voltage measurement

SparkView

MOTORTECH HIGH VOLTAGE INDICATOR

NEW

The SparkView is a new handheld device developed by MOTORTECH that can monitor the high voltage required by the spark plug while the engine is running. With a measuring clamp or cable and the display for up to 40 kV, it is easy to determine the condition of the spark plugs and the time at which they need to be replaced. See page 100.

37


IGNITION COILS

SHIELDED CSA Certified Ignition Coils – Externally Mounted Shielded – externally mounted – ignition coils are encapsulated in a steel housing with welded lids. A bracket is used to install the coils on a wiring rail or directly on the engine. This type of ignition coil is connected to the shielded spark plug by a braided high tension lead with a 3/4 in. or 1 in. termination. Primary voltage connection is made by a 2 or 3 pole military style screw connector. All parts meet the CSA Class I, Division 2, Group C/D.

CSA Certified Ignition Coils – Externally Mounted P/N

Supersedes

95.09.005

38

Color

Primary Termination

HV Termination

Polarity

ASC

MOST

silver

MIL Style 3 pole pin

3/4-20 UNEF

(-) ground

x

x

Equivalent to

95.09.053

95.09.001

silver

MIL Style 3 pole pin

3/4-20 UNEF

(+) ground

not applicable

not applicable

291001-S/ 10-382080

95.09.054

95.09.003

silver

MIL Style 3 pole pin

3/4-20 UNEF

(-) ground

not applicable

not applicable

591010-S

95.09.055

95.09.002

silver

MIL Style 3 pole pin

3/4-20 UNEF

(-) ground

not applicable

not applicable

501061-S

95.08.003

95.08.001/ 95.08.002

silver

MIL Style 2 pole pin

1-20 UNEF

(-) ground

x

x

PPT2477AD/ ADL/ 10-382040-1


CSA Certified Ignition Coils – Integral Standard Versions Integral ignition coils are designed to be mounted directly on a dual threaded spark plug. No spark plug lead is required. These ignition coils are mostly used in hazardous applications. Coil life is effected by the temperature that is transferred into the coil by the spark plug. On occasions where the spark plug leaks high combustion pressure enters the ignition coil and forces the base coil to blow out of it`s housing. MOTORTECH has designed a top cover safety ring that will not allow this to happen. Also, the actual coil is located in upper end of the coil housing and is effected less by the temperature (cooler location).

HV Termination P/N

Supersedes

Color

Length

Primary Termination

Outer Thread Inner Thread

Polarity

ASC

13/16-20 UNEF

MOST

Equivalent to

(-) ground

not applicable not applicable 591007

13/16-20 UNEF

(+) ground not applicable not applicable 591008

95.09.030

95.09.010

silver

5.82 in.

MIL Style 3 pole pin

1-20 UNEF

95.09.031

95.09.011

silver

5.82 in.

MIL Style 3 pole pin

1-20 UNEF

95.09.040-6

95.09.012-6

silver

5.78 in.

MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable 591011A

95.09.040-10

95.09.012-10 silver

10.15 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable

95.09.040-12

95.09.012-12 silver

12.15 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable

IGNITION SYSTEMS

CSA Certified Ignition Coils – Integral Standard Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible

591011B/ 591011C

CSA Certified Ignition Coils – Integral Standard Versions – 2 Pole Primary Connector Arrangement HV Termination P/N

Supersedes

Color

Length

Primary Termination

Polarity

ASC

13/16-20 UNEF

(-) ground

not applicable not applicable PPT2477AA6

Outer Thread Inner Thread

MOST

Equivalent to

95.08.030-6

95.08.010-6

silver

5.78 in.

1-20 MIL Style 2 pole pin UNEF

95.08.030-8

95.08.010-8

silver

8.15 in.

MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable PPT2477AA8

95.08.030-10

95.08.010-10 silver

10.15 in. MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable PPT2477AA10

95.08.030-12

95.08.010-12 silver

12.15 in. MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable PPT2477AA12

NEW

HEX for easy installation/deinstallation

39


IGNITION COILS

CSA Certified Ignition Coils – Integral High Energy Versions Integral ignition coils are encapsulated in a steel housing to meet CSA requirements. For slow and mid speed engines it is favorable to have more spark energy available. MOTORTECH has a full line of these special coils with 3-pin primary connector for use with MOTORTECH MIC500, MIC850, MIC4 and MIC5 series ignition controllers (includes support of ASC and MOST) available in different length to meet the application and spark plug requirement. Safety First!

CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement HV Termination P/N

Supersedes

Color

Length

Primary Termination Outer Thread Inner Thread

Polarity

ASC

MOST

95.09.050-6

95.09.013-6

silver

5.50 in.

MIL Style 3 pole pin 1-20 UNEF

13/16-20 UNEF

(-) ground

x

x

silver

11.00 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

x

x

95.09.060-12

95.09.013-12/ silver 95.09.021-12

12.00 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

x

x

95.09.060-14.5

95.09.021-14.5 silver

14.50 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

x

x

95.09.060-111)

1)

Equivalent to

For use on WAUKESHA® VHP-GSI with rain shield.

CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible For existing installations with ALTRONIC® ignition controllers, MOTORTECH offers a special series of high energy integral ignition coils with 3-pin primary connector. The ignition coils

are designed to have the electrical characteristics to function with the ALTRONIC® patented “Spark Reference“ high voltage indication system.

CSA Certified Ignition Coils – Integral High Energy Versions – 3 Pole Primary Connector Arrangement – ALTRONIC® Compatible HV Termination P/N

Supersedes

Color

Primary Termination

Polarity

ASC

13/16-20 UNEF

(-) ground

not applicable not applicable

silver

5.50 in.

95.09.061-111)

silver

11.00 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable

95.09.061-12

silver

12.00 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable

95.09.061-14.5

silver

14.50 in. MIL Style 3 pole pin

13/16-20 UNEF

(-) ground

not applicable not applicable

For use on WAUKESHA® VHP-GSI with rain shield.

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

MIL Style 3 pole pin 1-20 UNEF

MOST

95.09.051-6

1)

40

Length

Outer Thread Inner Thread

Equivalent to


CSA Certified Ignition Coils – Integral High Energy Versions – 2 Pole Primary Connector Arrangement MOTORTECH high energy integral ignition coils are also available with 2-pole primary connector for use with

MOTORTECH MIC500, MIC850, MIC4 and MIC5 (includes support of ASC and MOST feature) series ignition controllers. HV Termination

P/N

Supersedes

Color

Length

Primary Termination Outer Thread Inner Thread

Polarity

ASC

MOST

Equivalent to

95.08.040-6

95.08.020-6

silver

5.50 in.

MIL Style 2 pole pin 1-20 UNEF

13/16-20 UNEF

(-) ground

x

x

PPT2477AB6

silver

11.00 in. MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

x

x

95.08.050-12

95.08.020-12/ silver 95.08.021-12

12.00 in. MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

x

x

95.08.050-14.5

95.08.021-14.5 silver

14.50 in. MIL Style 2 pole pin

13/16-20 UNEF

(-) ground

x

x

95.08.050-111)

For use on WAUKESHA® VHP-GSI with rain shield.

NEW

IGNITION SYSTEMS

1)

PPT2477AB12

HEX for easy installation/deinstallation

CSA Certified Ignition Coils – Integral Standard and High Energy Versions – Accessories – Teflon Grommets P/N

Description

Integral Ignition Coil Type

Engine Make and Model

06.84.060

Teflon grommet

standard / high energy

CATERPILLAR® G3300 series

06.84.061

Teflon grommet

standard / high energy

CATERPILLAR® G3400 series

06.84.069

Teflon grommet

standard / high energy

WAUKESHA® VHP and VGF series

41


42


TRIGGERING Any Electronic Ignition System requires signals from the Crankshaft and/or from the Camshaft. These events are sensed by teeth, pins or holes on the flywheel and magnets or holes on the camshaft. These events are being picked up by the appropriate pickups • Magnetic Pickup (MPU) • Hall Effect Pickup • Inductive Pickup The generated signal will be used by the ignition controller to calculate the position of the camshaft, crankshaft as well as the speed of the rotating equipment.

43


TRIGGERING

NON-SHIELDE

D

Pickups A wide range of special ignition pickups are available from MOTORTECH to allow service companies and operators to select what they need to do a professional installation.

High Quality, designed to meet the application and temperature requirements, MOTORTECH Pickups will last and ensure you are not experiencing any unexpected shut downs.

Non CSA Certified Magnetic Pickups – Thread Size 5/8-18 UNF P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

66.60.001-125

1

06.60.101

5/8-18 UNF

1.25 in.

Holes, Pins, Teeth, Screws

66.60.001-175

1

06.60.105

5/8-18 UNF

1.75 in.

Holes, Pins, Teeth, Screws

691118-1

66.60.001-250

1

06.60.102

5/8-18 UNF

2.50 in.

Holes, Pins, Teeth, Screws

691118-2

66.60.001-400

1

06.60.103

5/8-18 UNF

4.00 in.

Holes, Pins, Teeth, Screws

691118-4

66.60.001-600

1

06.60.107

5/8-18 UNF

6.00 in.

Holes, Pins, Teeth, Screws

691118-6

NEW Non CSA Certified Magnetic Pickups – Thread Size 3/4-16 UNF P/N 66.60.011-180

Figure

Supersedes

2

Thread Size

Thread Length

Trigger

Equivalent to

3/4-16 UNF

1.80 in.

Holes, Pins, Teeth, Screws

791015-1

Non CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active Low P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

66.60.002-175

3

06.60.020

5/8-18 UNF

1.75 in.

Magnets

791050-1

66.60.002-250

3

06.60.021

5/8-18 UNF

2.50 in.

Magnets

791050-2

66.60.002-450

3

06.60.022

5/8-18 UNF

4.50 in.

Magnets

791050-4

66.60.002-600

3

5/8-18 UNF

6.00 in.

Magnets

791050-6

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

44


Non CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active High1) P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

66.60.012-175

3

5/8 in.-18UNF

1.75 in.

Magnets

591014-1

66.60.012-250

3

5/8 in.-18UNF

2.50 in.

Magnets

591014-2

66.60.012-450

3

5/8 in.-18UNF

4.50 in.

Magnets

591014-4

66.60.012-600

3

5/8 in.-18UNF

6.00 in.

Magnets

591014-6

1)

For use with ALTRONIC CPU90 / CPU95 / CPU2000 ignition controllers. ®

Non CSA Certified Inductive Pickups – Thread Size M12 x 1 P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

4

06.60.027 / 06.60.042 M12x1

60 mm

Pins, Screws, Slots

66.60.003-100

4

06.60.023 / 06.60.040 M12x1

100 mm

Pins, Screws, Slots

IGNITION SYSTEMS

66.60.003-60

Legend slots

1

magnets

pins

2

teeth

3

screws

holes

4 Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

45


TRIGGERING SHIELDED CSA Certified Magnetic Pickups – Thread Size 5/8-18 UNF P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

95.70.001-125

1

5/8-18 UNF

1.25 in.

Holes, Pins, Teeth, Screws

95.70.001-175

1

5/8-18 UNF

1.75 in.

Holes, Pins, Teeth, Screws

691118-1

95.70.001-250

1

5/8-18 UNF

2.50 in.

Holes, Pins, Teeth, Screws

691118-2

95.70.001-400

1

5/8-18 UNF

4.00 in.

Holes, Pins, Teeth, Screws

691118-4

95.70.001-600

1

5/8-18 UNF

6.00 in.

Holes, Pins, Teeth, Screws

691118-6

CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active Low P/N

Thread Size

Thread Length

Trigger

Equivalent to

95.70.002-175

Figure

2

Supersedes

5/8-18 UNF

1.75 in.

Magnets

791050-1

95.70.002-250

2

5/8-18 UNF

2.50 in.

Magnets

791050-2

95.70.002-450

2

5/8-18 UNF

4.50 in.

Magnets

791050-4

95.70.002-600

2

5/8-18 UNF

6.00 in.

Magnets

791050-6

CSA Certified Hall Effect Pickups – Thread Size 5/8-18 UNF – Active High1) P/N

Figure

Supersedes

Thread Size

Thread Length

Trigger

Equivalent to

95.70.012-175

2

5/8-18 UNF

1.75 in.

Magnets

591014-1

95.70.012-250

2

5/8-18 UNF

2.50 in.

Magnets

591014-2

95.70.012-450

2

5/8-18 UNF

4.50 in.

Magnets

591014-4

95.70.012-600

2

5/8-18 UNF

6.00 in.

Magnets

591014-6

Thread Size

Thread Length

Trigger

Equivalent to

1)

For use with ALTRONIC CPU90 / CPU95 / CPU2000 ignition controllers. ®

CSA Certified Inductive Pickups – Thread Size M12 x 1 P/N

Figure

Supersedes

95.70.003-60

3

M12x1

60 mm

Pins, Screws, Slots

95.70.003-100

3

M12x1

100 mm

Pins, Screws, Slots

Outer Thread

Inner Thread

Length

5/8-18 UNF

M12 x 1

40 mm

Accessories – Thread Adaptor P/N

Figure

06.60.908

Supersedes

4

Equivalent to

Legend slots

magnets

1 Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

46

pins

2

teeth

screws

3

holes

4


Pickup Leads The reliability of an electronic ignition system comes with its accessories. Every Pickup needs a lead to connect to the ignition controller and ensure that the signal is transmitted without any malfunctions. MOTORTECH offers high grade pickup leads that are all shielded against RFI interference. Preferably

a 90° Connector is used as it routes the wire downwards and puts less side load stress on the pickup. There are two lines of pickup leads available • NON shielded standard versions • Braided versions which meet CSA Class I; Division2; Group C

Non CSA Certified Magnetic Pickup Leads P/N

Figure

06.71.001-L

Supersedes

1

Connector

Length

2 pole socket, 90°

"L"= 5/15/25/50 ft.

Equivalent to

Connector

Length

3 pole socket, 90°

"L"= 5/15/25/50 ft.

Connector

Length

4 pole socket, 90°

400 in.

Non CSA Certified Hall-Effect Pickup Leads Figure

06.71.002-L

Supersedes

2

Equivalent to

IGNITION SYSTEMS

P/N

Non CSA Certified Inductive Pickup Leads P/N

Figure

06.71.007

Supersedes

3

Equivalent to

CSA Certified Magnetic Pickup Leads P/N

Figure

Supersedes

Connector

Braid Length1)

Adaptor to Outlet Box

Equivalent to

95.60.010-L

4

2 pole socket, 180°

"L"= 12/24/48/72/96 in.

1/2-14 NPT

593048-L

95.60.020-L

4

2 pole socket, 90°

"L"= 12/24/48/72/96 in.

1/2-14 NPT

593054-L

Connector

Braid Length 1)

Adaptor to Outlet Box

Equivalent to

95.60.030-L

5

3 pole socket, 180°

"L"= 12/24/48/72/96 in.

1/2-14 NPT

593052-L

95.60.040-L

5

3 pole socket, 90°

"L"= 12/24/48/72/96 in.

1/2-14 NPT

593057-L

Connector

Lead Length

Adaptor to Outlet Box

Equivalent to

4 pole socket, 90°

400 in.

M12 x 1.5

1)

Other lengths available on request.

CSA Certified Hall-Effect Pickup Leads P/N

1)

Figure

Supersedes

Other lengths available on request.

CSA Certified Inductive Pickup Leads P/N

Figure

95.60.050-400

1

Supersedes

6

2

3

4

5

6

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

47


TRIGGERING

TriDev

A = Gear Ratio 1

= 1:1

2

= 2:1

Trigger Devices

3

= 3:1

For applications where a trigger disc can not be mounted due to difficult camshaft access, a trigger device is available. This unit is mounted at the location where the ignition magneto was installed. A built in trigger disc will sense the events necessary to trigger the ignition control unit. One (1) to a maximum of eight (8) trigger events are possible.

6

= 1.5:1

This covers most of the engines up to 16 cylinders operated in the field today. A proper mounting flange can be selected from a variety of flange designs typically used in the industry. Heavy duty bearings and a smart product design offer a long operating life cycle. For specification help, call your nearest distributor and let him know which Magneto Part Number is installed today.

MOTORTECH TRIGGERING DEVICES

B = Rotation = CCW (counterclockwise)

1

= 1 only

- Pin

2

= 2+1

- Pin

3

= 3+1

- Pin

4

= 4+1

- Pin

6

= 6+1

- Pin

8

= 8+1

- Pin

9

= 1 only

- Magnet

D = Flange

Before trying to specify the correct Trigger Device, please make available the Ignition Magneto Part Number. For details you might even want to look up the ALTRONIC® Application Chart. That Information will lead you to the MOTORTECH TriDev Part Number. If any help is required, please call your nearest MOTORTECH Sales Partner.

A

= Flange mount, vertical, 1 slot

B

= Base mount

D

= Flange mount, horizontal, 3 in. pilot, 2 slots

G

= Flange mount, horizontal, 2 slots

GL

= Flange mount, horizontal, flex coupling

GN

= Flange mount, horizontal, gear coupling

GO

= Flange mount, horizontal, 2 slots

GV

= Flange mount, vertical, 2 slots

GVN = Flange mount, vertical, gear coupling J

= Flange mount, vertical, 3 slots

E = Pickup Port Arrangement

B C - D - E

NOTE: Pickup and lead have to be ordered separately.

48

= CW (clockwise)

2

C = Trigger Arrangement

Specification Table

P/N 06.22. A

1

A

= Pickup port - M12 x 1

F

= Pickup port - 5/8-18 UNF1)

1)

to be used for - C - Trigger Arrangement 9 (1 magnet) only.


Trigger Conversion Kits for CATERPILLAR® G3300 & G3400 Series P/N

Figure

Supersedes

Description

Events

75.30.131

1

75.30.101

Trigger conversion kit for CATERPILLAR G3306

6+1

75.30.131-1

1

75.30.119-1 /101-1

Trigger conversion kit for CATERPILLAR® G3304/3306

1

75.30.132

1

75.30.119

Trigger conversion kit for CATERPILLAR G3304

4+1

75.30.133

1

75.30.100

Trigger conversion kit for CATERPILLAR® G3406

6+1

75.30.133-1

1

75.30.100-1

Trigger conversion kit for CATERPILLAR G3406

1

®

®

®

Accessories for Trigger Conversion Kits for CATERPILLAR® G3300 & G3400 Series P/N

Figure

1)

Supersedes

1a

44.04.0051)

Description

Engine

Fork spanner, swan-necked

G3406

Needs to be ordered separately.

P/N 06.24.009 1)

Figure

Supersedes

Description

2

1)

IGNITION SYSTEMS

Basic Trigger Device for CATERPILLAR® G379 / G398 / G399 Events

Trigger device for CATERPILLAR G379/G398/G399 ®

Pickup and lead have to be ordered separately.

Trigger Conversion Kit for DOOSAN® GV222TI P/N 75.30.137 1)

Figure

Supersedes

Description

3

1)

Events

Trigger conversion kit for DOOSAN GV222TI ®

Pickup and lead have to be ordered separately. Illustration shows mounted kit on camshaft gear.

Trigger Devices for WHITE SUPERIOR® G825 & GT825 P/N

Figure

Supersedes

Description

Events

06.22.400-1

4

Trigger device for WHITE SUPERIOR Model G825 / GT825

1

06.22.400-6

4

Trigger device for WHITE SUPERIOR® Model G825 / GT825

6+1

06.22.400-8

4

Trigger device for WHITE SUPERIOR Model G825 / GT825

8+1

®

®

Trigger Device for MAN® E2842E302 & DOOSAN® GV222TI P/N

Figure

Supersedes

Description

5

06.23.001

Events

Trigger device for MAN E2842E302 & DOOSAN GV222TI

6+1

Description

Events

Trigger device for MAN® E2866E302

6+1

®

®

Trigger Device for MAN® E2866E302 P/N

Figure

Supersedes

6

06.23.004

1a 1

2

3

4

5

6

49


TRIGGERING

Trigger Discs A large variety of different trigger discs is available to support upgrades performed by installing new electronic ignition systems on engines that used to be equipped with

mechanical driven magneto ignition. Select between universal trigger discs with magnets, metal inlets or discs that are specially designed for particular engine models.

Trigger Discs with Magnets P/N

Supersedes

Description

Diameter

Events

06.20.300

Trigger disc with magnet

5.00 in.

1

06.20.301

Trigger disc with magnet

7.45 in.

1

06.20.302

Trigger disc with magnets

5.00 in.

2+1

06.20.303

Trigger disc with magnets

7.45 in.

2+1

06.20.304

Trigger disc with magnets

5.00 in.

3+1

06.20.305

Trigger disc with magnets

7.45 in.

3+1

06.20.306

Trigger disc with magnets

5.00 in.

4+1

790114-1

06.20.307

Trigger disc with magnets

7.45 in.

4+1

790104-1

06.20.308

Trigger disc with magnets

5.00 in.

5+1

790115-1

06.20.309

Trigger disc with magnets

7.45 in.

5+1

790105-1

06.20.310

Trigger disc with magnets

3.40 in.

6+1

790165

06.20.311

Trigger disc with magnets

4.00 in.

6+1

790144

06.20.312

Trigger disc with magnets

5.00 in.

6+1

790169

06.20.313

Trigger disc with magnets

5.00 in.

6+1

790116-1

06.20.314

Trigger disc with magnets

7.45 in.

6+1

790106-1

06.20.315

Trigger disc with magnets

3.40 in.

8+1

790166

06.20.316

Trigger disc with magnets

5.00 in.

8+1

790118-1

06.20.317

Trigger disc with magnets

7.45 in.

8+1

790150

06.20.318

Trigger disc with magnets

7.45 in.

8+1

790108-1

06.20.319

Trigger disc with magnets

7.45 in.

8+1

790022

06.20.320

Trigger disc with magnets

5.00 in.

12+1

790132-1

06.20.321

Trigger disc with magnets

7.45 in.

12+1

790122-1

06.20.322

Trigger disc with magnets

7.45 in.

12+1

790151

06.20.323

Trigger disc with magnets

7.45 in.

12+1

790021

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

50

Equivalent to


Trigger Discs with Metal Inlets P/N

Figure

Supersedes

Description

Diameter

Events

Equivalent to

06.20.400

1

Trigger disc with metal inlets

7.45 in.

2+1

790302-1

06.20.401

1

Trigger disc with metal inlets

7.45 in.

3+1

790303-1

06.20.402

1

Trigger disc with metal inlets

5.00 in.

