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Engine News
2010/10/20
Media Number -SEBD9674-00

Publication Date -20/10/2010

Date Updated -20/10/2010

i04010030

Recommendations for Gas Engine Spark Plugs {1550, 1555}

SMCS - 1550; 1555
Caterpillar Products:
G3300 Family Generator Sets
G3400 Family Generator Sets
G3500 Family Generator Sets and Power Modules
Engine: Commercial
G3400 Family
G3500 Family
Engine:
All G3600
G300 Family
G3300 Family
Engine News SEBD9500, 7 February 2007, "Recommended Spark Plugs". Disregard the old article.
Recommendations have been enhanced and part numbers have been changed and added. Refer to the
information below.

Introduction
In order to ensure the maximum performance for Caterpillar Gas Engines, always use the correct
spark plug. Failure to follow this recommendation can result in less than optimum engine
performance and in reduced service life of the spark plug. Table 1 lists the recommended spark plugs
for current Caterpillar Gas Engines.
Table 1
Engine

Description

Serial Number

Recommended
Spark Plug

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G3300

G3304 and
G3306
Std plug

S/N:37Y, 07Y

2N-2839 Spark Plug

108-3515 Spark Plug
Gasket

G3300

G3304 and
G3306
Canadian
Standard
Association
(CSA)

S/N:37Y, 07Y

4W-2256 Spark Plug

176-7748 Spark Plug
Gasket

G3406
Std plug for 9.4:1
and 10.3:1

G3400

G3408
Std plug for 9.4:1 S/N:4FD, 1RK, 5NW, CTS, 6NB, 7DB,
and 10.3:1
CTP (1)

2N-2839 Spark Plug

108-3515 Spark Plug
Gasket

G3412
Std plug for
8.5:1, 9.7:1, and
11.4:1
G3406
CSA for 9.4:1
and 10.3:1
G3400

G3408
CSA for 9.4:1
and 10.3:1

S/N:4FD, 1RK, 5NW, CTS, 6NB, 7DB,

CTP (1)

4W-2256 Spark Plug

176-7748 Spark Plug
Gasket

S/N:6RJ, BAZ, 3WR, 6FW, 3NK, 6ZM,

8LW, CTP (2)

104-3170 Spark Plug

108-3515 Spark Plug
Gasket

G3412
CSA for 8.5:1,
9.7:1, and 11.4:1
G3408
Std plug for
11.4:1
G3408C
Std plug for
11.4:1
G3400
G3412
Std plug for
11.4:1
G3412C
Std plug for
11.4:1

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G3408C
Std plug for 8.5:1
S/N:BAZ, 3WR, 6FW, 6ZM, 8LW, CTP (2)

128-6238 Spark Plug

108-3515 Spark Plug
Gasket

G3500

G3500
Std plug for all
Magneto, EIS,
and ADEM III

S/N:2JF, 4KC, 3RC, 4WD, 5JD, 8LD,

9TG, 7NJ, 4EK, 5PN, 9AW, 6JW, 8PW,
2TJ, 9FP, 5ZZ, 8JZ, 7SZ, 8BZ, GET

194-8518 Spark Plug

9Y-6792 Spark Plug
Gasket

G3500

G3500
EIS

S/N:4WD, 5JD, 8LD, 9TG, 7NJ, 4EK,

5PN, 9AW, 6JW, 8PW, 2TJ, 9FP, 5ZZ,
8JZ, 7SZ, 8BZ

224-2700 Spark Plug

9Y-6792 Spark Plug
Gasket

G3500

G3500B and
G3500C

S/N:7EZ, CEY, CTW, CSC, CME, CFD,

CTK, BGW, GAS, GSB, GZA, GZB, GZC,
346-5123 Spark Plug
GZG, GZH, GZL, GZM, GZN, GZP, GZZ,
9Y-6792 Spark Plug
GWD, CWD, CWW, CWY, B9P, GHC,
Gasket
GHE, HEB, ZBB, ZBC, TJB, TJC, SLY,
RLP, HAL, SXY

G3600

All G3600
Natural Gas

S/N:3XF, 4WF, 1YG, 4CG, 4ZS, BEN,

BKE, BLB

G3500c
and
G3600

G3500c and all

G3600
S/N:3XF, 4WF, 1YG, 4CG, 4ZS, BEN,
Bio-Gas
BKE, BLB, MAD, HAT, GZK, GZJ, LGS
(Landfill Gas and
Digester Gas)