4+1

790314-1

06.20.403

1

Trigger disc with metal inlets

5.00 in.

6+1

790316-1

06.20.404

1

Trigger disc with metal inlets

5.00 in.

8+1

790318-1

P/N

Description

Application

Diameter

Events

Equivalent to

06.20.069-6

Figure

2

Trigger disc with magnets

WAUKESHA® VHP series - 6 cylinders

7.45 in.

6+1

305805R

06.20.069-12

2

Trigger disc with magnets

®

WAUKESHA VHP series - 12 cylinders

7.45 in.

12+1

305805P

06.20.069-1

2

Trigger disc with magnet

WAUKESHA® VHP series

7.45 in.

1

06.20.252

3

Trigger disc with magnets

WAUKESHA® VHP series - 16 cylinders

5.35 in.

8+1

06.20.254

3

Trigger disc with magnet

WAUKESHA® VHP series

5.35 in.

1

06.20.0251)

3

Trigger disc with magnets

WAUKESHA® VHP series - 6 cylinders

7.45 in.

6+1

305805F

06.20.026

3

Trigger disc with magnets

®

WAUKESHA VHP series - 12 cylinders

7.45 in.

12+1

305805G

06.20.026-11)

3

Trigger disc with magnet

WAUKESHA® VHP series

7.45 in.

1

06.20.045-6

3

Trigger disc with magnets

WAUKESHA® VGF series - 6 cylinders

5.00 in.

6+1

305805

06.20.045-8

3

Trigger disc with magnets

WAUKESHA® VGF series - 8 cylinders

5.00 in.

8+1

305805A

06.20.045-1

3

Trigger disc with magnet

WAUKESHA VGF series

5.00 in.

1

1)

1)

Supersedes

06.20.025-1

®

305805N

IGNITION SYSTEMS

Trigger Discs with Magnets – Compatible with WAUKESHA® CEC

Comes with lock nut.

Accessories for Trigger Discs for WAUKESHA® VHP Series P/N

Figure

Supersedes

4

06.20.070

Description

Application

Equivalent to

Hub for trigger discs

WAUKESHA® VHP series

A168368E

Trigger Disc for IVECO® 5.9 P/N

Figure

Supersedes

5

06.20.251

1

2

Description

Diameter

Events

Trigger disc with metal inlets

11.50 in.

3+1

3

4

Equivalent to

5 Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

51


TRIGGERING Trigger Magnets P/N

Figure

Supersedes

Description

Thread

Length

Equivalent to

06.60.900

1

Trigger magnet

1/4-20 UNC

0.65 in.

06.60.922

1

Trigger magnet

M8x1.25

0.70 in.

720002

Description

Diameter

Length

Equivalent to

Trigger reluctor pin

0.25 in.

0.75 in.

Trigger Reluctor Pin P/N 06.80.104

Figure

Supersedes

2

Installation Tool for Reluctor Pin P/N 44.99.011

Figure

3

1

52

Description

Equivalent to

Installation tool for reluctor pin

2

3


IGNITION SYSTEMS

NOTES

53


54


HIGH TENSION LEADS AND ACCESSORIES Since the mid of the 90‘s, MOTORTECH has become one of the leading manufacturers of unshielded and shielded high tension leads (spark plug leads). The PolyMotTM design, which was patented in 1996, has created a big change in the industry to more reliable equipment that is capable to transfer high voltages from the ignition coil to the spark plug. Increasing load demand, higher efficiencies and lean burn operation coupled to the use of alternative gas qualities like bio gases have made it mandatory to have a good terminal connection to the coil as well as to the spark plug. A built in suppression resistor reduces the RFI noise that can be critical when electronic ignition is used and extra electrical spikes are recognized as pickup signal. In the industry where Class I; Div 2 certification is required, MOTORTECH today offers the MOT-Blues MotBlues ––aashielded shieldedand CSA CSA and approved approved highhigh tension tension leadlead – which – which doesdoes not have not have the poor the poor performance performance as the asstandard the standard shielded shielded designs. deThe MotBlues signs. The MOT-Blues has been has accepted been accepted very wellvery by the wellbig by integral the big integral compressor compressor engine market. engine market.

55


HIGH TENSION LEADS AND ACCESSORIES

PolyMot™

MOTORTECH SPARK PLUG LEADS & EXTENSIONS

High Tension Leads – PolyMotTM Style The PolyMot™ high tension lead was globally patented in 1996. Since then more than half a million leads were manufactured to this patented design. Patent No. 19611283

Ceramic Insert with 5 kΩ resistor Silicone Seal

Features: The unique structure has achieved tremendous reliability records in the field. • Rigid design • TEFLON extension up to 36 in. length • 5 kΩ built in ceramic insert • Reliable coil and spark plug terminal • The blue silicone spark plug wire is specially designed and has a dielectric strength of 68 kV • Critical high voltage areas are protected with a silicone seal against water and dirt • Designed to match the engine model, the spark plug type and application • Leads are labeled with P/N and production code for easy traceability • Comes with 2 years warranty

Comparison between OEM part (slim) and MOTORTECH PolyMotTM

56

Perfect fit

Water flood test


IGNITION SYSTEMS

High Tension Lead Specification Chart

Please consult factory or your nearest MOTORTECH distributor to get the correct PolyMotTM high tension lead, specified for your engine application. Questionnaire for PolyMotTM specification. A Length of insulator B Spark plug type C Spark plug well inner diameter D Spark plug well outer diameter E Well to cover distance F Length of wire G Type of coil

Terminal to coil

Seal ring on spark plug insulator

Grommet to cover the spark plug well

Built in 5 k立 ceramic resistor (recommended)

Engine mark and model

Lead output from teflon insulator 57


HIGH TENSION LEADS AND ACCESSORIES PolyMot High Tension Leads – for common Applications P/N

58

1) 2)

Engine Make

Model

Popular Length1)

Spark Plug

P/N Silicone Extension Lead Output Resistance2) Seal Ring Length fromExtension

Wire Length

Ignition Coil Connection

06.85.908-L

AJAX®

2802

L=22 in.

3076

06.84.059

6 in.

6 kΩ

180°

17 in.

6

06.85.751-L

CATERPILLAR®

G3400 series

L=18 in.

GE3-5

06.84.059

13 in.

5 kΩ

90°

18 in.

1

06.85.939-L

®

CATERPILLAR

G3400 series

L=18 in.

GE3-5

06.84.059

13 in.

5 kΩ

90°

18 in.

5a

06.85.594-L

CATERPILLAR®

G3500 series

L=16 in.

GI3-1

06.84.040

15 in.

5 kΩ

90°

16 in.

1

06.85.954-L

CATERPILLAR

G3500 series

L=16 in.

GI3-1

06.84.040

15 in.

6 kΩ

90°

16 in.

6

06.85.505-L

CLARK®

TLA-6

L=18 in.

RW80N

06.84.040

11 in.

5 kΩ

90°

18 in.

5a

06.85.966-L

CLARK®

TCV-16

L=35 in.

GK3-5

06.84.044

11 in.

5 kΩ

180°

24 in.

5a

06.85.670-L

COOPER®

GMV-8

L=12 in.

RW77PP

06.84.040

11 in.

5 kΩ

90°

12 in.

5a

06.85.910-L

COOPER

LSV-16 (Middle of Head)

L=18 in.

RW80PP

06.84.040

22 in.

5 kΩ

90°

18 in.

1

06.85.909-L

COOPER

LSV-16 (Side of Head)

L=24 in.

RW80PP

06.84.040

14 in.

5 kΩ

90°

24 in.

1

06.85.083-L

CUMMINS®

5.9 / GTA 8.3

L=22 in.

GK3-5

06.84.033

6 in.

5 kΩ

180°

16 in.

4

06.85.683-L

CUMMINS

G855

L=18 in.

GK3-5

06.84.044

12 in.

5 kΩ

90°

18 in.

1

06.85.947-L

CUMMINS®

QSK60G

L=8 in.

GI3-5

06.84.040

15 in.

5 kΩ

90°

8 in.

1

06.85.946-L

CUMMINS

QSV81G/QSV91G

L=8 in.

GI3-5

06.84.040

17 in.

5 kΩ

90°

8 in.

1

06.85.320H-L

DEUTZ®/MWM®

234 series

L=18 in.

GE3-5

06.84.059

6 in.

5 kΩ

90°

18 in.

1

06.85.310H-L

®

DEUTZ /MWM

616 series

L=11 in.

GL3-3

06.84.040

9 in.

5 kΩ

90°

11 in.

1

06.85.179-L

DEUTZ®/MWM®

620 series

L=20 in.

GL3-3

06.84.040

10 in.

5 kΩ

90°

20 in.

1

06.85.178-L

DEUTZ /MWM

620 series

L=20 in.

GL3-3

06.84.040

10 in.

5 kΩ

90°

20 in.

2

06.85.926-L

IVECO®

GE8291SRG75

L=20 in.

GK3-5

06.84.044

10 in.

5 kΩ

90°

20 in.

1

06.85.487-L

LIEBHERR

G924 / G926

L=18 in.

GK3-5

06.84.033

6 in.

5 kΩ

180°

12 in.

2

06.85.873-L

LIEBHERR

G926TI

L=18 in.

GK3-5

06.84.033

6 in.

5 kΩ

180°

12 in.

7

06.85.709H-L

MAN

E0834E/LE / E0836E

L=16 in.

GK3-5

06.84.044

6 in.

5 kΩ

180°

10 in.

1

06.85.989-L

®

MAN

E0834E/LE / E0836E

L=16 in.

GE3-5

06.84.059

6 in.

5 kΩ

180°

10 in.

1a

06.85.577H-L

MAN®

E0834E/LE / E0836E

L=16 in.

GK3-5

06.84.044

6 in.

5 kΩ

180°

10 in.

2

06.85.879-L

®

MAN

E0834E/LE / E0836E

L=16 in.

GK3-5

06.84.044

6 in.

5 kΩ

180°

11 in.

4

06.85.717H-L

MAN®

E0834E/LE / E0836E

L=24 in.

GK3-5

06.84.044

6 in.

6 kΩ

180°

18 in.

6

06.85.839H-L

MAN

E0834E/LE / E0836E

L=16 in.

GK3-5

06.84.044

6 in.

5 kΩ

180°

10 in.

7

06.85.580H-L

MAN®

E0836LE / E28 series

L=18 in.

GE3-5

06.84.059

6 in.

5 kΩ

180°

12 in.

1

06.85.988-L

®

MAN

E0836LE / E28 series

L=16 in.

GK3-5

06.84.044

6 in.

5 kΩ

180°

10 in.

1a

06.85.415H-L

MAN®

E0836LE / E28 series

L=16 in.

GE3-5

06.84.059

6 in.

5 kΩ

180°

10 in.

2

06.85.836H-L

MAN

E0836LE / E28 series

L=16 in.

GE3-5

06.84.059

6 in.

5 kΩ

180°

10 in.

7

06.85.929-L

MAN®

E2676LE202

L=20 in.

GK3-5

06.84.044

11 in.

5 kΩ

180°

10 in.

7

06.85.959-L

MAN

E3262LE202

L=22 in.

GE3-5

06.84.059

10 in.

5 kΩ

180°

13 in.

7

®

® ®

®

®

®

®

®

® ®

®

®

®

®

06.85.271

®

WÄRTSILÄ

25SG series

GE3-5

06.84.059

17 in.

5 kΩ

90°

14 in.

4

06.85.272

WÄRTSILÄ®

25SG series

GI3-1

06.84.040

17 in.

5 kΩ

90°

14 in.

4

06.85.948-L

®

WÄRTSILÄ

28SG series

GI3-5

06.84.040

21 in.

5 kΩ

90°

8 in.

1

06.85.281

WÄRTSILÄ®

28SG series

GI3-1

06.84.040

21 in.

5 kΩ

180°

14 in.

4

L=8 in.

06.85.306-L

®

WAUKESHA

VGF series

L=18 in.

GI3-1

06.84.040

12 in.

5 kΩ

90°

18 in.

1

06.85.326-L

WAUKESHA®

VGF series

L=16 in.

GI3-1

06.84.040

10 in.

5 kΩ

180°

6 in.

1

06.85.429-L

®

WAUKESHA

VGF series

L=14 in.

GI3-1

06.84.040

11 in.

5 kΩ

90°

14 in.

1

06.85.666

WAUKESHA®

VGF series

GI3-1

06.84.040

12 in.

6 kΩ

90°

18 in.

6

06.85.423-L

WAUKESHA

VHP GL series

GT3-1

06.84.040

11 in.

5 kΩ

90°

16 in.

1

®

L=16 in.

"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.908-K) For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.908-22-0).


PolyMot High Tension Leads – for common Applications Engine Make

Popular Length1)

Model

Spark Plug

P/N Silicone Extension Lead Output Resistance2) Seal Ring Length fromExtension

Wire Length

Ignition Coil Connection

06.85.739-L

WAUKESHA®

VHP GL series

L=16 in.

GT3-1

06.84.040

9 in.

5 kΩ

90°

16 in.

1

06.85.649-L

WAUKESHA®

VHP GL series

L=24 in.

GT3-1

06.84.040

11 in.

5 kΩ

90°

24 in.

5a

06.85.945-L

WAUKESHA®

VHP GL series

L=16 in.

GT3-1

06.84.040

9 in.

6 kΩ

90°

16 in.

6

06.85.422-L

WAUKESHA®

VHP GU series

L=16 in.

GT3-1

06.84.040

13 in.

5 kΩ

90°

16 in.

1

06.85.688-L

WAUKESHA

VHP GU series

L=16 in.

GI3-1

06.84.040

11 in.

5 kΩ

90°

16 in.

1

06.85.699-L

WAUKESHA®

VHP GU/GSI series

L=16 in.

M82N

06.84.040

12 in.

5 kΩ

90°

16 in.

1

06.85.705-L

®

WAUKESHA

VHP GU/GSI series

L=16 in.

GT3-1

06.84.040

12 in.

5 kΩ

90°

16 in.

1

06.85.720-L

WAUKESHA®

VHP GU/GSI series

L=18 in.

GT3-1

06.84.040

12 in.

5 kΩ

90°

18 in.

1

06.85.672H-L

WAUKESHA

VHP GU/GSI series

L=22 in.

GI3-1

06.84.040

14 in.

5 kΩ

90°

22 in.

5a

06.85.894-L

WAUKESHA

VHP GU/GSI series

L=18 in.

GT3-1

06.84.040

14 in.

6 kΩ

90°

18 in.

6

06.85.714-L

WAUKESHA

VHP/AT series

L=24 in.

GI3-1

06.84.040

18 in.

5 kΩ

90°

24 in.

1

06.85.678-L

WAUKESHA

VSG series

L=24 in.

GE3-5

06.84.059

5 in.

5 kΩ

180°

18 in.

1

06.85.667-L

WHITE SUPERIOR® G825 series

L=24 in.

GT3-1

06.84.040

8 in.

5 kΩ

90°

24 in.

1

06.85.723-L

WHITE SUPERIOR

L=24 in.

D16

06.81.005

6 in.

5 kΩ

90°

24 in.

1

®

® ® ® ®

®

GTLB825

IGNITION SYSTEMS

P/N

"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.908-K) 2) For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.908-22-0). 1)

1

1a

2

3

4

5*

6

7

8

9

10

5a = ALTRONIC® style; 5b = BENDIX® style; 5c = MOTORTECH

PolyMot High Tension Leads − Silicone Seal Rings1) P/N

Description

Size

Quantity

06.84.033-100

Silicone seal ring

10.0 x 5.0 mm

100 pcs.

06.84.034-100

Silicone seal ring

12.0 x 4.0 mm

100 pcs.

06.84.038-100

Silicone seal ring

14.4 x 2.8 mm

100 pcs.

06.84.040-100

Silicone seal ring

14.6 x 2.7 mm

100 pcs.

06.84.044-100

Silicone seal ring

10.0 x 5.0 mm

100 pcs.

06.84.059-100

Silicone seal ring

11.0 x 4.0 mm

100 pcs.

1)

Silicone seal rings require replacement every 3000 running hours. See MOTORTECH homepage for appropriate instruction for replacing silicone seal rings.

PolyMot High Tension Leads − Installation Tool for WAUKESHA® Grommet P/N

Description

07.99.016

Installation tool for WAUKESHA® VHP grommet

PolyMot High Tension Leads − Flange Kit for High Tension Leads for WAUKESHA® VHP / AT and CATERPILLAR® G3500 Series P/N

Description

06.51.248

Flange kit for use with P/N 06.85.714-L, P/N 06.85.594-L and P/N 06.85.954-L Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

59


HIGH TENSION LEADS AND ACCESSORIES D

NON-SHIELDE

High Tension Leads for CATERPILLAR® Gas Engines Popular Length1)

Spark Plug

P/N Silicone Extension Lead Output Wire Ignition Coil Resistance2) Seal Ring Length fromExtension Length Connection

G3300 series

L=16 in.

GE3-5 / GN3-1

06.84.059

3.75 in.

0 kΩ

180°

12 in.

1

G3300 series

L=16 in.

GE3-5

06.84.059

4.25 in.

0 kΩ

180°

12 in.

2

G3400 series

L=18 in.

GE3-5

06.84.059

13.00 in.

5 kΩ

90°

18 in.

1

06.85.939-L

G3400 series

L=18 in.

GE3-5

06.84.059

13.00 in.

5 kΩ

90°

18 in.

5a

06.88.004-L

G342/G379/G398/G399

L=20 in.

GE3-5

06.84.059

4.25 in.

0 kΩ

180°

16 in.

2

P/N

Supersedes

06.88.009-L3)

06.88.008-L/-K

Model

06.88.010-L 06.85.751-L4)

06.88.003-L/-K 06.85.687-L

G342/G379/G398/G399

L=20 in.

GN3-1

06.84.044

4.25 in.

0 kΩ

180°

16 in.

3

06.88.006-L

06.88.001-L/-K

G342/G379/G398/G399

L=20 in.

GE3-5

06.84.059

4.25 in.

0 kΩ

180°

16 in.

1

06.88.007-L

06.88.002-L/-K

06.88.005-L

G342/G379/G398/G399

L=20 in.

GI3-1

06.84.040

3.70 in.

0 kΩ

180°

16 in.

1

06.88.011-L

G342/G379/G398/G399

L=20 in.

GE3-5

06.84.059

4.25 in.

0 kΩ

180°

16 in.

9

06.85.674-L

G342/G379/G398/G399

L=16 in.

GT3-1

06.84.040

5.00 in.

0 kΩ

90°

16 in.

9

"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.751-K) For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.939-18-0). P/N 06.88.009-16 equivalent to P/N 7W2479. 4) P/N 06.85.751-18 equivalent to P/N 7W8542 / 2624855 / 2502149. 1) 2) 3)

High Tension Leads – for common Applications P/N

Engine Make

Model

Popular Length1)

Spark Plug

P/N Silicone Extension Lead Output Wire Ignition Coil Resistance2) from Extension Length Connection Seal Ring Length

L=20 in.

GT3-1

06.84.040

20 in.

1

90°

30 in.

5a

90°

16 in.

1

0 kΩ

90°

15 in.

5a

1 kΩ

90°

14 in.

6

8 in.

0 kΩ

90°

16 in.

5a

5 in.

5 kΩ

180°

17 in.

8

14GZ6-77-2 06.84.033

9 in.

6 kΩ

90°

10 in.

6

GK3-5

06.81.071

12 in.

5 kΩ

90°

10 in.

1

L=18 in.

RW80N

06.84.040

4 in.

0 kΩ

180°

14 in.

5a

L=20 in.

GK3-5

06.81.071

6 in.

5 kΩ

180°

14 in.

2

G825 series

L=24 in.

GK3-5

06.84.044

8 in.

0 kΩ

90°

24 in.

1

WHITE SUPERIOR

G825 series (Lean Burn)

L=24 in.

GK3-5

06.84.044

4 in.

0 kΩ

90°

24 in.

1

WHITE SUPERIOR

G825 series

L=24 in.

D14N

06.84.040

8 in.

0 kΩ

90°

24 in.

5a

06.85.697-L

AJAX®

230

5 in.

0 kΩ

06.85.698-L

®

AJAX

230

L=30 in.

GT3-1

06.84.040

5 in.

0 kΩ

06.85.719-L

AJAX®

230

L=16 in.

W18

06.81.017

5 in.

0 kΩ

06.85.773-L

AJAX

230

L=15 in.

GT3-1

06.84.034

5 in.

06.85.860-L

ARROW®

VRG176/VRG220/VRG330 L=14 in.

J6C / J8C

06.84.059

5 in.

06.85.514-L

CLARK

TLA-6

L=16 in.

RW80N

06.84.038

06.85.903-L3)

CUMMINS®

GTA 8.3

L=22 in.

GK3-5

06.85.949-L

DEUTZ

2015 series

L=10 in.

06.85.953-L

DOOSAN®

GV222TIC

L=10 in.

06.88.015-L

INGERSOLL RAND

KVSR12

06.85.964-L

LIEBHERR®

G9408

06.85.690-L

WHITE SUPERIOR

06.85.689-L 06.85.695-L

®

®

®

®

® ® ®

90°

"-L" can be any length from 8 in. to 36 in. in 2 in. increments. For loose connector and 36 in. length add "-K" to part number (e.g. 06.85.751-K) For 0 kΩ resistance, please add "-0" to part number (e.g. 06.85.939-18-0). 3) P/N 06.85.903-22 equivalent to P/N 4989132. 1) 2)

1

1a

2

3

5a = ALTRONIC® style; 5b = BENDIX® style; 5c = MOTORTECH

60

4

5*

6

7

8

9

10


P/N1)

SP Termination Well Depth

Spark Plug End

09.02.1000-L

2.125 in.

180°

09.02.1001-L

2.125 in.

90°

09.02.1010-L

2.125 in.

09.02.1011-L

2.125 in.

09.02.1100-L 09.02.1101-L

Ignition Coil End

Inductive Pickup Spacer

5KOhm Resistor

Ignition Coil

Equivalent to

180°

291001-S, 501061-S, 591010-S

USL2A-"L"A / AWH81-"L"

180°

291001-S, 501061-S, 591010-S

USL2LA-"L"A

180°

90°

291001-S, 501061-S, 591010-S

USL2AL-"L"A

90°

90°

291001-S, 501061-S, 591010-S

USL2LAL-"L"A

2.125 in.

180°

180°

x

291001-S, 501061-S, 591010-S

USL2A-"L"AIPS

2.125 in.

90°

180°

x

291001-S, 501061-S, 591010-S

USL2LA-"L"AIPS

09.02.1110-L

2.125 in.

180°

90°

x

291001-S, 501061-S, 591010-S

USL2AL-"L"AIPS

09.02.1111-L

2.125 in.

90°

90°

x

291001-S, 501061-S, 591010-S

USL2LAL-"L"AIPS

09.02.1200-L

2.125 in.

180°

180°

x

291001-S, 501061-S, 591010-S

RSL2A-"L"A

09.02.1201-L

2.125 in.

90°

180°

x

291001-S, 501061-S, 591010-S

RSL2LA-"L"A

09.02.1210-L

2.125 in.

180°

90°

x

291001-S, 501061-S, 591010-S

RSL2AL-"L"A

09.02.1211-L

2.125 in.

90°

90°

x

291001-S, 501061-S, 591010-S

RSL2LAL-"L"A

09.02.1300-L

2.125 in.

180°

180°

x

x

291001-S, 501061-S, 591010-S

RSL2A-"L"AIPS

09.02.1301-L

2.125 in.

90°

180°

x

x

291001-S, 501061-S, 591010-S

RSL2LA-"L"AIPS

09.02.1310-L

2.125 in.

180°

90°

x

x

291001-S, 501061-S, 591010-S

RSL2AL-"L"AIPS

09.02.1311-L

2.125 in.

90°

90°

x

x

291001-S, 501061-S, 591010-S

RSL2LAL-"L"AIPS

09.02.2000-L

2.125 in.

180°

180°

10-320790-1, 10-382040-1

USL2B-"L"A / AWH22-"L"

09.02.2001-L

2.125 in.

90°

180°

10-320790-1, 10-382040-1

USL2LB-"L"A

09.02.2010-L

2.125 in.

180°

90°

10-320790-1, 10-382040-1

USL2BL-"L"A

09.02.2011-L

2.125 in.

90°

90°

10-320790-1, 10-382040-1

USL2LBL-"L"A

09.02.2100-L

2.125 in.

180°

180°

x

10-320790-1, 10-382040-1

USL2B-"L"AIPS

09.02.2101-L

2.125 in.

90°

180°

x

10-320790-1, 10-382040-1

USL2LB-"L"AIPS

09.02.2110-L

2.125 in.

180°

90°

x

10-320790-1, 10-382040-1

USL2BL-"L"AIPS

09.02.2111-L

2.125 in.

90°

90°

x

10-320790-1, 10-382040-1

USL2LBL-"L"AIPS

09.02.2200-L

2.125 in.

180°

180°

x

10-320790-1, 10-382040-1

RSL2B-"L"A

09.02.2201-L

2.125 in.

90°

180°

x

10-320790-1, 10-382040-1

RSL2LB-"L"A

09.02.2210-L

2.125 in.

180°

90°

x

10-320790-1, 10-382040-1

RSL2BL-"L"A

09.02.2211-L

2.125 in.

90°

90°

x

10-320790-1, 10-382040-1

RSL2LBL-"L"A

09.02.2300-L

2.125 in.

180°

180°

x

x

10-320790-1, 10-382040-1

RSL2B-"L"AIPS

09.02.2301-L

2.125 in.

90°

180°

x

x

10-320790-1, 10-382040-1

RSL2LB-"L"AIPS

09.02.2310-L

2.125 in.

90°

90°

x

x

10-320790-1, 10-382040-1

RSL2LBL-"L"AIPS

09.02.2311-L

2.125 in.

180°

90°

x

x

10-320790-1, 10-382040-1

RSL2BL-"L"AIPS

1)

IGNITION SYSTEMS

Unshielded Safety Leads for Shielded Spark Plugs

"-L" can be any lead length from 8 in. to 36 in. in 2 in. increments.

End Coil

L-

Spark Plug End

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

61


HIGH TENSION LEADS AND ACCESSORIES Unshielded Safety Leads for Shielded Spark Plugs P/N1)

SP Termination Well Depth

Spark Plug End

09.02.3000-L

2.125 in.

180°

09.02.3001-L

2.125 in.

90°

09.02.3010-L

2.125 in.

09.02.3011-L

2.125 in.

09.02.3100-L 09.02.3101-L

Inductive Pickup Spacer

5KOhm Resistor

Ignition Coil

Equivalent to

180°

PPT2477AD, PPT2477AD-L

USL2C-"L"A / AWH42-"L"

180°

PPT2477AD, PPT2477AD-L

USL2LC-"L"A

180°

90°

PPT2477AD, PPT2477AD-L

USL2CL-"L"A

90°

90°

PPT2477AD, PPT2477AD-L

USL2LCL-"L"A

2.125 in.

180°

180°

x

PPT2477AD, PPT2477AD-L

USL2C-"L"AIPS

2.125 in.

90°

180°

x

PPT2477AD, PPT2477AD-L

USL2LC-"L"AIPS

09.02.3110-L

2.125 in.

180°

90°

x

PPT2477AD, PPT2477AD-L

USL2CL-"L"AIPS

09.02.3111-L

2.125 in.

90°

90°

x

PPT2477AD, PPT2477AD-L

USL2LCL-"L"AIPS

09.02.3200-L

2.125 in.

180°

180°

x

PPT2477AD, PPT2477AD-L

RSL2C-"L"A

09.02.3201-L

2.125 in.

90°

180°

x

PPT2477AD, PPT2477AD-L

RSL2LC-"L"A

09.02.3210-L

2.125 in.

180°

90°

x

PPT2477AD, PPT2477AD-L

RSL2CL-"L"A

09.02.3211-L

2.125 in.

90°

90°

x

PPT2477AD, PPT2477AD-L

RSL2LCL-"L"A

09.02.3300-L

2.125 in.

180°

180°

x

x

PPT2477AD, PPT2477AD-L

RSL2C-"L"AIPS

09.02.3301-L

2.125 in.

90°

180°

x

x

PPT2477AD, PPT2477AD-L

RSL2LC-"L"AIPS

09.02.3310-L

2.125 in.

180°

90°

x

x

PPT2477AD, PPT2477AD-L

RSL2CL-"L"AIPS

09.02.3311-L

2.125 in.

90°

90°

x

x

PPT2477AD, PPT2477AD-L

RSL2LCL-"L"AIPS

09.02.4000-L

2.125 in.

180°

180°

291001, 501061, 591010

USL2E-"L"A / AWH72-"L"

09.02.4001-L

2.125 in.

90°

180°

291001, 501061, 591010

USL2LE-"L"A

09.02.4100-L

2.125 in.

180°

180°

x

291001, 501061, 591010

USL2E-"L"AIPS

09.02.4101-L

2.125 in.

90°

180°

x

291001, 501061, 591010

USL2LE-"L"AIPS

09.02.4110-L

2.125 in.

180°

180°

x

291001, 501061, 591010

USL2E-"L"A w. 06.80.030

09.02.4200-L

2.125 in.

180°

180°

x

291001, 501061, 591010

RSL2E-"L"A

09.02.4201-L

2.125 in.

90°

180°

x

291001, 501061, 591010

RSL2LE-"L"A

09.02.4300-L

2.125 in.

180°

180°

x

x

291001, 501061, 591010

RSL2E-"L"AIPS

09.02.4301-L

2.125 in.

90°

180°

x

x

291001, 501061, 591010

RSL2LE-"L"AIPS

09.02.5000-L

2.125 in.

180°

180°

PPT2477P, PPT2477L

USL2F-"L"A / AWH82-"L"

09.02.5001-L

2.125 in.

90°

180°

PPT2477P, PPT2477L

USL2LF-"L"A

09.02.5100-L

2.125 in.

180°

180°

x

PPT2477P, PPT2477L

USL2F-"L"AIPS

09.02.5101-L

2.125 in.

90°

180°

x

09.02.5200-L

2.125 in.

180°

180°

09.02.5201-L

2.125 in.

90°

180°

09.02.5300-L

2.125 in.

180°

180°

x

09.02.5301-L

2.125 in.

90°

180°

x

09.02.7000-L

2.125 in.

180°

09.02.7001-L

2.125 in.

90°

09.02.7100-L

2.125 in.

180°

180°

09.02.7101-L

2.125 in.

90°

180°

09.02.7200-L

2.125 in.

180°

180°

09.02.7201-L

2.125 in.

90°

180°

09.02.7300-L

2.125 in.

180°

180°

09.02.7301-L

2.125 in.

90°

180°

1)

62

Ignition Coil End

PPT2477P, PPT2477L

USL2LF-"L"AIPS

x

PPT2477P, PPT2477L

RSL2F-"L"A

x

PPT2477P, PPT2477L

RSL2LF-"L"A

x

PPT2477P, PPT2477L

RSL2F-"L"AIPS

x

PPT2477P, PPT2477L

RSL2LF-"L"AIPS

180°

Unshielded in Coil Box inst.

USL2G-"L"A /AWH62-"L"

180°

Unshielded in Coil Box inst.

USL2LG-"L"A

x

Unshielded in Coil Box inst.

USL2G-"L"AIPS

x

Unshielded in Coil Box inst.

USL2LG-"L"AIPS

x

Unshielded in Coil Box inst.

RSL2G-"L"A

x

Unshielded in Coil Box inst.

RSL2LG-"L"A

x

x

Unshielded in Coil Box inst.

RSL2G-"L"AIPS

x

x

Unshielded in Coil Box inst.

RSL2-LG-"L"AIPS

"-L" can be any lead length from 8 in. to 36 in. in 2 in. increments.


P/N1)

Fits max. Spark Plug Ceramic Diameter End

Ignition Coil End

Inductive Pickup Spacer

5KOhm Resistor

Ignition Coil

Equivalent to

09.03.1000-L

0.485 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA14SPB-"L"A

09.03.4000-L

0.485 in.

180°

180°

291001, 501061, 591010

USLE14SPB-"L"A

09.04.1000-L

0.560 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA18SPB-"L"A

09.04.4000-L

0.560 in.

180°

180°

291001, 501061, 591010

USLE18SPB-"L"A

09.05.1000-L

0.485 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA35SPB-"L"A

09.05.4000-L

0.485 in.

180°

180°

291001, 501061, 591010

USLE35SPB-"L"A

09.06.1000-L

0.545 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA36SPB-"L"A

09.06.4000-L

0.545 in.

180°

180°

291001, 501061, 591010

USLE36SPB-"L"A

09.07.1000-L

0.385 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA45SPB-"L"A

09.07.4000-L

0.385 in.

180°

180°

291001, 501061, 591010

USLE45SPB-"L"A

09.08.1000-L

0.470 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA51SPB-"L"A

09.08.4000-L

0.470 in.

180°

180°

291001, 501061, 591010

USLE51SPB-"L"A

09.09.1000-L

0.580 in.

180°

180°

291001-S, 501061-S, 591010-S

USLA78SPB-"L"A

09.09.2000-L

0.580 in.

180°

180°

10-320790-1, 10-382040-1

USLB78SPB-"L"A

09.09.4000-L

0.580 in.

180°

180°

291001, 501061, 591010

USLE78SPB-"L"A

09.10.1000-L

Silicone Boot

180°

180°

291001-S, 501061-S, 591010-S

USLASB180-"L"A

09.10.2000-L

Silicone Boot

180°

180°

10-320790-1, 10-382040-1

USLBSB180-"L"A

09.10.3000-L

Silicone Boot

180°

180°

PPT2477AD, PPT2477ADL

USLCSB180-"L"A

09.10.4000-L

Silicone Boot

180°

180°

291001, 501061, 591010

USLESB180-"L"A

09.11.1000-L

Silicone Boot

90°

180°

291001-S, 501061-S, 591010-S

USLASL90-"L"A

09.11.2000-L

Silicone Boot

90°

180°

10-320790-1, 10-382040-1

USLBSL90-"L"A

09.11.3000-L

Silicone Boot

90°

180°

PPT2477AD, PPT2477ADL

USLCSL90-"L"A

09.11.4000-L

Silicone Boot

90°

180°

291001, 501061, 591010

USLESL90-"L"A

09.12.1000-L

Terminal

90°

180°

291001-S, 501061-S, 591010-S

USLA18T22-"L"A

09.12.2000-L

Terminal

90°

180°

10-320790-1, 10-382040-1

USLB18T22-"L"A

09.12.3000-L

Terminal

90°

180°

PPT2477AD, PPT2477ADL

USLC18T22-"L"A

09.12.4000-L

Terminal

90°

180°

291001, 501061, 591010

USLE18T22-"L"A

09.13.1000-L

Terminal

180°

180°

291001-S, 501061-S, 591010-S

USLA18T33-"L"A

09.13.2000-L

Terminal

180°

180°

10-320790-1, 10-382040-1

USLB18T33-"L"A

09.13.3000-L

Terminal

180°

180°

PPT2477AD, PPT2477ADL

USLC18T33-"L"A

09.13.4000-L

Terminal

180°

180°

291001, 501061, 591010

USLE18T33-"L"A

1)

IGNITION SYSTEMS

Unshielded Safety Leads for Conventional Spark Plugs

"-L" can be any lead length from 8 in. to 36 in. in 2 in. increments.

End Coil

L-

Spark Plug End

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

63


HIGH TENSION LEADS AND ACCESSORIES Accessories – Ignition Cables – Nickel Plated Copper Wire P/N

Figure

Description

Color

02.85.757

1

Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends

blue

02.85.758

2

Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends

orange

Accessories – Ignition Cable – Stainless Steel Wire P/N 02.85.658

Figure

2

Description

Color

Ignition cable, 7 mm silicone, 100 ft. spool, dielectric strength 68 kV, 17-19 stends

orange

Accessories – Silicone Hoses P/N

Figure

Description

Outer Diameter

Color

02.85.965

3

Silicone hose, 100 ft. spool

12 mm

blue

02.85.914

3

Silicone hose, 100 ft. spool

15 mm

blue

02.85.865

3

Silicone hose, 100 ft. spool

12 mm

orange

02.85.814

3

Silicone hose, 100 ft. spool

15 mm

orange

Description

Position

Quantity

Accessories – Inductive Pickup Spacer P/N

Figure

06.84.010-100

4

Inductive pickup spacer

end of lead

100 pcs.

06.84.043-100

5

Inductive pickup spacer

middle of lead

100 pcs.

Accessories – Spark Plug Terminals (for 14 mm Spark Plugs only) P/N

Figure

Description

Quantity

06.84.024-100

6

Spark plug terminal, 90°, silicone for use with 7 mm ignition cable, including terminal P/N 02.85.920

100 pcs.

06.84.025-100

7

Spark plug terminal, 180°, silicone for use with 7 mm ignition cable, including terminal P/N 02.85.920

100 pcs.

1

2

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

64

3

4

5

6

7


Accessories – Spark Plug Boots P/N

Figure

Description

Quantity

06.84.008-100

8

Spark plug boot, 90°, silicone for use with 7 mm ignition cable and terminal P/N 22.85.803

100 pcs.

06.84.009-100

9

Spark plug boot, 180°, silicone for use with 7 mm ignition cable and terminal P/N 22.85.802

100 pcs.

P/N

Figure

Description

Quantity

02.85.920-100

10

Terminal, for use with spark plug boot P/N 06.84.024 and P/N 06.84.025

100 pcs.

22.85.802-100

11

Terminal, for use with spark plug boot P/N 06.84.009

100 pcs.

22.85.803-100

12

Terminal, for use with spark plug boot P/N 06.84.008

100 pcs.

IGNITION SYSTEMS

Accessories – Terminals for Spark Plug Boots

Accessories – Spark Plug Terminals P/N

Figure

Description

Equivalent to

Quantity

02.85.924-100

13

Spark plug terminal, 90°, for use with 7 mm ignition cable

T-22

100 pcs.

02.85.925-100

14

Spark plug terminal, 180°, for use with 7 mm ignition cable

T-33

100 pcs.

Accessories – Ignition Coil Terminals P/N

Description

Quantity

06.80.030-100

15

Ignition coil terminal, 180°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126

100 pcs.

22.80.009-100

16

Ignition coil terminal, 90°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126

100 pcs.

06.80.091-1001)

17

Ignition coil terminal, 180°, 1 kΩ resistance, requires crimp terminal P/N 06.80.126

100 pcs.

1)

Figure

For ignition coils with positive secondary termination.

8

9

10

11

12

13

14

15

16

17

65


HIGH TENSION LEADS AND ACCESSORIES Accessories – Crimp Terminals P/N

Figure

Description

Quantity

06.80.012-100

1

Crimp terminal, 180°, for use with spreading adaptor P/N 02.85.1004

100 pcs.

06.80.116-100

2

Crimp terminal, 90°, for use with MOTORTECH style ignition coils

100 pcs.

06.80.116-180-100

3

Crimp terminal, 180°, for use with New MOTORTECH style ignition coils

100 pcs.

06.80.108-100

4

Crimp Terminal Base, for use with crimp terminals P/N 06.80.116-100 and P/N 06.80.116-180-100

100 pcs.

06.80.126-100

5

Crimp Terminal Base, for use ignition coil terminals P/N 06.80.030 and P/N 22.80.009

100 pcs.

Accessories – Spreading Adaptor P/N 02.85.1004-100

1

66

Figure 6

Description

Quantity

Spreading adaptor for ALTRONIC style ignition coils

100 pcs.

®

2

3

4

5

6


Accessories – Distance Collars P/N

Figure

Description

Quantity

06.86.001-100

7

Distance collar, for use with 7 mm ignition cable

100 pcs.

06.86.002-100

8

Distance collar, for use with 7 mm ignition cable

100 pcs.

06.86.003-100

9

Distance collar, for use with 7 mm ignition cable

100 pcs.

06.86.005-100

10

Distance collar, for use with 7 mm ignition cable

100 pcs.

P/N

Figure

Description

Dimensions

Quantity

06.84.033-100

11

Silicone seal ring

10.0 x 5.0 mm

100 pcs.

06.84.034-100

11

Silicone seal ring

12.0 x 4.0 mm

100 pcs.

06.84.038-100

11

Silicone seal ring

14.4 x 2.8 mm

100 pcs.

06.84.040-100

11

Silicone seal ring

14.6 x 2.7 mm

100 pcs.

06.84.044-100

11

Silicone seal ring

10.0 x 5.0 mm

100 pcs.

06.84.059-100

11

Silicone seal ring

11.0 x 4.0 mm

100 pcs.

1)

IGNITION SYSTEMS

Accessories – Silicone Seal Rings for High Tension Leads1)

Silicone seal rings require replacement every 3000 running hours. See MOTORTECH homepage for appropriate instruction for replacing silicone seal rings.

Accessories – Grommets for CUMMINS® Ignition Coils P/N

Figure

Description

Color

Quantity

06.84.048-100

12

Grommet, for use with CUMMINS ignition coil P/N 3930027

orange

100 pcs.

06.84.053-100

13

Grommet, for use with CUMMINS® 8.3 ignition coil

black

100 pcs.

®

Accessories – Silicone Seals for ALTRONIC®, BG®, CUMMINS® and WAUKESHA® Spark Plug Extensions P/N

Figure

Description

Color

Quantity

06.84.047-100

14

Silicone seal, for 14 mm spark plug extension

orange

100 pcs.

06.84.049-100

15

Silicone seal, for 18 mm spark plug extension

blue

100 pcs.

7

8

9

10

11

12

13

14

15

67


HIGH TENSION LEADS AND ACCESSORIES

MOT-Blues

SHIELDED HIGH TENSION LEAD

MOT-Blues – Shielded High Tension Leads There is an alternative to the commonly failing conventional shielded high tension lead. MOTORTECH has designed a CSA approved shielded spark plug lead for Class I, Division2, Group D that will perform better than the industry standard. There is no need to convert to non-shielded when you can not keep the engine running with the conventional leads.

The MOT-Blues spark plug wire is specially designed for shielded CSA certified high tension leads. It consists of a multi layer design: • Nickel plated copper core • 2 layers of silicone • Stainless steel braid • Silicone jacket This design ensures that no humidity can be trapped in the lead.

68


SHIELDED MOT-Blues Shielded High Tension Leads for Externally Mounted Ignition Coils – MOTORTECH Style P/N1)

Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.91.030-L

Shielded high tension lead

1-20 UNEF / 180°

180°

2 in.

A755-L-2 / HT2400-L

MOT-Blues Shielded High Tension Leads for Externally Mounted Ignition Coils – ALTRONIC® Style P/N1)

Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.90.030-L

Shielded high tension lead

3/4-20 UNEF / 180°

180°

2 in.

593030-L / HT2300-L

MOT-Blues Shielded High Tension Leads for MOTORTECH Igniter Assy Ignition Coils Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.91.031-L

Shielded high tension lead

M33x1.5 / 90°

180°

2 in.

IGNITION SYSTEMS

P/N1)

Standard lead lengths = "L" = 10 in., 13 in., 16 in., 18 in., 20 in., 24 in., 30 in.; other lengths available on request. Consult factory for 1 in. spark plug terminal well depth. All terminals made of ceramic. HEX-nut on spark plug side. 1) 2)

Conventional Shielded High Tension Leads for Externally Mounted Ignition Coils – MOTORTECH Style P/N1)

Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.85.030-L

Shielded high tension lead

1-20 UNEF / 180°

180°

2 in.

A755-L-2 / HT2400-L

Conventional Shielded High Tension Leads for Externally Mounted Ignition Coils – ALTRONIC® Style P/N1)

Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.90.030-L

Shielded high tension lead

3/4-20 UNEF / 180°

180°

2 in.

593030-L / HT2300-L

Conventional Shielded High Tension Leads for MOTORTECH Igniter Assy Ignition Coils P/N1)

Description

Ignition Coil Termination

Spark Plug Termination

Spark Plug Terminal Well Depth2) Equivalent to

95.85.031-L

Shielded high tension lead

M33x1.5 / 90°

180°

2 in.

Standard lead lengths = "L" = 10 in., 13 in., 16 in., 18 in., 20 in., 24 in., 30 in.; other lengths available on request. Consult factory for 1 in. spark plug terminal well depth. All terminals made of ceramic. HEX-nut on spark plug side. 1) 2)

-L

69


HIGH TENSION LEADS AND ACCESSORIES Terminal Kits for Shielded High Tension Leads – MOT-Blues (Metric) P/N

Figure

02.85.1006

1

Description

Adaptor Spark Plug1)

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, 2 in. terminal well depth

includes: 02.85.919

Cup & spring, M3

02.85.873

Insulator, KryptoMot

06.80.023

Threaded sleeve, M3

06.81.053

O-ring, Teflon

02.85.911

Nut, 3/4-20 UNEF

02.85.875

Inner ferrule

02.85.869

Crimp tube

1)

SN-75K

Consult factory for terminal kits to fit spark plugs with 3/4-20 UNEF thread and 1 in. terminal well depth.