G3400
G3412C
Std plug for 8.5:1

(1)

For CTP equipped with the Caterpillar Digital Ignition System (CDIS)

(2)

For CTP equipped with Electronic Ignition System (EIS)

301-6663 Spark Plug

9Y-6792 Spark Plug
Gasket
243-4291 Spark Plug
9Y-6792 Spark Plug
Gasket

Spark Plug Tools

Table 2
Part Number and
Description
4C-4601 Spark Plug Socket

Use

Size

Remove and install spark plug

(18 mm)

177.8 mm (7/8 inch Hex)

9S-5031 Socket

Remove and install combustion

sensor

127mm (5/8 inch Hex)

216-1685 Socket - Spark

Plug

Remove and install spark plug

(18 mm)

330.2 mm (13/16 inch)

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154-9521 Spark Plug Seat

Cleaner

Seat cleaner

14 mm (0.551 inch Thread/Seat

Cleaner)

9U-7511 Spark Plug Seat

Cleaner

Seat cleaner

18 mm (0.709 inch Thread/Seat

Cleaner)

Spark Plug Life

Spark plugs operate in severe conditions. Spark plugs require regular maintenance to provide desired
engine performance. The service life of a spark plug is directly related to the voltage required to
produce a spark in the electrode gap. As the voltage required to produce a spark increases, the service
interval is reduced and the overall service life decreases. Higher voltage reduces the service life of
components such as spark plugs, wires, and transformers.
The following six main factors affect the voltage required for spark plugs:
Air-fuel ratio - When the air-fuel ratio is near stoichiometric, the voltage required to produce a spark
is the lowest. As the air-fuel ratio becomes leaner, the voltage required becomes higher.
Compression ratio - As compression pressure increases, the required voltage increases.
Ignition timing - As ignition timing is retarded, the voltage required to produce a spark will increase.
Electrode wear - As the spark plug electrode wears and becomes more rounded, the voltage required
to produce a spark will increase.
Fuel BTU - Lower BTU fuel reduces the spark plug service life.
Electrode gap - The wider the spark plug gap, the more voltage is needed to produce a spark.
All of the factors above, except for compression, can be adjusted somewhat on most gas engines. As
compression increases, the required voltage increases. A cleaned and regapped plug requires more
voltage than a new plug. As the gap increases on a plug the voltage required for spark increases
dramatically. The required voltage can exceed the arc over voltage of the plug. Arc over voltage is the
amount of voltage required to produce a spark between the electrode and the ground strap. Fuels that
cause high levels of deposits can cause compression to rise well beyond normal. Higher compression
increases the voltage required closer to the arc over voltage.
The service life of the spark plug varies for different applications. The service life can be affected by
various factors and operating conditions.
To help predict the spark plug service life for G3500 and G3600 engines, use Caterpillar Electronic
Technician (ET) to monitor the "Cylinder #X Transformer Secondary Output Voltage Percentage"
parameter. The value of this parameter will increase over time. Experience at the particular site will
help to determine the proper interval for replacement of the spark plugs.
If a diagnostic code is generated for the ignition transformer secondary circuit, the spark plug may
need replacement. Misfire and a cold cylinder are other indications of a worn spark plug. Use Cat ET
to monitor the exhaust port temperatures in order to locate a cold cylinder.

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Recommended Maintenance of Spark Plugs

Spark Plug Removal
Remove a spark plug by hand after the initial torque is broken.
If the spark plug resists removal by hand, apply penetrating oil to the threads. To help the oil
penetrate the threads, turn the spark plug back and forth until the spark plug is loose.
If the spark plug could not be removed by hand, clean the threads with a spark plug seat
cleaner. Part numbers are listed in Table 2. The seat cleaner scrapes debris from the seat and
from the threads in the cylinder head. Be sure to remove any debris from the cylinder.

Spark Plug Gasket

After removing the spark plug, remove the compressible metal spark plug gasket.
Always install a new spark plug gasket when installing or reinstalling a spark plug.
Orient the tabs of the gasket toward the spark plug electrode. Otherwise, the gasket may not
seat properly.
If a gasket for a spark plug is installed incorrectly, do not increase the torque on the spark plug
in order to improve the seal.