Terminal Kits for Shielded High Tension Leads – MOT-Blues (Metric) P/N

Figure

02.85.1007

2

Description

Adaptor Igniton Coil

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, ALTRONIC Style ®

includes: 02.85.919

Cup & spring, M3

02.85.612

Gasket

02.85.872

Insulator, ceramic

02.85.929

Stud, M3

02.85.912

O-ring, silicone, 12x2

SOR-500

02.85.911

Nut, 3/4-20 UNEF

SN-75K

02.85.875

Inner ferrule

02.85.869

Crimp tube

510493

Terminal Kits for Shielded High Tension Leads – MOT-Blues (Metric) P/N

Figure

02.85.1008

3

Description

Adaptor Igniton Coil

Terminal kit with stud thread size M3

1-20 UNEF, MOTORTECH Style

Equivalent to

includes: 02.85.919

Cup & spring, M3

02.85.611

Gasket

02.85.006

Insulator, ceramic

02.85.929

Stud, M3

06.81.046

O-ring, silicone, 12x2

SOR-602

02.85.610

Nut, 1-20 UNEF

SN-FMOSK

02.85.875

Inner ferrule

02.85.869

Crimp tube 1

70

2

3


Terminal Kits for Shielded High Tension Leads – Conventional (Metric) P/N

Figure

02.85.991

1

Description

Adaptor Spark Plug

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, 1 in. terminal well depth

includes: 02.85.956

Stud, M3

02.85.913

Spring

02.85.013

Spacer

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.944

Insulator, ceramic

SC1

02.85.919

Cup & spring, M3

SP-3420

P/N

Figure

02.85.991-2

2

Description

Adaptor Spark Plug

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, 1 in. terminal well depth

SC1K / 504205

includes: 02.85.918

Stud 3/48 UNC

ST-44

02.85.913

Spring

SP-3420

02.85.013

Spacer

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.944

Insulator, ceramic

SC1

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

IGNITION SYSTEMS

Terminal Kits for Shielded High Tension Leads – Conventional (Imperial)

Terminal Kits for Shielded High Tension Leads – Conventional (Metric) P/N

Figure

02.85.992

3

Description

Adaptor Spark Plug

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, 2 in. terminal well depth

includes: 02.85.929

Stud M3

02.85.913

Spring

02.85.013

Spacer

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.910

Insulator, ceramic

SC2

02.85.919

Cup & spring, M3

1

SP-3420

2

3

71


HIGH TENSION LEADS AND ACCESSORIES Terminal Kits for Shielded High Tension Leads – Conventional (Imperial) P/N 02.85.992-2

Figure 1

Description

Adaptor Spark Plug

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, 2 in. terminal well

SC2K / 504137

includes: 02.85.902

Stud 3/48 UNC

ST-1125 / 510473

02.85.913

Spring

SP-3420

02.85.013

Spacer

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.910

Insulator, ceramic

SC2

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

Terminal Kits for Shielded High Tension Leads – Conventional (Imperial) P/N 02.85.979

Figure 2

Description

Adaptor Spark Plug

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, 1 in. terminal well

includes: 02.85.944

Insulator, ceramic

02.85.973

Cup, 3/48 UNC

02.85.954

Spring

Terminal Kits for Shielded High Tension Leads – Conventional (Metric) P/N 02.85.992-1

Figure 3

Description

Adaptor Igniton Coil

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, BENDIX Style ®

includes: 02.85.929

Stud, M3

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.910

Insulator, ceramic

SC2

02.85.919

Cup & spring, M3

Terminal Kits for Shielded High Tension Leads – Conventional (Imperial) P/N 02.85.992-3

Figure 4

Description

Adaptor Igniton Coil

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, BENDIX® Style

Equivalent to

includes: 02.85.902

Stud, 3/48 UNC

02.85.013

Spacer

06.81.098

O-ring, silicone, 8x2

SOR-375

02.85.910

Insulator, ceramic

SC2

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

1

72

2

ST-1125 / 510473

3

4


Terminal Kits for Shielded High Tension Leads – Conventional (Metric) P/N 02.85.996

Figure 1

Description

Adaptor Igniton Coil

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, ALTRONIC Style ®

includes: 02.85.929

Stud, M3

02.85.912

O-ring, silicone, 8x2

SOR-500

02.85.907

Insulator, ceramic

ALTSS-2C

02.85.612

Gasket

510493

02.85.919

Cup & spring, M3

Terminal Kits for Shielded High Tension Leads – Conventional (Imperial) 02.85.996-2

Figure 2

Description

Adaptor Igniton Coil

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, ALTRONIC Style ®

ALTSS-2

includes: 02.85.902

Stud, 3/48 UNC

ST-1125 / 510473

02.85.912

O-ring, silicone, 8x2

SOR-500

02.85.907

Insulator, ceramic

ALTSS-2C

02.85.612

Gasket

510493

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

IGNITION SYSTEMS

P/N

Terminal Kits for Shielded High Tension Leads – Conventional (Metric) P/N 02.85.997

Figure 3

Description

Adaptor Igniton Coil

Terminal kit with stud thread size 3/48 UNC

1-20 UNEF, MOTORTECH Style

Equivalent to

includes: 02.85.929

Stud, M3

06.81.059

O-ring

02.85.948

Insulator, ceramic

02.85.919

Cup & spring, M3

Terminal Kits for Shielded High Tension Leads – Conventional (Imperial) P/N 02.85.997-2

Figure 4

Description

Adaptor Igniton Coil

Terminal kit with stud thread size 3/48 UNC

1-20 UNEF, MOTORTECH Style

Equivalent to

includes: 02.85.902

Stud, 3/48 UNC

06.81.059

O-ring

02.85.948

Insulator, ceramic

02.85.901

Cup & spring, 3/48 UNC

1

2

ST-1125 / 510473

VS/SSC / 510474

3

4

73


HIGH TENSION LEADS AND ACCESSORIES Terminal Kits for Non-Shielded High Tension Leads – Conventional (Metric) P/N

Figure

02.85.993

1

Description

Adaptor Ignition Coil

Equivalent to

Terminal kit with stud thread size M3

3/4-20 UNEF, ALTRONIC Style ®

includes: 06.84.006

Boot

RB-ALT

02.85.911

Nut, 3/4-20 UNEF

SN-75K

02.85.929

Stud, M3

02.85.906

O-ring, Teflon™, 14x2

TOR-560

02.85.912

O-ring, silicone, 12x2

SOR-500

02.85.928

Insulator, ceramic

ALTOS-1C / 510695

02.85.612

Gasket

510493

02.85.919

Cup & spring, M3

Terminal Kits for Non-Shielded High Tension Leads - Conventional (Imperial) P/N

Figure

02.85.993-2

2

Description

Adaptor Ignition Coil

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, ALTRONIC Style

ALTOS-1 / 510480

®

includes: 06.84.006

Boot

RB-ALT

02.85.911

Nut, 3/4-20 UNEF

SN-75K

02.85.902

Stud 3/48 UNC

ST-1125 / 510473

02.85.906

O-ring, Teflon™, 14x2

TOR-560

02.85.912

O-ring, silicone, 12x2

SOR-500

02.85.928

Insulator, ceramic

ALTOS-1C / 510695

02.85.612

Gasket

510493

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

Terminal Kits for Non-Shielded High Tension Leads - Conventional (Metric) P/N

Figure

02.85.994

3

Description

Adaptor Ignition Coil

Terminal kit with stud thread size M3

3/4-20 UNEF, BENDIX® Style

Equivalent to

includes: 06.84.006

Boot

RB-ALT

02.85.911

Nut, 3/4-20 UNEF

SN-75K

02.85.929

Stud, M3

02.85.906

O-ring, Teflon™, 14x2

TOR-560

02.85.912

O-ring, silicone, 12x2

SOR-500

02.85.903

Insulator, ceramic

BENDOS-1C

02.85.919

Cup & spring, M3

1

74

2

3


Terminal Kits for Non-Shielded High Tension Leads - Conventional (Imperial) P/N

Figure

02.85.994-2

1

Description

Adaptor Ignition Coil

Equivalent to

Terminal kit with stud thread size 3/48 UNC

3/4-20 UNEF, BENDIX Style

BENDOS-1

®

06.84.006

Boot

RB-ALT

02.85.911

Nut, 3/4-20 UNEF

SN-75K

02.85.902

Stud 3/48 UNC

ST-1125 / 510473

02.85.906

O-ring, Teflon™, 14x2

TOR-560

02.85.912

O-ring, silicone, 12x2

SOR-500

02.85.903

Insulator, ceramic

BENDOS-1C

02.85.901

Cup & spring, 3/48 UNC

VS/SSC / 510474

Terminal Kits for Non-Shielded High Tension Leads - Conventional (Metric) P/N

Figure

02.85.995

2

Description

Adaptor Ignition Coil

Terminal kit with stud thread size M3

1-20 UNEF, MOTORTECH Style

Equivalent to

IGNITION SYSTEMS

includes:

includes: 06.84.006

Boot

RB-ALT

02.85.610

Nut, 1-20 UNEF

SN-FMOSK

02.85.929

Stud, M3

02.85.906

O-ring, Teflon™, 14x2

TOR-560

06.81.046

O-ring, silicone, 12x2

SOR-602

02.85.018

Insulator, ceramic

FMOS-1C

02.85.611

Gasket

02.85.919

Cup & spring, M3

Terminal Kits for Non-Shielded High Tension Leads - Conventional (Imperial) P/N

Figure

02.85.995-2

3

Description

Adaptor Ignition Coil

Equivalent to

Terminal kit with stud thread size 3/48 UNC

1-20 UNEF, MOTORTECH Style

FMOS-1

includes: 06.84.006

Boot

RB-ALT

02.85.610

Nut, 1-20 UNEF

SN-FMOSK

02.85.902

Stud 3/48 UNC

ST-1125 / 510473

02.85.906

O-ring, Teflon™, 14x2

TOR-560

06.81.046

O-ring, silicone, 12x2

SOR-602

02.85.018

Insulator, ceramic

FMOS-1C

02.85.611

Gasket

02.85.901

Cup & spring, 3/48 UNC

1

VS/SSC / 510474

2

3

75


76


PRIMARY LEADS Shielded ignition systems require all wiring to be approved for hazardous locations. MOTORTECH manufactures a wide a wide range range ofof shielded shielded primary primary leads leads that that meet meet the the CSA CSA Class Class I; I,Division2; Division2,Group GroupC/D; D requirements. T4 requirements. A variety of leads is available to fit all common ignition coils and the MOTORTECH AlphaRail wiring rails. Heavy duty connectors (non cadmium plated) and a thick stainless steel braid with hydraulic ends will make this product live in a harsh environment.

77


PRIMARY LEADS

New Style Shielded Primary Leads In addition to its conventional primary leads, MOTORTECH now offers a new type of primary lead that is produced with a special wire. The new primary leads are compliant with CSA Class I, Division 2, Group D, and they offer a significantly higher flexibility than conventional leads, shielded with braided steel, while being highly resistant to all kinds of environmental conditions. The multi-layer design of the wire is free of entrapped air and prevents the accumulation of condensed water which can result in high voltage flash-overs. Several different configurations with durable 90-degrees and 180-degrees 2-pole and 3-pole plugs are available.

The new oil and UV resistant multi-conductor wire is specially designed for shielded CSA certified primary leads. It consists of a multi layer design: ·Fine bare copper wire ·PVC/Nylon insulation · Aluminum-plated foil and tinned copper braid ·PVC jacket ·Temperature range -40° C to +90° C (-40° F to +194° F) This design ensures that no humidity can be trapped in the lead.

78


SHIELDED New Style Shielded Primary Leads for MOTORTECH AlphaRail Wiring Rails P/N1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Equivalent to

95.01.140-L

Supersedes

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

95.01.040-L

95.01.141-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

95.01.041-L

95.01.142-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

95.01.042-L

95.01.143-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

95.01.043-L

95.01.144-L

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

95.01.044-L

95.01.145-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

95.01.045-L

95.01.146-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

95.01.046-L

95.01.147-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

95.01.047-L

Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request. Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems.

Conventional Shielded Primary Leads for MOTORTECH AlphaRail Wiring Rails P/N1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

95.01.040-L

Supersedes

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

95.01.041-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

95.01.042-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

95.01.043-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

95.01.044-L

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

95.01.045-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

95.01.046-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

95.01.047-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

Equivalent to

IGNITION SYSTEMS

1)

Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request. Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems. 1)

Rail Connector

-L

Coil Connector

79


PRIMARY LEADS Conventional Shielded Primary Leads – 3 Pole Ignition Coil Connection P/N1)

Supersedes

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Equivalent to

95.01.010-L

Primary lead

MIL Style 3 pole socket, 180°

1/2-14 NPT, 180°

2 wire

593022-L

95.01.010-L-2

Primary lead

MIL Style 3 pole socket, 180°

1/4-18 NPT, 180°

2 wire

95.01.010-L-3

Primary lead

MIL Style 3 pole socket, 180°

3/8-18 NPT, 180°

2 wire

95.01.020-L

Primary lead

MIL Style 3 pole socket, 90°

1/2-14 NPT, 180°

2 wire

95.01.020-L-2

Primary lead

MIL Style 3 pole socket, 90°

1/4-18 NPT, 180°

2 wire

95.01.020-L-3

Primary lead

MIL Style 3 pole socket, 90°

3/8-18 NPT, 180°

2 wire

95.01.021-L

Primary lead

MIL Style 3 pole socket, 90°

1/2-14 NPT, 180°

2 wire

593029-L

2)

95.01.022-L

Primary lead

MIL Style 3 pole socket, 90°

1/2-14 NPT, 180°

2 wire

593036-L

95.01.023-L2)

Primary lead

MIL Style 3 pole socket, 180°

1/2-14 NPT, 180°

2 wire

593035-L

593027-L

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in., 96 in., 108 in., 120 in., 135 in., 138 in., 150 in.; other lengths available on request. 2) Wire length is double of braid length. 1)

Conventional Shielded Primary Leads – 2 Pole Ignition Coil Connection P/N1)

Supersedes

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Equivalent to

95.06.010-L

Primary lead

MIL Style 2 pole socket, 180°

1/2-14 NPT, 180°

2 wire

A754-L / LT2001-L

95.06.020-L

Primary lead

MIL Style 2 pole socket, 90°

1/2-14 NPT, 180°

2 wire

B754-L / LT2011-L

95.06.030-L

Primary lead

MIL Style 2 pole socket, 180°

5/8-24 NPT, 90°

2 wire

C754-L / LT2100-L

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in., 96 in., 108 in., 120 in., 135 in., 138 in., 150 in.; other lengths available on request. 1)

Conventional Shielded Primary Leads – 3 Pole Ignition Coil Connection - Special P/N1)

Description

Ignition Coil Connector

Wiring Rail Connector

95.01.030-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 3 pole socket, 180° 2 Wire

95.01.031-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 3 pole pin, 90°

95.01.033-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 3 pole socket, 180° 3 Wire

1)

Supersedes

Conductor

Equivalent to 539069-L

2 Wire

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.

Conventional Shielded Primary Lead – 2 Pole Ignition Coil Connection – Special P/N1) 95.01.032-L 1)

Supersedes

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Primary lead

MIL Style 2 pole pin, 90°

MIL Style 2 pole pin, 90°

2 Wire

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.

Adaptor Outlet Box

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

80

Equivalent to

-L

Coil Connector


Shielded Cable Assemblies P/N1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

95.01.011-L

Cable assembly

MIL Style 3 pole socket, 180°

1/2-14 NPT, 180°

3 wire

95.01.024-L

Cable assembly

MIL Style 3 pole socket, 90°

1/2-14 NPT, 180°

3 wire

593024-L

95.01.025-L

Cable assembly

MIL Style 4 pole socket, 90°

1/2-14 NPT, 180°

5 wire

593025-L

95.01.026-L

Cable assembly

MIL Style 5 pole socket, 90°

1/2-14 NPT, 180°

6 wire

593026-L

1)

Supersedes

Equivalent to

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.

Shielded Cable Assemblies P/N1)

Supersedes

95.01.012-11

1)

Ignition Coil Connector

Wiring Rail Connector

Conductor

Equivalent to

Primary lead

MIL Style 3 pole socket, 90°

3 pole socket, 90°

2 wire

593068-1

Standard braid length 11 in.; other lengths available on request.

NEW

Primary Leads for MOTORTECH AlphaRail Wiring Rails - For Non-Shielded Applications P/N1)

Supersedes

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

06.01.040-L

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

06.01.041-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

06.01.042-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 180°

2 wire

06.01.043-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 180°

2 wire

06.01.044-L

Primary lead

MIL Style 3 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

06.01.045-L

Primary lead

MIL Style 3 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

06.01.046-L

Primary lead

MIL Style 2 pole socket, 180°

MIL Style 2 pole pin, 90°

2 wire

06.01.047-L

Primary lead

MIL Style 2 pole socket, 90°

MIL Style 2 pole pin, 90°

2 wire

Equivalent to

IGNITION SYSTEMS

1)

Description

Standard lead lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request. Add suffix "-X" to part number for cross wired primary leads for positive grounded ignition systems. 1)

NEW

Primary Leads for CUMMINS® QSK60G and QSV81/91G Gas Engines P/N

Supersedes

06.30.142-141) 1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Primary lead

MIL Style 3 pole socket, 90°

3 pole socket, 180°

2 wire

Equivalent to

Fits application only, if conversion kits P/N 75.30.143 or 75.30.144 previously were used; other lengths available on request.

Primary Leads for unshielded Ignition Coils P/N

Supersedes

06.30.111-60

1)

1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

Equivalent to

Primary lead

2 wire, 180°

MIL Style 3 pole socket, 180° 2 wire

583017-60KT

Equivalent to

Standard lead length 60 inch; other lengths available on request.

Primary Leads for WAUKESHA® P/N1)

Description

Ignition Coil Connector

Wiring Rail Connector

Conductor

06.30.095-L

Primary lead

MIL Style 3 pole socket, 90°

3 pole socket, 180°

2 wire

06.30.107

Primary lead

MIL Style 3 pole socket, 90°

3 pole socket, 180°

2 wire

A740746

06.30.108

Primary lead

2 wire, 180°

3 pole socket, 180°

2 wire

740746B

1)

Supersedes

Standard braid lengths ("-L") = 6 in., 9 in., 12 in., 15 in., 18 in., 24 in., 30 in., 36 in., 42 in., 48 in., 54 in., 60 in., 72 in., 84 in.; other lengths available on request.

81


82


EXTENSIONS Hundreds of different engine models in this industry call for a great number of variations of unshielded and shielded Spark Plug Extensions, Coil Extensions and Repair Kits. Main purpose of an extension is to ensure that the high voltage can pass from the ignition coil to the spark plug. MOTORTECH has engineered a great number of excellent designs for high end or low end markets.

83


EXTENSIONS

PolyMot™

MOTORTECH SPARK PLUG LEADS & EXTENSIONS

Spark Plug Extensions − PolyMot™ Style Besides all the successful spark plug leads, MOTORTECH has also designed a large number of spark plug extensions under the PolyMot™ patented design. These extensions are unique and offer several advantages when being compared to the OEM or aftermarket competition. With the knowledge gathered in Ignition control and coil manufacturing, a lot of the details were implemented into these products. • Built in 5 kΩ resistor for RFI supression • Internal silicone seal for spark plug insulator • Top thread for easy removal with special tool • Long life product

Comparison between OEM and MOTORTECH Spark Plug Extension for CATERPILLAR® G3520C and G3600 Series Gas Engines Extra silicone seal ring for better insulation of ignition coil and spark plug extension 2 Spark plug extensions made of high-quality TeflonTM for high dielectric strength 3 Innovative spring-loaded secondary terminal inside ensures proper and reliable connection to spark plug (patented design) 4 MOTORTECH silicone seal ring for better insulation of spark plug insulator

MOTORTECH Spark Plug Extension P/N 06.80.459H

1

84

1

2

3

4

CATERPILLAR® Spark Plug Extension P/N 308-1380


NON-SHIELDE

D

PolyMot Spark Plug Extensions Model

Extension Length

Resistance Spark Plug

P/N Silicone Seal Ring

Thread on Top End

Equivalent to

06.80.320/H/H-T/ CATERPILLAR® 06.80.381H/H-T

G3500 series

11 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

123-4710

06.80.319-T

06.80.319/H/H-T

CATERPILLAR®

G3600 series

11 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

123-8641

06.80.202-T

06.80.202

COOPER®

2400G series

9 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

06.80.755-T1)

CUMMINS®

QSK60G

13 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

06.80.756-T1)

CUMMINS®

QSV81/91G

15 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

06.80.460

WÄRSTSILÄ®

34SG series

18 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

0012E002200

06.80.461

WÄRSTSILÄ®

34SG series

17 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

0012E006500

06.80.469-T

WAUKESHA®

APG series

10 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A211797M

Supersedes

06.80.320-T

Engine Make

656-701-003

06.80.206-T

06.80.206

WAUKESHA®

AT25 series

15 in.

5 kΩ

GT3-1/RM77N

06.84.040

x

A211357Y

06.80.330-T

06.80.330

WAUKESHA®

AT25GL series

15 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A211797Y

06.80.213-T

06.80.213

WAUKESHA®

AT27GL series

15 in.

5 kΩ

GT3-1/RM77N

06.84.040

x

A296064G

06.80.310-T

06.80.310

WAUKESHA®

AT27GL-LR series

14 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A296064H

06.80.309-T

06.80.309

WAUKESHA®

VGF series

9 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A211797J/ A211797K

06.80.321-T

06.80.321/H/H-T

WAUKESHA®

VHP-GL series 13 in.

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A211797H/ A211797P

06.80.340-T

06.80.340

WAUKESHA®

VHP-4 series

5 kΩ

GI3-1/RB77WPCC

06.84.040

x

A211797G

1)

13 in.

IGNITION SYSTEMS

P/N

Fits application only, if conversion kits P/N 75.30.143 or 75.30.144 previously were used.

PolyMot Spark Plug Extensions – Removal Tool for Spark Plug Extensions with Thread on Top End P/N

Coil Connection

44.99.912

Spark plug extension removal tool

Extension Rods – Low Cost Style1) P/N

Description

Primary Connection

Secondary Connection

Equivalent to

06.80.349-L2)

Extension rod

SAE

snap-on attachment

TCRC-"L"

2)

06.80.376-L

Extension rod

SAE

#8-32 screw-on attachment

TCR-"L"

06.80.376-10

Extension rod

SAE

#8-32 screw-on attachment

TCR-10WM / 207927A

1) 2)

We recommend using PolyMot high tension leads. Standard lengths ("-L") = 3 in., 4 in., 5 in., 6 in., 8 in., 10 in., 12 in., 14 in., 16 in., 18 in., 20 in., 24 in.; other lengths available on request.

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

85


EXTENSIONS NON-SHIELDE

D

Repair Kits for MOTORTECH Ignition Coils – For CATERPILLAR® G3400 and G3500 Series Gas Engines P/N

Figure

Description

Application

Extension Length

Extension Diameter

Fits Ignition Coil P/N

06.80.741

1

Ignition coil repair kit

G3400 – Non CSA

95 mm

30 mm

06.50.141/06.50.145

06.80.742

1

Ignition coil repair kit

G3400 – CSA

97 mm

30 mm

06.50.142/06.50.146

06.80.743

1

Ignition coil repair kit

G3400 – Non CSA

107 mm

30 mm

06.50.143/06.50.147

06.80.744

1

Ignition coil repair kit

G3400 – CSA

109 mm

30 mm

06.50.144/06.50.148

06.80.751

1

Ignition coil repair kit

G3500 – Non CSA

118 mm

30 mm

06.50.151/06.50.155

06.80.752

1

Ignition coil repair kit

G3500 – CSA

105 mm

30 mm

06.50.152/06.50.156

06.80.753

1

Ignition coil repair kit

G3500 – Non CSA

112 mm

30 mm

06.50.153/06.50.157

06.80.754

1

Ignition coil repair kit

G3500 – CSA

105 mm

30 mm

06.50.154/06.50.158

Above Repair Kits contain following sub components P/N

P/N Extension including Seal

P/N included Spark Plug Seal

06.80.741

06.80.741-2

06.84.059

06.80.742

06.80.742-2

06.84.059

06.80.743

06.80.743-2

06.84.059

06.80.744

06.80.744-2

06.84.059

06.80.751

06.80.751-2

06.84.040

06.80.752

06.80.752-2

06.84.040

06.80.753

06.80.753-2

06.84.040

06.80.754

06.80.754-2

06.84.040

P/N included Extension Seal

06.81.084

06.81.084

06.81.084

06.81.084

P/N Lip Seal

P/N Secondary Terminal

06.81.051

02.85.881

06.81.051

06.51.134

06.81.051

06.51.136

06.81.051

06.51.133

06.81.051

02.85.881

06.81.051

02.85.870

06.81.051

02.85.881

06.81.051

02.85.870

Repair Kits for CATERPILLAR® Ignition Coils – for CATERPILLAR® G3400 and G3500 Series Gas Engines P/N

Figure

Supersedes

Description

Application

Extension Length

Extension Diameter Fits Ignition Coil P/N

Ignition coil repair kit

G3400 - Non CSA

95 mm

30 mm

232-6348, 165-1591, 131-3277, 129-8802, 108-0615

Ignition coil repair kit

G3400 - CSA

97 mm

30 mm

232-6349, 165-1592, 122-8070

Ignition coil repair kit

G3400 - Non CSA

107 mm

30 mm

232-6352, 213-7443

06.80.419H

1

06.80.742

1

06.80.420H

1

06.80.744

1

06.80.417H

Ignition coil repair kit

G3400 - CSA

109 mm

30 mm

232-6353, 213-7444

06.80.515H

1

06.80.315H

Ignition coil repair kit

G3500 - Non CSA

118 mm

30 mm

232-6346, 165-1589, 124-0749

06.80.752

1

06.80.415H

Ignition coil repair kit

G3500 - CSA

105 mm

30 mm

232-6347, 165-1590

06.80.480

1

Ignition coil repair kit

G3500 - Non CSA

112 mm

30 mm

232-6350

06.80.754

1

Ignition coil repair kit

G3500 - CSA

105 mm

30 mm

259-2078

06.80.418H

06.80.415H

Above Repair Kits contain following sub components P/N

P/N Extension including Seal

P/N included Spark Plug Seal

06.80.419H

06.80.279H

06.84.059

06.80.742

06.80.742-2

06.84.059

06.80.420H

06.80.280H

06.84.059

06.80.744

06.80.744-2

06.84.059

06.80.515H

06.80.335H-1

06.84.040

06.80.752

06.80.752-2

06.84.040

06.80.480

06.80.481

06.84.040

06.80.754

06.80.754-2

06.84.040

Conversion 1 inch = 25,4 mm / 1 foot = 0,3 m

86

P/N included Extension Seal

06.81.084

06.81.084

06.81.084

06.81.084

P/N Lip Seal

P/N Secondary Terminal

06.81.051

02.85.881

06.81.051

06.51.134

06.81.051

06.51.136

06.81.051

06.51.133

06.81.051

02.85.881

06.81.051

02.85.870

06.81.051

02.85.881

06.81.051

02.85.870


Teflon Extensions for CATERPILLAR® Ignition Coils P/N

Figure

Description

Extension Length

Extension Diameter

Equivalent to

06.80.356H

2

Teflon extension

118 mm

25 mm

133-5078

06.80.360H

2

Teflon extension

118 mm

30 mm

169-4295

Spark Plug Extension for MOTORTECH/CATERPILLAR® Ignition Coil – For CATERPILLAR® G3520C and G3600 Series Gas Engines1)

06.80.459H 1)

Figure

Description

Application

3

Spark Plug Extension

Resistance

G3520C/G3600 0 kΩ

Extension Length Extension Diameter

Fits Ignition Coil P/N

Equivalent to

248 mm

06.50.161/06.50.162

283-5271, 308-1380

26 mm

Supersedes spark plug extensions P/N 06.80.375H and 06.80.446H.

SHIELDED

CSA Certified Integral Ignition Coil Adaptors for shielded Spark Plugs P/N1)

Figure

Description

Spark Plug Connection

Terminal Well Depth

Ignition Coil Connection Terminal Well Depth

Equivalent to

95.07.010-L

4

Integral ignition coil adaptor 5/8-24 UNEF

1 in.

1-20 UNEF

2 in.

BG E Series

95.07.011-L

4

Integral ignition coil adaptor 3/4-20 UNEF

1 in.

1-20 UNEF

2 in.

593120-L / M"L"-2C

95.07.012-L

4

Integral ignition coil adaptor 3/4-20 UNEF

2 in.

1-20 UNEF

2 in.

593130-L / M"L"1C

95.07.013-L

4

Integral ignition coil adaptor 13/16-20 UNEF

2 in.

1-20 UNEF

2 in.

593140-L

1)

IGNITION SYSTEMS

P/N

Standard lengths ("-L") = 1.5 in., 3 in., 6 in., 9 in., 11 in., 19 in.; other lengths available on request.

CSA Certified Extensions for shielded Spark Plugs P/N1)

Figure

Description

Spark Plug Connection Terminal Well Depth Ignition Coil Connection Terminal Well Depth

Equivalent to

95.07.020-L

5

Shielded spark plug extension 5/8-24 UNEF

1 in.

5/8-24 UNEF

1 in.

95.07.021-L

5

Shielded spark plug extension 3/4-20 UNEF

1 in.

3/4-20 UNEF

1 in.

M"L"-2S

95.07.022-L

5

Shielded spark plug extension 3/4-20 UNEF

2 in.

3/4-20 UNEF

2 in.

M"L"-2E

95.07.023-L

5

Shielded spark plug extension 5/8-24 UNEF

1 in.

3/4-20 UNEF

2 in.

95.07.024-L

5

Shielded spark plug extension 3/4-20 UNEF

1 in.

3/4-20 UNEF

2 in.

1)

Standard lengths ("-L") = 4 in., 5 in., 6 in., 8 in., 10 in., 12 in., 18 in.; other lengths available on request.

1

2

2

3

4

87


88


WIRING RAIL SYSTEMS SYSTEM MOTORTECH wiring rails are available for ignition, detonation detection and thermocouple wiring. They are made of stainless steel which performs better than aluminum in harsh environments and where operators use any kind of equipment to hold or stand on. Rigid military style connectors are securely fastened into stainless steel. No screws will come loose when the engine vibrates as the AlphaRail is assembled with watertight industrial rivets (used as joints in the aircraft industry). Rails are filled with special foam to ensure that all wires are separated from ground and will not vibrate and eventually short out to ground. It‘s a water proof design built to last in an uncovered environment. Don‘t go low-tech and take the risk of engine down time because of equipment being under repair. Eliminate the need for constant rewiring, connector exchanges or straightening out weak and bent aluminum wiring rails.

89


WIRING RAIL SYSTEMS

AlphaRail

MOTORTECH IGNITION RAIL SYSTEM

MOTORTECH AlphaRail – Wiring Rail System for Ignition Control MOTORTECH stainless steel, vibration resistant rail assembly will withstand any harsh environment commonly found in the oil & gas industry. Our proven design is made for engine manufacturers and the global aftermarket. Do not go Low-Tech and take the risk of engine down time because of equipment being under repair. Eliminate the need for constant rewiring, connector exchanges or straightening out weak and bent aluminum wiring rails.

• Made of stainless steel which performs better than aluminum in harsh environments (and where operators use any kind of equipment to hold or stand on) • Ignition rails may be specified with Ignition coils mounted on the wiring rail or the coils can be installed on-engine. Made to perfectly fit the application • Rigid military style connectors are securely fast ened into the stainless steel • No screws will come loose when the engine vibrates as the AlphaRail is assembled with watertight industrial rivets (used as joints in the aircraft industry!) • Rails are filled with special foam to ensure that all wires are separated from ground and will not vibrate and eventually short out to ground • Water proof design – built to last in uncovered environment • Repairable by MOTORETCH‘s assigned distributors in the event of mechanically damage • No need for a timing light connector as MOTORTECH offers a unique timing light. The „ScopeLite“ is able to pick up the ignition signal through shielded primary and secondary leads

90


IGNITION SYSTEMS

Application Chart – Common Igniton Wiring Rails

Wiring Rail

Engine Information

Engine Make

Engine Model

Cylinder Arrangement

Mounting Brackets

Number of Cylinders

Amount of Ignition Coils per Cylinder

Ignition Wiring Rail

2

95.87.222-NAN-10

Amount of Bracket P/N 75.10.303

Amount of Amount of Amount of Flatbar optional Flatbar optional Flatbar 75.10.280 P/N .120 P/N 75.10.097 P/N 75.10

1

2

2

1

2

Amount of Wiring Rails

Ignition Coil

Harness

Junction Box

Amount of Ignition Coils

Amount of Harness P/N 95.40.314-L

Amount of Junction Box P/N 6.05.067

2

4

1

1

2

1

2

6

1

2

2 8

2

1

8

12

8

16

2

1

1

1

AJAX

DPC-300

In-Line

2

In-Line

3

2

AJAX

DPC-600

95.87.323-NAN-10

8

CATERPILLAR

V-Type

12

2

G398

95.86.611-NBN

8

1

8

8

16

2

1

2 2

1

4

1

6

6

1

1

12

6

8

8

1

10

8

4

4

1

8

6

4

1

1

1

6

8

1

12

4

4

4

1

12

3

SUPERIOR

6

1

3

In-Line

1

6G825

95.86.613-NAN

3

6

1

E2842E312

3

MAN

V-Type

2

4

1

95.86.606-NAN

4

2

1

8

12

INGERSOLL RAND

1

4

V-Type

2

XVG -8

95.86.437-NAN

4

2

PKVGR -12

4

8

INGERSOLL RAND

V-Type

2

8

12

95.86.627-NFN

8

1

8

8

1

12

2

INGERSOLL RAND

1

8

V-Type

2

PKVG -12

95.86.627-NDN

8

2

KVS-6

8

12

INGERSOLL RAND

V-Type

2

6

12

95.87.344-NAN-04

6

2

6

6

1

TCG 2015 V6

6

2

DEUTZ

V-Type

2

4

4

95.86.310-NAN

4

2

4

6

DEUTZ

8

1

4

V-Type

2

TCG 2015 V8

95.86.410-NAN

4

8

1

16

4

DEUTZ

V-Type

2

TBG 620 V16

95.86.809-NAN

8

1

8

8

2

8

2

1

12

16

DeLAVAL

2

6

V-Type

2

HVA-12

95.87.622-NAN-04

6

2

GV TIR/CIR 158

6

24

DAEWOO

V-Type

2

4

1

95.86.406-NAN

4

2

1

10

8

COOPER BESSEMER

2

8

V-Type

2

GMW_ -10

95.87.541-NEN-10

8

2

GMVA-10

8

20

COOPER BESSEMER

V-Type

2

8

2

95.87.548-NGN-04

8

2

1

8

20

COOPER BESSEMER

1

6

In-Line

1

G2408GTL

95.86.814-NAN

6

1

G3612

6

8

CATERPILLAR

V-Type

2

6

12

95.86.618-NAN

6

1

6

6

1

16

2

CATERPILLAR

V-Type

2

G3516

95.86.811-NAN

6

6

1

8

2

G3408

16

CATERPILLAR

V-Type

2

4

8

95.86.407-NAN

4

4

1

G3406

6

2

CATERPILLAR

In-Line

1

2

2

95.86.607-NAN

2

1

1

6

6

CATERPILLAR

1

2

In-Line

1

G3306

95.86.606-NAN

2

1

G3304

2

6

CATERPILLAR

In-Line

1

2

1

2

4

95.86.406-NAN

2

4

CATERPILLAR

1

8

V-Type

2

G399

95.86.811-NDN

...

Charts: Specification ch.de www.motorte 91


WIRING RAIL SYSTEMS

SHIELDED Wiring Rail Kits for CATERPILLAR® G3300 Series Gas Engines – Shielded Ignition P/N 95.75.025-1

Ignition wiring rail kit without ignition unit for CATERPILLAR® G3304 • Incl. harness to ALTRONIC® magneto • Mounting bracket welded to the rail • G-lead connector • 4 shielded primary leads P/N 95.01.040-15 to fit ALTRONIC® 3 pole integral ignition coils • 1 Timing adaptor P/N 06.98.109

95.75.024-1

Ignition wiring rail kit without ignition unit for CATERPILLAR® G3306 • Incl. harness to ALTRONIC® magneto • Mounting bracket welded to the rail • G-lead connector • 6 shielded primary leads P/N 95.01.040-15 to fit ALTRONIC® 3 pole integral ignition coils • 1 Timing adaptor P/N 06.98.109

Wiring Rail Kits for CATERPILLAR® G3600 Series Gas Engines – Ignition / Detonation

92

P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

Primary Lead

Equivalent to

95.75.108

Wiring rail kit

CATERPILLAR

G3606

not included

not included

95.01.045-12

213-6308

95.75.103

Wiring rail kit

®

CATERPILLAR

G3608

not included

not included

95.01.045-12

219-9946

95.75.106

Wiring rail kit

CATERPILLAR®

G3612

not included

not included

95.01.045-12

191-5007 / 191-5008

95.75.107

Wiring rail kit

CATERPILLAR

G3616

not included

not included

95.01.045-12

198-2938 / 198-2941

®

®


Wiring Rail Kits for ARROW® Gas Engines – Shielded Ignition P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

95.75.055

Wiring rail kit

®

ARROW

VRG176

06.00.520

95.75.056

Wiring rail kit

ARROW®

VRG220

06.00.520

95.75.057

Wiring rail kit

ARROW

VRG330

06.00.520

®

Primary Lead

Equivalent to

COMING SOO

N

Wiring Rail Kits for DEUTZ® Gas Engines Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

High Tension Lead

77.75.015

Wiring rail kit

®

DEUTZ

TBG620V12

not included

06.50.055

06.85.179-20

77.75.016

Wiring rail kit

DEUTZ®

TBG620V16

not included

06.50.055

06.85.179-20

Equivalent to

Wiring Rail Kit for WAUKESHA® Gas Engines P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

Primary Lead

Equivalent to

95.75.048

Wiring rail kit

WAUKESHA

VHP L7042

not included

95.01.041-24

740283

®

not included

IGNITION SYSTEMS

P/N

STOP

93


WIRING RAIL SYSTEMS

NON-SHIELDE

D

Ignition Kits for MAN® Gas Engines – Non-Shielded

94

P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

High Tension Lead

Pickup

75.00.401

Ignition kit

MAN®

E0834E302/312/LE302

66.00.410-8

06.50.104

06.85.839H-16

66.60.003-60

75.00.359

Ignition kit

MAN

E0834E302/312/LE302

06.00.520

06.50.100

06.85.839H-16

66.60.003-60

75.00.402

Ignition kit

MAN®

E0836E302/312

66.00.410-8

06.50.104

06.85.839H-16

66.60.003-60

75.00.366

Ignition kit

MAN

E0836E302/312

06.00.525

06.50.100

06.85.839H-16

66.60.003-60

75.00.403

Ignition kit

MAN®

E0836LE202

66.00.410-8

06.50.104

06.85.836H-16

66.60.003-60

75.00.353

Ignition kit

MAN

E0836LE202

06.00.525

06.50.100

06.85.836H-16

66.60.003-60

75.00.404

Ignition kit

®

MAN

E2876E312/TE302

66.00.410-8

06.50.104

06.85.836H-16

66.60.003-60

75.00.347

Ignition kit

MAN®

E2876E312/TE302

06.00.520

06.50.100

06.85.836H-16

66.60.003-60

75.00.405

Ignition kit

MAN

E2676LE202

66.00.410-8

06.50.104

06.85.929-20

66.60.003-60

75.00.406

Ignition kit

MAN®

E2876LE202/302

66.00.410-8

06.50.104

06.85.836H-16

66.60.003-60

75.00.352

Ignition kit

MAN

E2876LE202/302

06.00.520

06.50.100

06.85.836H-16

66.60.003-60

75.00.407

Ignition kit

MAN®

E2848LE322

66.00.410-8

06.50.104

06.85.836H-16

66.60.003-100

75.00.348

Ignition kit

MAN

E2848LE322

06.00.520

06.50.100

06.85.836H-16

66.60.003-100

75.00.408

Ignition kit

MAN®

E2842E/LE312

66.00.410-16

06.50.104

06.85.836H-16

66.60.003-100

75.00.356

Ignition kit

MAN

E2842E/LE312

06.00.525

06.50.100

06.85.836H-16

66.60.003-100

75.00.409

Ignition kit

MAN®

E2842LE322

66.00.410-16

06.50.104

06.85.836H-16

66.60.003-100

75.00.349

Ignition kit

MAN

E2842LE322

06.00.525

06.50.100

06.85.836H-16

66.60.003-100

75.00.410

Ignition kit

MAN

E3262LE202

66.00.410-16

06.50.104

06.85.959-22

66.60.003-100

®

®

®

®

®

®

®

® ®


Ignition Kits for LIEBHERR® Gas Engines – Non-Shielded P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

Spark Plug1)

Pickup2)

75.00.433

Ignition kit

®

LIEBHERR

G944

66.00.410-8

06.50.107

not included

LIEBHERR® pickup

75.00.434

Ignition kit

LIEBHERR®

G946

66.00.410-8

06.50.107

not included

LIEBHERR® pickup

75.00.435

Ignition kit

®

LIEBHERR

G9508

66.00.410-8

06.50.107

not included

LIEBHERR® pickup

75.00.436

Ignition kit

LIEBHERR®

G9512

66.00.410-16

06.50.107

not included

LIEBHERR® pickup

1) 2)

MOTORTECH XTL PLUG P/N B432BEX9-A107 has to be ordered separately in required quantity. Scope of supply only includes pickup wiring.

P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

High Tension Lead

Pickup

75.00.288

Ignition kit

ARROW®

VRG176

06.00.520

06.50.102

06.85.860-14

66.60.001-125

75.00.289

Ignition kit

®

ARROW

VRG220

06.00.520

06.50.102

06.85.860-14

66.60.001-125

75.00.290

Ignition kit

ARROW®

VRG330

06.00.520

06.50.102

06.85.860-14

66.60.001-125

IGNITION SYSTEMS

Ignition Kits for ARROW® Gas Engines – Non-Shielded

95


WIRING RAIL SYSTEMS Ignition Kits for CATERPILLAR® Gas Engines – Non-Shielded P/N

Figure

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil

High Tension Lead

Pickup1)

75.00.338

1

Ignition kit

®

CATERPILLAR

G3304

06.00.520

06.50.102

06.88.009-18

66.60.003-60

75.00.337

2

Ignition kit

CATERPILLAR®

G3306

06.00.520

06.50.102

06.88.009-18

66.60.003-60

75.00.336

3

Ignition kit

CATERPILLAR

G3406

06.00.520

06.50.102

06.85.751-16

66.60.003-60

1)

®

Suitable trigger conversion kit included in each ignition kit.

Ignition Kits for CATERPILLAR® Gas Engines – Shielded P/N

Description

Engine Make

Engine Model

Ignition Controller Ignition Coil1)

High Tension Lead

Pickup1)

95.75.338

Ignition kit

CATERPILLAR®

G3304

06.00.520

not included

95.01.040-16

95.70.003-60

95.75.337

Ignition kit

CATERPILLAR

G3306

06.00.520

not included

95.01.040-16

95.70.003-60

95.75.336

Ignition kit

CATERPILLAR

G3406

06.00.520

not included

95.01.040-16

95.70.003-60

1) 2)

® ®

Shielded ignition coils have to be ordered separately. P/N 95.09.040-6 for CATERPILLAR® G3304/G3306. P/N 95.09.040-12 for CATERPILLAR® G3406. Suitable trigger conversion kit included in each ignition kit.

NON-SHIELDE

D

The Century of Ignition Magnetos is over. Move forward to the generation of electronic ignition.