Spark Plug Installation

Always regap the spark plug when the spark plug has been removed.
Always use a new gasket when installing the spark plug.
Install the spark plug into the seat by hand. If the spark plug cannot be seated by hand, there is a
problem with the threads.
Always finish installing a spark plug with a torque wrench and spark plug socket.

Recommended Maintenance Practices for Spark Plugs with

Adjustable Electrodes
Inspection
Note: Normal operation will produce a light ash deposit on the portion of the plug exposed to
combustion. Heavy ash deposits are a sign of poor combustion or high oil consumption. Clean such
deposits from the plug.
Inspect the spark plugs closely to look for damage and/or to determine if the ignition system is
operating correctly.

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Check the entire plug for mechanical damage, such as cracked insulators or metal cases. If any
cracks are found, replace the plug.
Faint marks may extend from the top edge of the metal case onto the insulator. The marks may
be the result of corona that forms at the top of the metal case. Corona develops when a high
voltage potential ionizes the air that surrounds a conductor. The marks are a normal condition.
The marks are not a result of leakage between the metal case and the insulator. Many times
these marks are misinterpreted as combustion leaks and the plugs are discarded with many more
service hours available.
Look for eroded electrodes. An eroded plug is a worn out plug. Spark plugs in this condition
will require more voltage to produce a spark. A worn plug can require more voltage than the
ignition system can supply.

Spark Plug Cleaning

Solvents can be used to clean oil and tar deposits from all plug surfaces with no adverse affects
on the plug.
When used with caution, glass beads can be used to clean the combustion end of the spark plug.
Apply the glass beading only to the electrode area of the spark plug. Do not apply glass beads
to the case or to the threads. Clean the threads with solvent and a clean wipe. Do not reuse the
glass beads.
Always keep the ignition components clean and free of dirt and oil.

Recommended Maintenance Practices for Spark Plugs with Pre

-combustion Chambers
Inspection
Note: A spark plug can operate despite a buildup of ash. Large deposits may retain heat that can cause
premature fuel ignition. Large deposits can lead to uncontrollable detonation.
Inspect the spark plug pre-combustion chamber for deposits.
Make sure that the holes in the spark plug pre-combustion chamber are not blocked.
A light brown deposit or a beige deposit is produced by normal operation. Deposits that are
gray or black may be caused by the following conditions: excessive oil, use of the wrong oil, a
substance that is introduced through the fuel system or the air system and poor combustion
because of a rich air/fuel mixture.
Condensation can form in spark plugs that have pre-combustion chambers. Condensation can
cause difficulty for cold start-ups. If an engine shuts down during the warm-up cycle,
condensation can form. The condensation can cause start-up difficulty until the condensation
evaporates or until the plugs are changed. Engine block heaters will help avoid this situation.

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Spark Plug Cleaning

Do not clean and reuse spark plugs with pre-combustion chambers. If the buildup of ash is
considerable, change the plug.

Maintenance and Installation Practices to Avoid

Maintenance
Note: If you change all of the spark plugs from J-gap plugs to plugs with pre-combustion chambers,
the air fuel ratio may need adjustment. The engine can be run leaner with plugs that have precombustion chambers.
Do not clean the spark plug with a wire brush. Deposits of brass on ceramic can cause the spark
plug to short circuit.
Do not use a thread tap to clean spark plug threads in the head. A tap is designed to remove
metal. This practice will eventually result in thread failure in the cylinder head.
Do not mix types of transformers in an engine.
Do not mix types of spark plugs in an engine.
Do not mix spark plugs with pre-combustion chambers and J-gap spark plugs in the same
engine.

Installation
Do not use anti-seize compound on spark plugs. Most of the heat is transferred through the
threads and the seat area of the spark plug. Contact of the metal surfaces must be maintained in
order to provide the heat transfer that is required.
If a gasket for a spark plug is installed incorrectly, do not increase the torque on the spark plug
in order to improve the seal.
Do not over tighten a spark plug. Over tightening the spark plug can cause cracks. Over
tightening can also yield the metal, which loosens the shell. Discard any spark plug that has a
shell that is cracked or loose.
Copyright 1993 - 2011 Caterpillar Inc.

Mon May 16 13:51:50 EST 2011

All Rights Reserved.

Private Network For SIS Licensees.

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