96


1

Ignition Kit for CATERPILLAR® G3304

2

Ignition Kit for CATERPILLAR® G3306

IGNITION SYSTEMS

∙ Preprogrammed MIC520 ignition controller ∙ Wiring rail with ignition coils and brackets ∙ Harnesses for in- and output ∙ Pickup ∙ High tension leads ∙ Mechanical trigger kit with disc and adapter ring/gaskets ∙ Magneto drive cover plate and gasket

∙ Preprogrammed MIC520 ignition controller ∙ Wiring rail with ignition coils and brackets ∙ Harnesses for in- and output ∙ Pickup ∙ High tension leads ∙ Mechanical trigger kit with disc and adapter ring/gaskets ∙ Magneto drive cover plate and gasket

3

Ignition Kit for CATERPILLAR® G3406 ∙ Preprogrammed MIC520 ignition controller ∙ Wiring rail with ignition coils and brackets ∙ Harnesses for in- and output ∙ Pickup ∙ High tension leads ∙ Mechanical trigger kit with disc and adapter ring/gaskets ∙ Magneto drive cover plate and gasket

Optional available: Tool for CATERPILLAR® G3406 Fork spanner, swan-necked for easy removal of camshaft drive gear. P/N 44.04.005

97


98


TOOLS AND TEST EQUIPMENT Service Engineers today are constantly under pressure to keep the engine downtime as short as possible. For this reason MOTORTECH has designed a wide range of test equipment and tools. Electrical problems can create frustration to those who have to deal with it on a daily base. We try harder every day to design and manufacture what you are looking for!

99


TOOLS AND TEST EQUIPMENT

NEW

SparkView

MOTORTECH HIGH VOLTAGE INDICATOR

SparkView – High Voltage Indicator The SparkView is a new handheld device developed by MOTORTECH that can monitor the high voltage required by the spark plug while the engine is running. With a measuring clamp or cable and the display for up to 40 kV, it is easy to determine the condition of the spark plugs and the time at which they need to be replaced. This guarantees a constant performance of the engine and a maximum utilization of the spark plugs. Quick and comfortable monitoring on a running engine makes it possible to detect • Wear of spark plugs • Failure of the ignition system (damaged ignition coil, high tension lead or ignition controller) • Faulty compression of a cylinder

SparkView – High Voltage Indicator P/N

Figure

06.90.099-100

1

SparkView high voltage indicator incl. SparkScan1 high voltage clamp P/N 06.90.100

06.90.099-105

2

SparkView high voltage indicator incl. BNC cable P/N 06.90.105

1

100

Description

2


SparkScan1

MOTORTECH IGNITION ACCESSORIES

SparkScan1 – High Voltage Clamp

IGNITION SYSTEMS

SparkScan is designed for operators who want to monitor their high voltage traces in a simple way. The inductive high voltage clamp is connected to a Scope. When attaching the clamp to a conventional spark plug wire (7mm), the probe measures the high voltage pulse and via scope screen the operator can analyse the trace. Measuring high voltage peak (kV) and spark duration (µsec) of all cylinders of an engine in a routine manner, will allow preventive maintenance of the equipment.

SparkScan1 – High Voltage Clamp P/N

Description

Length

06.90.100

SparkScan1 high voltage clamp

2.0 m

BNC Cable for use with SparkView or Scope Meter P/N

Description

Length

06.90.105

BNC cable

2.0 m

Scope Meter – Digital Oscilloscope The Digital scopemeter is a compact 20 MHz or 40MHz two channel scope. Ideal for troubleshooting industrial machinery, instrumentation, control and power systems.

The Scopemeter has unique features like connect-and-view and trendplot that simplify taking measurements and reduce troubleshooting time when working in the field or in industrial environments.

Scope Meter – Digital Oscilloscope P/N

Description

06.98.005-110

Digital scope meter - 110V

06.98.005-220

Digital scope meter - 220V

101


TOOLS AND TEST EQUIPMENT

ICT

MOTORTECH IGNITION COIL TESTER

Ignition Coil Tester This test equipment is designed to offer service companies a professional tool to test all different kinds of coils that were sold by engine manufacturers or aftermarket companies. A built in CD ignition, high voltage clamp and a spark gap allow realistic testing.

Ignition Coil Tester P/N

Description

06.98.054

Ignition coil tester incl. adaptor kits for popular ignition coils

Ignition Coil Tester – Adaptor Kits - Standard1) – including Teflon Ignition Coil Adaptors and Connecting Leads Connections of included Lead P/N

Description

Ignition Coil

Ignition Coil Tester

06.98.054-1

Adaptor kit – CATERPILLAR® ignition coils

DEUTSCH® connector

XLR connector

06.98.054-2

Adaptor kit – ALTRONIC ignition coils

2 pole

XLR connector

06.98.054-3

Adaptor kit – MOTORTECH style ignition coils

2 pole

XLR connector

06.98.054-4

Adaptor kit – Flange ignition coils

MIL Style 3 pole socket, 180°

XLR connector

06.98.054-5

Adaptor kit – CSA certified integral ignition coils, outer thread

MIL Style 2/3 pole socket, 180°

XLR connector

06.98.054-6

Adaptor kit – CSA certified integral ignition coils, inner thread

MIL Style 2/3 pole socket, 180°

XLR connector

06.98.054-7

Adaptor kit – CSA certified ignition coils, externally mounted

MIL Style 2/3 pole socket, 180°

XLR connector

1)

®

All adaptor kits included in ignition coil tester.

Ignition Coil Tester – Adaptor Kits – Non Standard – including Connecting Leads Connections of included Lead

102

P/N

Description

Ignition Coil

Ignition Coil Tester

06.70.192-5

Adaptor kit – CUMMINS® ignition coil P/N 3964547

4 pole, 180°

XLR connector

06.70.192-6

Adaptor kit – GE JENBACHER ignition coil P/N 369083

4 pole, 180°

XLR connector

®


Adaptor Kits – Standard

IGNITION SYSTEMS

Test Arrangement

Test of CATERPILLAR® ignition coil

Test of flange ignition coil

Oscilloscope not included in scope of supply.

Oscilloscope not included in scope of supply.

Check of insulation by moving the grounding probe closely along the insulation surface.

103


TOOLS AND TEST EQUIPMENT

IPS

MOTORTECH IGNITION PICKUP SIMULATOR

Ignition Pickup Simulator Who ever has been trying to troubleshoot electronic ignition has come to the conclusion that there are so many different things that can create problems. The ignition pickup simulator allows the operator to simulate all pickup signals that are supposed to be generated by the different pickups installed on flywheel and camshaft. This way the ignition can actually be triggered with the appropriate amount of trigger events while the engine is not cranking. The IPS can be programmed for single and multiple pickup signal frequency. A variety of adaptor harnesses is available to allow use of the IPS with different ignition controller brands and models.

IPS – Ignition Pickup Simulator P/N

Description

07.98.047

IPS Ignition Pickup Simulator

IPS – Ignition Pickup Simulator – Adaptor Kits1) P/N

Adaptor Kit for

07.70.001

IPS ADAPTOR KIT – WOODWARD® IC9xx series

07.70.002-1

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with inductive pickup

07.70.002-22)

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with hall-effect pickup

07.70.002-3

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.508) with magnetic pickup

07.70.003

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.510)

07.70.004

IPS adaptor kit - MOTORTECH MIC500 (P/N 06.00.513/06.00.514), ALTRONIC® DISN, CATERPILLAR® 163-6164/163-6108

07.70.005

IPS ADAPTOR KIT – FAIRBANKS MORSE® IQ250

07.70.006

IPS adaptor kit – ALTRONIC® CPU95

07.70.009

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.511)

07.70.010

IPS adaptor kit - MOTORTECH MIC500 (P/N 06.00.515-6/06.00.515-8/06.00.516/06.00.517), WAUKESHA® CEC (VHP/VGF series)

07.70.011

IPS adaptor kit – ALTRONIC® DIS

07.70.012

IPS ADAPTOR KIT – FAIRBANKS MORSE® IQ750

07.70.013

IPS adaptor kit – MOTORTECH MIC500 (P/N 06.00.520/06.00.525/06.00.530)

07.70.014

IPS adaptor kit – MOTORTECH MIC850 series

07.70.015

IPS adaptor kit – MOTORTECH MIC4/5 series

2)

2)

1) 2)

104

Need to be ordered separately. Also for use with WOODWARD® IC100 ignition controller.


ScopeLite

MOTORTECH TIMING LIGHT

MOTORTECH Timing Light

IGNITION SYSTEMS

No need to open wiring outlet or junction boxes to get access to the ignition pulse! Self powered ScopeLite is designed to work with fully shielded ignition systems. A special clamp will pick up the small trigger signal through the braid of the shielded high tension lead. The signal is processed by the timing light and via LED Technology a sequence of flashes is generated. On applications where integral coils are used, the clamp can also be attached to the shielded primary lead. When timing is checked on engines with non-shielded spark plug wire, a selector switch needs to be pushed which then steps down sensitivity. An automatic time based Shut Off Function saves the 2 built in 9V batteries in case the operator forgets to turn off power. Make it easy and safe for the Operator!

ScopeLite – MOTORTECH Timing Light P/N

Description

06.98.100-200

ScopeLite LED timing light, incl. clamp, 200 in. standard connecting lead and carrying case

ScopeLite – MOTORTECH Timing Light – Connecting leads (Standard and Non Standard Lengths1)) P/N

Description

Length

06.90.104-100

ScopeLite connecting lead

100 in.

06.90.104-200

ScopeLite connecting lead

200 in.

06.90.104-300

ScopeLite connecting lead

300 in.

06.90.104-400

ScopeLite connecting lead

400 in.

06.90.104-600

ScopeLite connecting lead

600 in.

1)

If non standard length is required, please order separately from above chart.

Conversion 1 inch = 25,4 mm / 1 foot = 0,3 m

105


TOOLS AND TEST EQUIPMENT Timing Light – Conventional Style P/N

Description

Length

06.98.043-10

Timing light

10 ft.

06.98.043-30

Timing light

30 ft.

Digital Protractor The digital protractor is a compact rotational angle measuring tool. The unit is equipped with magnets for easy and flexible installation on flywheel, camshaft, pully or any other rotating shaft gear. P/N

Description

06.98.096

Digital protractor

High Tension Lead Removal Tool for MAN® Gas Engines P/N

Description

44.99.918

High tension lead removal tool for MAN® gas engines

Installation Tool for Reluctor Pin P/N

Description

44.99.011

Installation tool for reluctor pin P/N 06.80.104

Workshop Equipment P/N

Picture

Description

06.05.903-1

1

Spark plug test stand for M14 and M18 spark plugs

06.05.904-1

2

Engine simulator with 24 ignition coil rack

1

Conversion 1 inch = 25,4 mm / 1 foot = 0,3 m

106

2


Harness Connector Assembly Tools P/N

Picture

Description

06.98.011

5

Crimping tool for stainless steel wire studs

06.98.017

1

Extraction tool for ITT速 contacts "16S"

06.98.046

8

Installation tool for MIL style connector pins

06.98.051

7

Removal tool for MIL style connector pins

High Tension Lead Assembly Tools Picture

Description

06.98.011

5

Crimping tool for stainless steel wire studs

06.98.013

6

Crimping tool for P/N 06.80.116

06.98.019

3

Assembly tool for P/N 06.98.109

06.98.047

4

Crimping tool for P/N 06.80.126 (already included crimping tool insert P/N 06.98.048)

06.98.048

9

Crimping tool insert for P/N 06.98.047 to crimp terminal P/N 06.80.126

06.98.050

10

Crimping tool insert for P/N 06.98.047 to crimp terminal P/N 22.85.802 and P/N 22.85.803

1

2

IGNITION SYSTEMS

P/N

3

4

5

6

7

8

9

10

107


108


SPARK PLUGS AND ACCESSORIES As the market changes due to emission regulations, new fuel qualities, higher energy ignition or only to the demand for higher efficiency, the request for better spark plugs has been raised. The Industrial Spark Plug manufacturers have done their homework and offer today all kinds of spark plugs with special electrode materials or even completely new firing end designs. The Market is ready for Iridium Spark Plugs!

109


SPARK PLUGS AND ACCESSORIES

MOTORTECH Extended Barrel Spark Plugs For certain applications extended barrel plugs are required. For example when the operator cannot get a conventional spark plug down the narrow spark plug well, he will need a special product that allows him to torque the plug from the top end. MOTORTECH offers an improved product to the market. Several of the known problems of products made by competitors are eliminated. Features • No more trapped air in the extension barrel • No more condensation • No internal flash over • Built in ceramics • High dielectric strength • Rigid welds

Besides an increase in reliability the spark plug run time needed to be extended. To achieve this, MOTORTECH uses base plugs with Iridium alloy (J-Type) or Nickel/Aluminum alloy (X-Type) on center & ground electrode.

The J-Type ground electrode ensures better combustion, particularly on lean burn gas engines.

The alternative X-Type double-stage electrodes are ideally suited for slow-speed gas engines.

XT-Plugs

MOTORTECH EXTENDED SPARK PLUGS

MOTORTECH XT-PLUGS MOTORTECH XT-PLUGS are available with three different terminal styles to be connected directly to a high tension lead or a short integral ignition coil.

The “S2-Type” has a 5/8 in. male thread and used to be called the AIRCRAFT STYLE spark plug. This spark plug is designed to be connected to a shielded high tension lead.

110

The “DCP-Type” has a female thread to adapt to a short integral ignition coil. This combination is popular in some applications, where customers have had bad experiences with shielded high tension leads.

The “C-Type” is an extended barrel plug that has a conventional ceramic insulator on the top end. This allows the use of a standard spark plug boot. Preferable a connector that includes a 5 kΩ resistor to suppress the RFI.


Specification Table – MOTORTECH XT Plugs E

C

D B

A

A

F

A

A = Spark Plug Style C

= C Type

DCP = DCP Type S2

= S2 Type

B = Thread Size B4

= M14 x 1.25

B8

= M18 x 1.5

B7

= 7/8 in.

1

= 0.500 in.

2

= 0.600 in.

3

= 0.750 in.

SPARK PLUGS

C = Thread Reach

D = Electrode Design 1

= X-Type

2

= J-Type

E = Extended Barrel Length1) BEX6 = 6 in.

BEX12 = 12 in.

BEX8 = 8 in.

BEX16 = 16 in.

BEX10 = 10 in. optional

F = Electrode Gap 010

= 0.010 in. / 0.25 mm

012

= 0.012 in. / 0.30 mm

014

= 0.014 in. / 0.35 mm

Recommended Tightening Torque1)

P/N A B C D E - F

Thread Size

Tightening Torque (Cast Iron Head)

M14 x 1.25

30-40 Nm

22-30 lb-ft

M18 x 1.5

50-60 Nm

37-44 lb-ft

7/8-18

70-80 Nm

52-59 lb-ft

Other barrel lenghts available on request.

1)

Please observe the tightening torques rendered by each engine manufacturer. 1)

Conversion 1 inch = 25,4 mm / 1 foot = 0,3 m

111


SPARK PLUGS AND ACCESSORIES

XTL-Plugs

MOTORTECH EXTENDED SPARK PLUGS

MOTORTECH XTL-PLUGS for non shielded Applications Based on the concept of the extended barrel spark plugs, MOTORTECH offers a new style of spark plug. MOTORTECH XTL-PLUGS are manufactured with an integrated 7 mm spark plug lead, which allows a direct connection to an externally mounted ignition. MOTORTECH XTL-PLUGS can be ordered with different barrel and lead lengths, different lead outputs from the barrel and a wide range of ignition coil connectors. This guarantees a custom-made spark plug which definitely fits your application.

F D

C

E

A

G

B

H

F G

Available Connectors to Ignition Coil

1

1a

2

5A = ALTRONIC速 style; 5B = BENDIX速 style; 5C = MOTORTECH style

112

3

4

5*

6

7

8

9


Specification Table – MOTORTECH XTL Plugs for non shielded Applications

A = Thread Size

F = Lead Length1)

B4

= M14 x 1.25

8

= 8 in.

B8

= M18 x 1.5

10

= 10 in.

B7

= 7/8-18

12

= 12 in.

14

= 14 in.

16

= 16 in.

18

= 18 in.

B = Thread Reach = 0.500 in.

2

= 0.600 in.

3

= 0.750 in.

G = Connector to Ignition Coil

C = Electrode Design

1)

1

= Non CSA – ALTRONIC® Style – male, 180°

1

= X-Type

1A

= Non CSA – ALTRONIC® Style – female, 180°, with spreading adaptor

2

= J-Type

2

= Non CSA – MOTORTECH Style – M6, 90°

3

= Non CSA - ALTRONIC® Style – male, 180°

D = Extended Barrel Length 1)

4

= Non CSA – ALTRONIC® Style – female, 90°

BEX6 = 6 in.

5A

= CSA – ALTRONIC® Style – Externally Mounted – 3/4-20 UNEF

BEX8 = 8 in.

5B

= CSA – BENDIX® Style – Externally Mounted – 3/4-20 UNEF

BEX10 = 10 in.

5C

= CSA – MOTORTECH Style – Externally Mounted – 1-20 UNEF

BEX12 = 12 in.

6

= Non CSA – ALTRONIC® Style – male, 90°

BEX16 = 16 in.

7

= Non CSA – New MOTORTECH Style – M6, 180°

8

= Non CSA – ALTRONIC® Style – female, 90°

9

= Non CSA – FM®-Style – male - no boot

E = Lead Output from Extended Barrel A

= 90°

B

= 180°

SPARK PLUGS

1

optional

H = Electrode Gap 010

= 0.010 in. / 0.25 mm

012

= 0.012 in. / 0.30 mm

014

= 0.014 in. / 0.35 mm

1)

Other barrel and lead lenghts

available on request. Recommended Tightening Torque1)

P/N A B C D - E F G - H

Thread Size

Tightening Torque (Cast Iron Head)

M14 x 1.25

30-40 Nm

22-30 lb-ft

M18 x 1.5

50-60 Nm

37-44 lb-ft

7/8-18

70-80 Nm

52-59 lb-ft

Please observe the tightening torques rendered by each engine manufacturer.

1)

Conversion 1 inch = 25,4 mm / 1 foot = 0,3 m

113


SPARK PLUGS AND ACCESSORIES

XTL-Plugs

MOTORTECH EXTENDED SPARK PLUGS

MOTORTECH XTL-PLUGS for shielded Applications MOTORTECH XTL-PLUGS are also available for shielded applications. To meet CSA requirements, this type of spark plug is fitted with an integrated and specially designed spark plug lead. This is also known from MOTORTECH´s MOT-Blues high tension leads. The multi layer design ensures that no humidity can be trapped in the lead. MOTORTECH XTL-PLUGS can be ordered with different barrel and lead lengths and suitable ignition coil connectors, to allow direct connection to a shielded ignition coil. This guarantees a custom-made spark plug which definitely fits your application.

H

G

F

E

D B C

I

The specially designed spark plug lead consists of a multi layer design: • Nickel plated copper core • 2 layers of silicone • Stainless steel braid • Silicone jacket This design ensures that no humidity can be trapped in the lead.

114


Specification Table – MOTORTECH XTL Plugs for shielded Applications

A = Spark Plug Style

F = Lead Output from Extended Barrel

I

B

= Shielded Application

= 180°

B = Thread Size

G = Lead Length1)

B4

= M14 x 1.25

8

= 8 in.

= M18 x 1.5

10

= 10 in.

= 7/8-18

12

= 12 in.

14

= 14 in.

16

= 16 in.

18

= 18 in.

B8 B7

C = Thread Reach 1 = 0.500 in. 2 = 0.600 in.

D = Electrode Design 1

= X-Type

2

= J-Type

E = Extended Barrel Length1)

H = Connector to Ignition Coil 5A

= CSA - ALTRONIC® Style – Externally Mounted – 3/4-20 UNEF

5B

= CSA - BENDIX® Style–- Externally Mounted – 3/4-20 UNEF

5C

= CSA - MOTORTECH Style – Externally Mounted – 1-20 UNEF

SPARK PLUGS

3 = 0.750 in.

optional

I = Electrode Gap 010

= 0.010 in. / 0.25 mm

BEX6 = 6 in.

012

= 0.012 in. / 0.30 mm

BEX8 = 8 in.

014

= 0.014 in. / 0.35 mm

BEX10= 10 in. BEX12= 12 in.

1)

BEX16= 16 in.

Other barrel and lead lenghts

available on request.

Recommended Tightening Torque1)

P/N A B C D E - F G H - I

5*

Thread Size

Tightening Torque (Cast Iron Head)

M14 x 1.25

30-40 Nm

22-30 lb-ft

M18 x 1.5

50-60 Nm

37-44 lb-ft

7/8-18

70-80 Nm

52-59 lb-ft

Please observe the tightening torques rendered by each engine manufacturer.

1)

115


SPARK PLUGS AND ACCESSORIES NEW MOTORTECH MPC Pre-Chamber Spark Plug1) MOTORTECH introduces the new high quality pre-chamber spark plug series. First to come is the M18 x 1.5 with 3/4 in. thread reach. • New design • High quality electrode material • Designed for long life • Industrial rigid construction Designed for use with • CATERPILLAR® G3520C • MTU® 4000 series • DRESSER RAND GUASCOR® HGM and SFGM 560 series P/N

Description

Thread Size

Thread Reach

Electrode Design

Hex

MPC1800

MPC spark plug

M18 x 1.5

0.750 in.

Pre-chamber

7/8 in.

1)

Equivalent to

MOTORTECH MPC spark plugs only available in packs of 4 pcs.

MOTORTECH ICP Spark Plugs with Dual Thread for use with Integral Ignition Coils1) For Operators who prefer to use a long integral ignition coil, MOTORTECH manufactures the dual threaded spark plugs. These are available in M14 and M18 thread sizes. P/N

Description

Thread Size

Thread Reach

Electrode Design

Hex

Thread Size Ignition Coil

Equivalent to

ICPB412

ICP spark plug

M14 x 1.25

0.500 in.

J-Type

15/16 in.

13/16-20 UNEF

RTL85G

ICPB432

ICP spark plug

M14 x 1.25

0.750 in.

J-Type

15/16 in.

13/16-20 UNEF

RTN79G

ICPB812

ICP spark plug

M18 x 1.5

0.500 in.

J-Type

15/16 in.

13/16-20 UNEF

RTM77N

ICPB832

ICP spark plug

M18 x 1.5

0.750 in.

J-Type

15/16 in.

13/16-20 UNEF

RTB77WPCC

1)

116

All plugs have iridium center and ground electrodes. For years these plugs have been successfully operated worldwide.

MOTORTECH ICP spark plugs only available in packs of 4 pcs.


Distribution partner for DENSO spark plugs

117

SPARK PLUGS

All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.


The DDI's key to long plug life

DENSO has launched the latest generation of hardwearing spark plugs − the DENSO DOUBLE IRIDIUM (DDI) spark plug. DDI spark plug technology improves and extends the spark plug's lifespan and requires significantly less maintenance than competitor spark plugs. The DDI spark plug is particularly effective when used in biogas engines. Try DENSO DDI spark plugs today.

Unique "Iridium alloy"

A unique, high welding point "Iridium alloy" developed and patented by DENSO, dramatically improves wear resistance compared to other Iridium plug.

Iridium Design

Iridium pads both on center electrode and on ground electrode, to minimize spark gap expansion.

Patent:Japan (2877035), UK (2302367), USA (6094000)

Convergence laser welding

Electrical resistance welding

Iridium alloy pad

Platinum alloy pad

Iridium alloy 360° Laser welding

Convergence laser welding

360° laser welding

Wedge by laser welding fixes Iridium alloy pad on ground electrode securely, which realizes high reliability in high temperature combustion engine.

Secure welding of the Iridium tip by "360° laser welding" can withstand all extreme engine conditions.

Proving longer life

This suppression of gap expansion results in a longer life than Iridium Saver.

Patent: Japan (2921524), USA (6078129)

Gap expansion is suppressed by Double Iridium Pads on both sides.

The above is analysed by DENSO

Hours

Required Voltage (kV)

(biogas)

0

118

Ignition Voltage limit

Analyzed by DENSO

Gap expansion

Gap expansion

0

(biogas) Hours


Key to high reliability

High Dielectric Ceramics Newly developed ceramics with finer grain, molded-in higher pressure and higher density prevents electrical breakdown of insulator.

Transverse Rupture Strength

Electrical Breakdown Voltage (kV)

10% up

Conventional Ceramics

SPARK PLUGS

up to 5kV

Conventional Plug

Conventional Plug

Highly Reliable Monolithic Resistor The Iridium Saver Plug guarantees high reliability for withstanding high combustion pressures by incorporating a stress resistant monolithic resistor that adheres to the resistor glass in the high temperature furnace. In addition, this eliminates interference to electronic equipment from high energy coil noise.

NORMAL PLUG

Better corrosive resistance for condensed acid water. Exposure Test By Acid Steam Atmosphere. Test length: Temperature: Acid Water:

700 hours 90째C pH=2

Analyzed by DENSO

Special Nickel Plating With Better Corrosive Resistance Analyzed by DENSO

All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.

Newly Developed Ceramics

119


The SAVER's key to long plug life

DENSO's OEM expertise and commitment to innovation enables them to remain at the forefront of cutting-edge gas engine spark plug development. The unique and specialist technology used in the Iridium Saver and Iridium Saver Performer spark plugs range extends their lifespan, making them ideal for high-compression lean-burn engines. Iridium Saver and Iridium Performer spark plugs also help to maximise engine performance and deliver extra durability. Because they require minimal maintenance compared to standard plugs, Iridium Saver and Iridium Saver Performer spark plugs increase service interval times. Try DENSO's Iridium Saver or Iridium Saver Performer spark plugs today.

Unique"Iridium alloy"

360째 laser welding

A unique, high welding point "Iridium alloy" developed and patented by DENSO, dramatically improves wear resistance compared to other Iridium plug.

Secure welding of the Iridium tip by "360째 laser welding" can withstand all extreme engine conditions. Patent: Japan (2921524), USA (6078129)

Patent: Japan (2877035), UK (2302367), USA (6094000)

Platinum alloy pad Cross Groove Iridium alloy 360째 Laser welding

Cross Groove design (M18 Spark Plug)

Proving longer life

4 small electrodes created by Cross Groove improve sparking performance and suppress dispersion in voltage value, for an outstanding voltage decrease.

Required voltage is suppressed by 1) unique "Iridium alloy" 2) Cross Groove electrode, resulting in a longer life than conventional plug.

Patent: USA(6215234)

The Cross Groove Design 20

Ignition Voltage Limit

25

30

Conventional Plug FEM Ground Electrode

IRIDIUM SAVER PERFORMER Center Electrode

IRIDIUM SAVER

Ground Electrode

Center Electrode

CONVENTIONAL PLUG

The above is analysed by DENSO

120

Required Voltage (kV)

4kV

(Electric Field Strength) Weak Strong (spark easier)

(V12 Engine, Natural Gas) 0

Hours


Specifications and cross reference

G

3 - 1

I

( A )

for Gas Engines

Spark Plug Type and Installation Dimension No

Thread

Hex Size

Reach

Initial Gap

Terminal Design

No

Norminal Value

No

SPEC.

3

0.3 mm

none

solid

4

0.4 mm

A

with nut

5

0.5 mm

Spark Plug Type and Installation Dimension 1.

12.7 mm

3.

20.8 mm M 14 x 1.25

5. K

16 mm

L

20.8 mm

19 mm

1. 20.6 mm

I

3.

M 18 x 1.5 22.2 mm

T

5. 13.8 mm

For vehicle Iridium pad without cross groove on center electrode and Iridium pad on ground electrode.

Iridium pad with cross groove on center electrode and Platinum pad on ground electrode. Iridium pad without cross groove on center electrode and Platinum pad on ground electrode. Iridium pad without cross groove on center electrode and Iridium pad on ground electrode.

Cross Reference CHAMPION®

M14

RN79G (0.015)

STITT®

407XL / R407XL

ALTRONIC®

J1463DP

BERU® 14R-3CPU / 14-3CPU / 14R-5DPU / 14R-4CDP

GE3-1

14R-4CIU (Z187) / 14R-4CIU2 (Z215) / 14R-4DIU2 (Z258) / 14R-4DIU3 14R-4CIU (Z205)

GE5-1

RC78PYP / RC78PYP15

14FR-4DPUO

GK3-1

RC78WYP15

14FR-4DIU

GK3-5

407L / R407L

RB77WPCC / KB77WPCC / RB77CC / PB78WPC RB75N / RB75PP

R807LL

J1443DP

14R-5BPU / 14R-4ADP / 14R-5BIU

GN3-1

L1863IP

18GZ4-77 / 18GZ6-77-2

GI3-3

GI3-5

GI3-1

L1863B / L1863DP

18GZ20

GI3-3

GI3-5

GI3-1

18GZ5-77-2

GL3-3

GL3-5

GL3-1

18GZ7

GI3-3

GI3-5

GI3-1

RB75WPCC-1 RB76N / RB76PP RM77N RM77PP

GE3-5 GE3-5

RN79G (0.020)

RL85G / RL15B

M18

All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.

N

Iridium pad without cross groove on center electrode and Platinum pad on ground electrode.

SPARK PLUGS

19 mm

E

R807LL 807 / 827 / 847 / U827 / U847

L1843B L1843IP

18GZ22

GT3-1

121


Spark Plugs M14

GN3-1

GE3-1 GE5-1 GE3-5

GK3-1 GK3-5

Ø 6.4 Solid terminal ISO 14508

Ø 6.4 Solid terminal ISO 14508

10.2

Ø 6.4 Solid terminal ISO 14508

10.2 10.2 43 37.1

70

36.3

Ø 12.2

50.4

56.1 Ø 10.5

Ø 12.2

Hex 20.8

M14X1.25

19

Hex 20.8

Hex 16

M14X1.25

M14X1.25

19

12.7

GE3-1

GN3-1

GE5-1

Inital Gap 0.3 mm

GK3-1

Inital Gap 0.3 mm

Inital Gap 0.5 mm

Inital Gap 0.3 mm

Recommended Tightening Torque Thread Size

M14 x 1.25

GE3-5 Double Iridium

122

Inital Gap 0.28 mm

M18 x 1.5

Lubricant on Thread

Tightening Torque (Cast Iron Head)

With lubricant

20 Nm

15 lb-ft

Without lubricant

30 Nm

22 lb-ft

With lubricant

30 Nm

22 lb-ft

Without lubricant

45 Nm

33 lb-ft

GK3-5 Double Iridium

Inital Gap 0.28 mm


Spark Plugs M18

GL3-1 GL3-3 GL3-5

GI3-1 GI3-3 GI3-5 Ø 6.4 Solid terminal

Ø 6.4 Solid terminal

ISO 14508

ISO 14508

10.2

10.2

63.5

65

Ø 14.4

Ø 6.4 Solid terminal

Ø 14.4

ISO 14508

89

10.2

89

46.4 Hex 22.2

Hex 20.8

69.7

Ø 14.4

SPARK PLUGS

All DENSO data in this page is supplied by DENSO. MOTORTECH publishes this information without liability or responsibility for its content, integrity and accuracy.

GT3-1

Hex 22.2

M18X1.5

M18X1.5 20.6

20.6

M14X1.5 13.8

GL3-3

GI3-3

Inital Gap 0.28 mm

Inital Gap 0.28 mm

GL3-1

GI3-1 with cross groove

Inital Gap 0.28 mm

with cross groove

Inital Gap 0.28 mm

with cross groove

Inital Gap 0.28 mm

GL3-5

GI3-5 Double Iridium

Inital Gap 0.28 mm

GT3-1

Double Iridium

Inital Gap 0.28 mm

123


SPARK PLUGS AND ACCESSORIES Torque Wrench P/N

Supersedes

07.98.063

Description

Drive

Torque wrench, 200 Nm/150 ft./lb.

1/2 in. / 3/8 in.

Extended Barrel Magnetic Spark Plug Sockets – 1/2 Inch Drive - Standard Versions1) P/N

Supersedes

Description

Hex

Drive

07.99.022-1-L

07.99.021-L

Magnetic spark plug socket

1 in.

1/2 in.

07.99.022-2-L

07.99.020-L

Magnetic spark plug socket

15/16 in.

1/2 in.

07.99.022-3-L

07.99.019-L

Magnetic spark plug socket

7/8 in.

1/2 in.

07.99.022-4-L

07.99.018-L

Magnetic spark plug socket

13/16 in.

1/2 in.

1)

Standard barrel lengths ("L") = 6 in., 12 in., 16 in., 18 in. Other lengths available on request.

Extended Barrel Magnetic Spark Plug Sockets – 1/2 Inch Drive - Special Versions P/N

Description

Hex

Drive

07.99.022-3-36

Supersedes

Magnetic spark plug socket – NORDBERG®

7/8 in.

1/2 in.

07.99.022-6-6

Magnetic spark plug socket – MAN

13/16 in.

1/2 in.

07.99.022-6-1

Magnetic spark plug socket – MAN®, Liebherr®

5/8 in.

1/2 in.

®

Seat & Thread Reconditioner Use Seat & Thread Reconditioner to clean Cylinder Threads and Gasket Seats in one operation. P/N

Supersedes

Description

Thread Size

Thread Reach

07.98.114-12

07.98.022

Seat & thread reconditioner

M14 x 1.25

1/2 in.

07.98.114-34

07.98.023

Seat & thread reconditioner

M14 x 1.25

3/4 in.

07.98.118-12

07.98.024

Seat & thread reconditioner

M18 x 1.5

1/2 in.

07.98.118-34

07.98.025

Seat & thread reconditioner

M18 x 1.5

3/4 in.

07.98.178-58

07.98.026

Seat & thread reconditioner

7/8-18

5/8 in.

07.98.178-78

07.98.026-1

Seat & thread reconditioner

7/8-18

7/8 in.

Thread Lubricant This lubricant is non-metallic and non-conductive. Guarantees easy spark plug removal and prevents thread damage. Also for use with seat & thread reconditioner. P/N

Description

07.98.718

Thread lubricant (4 oz / 115 g)

Spark Plug Cleaning Kit Cleaning of the spark plug electrode area by using a special glass bead blaster extends spark plug life and reduces purchasing cost. P/N

Description

44.01.000

Spark plug cleaning kit

44.01.009

Blasting grid, bottle (1.0 kg)1)

1)

124

Spark plug cleaning kit already includes a package of blasting grit.


Spark Plug Cleaning Process Overview

∙ Screw the threaded spark plug end into the cleaning nozzle. ∙ Hold the spark plug tightly during the entire cleaning process.

∙ Actuate the trigger in spurts to perform the cleaning. The blasting grit is suctioned in and ejected to blast the spark plug surface. The nozzle prevents the blasting grit from escaping. The blasting grit is collected in the dust collection bag. ∙ Check the result after a few cleaning blasts. All solid deposits and oil residue should have been lifted off the surface.

∙ Remove the loose residues with compressed air. ∙ When you reuse the cleaned spark plug, adjust the electrode gap. ∙ Install new spark plug gasket.

SPARK PLUGS

∙ Select the appropriate cleaning nozzle for the spark plug used based on the following list. – small cleaning nozzle (dia. aperture: 12 mm/0.47'') for spark plugs with M14 thread – large cleaning nozzle (dia. aperture: 18 mm/0.71'') for spark plugs with 7/8" or M18 thread ∙ Attach the cleaning nozzle.

NOTE: This is only a short operation overview. Before you use the spark plug cleaning kit, read and understand the original operating manual.

125


SPARK PLUGS AND ACCESSORIES Gaskets for Spark Plugs Made of high quality folded zinc plated steel. To ensure proper spark plug installation and best heat tranfer, it is important to use a new gasket every time the spark plug is reinstalled. P/N

Description

For Thread Size

Quantity

02.85.015-100

Spark plug gasket

M14 x 1.25

100 pcs.

02.85.015-500

Spark plug gasket

M14 x 1.25

500 pcs.

02.85.015-1000

Spark plug gasket

M14 x 1.25

1000 pcs.

02.85.015-5000

Spark plug gasket

M14 x 1.25

5000 pcs.

02.85.016-100

Spark plug gasket

M18 x 1.5

100 pcs.

02.85.016-500

Spark plug gasket

M18 x 1.5

500 pcs.

02.85.016-1000

Spark plug gasket

M18 x 1.5

1000 pcs.

02.85.016-5000

Spark plug gasket

M18 x 1.5

5000 pcs.

02.85.017-100

Spark plug gasket

7/8-18

100 pcs.

02.85.017-500

Spark plug gasket

7/8-18

500 pcs.

02.85.017-1000

Spark plug gasket

7/8-18

1000 pcs.

02.85.017-5000

Spark plug gasket

7/8-18

5000 pcs.

Gaskets for Spark Plugs – MOTORTECH ICP Spark Plugs – Dual Threaded Version P/N

Supersedes

75.90.295-100

Description

Quantity

Spark plug gasket, copper

100 pcs.

Gap Setting Tool for MOTORTECH Spark Plugs with X-Type Electrode Design A unique electrode design requires a special gapping tool. For spark plugs with X-Type double stage electrodes, MOTORTECH offers a new and specially designed tool. This makes regapping easy. P/N 07.98.113

126

Supersedes

Description Gap setting tool incl. gap gauges 0.010 in./0.25 mm, 0.012 in./0.30 mm, 0.014 in./0.35 mm


Bench Gap Setting Tool for CHAMPION速 Spark Plugs with N-Type Electrode Design The more professional way to gap N-Type spark plugs is the bench mounted gapping tool. Each electrode is gapped individually. P/N

Supersedes

Description

07.98.111

07.98.109

Bench gap setting tool

Size

includes: 07.98.100-18

Handwheel

M18 x 1.5

07.98.100-78

Handwheel

7/8-18

07.98.101

Spreader

07.98.103-012

Gap gauge

0.012 in. / 0.30 mm

07.98.103-015

Gap gauge

0.015 in. / 0.38 mm

07.98.103-020

Gap gauge

0.020 in. / 0.51 mm

P/N

Supersedes

Description

Size

07.98.103-010

Gap gauge

0.010 in. / 0.25 mm

07.98.103-011

Gap gauge

0.011 in. / 0.28 mm

07.98.103-012

Gap gauge

0.012 in. / 0.30 mm

07.98.103-013

Gap gauge

0.013 in. / 0.33 mm

07.98.103-014

Gap gauge

0.014 in. / 0.35 mm

07.98.103-015

Gap gauge

0.015 in. / 0.38 mm

07.98.103-020

Gap gauge

0.020 in. / 0.51 mm

07.98.103-025

Gap gauge

0.025 in. / 0.64 mm

SPARK PLUGS

Gap Gauges for Bench Gap Setting Tool

Gap Setting Tool for CHAMPION速 Spark Plugs with N-Type Electrode Design P/N

Figure

Description

Size

07.98.100-18

1

Handwheel

M18 x 1.5

07.98.100-78

1

Handwheel

7/8-18

07.98.101

2

Spreader

07.98.102-010

3

Gap gauge

0.010 in. / 0.25 mm

07.98.102-013

3

Gap gauge

0.013 in. / 0.33 mm

07.98.102-015

3

Gap gauge

0.015 in. / 0.38 mm

07.98.102-020

3

Gap gauge

0.020 in. / 0.51 mm

07.98.102-025

3

Gap gauge

0.025 in. / 0.64 mm

1

Supersedes

2

3

127


128


GAS ENGINE MANAGEMENT The All-In-One is a complete genset or CHP unit control system. Forget the days where a genset required multiple control boxes to be tied together to one system. We have included all functions, including lean burn control into one unit with large separate display. Tie up to 32 gensets together and connect yourself to the grid. This controller has the capabilities of a large PLC system at a much lower price !

129


GAS ENGINE MANAGEMENT

ALL-IN-ONE

MOTORTECH GAS ENGINE MANAGEMENT

Gas Engine Management − ALL-IN-ONE For monitoring, controlling, regulating and system protection. ALL-IN-ONE.NT is an expandable controller for both single and multiple gen-sets operating in standby or parallel modes, especially in cogeneration (CHP) and other complex applications. Modular design (consisting of AIO.NT-controller and AIO.NT- or AIO.VISION-display) allows easy installation with the ability to add many different extension modules designed to suit individual customer requirements. Built-in synchronizing, digital isochronous load sharing and air-fuel-ratio functions (requires additional dongle) allow a total integrated solution for gen-sets in standby, island, parallel or mains parallel. Native co-operation of up to 32 gen-sets is a standard feature.

Benefits

∙ Voltage and PF control (AVR)

• Support of engines with ECU (Electronic control unit)

∙ Generator measurement: U, I, Hz, kW, kVAr, kVA,

• Excellent configurability to match customer´s needs exactly • Complete integrated gen-set solution incorporating built-in PLC and signal sharing via CAN bus – minimum external components needed • Many communication options – easy remote supervising and servicing

PF, kWh, kVAhr

Integrated fixed and configurable protections ∙ 3 phase integrated generator protections (U + f)

∙ Mains measurement: U, I, Hz, kW, kVAr, PF

∙ IDMT overcurrent + shortcurrent protection

∙ Selectable measurement ranges for AC voltages

∙ Overload protection

and currents – 120 / 277 V, 0–1 / 0–5 A ∙ Inputs and outputs configurable for various customer needs ∙ Controller redundancy

∙ Reverse power protection ∙ Earth fault protection ∙ 3 phase integrated mains protections (U + f) ∙ Vector shift protection

• Perfect price / performance ratio

∙ 2× RS232 / RS485 interface with Modbus protocol

• Gen-set performance log for easy problem tracing

∙ Support; Analog / GSM / ISDN / CDMA modem

• Air-Fuel-Ratio function for lean burn gas engines

communication support; SMS messages; ECU

Only / Alarm + History indication / Warning / Off

Modbus interface; secondary RS485 converter is

load / Slow stop / BreakerOpen&Cooldown /

isolated

Shutdown / Shutdown override / Mains protect /

Features ∙ CHP support (programmable PID loops and other built-in PLC functions) ∙ Support of engines with ECU (J1939, Modbus

∙ Event-based history (up to 1000 records) with customer-selectable list of stored values; RTC; statistic values

∙ All binary / analog inputs free configurable for various protection types: HistRecOnly / Alarm

sensor fail ∙ Phase rotation and phase sequence protection ∙ Additional 160 programmable protections

and other proprietary interfaces); alarm codes

∙ Integrated PLC programmable functions

configurable for any measured value to create

displayed in text form

∙ Interface to remote display units (3× AIO.NT- or

customer-specific protections

∙ Automatic synchronizing and power control (via speed governor or ECU)

130

AIO.NT supports many standard ECU (electronic control unit) types and is specially designed to easily integrate new ones. A powerful graphic display with user-friendly controls allows any user whatever their ability to find the information they need. The display on the basic version is capable of displaying graphical languages (e.g. Chinese).

AIO.Vision-display) ∙ USB 2.0 slave interface

∙ Baseload, Import / Export, TempByPower

∙ Dimensions 284 × 180 mm (front panel)

∙ Peak shaving

∙ Sealed to IP65

∙ Application security


InteliMains ∙ Import/Export ∙ Load Sharing ∙ Power Plant Managment ∙ Grid Monitoring ∙ Running Hours Optimization

or InteliPro ∙ Designed to meet utility protection requirements ∙ Combines standard and optional features ∙ Advanced communications ∙ Data/event logging

MainsPro ∙ Protective functionalities ∙ Free assignment of 5 relay outputs ∙ 4 binary switches to remotely change operation of the unit ∙ Last trip recorded in order to provide the evidence of cause of trip

Generator ∙ 3 Phase Monitoring ∙ Over/Under Frequency ∙ Over/Under Voltage ∙ Interrupt free reverse synchronizing ∙ Overload Protection ∙ TempByPower load control ∙ Reverse Power Protection ∙ Load Surge Protection ∙ Voltage and PF Control (AVR) LOAD GCB

MCB

Main Circuit Breaker ∙ Control ∙ Reverse Synchronization ∙ Grid Monitoring

Load Monitoring ∙ Base Load ∙ Import/Export ∙ Peak Shaving

Generator Circuit Breaker ∙ Control Synchronization

Modem ∙ Remote Control ∙ Internet Bridge

PC Monitoring Tool ∙ Visualization ∙ Programming

GSM ∙ Active/Passive calls ∙ SMS Service

CAN2

CAN1

up to 32 gensets

Ethernet (only AIO.NTC-BB)

RS 232 / RS 485 ∙ Modbus ∙ Direct PC-Connection ∙ Modem Connection ∙ SMS Managment ∙ Active Calls ∙ Internet

Engine Managment (ECU) ∙ Speed Measurement/Control ∙ Engine Monitoring and Protection ∙ Exhaust Gas Temperature monitoring ∙ Air/Fuel Ratio Control ∙ Start/Stop Routines

GAS ENGINE MANAGEMENT

@

AIN8 / BIN16/8 / I-AOUT8 Modules etc. ∙ Digital inputs (80 max) ∙ Digital outputs (48 max) ∙ Analog inputs (84 max) ∙ Analog outputs (33 max) ∙ All kind of sensors usable (programmable) ∙ Status LEDs for In- and outputs

up to 32 devices

131


GAS ENGINE MANAGEMENT ALL-IN-ONE – Gas Engine Management – ALL-IN-ONE.NT/.NTC Controllers P/N

Description

63.50.102

ALL-IN-ONE.NT controller – cogeneration Gen-Set controller (incl. AFR control)

63.50.102-HSS

ALL-IN-ONE.NT controller – cogeneration Gen-Set controller P/N 63.50.102 incl. plug-on module I-HSS-BIN6/10

63.50.104

ALL-IN-ONE.NTC controller – universal Gen-Set controller (incl. AFR control and AirGate® technology)

63.50.104-HSS

ALL-IN-ONE.NTC controller – universal Gen-Set controller P/N 63.50.104 incl. plug-on module I-HSS-BIN6/10

63.50.082

Mini-ALL-IN-ONE controller – universal controller for small Gen-Sets (incl. AFR control)

ALL-IN-ONE – Gas Engine Management – Display Units for ALL-IN-ONE.NT/.NTC Controllers P/N

Description

63.50.105

ALL-IN-ONE.Vision display – 5.7 in. color display unit for ALL-IN-ONE.NT and ALL-IN-ONE.NTC controller

63.50.101

ALL-IN-ONE.Vision display – 8.0 in. color display unit for ALL-IN-ONE.NT and ALL-IN-ONE.NTC controller

63.50.115

ALL-IN-ONE.Vision display – 17.0 in. color display unit for ALL-IN-ONE.NT and ALL-IN-ONE.NTC controller for multiple Gen-Sets – touch screen

63.50.103

ALL-IN-ONE.NT display – detachable display unit for ALL-IN-ONE.NT and ALL-IN-ONE.NTC controller

ALL-IN-ONE – Gas Engine Management – Dongles for ALL-IN-ONE.NT/.NTC Controllers P/N

Description

63.50.061

Hardware dongle for ALL-IN-ONE.NT/.NTC controllers - AFR-PCM • Enables single isolated parallel with mains • Power management operation (with CAN Bus)

63.50.062

Hardware dongle for ALL-IN-ONE.NT/.NTC Controllers - AFR-PCLSM+PMS • Enables multiple isolated parallel or multiple parallel with mains • Power management operation (with CAN Bus) • Digital load sharing • Digital VAr sharing

63.50.085

• Optimizing number of running engines: Power management; kW, kVA or % load based • Air/Fuel Ratio function for lean burn gas engines

Hardware dongle for Mini-ALL-IN-ONE - miniAFR-PCM • Enables single isolated parallel with mains for applications up to 75 kW (el.) • Air/Fuel Ratio function for lean burn gas engines • For applications up to 75 kW (el.)

AIO.NT/.NTC Controllers

AIO.NT Controller P/N 63.50.102

AIO.NTC Controller P/n 63.50.104

Available Display Units for AIO.NT/.NTC Controllers

AIO.Vision (17.0 in.) P/N 63.50.115

132

AIO.Vision (8.0 in.) P/N 63.50.101

AIO.Vision (5.7 in.) P/N 63.50.105

AIO.NT P/N 63.50.103


ALL-IN-ONE – Gas Engine Management – Other Controllers P/N

Description

63.50.064

Mains supervision controller – IM-NT

63.50.064-BTB

Mains supervision controller Bus Tie Breaker – IM-NT BTB

63.50.064-MCB

Mains supervision controller Main Circuit Breaker – IM-NT MCB

ALL-IN-ONE - Gas Engine Management - Accessories Supersedes

Description

63.50.002

Analog input module – AIN8

63.50.108

Analog input module (for thermocouples only) – AIN8TC

63.50.005

Binary input/output unit – IS-BIN16/8

63.50.007

Analog/binary input/output unit – IGS-PTM

63.50.007-HSS

Analog/binary input/output unit P/N 63.50.007 incl. plug-on module I-HSS-BIN8

63.50.011

AVR interface module – IG-AVRi

63.50.010-100

Power supply transformer for IG-AVRi module, 100-120 VAC, 50-60 Hz

63.50.010-230

Power supply transformer for IG-AVRi module, 230-480 VAC, 50-60 Hz

63.50.054

Analog output module – I-AOUT8

63.50.075

63.50.006

Modem unit – I-LB+

63.50.112

63.50.022

Internet bridge communication module – IB-NT

63.50.088

CAN repeater – I-CR

Sample Control Panel AIO.NT-Base Box P/N 63.50.102

IS-AIN8 P/N 63.50.002

GAS ENGINE MANAGEMENT

P/N

IG-AVRi P/N 63.50.011

IG-AVRi trans P/N 63.50.010-xxx

I-LB+ P/N 63.50.075

IB-NT P/N 63.50.112

IS-BIN 16/8 P/N 63.50.005

IGS-PTM P/N 63.50.007

IAOUT8 P/N 63.50.054

133


GAS ENGINE MANAGEMENT

DetCon20

MOTORTECH DETONATION CONTROL SYSTEM

Detonation Control System − DetCon20 The Gas Engine Operators are calling for increased power output from their engines. More load means higher temperatures, pressures and tougher operation. This mostly ends in catastrophic engine damages due to detonation or pre ignition. As MOTORTECH has proven for years, detonation can be detected professionally with the DetCon20. Single cylinder sensors constantly monitor the sound level of the combustion chamber. If Detonation is detected the system will take steps to eliminate detonation immediately. Upgrade your engines and increase availability of the equipment!

Detonation sensor Can be installed on any cylinder head bolt or stud. Measures the detonation signal and transfers it to the controller.

Detonation Software DetCon20 comes with a WIN based Software package that allows the operator to analyze all data in real time on his PC.

Function Once the controller detects soft detonation on one of the sensors (this is a specific stage before real detonation occurs), several steps will take place: ∙ Alarm signal turns on

∙ If this action does not cure the detonation, the load reduction output will be activated. ∙ If the load drop does not stop the engine from detonating the engine STOP output will be activated.

∙ Ignition retard by 0-5 V or 4-20 mA analog output.

STOP

... THIS FROM HAPPENING!

134


Ignition Controller HMI Display

CAN

AIO Display

Ignition Timing Control (0-5 VDC / 4-20 mA)

Analog Output

USB

Power Supply 10-30 VDC ISU (Ignition Sensor Unit)

(not required with MIC850, MIC4, MIC5)

Binary Outputs

GAS ENGINE MANAGEMENT

Alarm Load Reduction Engine Stop

USB

CAN

Signal from Ignition Coil #1 Cylinder

Up to 20 Detonation Sensors

135


GAS ENGINE MANAGEMENT DetCon20 – Detonation Control System – Control Units P/N

Description

Gas

Dual Fuel x

43.00.020

DetCon20 control unit, 20 outputs, CSA, IP20

x

43.00.120

DetCon20 control unit, 20 outputs, CSA, in enclosure, includes ignition sensor unit

x

43.00.2202)

DetCon20 control unit, 20 outputs, CSA, in enclosure

x

1)

1) 2)

The control unit has to be installed in (CSA approved) control panel. For use with MIC4, MIC5 and MIC850 series ignition controllers. Ignition sensor unit is not required.

DetCon20 – Detonation Control System – Detonation Sensor (1 per Cylinder required) P/N

Description

43.20.001

Detonation sensor w/o lead, 2 pole

Gas

Dual Fuel

x

x

Gas

Dual Fuel

x

x

Gas

Dual Fuel

DetCon20 – Detonation Control System – Detonation Sensor Lead (1 per Detonation Sensor required) P/N

Description

43.30.004-60

Detonation sensor lead, 60 ft.

DetCon20 – Detonation Control System – ISU Ignition Sensor Unit (1 per System required) P/N

Description

43.20.002

ISU ignition sensor unit

1)

x

1)

Not required if MIC4, MIC5, MIC850 or DetCon20 control unit P/N 43.00.120 is used.

DetCon20 – Detonation Control System –Inductive Pickup (1 per System required – Dual Fuel Applications only) P/N

Description

66.60.003-60

Inductive pickup, M12x1, 60 mm length

Gas

Dual Fuel x

66.60.003-100

Inductive pickup, M12x1, 100 mm length

x

DetCon20 – Detonation Control System – Inductive Pickup Lead (1 per Pickup required – Dual Fuel Applications only) P/N

Description

Connector

Length

06.71.007

Inductive pickup lead

4 pole socket, 90°

400 in.

Equivalent to

Gas

Dual Fuel x

DetCon20 – Detonation Control System – Trigger Reluctor Pin1) (1 per System required – Dual Fuel Applications only) P/N

Description

06.80.104

Trigger reluctor pin

1)

136

1)

Diameter

Length

0.25 in.

0.75 in.

Please also see chapter TriDev Trigger Devices for possible triggering.

Equivalent to

Gas

Dual Fuel x


PowerView3

NEW

MOTORTECH ENGINE INFORMATION MONITOR

PowerView3 – HMI Module The operating data of DetCon20 Detonation Control System will be completely visualized via HMI module (Human Machine Interface). The overview sheet shows the relevant information as engine knocking, knock intensity and status for activated load reduction or emergency shutdown of engine. The control keys guarantee simple navigation through different display pages and menus. All in all the PowerView3 HMI module is also able to provide error diagnostics on-site without requiring a laptop! The PowerView3 is also available for data visualization of: • Ignition Control (MIC4 and MIC5 series) • Temperature monitoring (available soon)

DetCon Overview Screen shows the most important operating data of the connected DetCon control unit.

Knocking Intensity Visualization of knocking intensity of each monitored cylinder. Different colors inform about the system status (Normal – Reduction – Critical).

Trending Knocking Intensity Visualization of knocking intensity trend data for each individual cylinder.

GAS ENGINE MANAGEMENT

Sample Screens

PowerView3 HMI Module P/N

Description

06.05.085

PowerView3 HMI module

06.05.087-F

PowerView3 activation code for visualization of DetCon20 data1)

06.05.087-U

PowerView3 activation code for visualization of DetCon20 data2)

1) 2)

Activation code has to be ordered separately with each PowerView3 HMI module. Only available for upgrade of existing PowerView3 HMI module in the field.

137


GAS ENGINE MANAGEMENT

AlphaRail

MOTORTECH WIRING RAIL SYSTEM

MOTORTECH AlphaRail – Wiring Rail System for Detonation Control

MOTORTECH Stainless Steel, vibration resistant rail assembly will withstand any harsh environment commonly found in oil & gas industry. Our proven design is made for engine manufacturers and the global aftermarket. Do not go low-tech and take the risk of engine down time because of equipment being under repair. Eliminate the need for constant rewiring, connector exchanges or straightening out weak and bent aluminum wiring rails.

• Made of stainless steel which performs better than aluminum in harsh environments (and where operators use any kind of equipment to hold or stand on) • Made to perfectly fit the application • Rigid military style connectors are securely fastened into the stainless steel

138

• Rails are filled with special foam to ensure that all wires are separated from ground and will not vibrate and eventually short out to ground • Water proof design – built to last in uncovered environment • Repairable by MOTORETCH‘s assigned distributors in the event of mechanically damage


AlphaRail – Wiring Rail System for Detonation Control – Wiring Rail P/N

Description

77.81.xxx-xx

Call your nearest Motortech Distributor for detailed specification.

AlphaRail – Wiring Rail System for Detonation Control – Harness to connect Wiring Rail and DetCon20 Control Unit (1 per Rail required) P/N

Description

Rail Connector

Length

77.41.117-L

Harness

17 pole pin, 180°

"L"= 15/25/50 ft.

77.41.317-L

Harness

17 pole pin, 90°

"L"= 15/25/50 ft.

AlphaRail – Wiring Rail System for Detonation Control – Lead to connect Detonation Sensor and Wiring Rail (1 per Sensor required) P/N

Description

Sensor Connector

Rail Connector

Length

43.30.016-L

Sensor lead

2 pole socket, 180°

3 pole socket, 180°

"L"= 10/20/30/40/60 in.

AlphaRail – Wiring Rail System for Detonation Control - Detonation Sensor (1 per Cylinder required) P/N

Description

43.20.001

Detonation sensor w/o lead, 2 pole

P/N1)

Description

75.10.303

Bracket, 40x40 mm (standard)

75.10.097

Flat bar, 180° (standard)

75.10.120

Flat bar, 150°

75.10.280

Flat bar, 90°

1)

For packs of ten please add suffix "-10" to part number.

AlphaRail – Wiring Rail System for Detonation Control – Accessories P/N

Description

15.07.134-1

3/4 in. connecting flex conduit

15.07.231-1

3/4 in. adaptor, junction box to connecting flex conduit

06.05.067

Junction box

GAS ENGINE MANAGEMENT

AlphaRail – Wiring Rail System for Detonation Control – Bracket Configuration

139


140


SENSOR SYSTEMS The gas engine Engine Industry industry has changed rapidly over during thethe last last couple few years. of years. Modern Modern engine Engine control Control systems Systems call call for for reliable sensors supplying the data for temperatures, pressures or oxygen content. MOTORTECH offers a variety of sensors that have a longer life expectancy and are made for industrial application rather than being automotive MOTORTECH offers a variety of sensors that have a longer life expectancy and are made for industrial application origin. rather than being automotive origin.

141


SENSOR SYSTEMS

AlphaRail

MOTORTECH WIRING RAIL SYSTEM

MOTORTECH AlphaRail – Wiring Rail System for Temperature Control The stainless steel wiring rails which are water tight due to a well approved foaming process, offer an easy and fast installation of accessory control systems such as • Pyrometer/temperature control • Gas valve systems With individual outlet port connectors, the sensors can be individually connected and easily wired to the rail. A disconnect able main harness routs all sensors to one main control unit or individual wiring boxes.

142

Details on the Pyrometer/ Thermocouple Wiring Rail: • Up to 10 exhaust sensor inputs per rail • Additionally 2 turbo charger thermocouples • All sensors need to be NiCr-Ni – Type K sensors

General Details: • Low voltage signals can be grouped in one rail. It is not recommended to have low and high voltage signals in one rail. In this case, detonation sensors and thermocouple leads match perfectly. • Ignition and gas valve control wire work together well.

• Made of stainless steel which performs better than aluminum in harsh environments (and where operators use any kind of equipment to hold or stand on) • Made to perfectly fit the application • Rigid military style connectors are securely fastened into the stainless steel

• Rails are filled with special foam to ensure that all wires are separated from ground and will not vibrate and eventually short out to ground • Water proof design – built to last in uncovered environment • Repairable by MOTORETCH‘s assigned distributors in the event of mechanically damage


AlphaRail – Wiring Rail System for Temperature Control – Wiring Rail P/N

Description

77.82.xxx-xx

Call your nearest MOTORTECH Distributor for detailed specification.

AlphaRail – Wiring Rail System for Temperature Control – Harness to connect Wiring Rail and Junction Box (1 per Rail required) P/N

Description

Rail Connector

Length

77.42.125L

Harness

25 pole socket, 180°

"L"= 15/25/50 ft.

77.42.325-L

Harness

25 pole socket, 90°

"L"= 15/25/50 ft.

Equivalent to

AlphaRail – Wiring Rail System for Temperature Control – Thermocouples with Lead and Rail Connector (1 per Cylinder required) P/N

Description

Rail Connector

Length

56.01.180-L / -K

Thermocouple, 180°

3 pole pin, 180°

"L"= 10/20/25/30/40/60 in.

56.01.090-L / -K1)

Thermocouple, 90°

3 pole pin, 180°

"L"= 10/20/25/30/40/60 in.

1)

1)

Equivalent to

Comes with loose connector and 177 in. lead length.

AlphaRail – Wiring Rail System for Temperature Control – Bracket Configuration P/N1)

Description

75.10.303

Bracket, 40x40 mm (standard)

75.10.097

Flat bar, 180° (standard)

75.10.120

Flat bar, 150°

75.10.280

Flat bar, 90°

1)

For packs of ten please add suffix "-10" to part number.

P/N

Description

15.07.134-1

3/4 in. connecting flex conduit

15.07.231-1

3/4 in. adaptor, junction box to connecting flex conduit

06.05.067

Junction box

SENSOR SYSTEMS

AlphaRail – Wiring Rail System for Temperature Control – Accessories

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

143


SENSOR SYSTEMS

Sensor Harnesses for MAN® Gas Engines Modern gas engines are equipped with various kinds of sensors that enable the operators to monitor, process and evaluate important data continuously, e.g. with an ALL-IN-ONE gas engine management. MOTORTECH offers pre-configured sensor harnesses which are designed individually for each type of MAN® engine. All wires are embedded in a temperature-resistant and flexible insulation. The harness is individually customized for each type of engine, and therefore it is easy to install. The scope of supply1) includes all sensors necessary for the operation of the specific engine, and the following operational data can be obtained: Pressure sensors for • Oil • Coolant water • Charge air Temperature sensors for • Oil • Coolant water • Charge air

The wiring has a central plug that is mounted on the engine with a suitable bracket. MOTORTECH offers compatible harnesses to connect the engine controller. 1)

Speed sensors for • Speed control • Gas engine management Connectors for • Exhaust temperature sensors • Actuator

Sensor Harnesses for MAN® Gas Engines – MAN® E0834E302/312 P/N

Description

06.30.024

Harness with all sensors for MAN® E0834E302/312

06.30.022

Connecting harness to PLC for MAN® E0834E302/312

Sensor Harnesses for MAN® Gas Engines – MAN® E0834LE302 P/N

Description

06.30.101

Harness with all sensors for MAN® E0834LE302

06.30.102

Connecting harness to PLC for MAN® E0834LE302

Sensor Harnesses for MAN® Gas Engines – MAN® E0836E302/312 P/N

Description

06.30.023

Harness with all sensors for MAN® E0836E302/312

06.30.022

Connecting harness to PLC for MAN® E0836E302/312

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

144

Scope of supply and design depends on the type of engine.


Sensor Harnesses for MAN® Gas Engines – MAN® E0836LE202 P/N

Description

06.30.026

Harness with all sensors for MAN® E0836LE202

06.30.027

Connecting harness to PLC for MAN® E0836LE202

Sensor Harnesses for MAN® Gas Engines – MAN® E2876E312 P/N

Description

06.30.042

Harness with all sensors for MAN® E2876E312

06.30.043

Connecting harness to PLC for MAN® E2876E312

Sensor Harnesses for MAN® Gas Engines – MAN® E2876TE302 P/N

Description

06.30.093

Harness with all sensors for MAN® E2876TE302

06.30.060

Connecting harness to PLC for MAN® E2876TE302

Sensor Harnesses for MAN® Gas Engines – MAN® E2876LE202/302 P/N

Description

06.30.025

Harness with all sensors for MAN® E2876LE202/302

06.30.028

Connecting harness to PLC for MAN® E2876LE202/302

Sensor Harnesses for MAN® Gas Engines – MAN® E2848LE322 P/N

Description

06.30.053

Harness with all sensors for MAN® E2848LE322

06.30.054

Connecting harness to PLC for MAN® E2848LE322

P/N

Description

06.30.055

Harness with all sensors for MAN® E2842E312

06.30.056

Connecting harness to PLC for MAN® E2842E312

Sensor Harnesses for MAN® Gas Engines – MAN® E2842LE312 P/N

Description

06.30.040

Harness with all sensors for MAN® E2842LE312

06.30.039

Adaptor harness for MAN® E2842LE312

06.30.041

Adaptor harness for MAN® E2842LE312

06.30.044

Connecting harness to PLC for MAN® E2842LE312

SENSOR SYSTEMS

Sensor Harnesses for MAN® Gas Engines – MAN® E2842E312

Sensor Harnesses for MAN® Gas Engines – MAN® E2842LE322 P/N

Description

06.30.053

Harness with all sensors for MAN® E2842LE322

06.30.054

Connecting harness to PLC for MAN® E2842LE322

145


SENSOR SYSTEMS

Sensor Harnesses for LIEBHERR® Gas Engines MOTORTECH also offers pre-configured sensor harnesses for the latest generation of LIEBHERR® gas engines. All wires are embedded in a temperature-resistant and flexible insulation. The harness is individually customized for each type of engine, and therefore it is easy to install. The scope of supply1) includes all sensors necessary for the operation of the specific engine, and the following operational data can be obtained: Pressure sensors for • Oil • Coolant water • Charge air Temperature sensors for • Oil • Coolant water • Charge air

The wiring has a central plug that is mounted on the engine with a suitable bracket. MOTORTECH offers compatible harnesses to connect the engine controller. 1)

Speed sensors for • Speed control • Gas engine control Connector for • Actuator

Sensor Harnesses for LIEBHERR® Gas Engines – LIEBHERR® G944 P/N

Description

06.30.106

Harness with all sensors for LIEBHERR® G944

06.30.060

Connecting harness to PLC for LIEBHERR® G944

Sensor Harnesses for LIEBHERR® Gas Engines – LIEBHERR® G946 P/N

Description

06.30.104

Harness with all sensors for LIEBHERR® G946

06.30.060

Connecting harness to PLC for LIEBHERR® G946

Sensor Harnesses for LIEBHERR® Gas Engines – LIEBHERR® G9508 P/N

Description

06.30.113

Harness with all sensors for LIEBHERR® G9508

06.30.060

Connecting harness to PLC for LIEBHERR® G9508

Sensor Harnesses for LIEBHERR® Gas Engines – LIEBHERR® G9512 P/N

Description

06.30.116

Harness with all sensors for LIEBHERR® G9512

06.30.060

Connecting harness to PLC for LIEBHERR® G9512

Conversion: 1 inch = 25,4 mm / 1 foot = 0,3 m

146

Scope of supply and design depends on the type of engine.


Sensors For several years MOTORTECH offers Oxygen sensors that can be used as replacements for the OEM part. Shielded and unshielded versions can be selected. To increase life time of these critical sensors, there is also a stainless steel hub available that is welded into the exhaust pipe.

A Heat shield can be screwed on top. This way the sensor does reach directly into the exhaust gas stream with all its deposits and the heat shield protects the sensor against transient temperature from the hot exhaust manifold.

Oxygen Sensors for CATERPILLAR® G3400 and G3500 Series Gas Engines P/N

Figure

Description

Connector

Length

Equivalent

19.60.027

1

Oxygen sensor, non shielded

6 pole pin, 180°

10.00 in.

196-5391

19.60.029

2

Oxygen sensor, shielded

6 pole pin, 180°

51.00 In.

141-2494

Description

Connector

Length