TSB103765-060215

Spark Plugs (Non Shielded) Procedure, Clean and Inspect for Reuse Section Revision
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Technical Service Bulletin Number
TSB103765
Technical Service Bulletin
Subject
Spark Plugs (Non Shielded) Procedure, Clean and Inspect for Reuse Section Revision
Original Topic Number: 09T13-16.
Warranty Statement
The information in this document has no effect on present warranty coverage or repair practices, nor
does it authorize TRP or Campaign actions.
Contents
Warranty Impact
None
The information in this document has no effect on current warranty coverages or repair
practices, nor does it authorize TRP or Campaign actions.
This Service/Parts Topic revises the Clean and Inspect for Reuse section of Procedure 013-016 in
Section 8 of various Operation and Maintenance, Troubleshooting and Repair Manuals and Service
Manuals.
Refer to Procedure 013-016 (Spark Plugs (Non Shielded).
Document History
Date
2015-6-2
Details
QSOL Work Order
Last Modified: 08-Jun-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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Spark Plugs (Non Shielded)
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013-016 Spark Plugs (Non Shielded)
Initial Check
CAUTION
Spark plug life is largely dependent on
cleanliness of the plug's porcelain. Dirt,
oil, and fingerprints reduce the seal
strength between the spark plug boot
and the porcelain causing reduced
spark plug life. Do not touch the
porcelain area on the spark plug. Use
rubbing alcohol and a lint-free cloth to
clean the spark plug porcelain and
rubber boot before installing the spark
plugs.
CAUTION
Do not clean boots on C8.3G, C Gas
Plus, L Gas Plus, or ISL G applications.
These boots are pre-greased.
A convenient option is an alcohol prep pad
that does not contain any moisturizers or
other cleaners. Compliant alcohol prep
pads are available at many department
stores, drug stores, and industrial supply
centers.
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Spark Plugs (Non Shielded)
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CAUTION
Damage to the electrodes due to
improper use of a feeler gauge will
shorten the life of the spark plug.
Clean the tool gauges prior to usage.
Use a wire spark plug gap-check tool to
make sure that the spark plug gap is within
specification. If the gap is not within
specification, the plug is not to be used
and must be returned to Cummins Inc.
Table 1. Initial Gap Specification
mm
in
Final Settings
B5.9G -150 and 195 hp and
B5.9LPG
0.330 to
0.483
0.013 to
0.019
Do not adjust gap
B Gas Plus - 195 hp
0.330 to
0.483
0.013 to
0.019
Do not adjust gap
B5.9G - 230 hp
0.356 to
0.483
0.014 to
0.019
Adjust gap 0.508 mm
[0.020 in]
B Gas Plus - 200 and 230 hp
0.356 to
0.483
0.014 to
0.019
Adjust gap 0.508 mm
[0.020 in]
B LPG Plus
0.330 to
0.483
0.013 to
0.019
Do not adjust gap
B Gas International - 150 and
195 hp
0.330 to
0.483
0.013 to
0.019
Do not adjust gap
B Gas International - 230 hp
0.356 to
0.483
0.014 to
0.019
Adjust gap 0.508 mm
[0.020 in]
ISB5.9 G - 230 hp
0.320 to
0.380
0.013 to
0.015
Do not adjust gap
ISB5.9 G - Less than 230 hp
0.350 to
0.450
0.014 to
0.018
Do not adjust gap
C8.3G and C Gas Plus
0.320 TO
0.380
0.013 to
0.015
Do not adjust gap
0.356 to
0.014 to
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Spark Plugs (Non Shielded)
L10G Automatic Transmission
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0.483
0.019
Do not adjust gap
L10G Manual Transmission
0.356 to
0.483
0.014 to
0.019
Adjust gap 0.508 mm
[0.020 in]
CNGE (Prime Power)
0.356 to
0.483
0.014 to
0.019
Adjust gap 0.508 mm
[0.020 in]
ISL G and L Gas Plus
0.320 to
0.380
0.013 to
0.015
Do not adjust gap
CAUTION
Only gap B5.9G-230 hp, B Gas
International-230 hp, B Gas Plus-200
hp, B Gas Plus-230 hp, or C8.3G and
CNGE Prime Power applications or loss
of spark plug life will occur.
Adjust the gap by bending the ground
(side) electrode, using the slots on the gap
tool. Align the center and ground
electrodes. The ground electrode should
be parallel to, and centered over, the
middle of the center electrode.
If the electrodes can not be aligned,
discard the plug.
CAUTION
Failure to remove the terminal nut from the
spark plug for C8.3G and C Gas Plus
applications with straight harness
connector coils will result in severe misfire
causing reduced spark plug life or possible
engine damage.
For C8.3G and C Gas Plus applications
with straight harness connector coils:
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Spark Plugs (Non Shielded)
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Remove and discard the terminal nut from
the spark plug.
CAUTION
Do not remove the terminal nut from the
spark plug for C8.3G, C Gas Plus, L Gas
Plus, and ISL G applications with angled
harness connector coils. Angled harness
connector coils use the terminal nut as a
connection point from the spark plug to the
angled harness connector coils.
Check the spark plug. The ground
electrode must be parallel to the center
electrode and must be aligned along the
centerline of the plug.
Remove
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WARNING
To reduce the possibility of personal
injury, do not touch any ignition wires or
components while the engine is
operating, unless using suitably
insulated tools.
For C8.3G, C Gas Plus, L Gas Plus, and
ISL G Applications:
Disconnect the wiring harness.
Remove the capscrews from the coil
bracket.
Remove the ignition coil. Refer to
Procedure 013-012 in Section 13 in the
appropriate service manual.
Blow out any dirt and debris from the
spark plug cavity.
Loosen the spark plugs. Use a 5/8-inch
magnetic spark plug socket, Part Number
3824876.
Do not use a spark plug socket with a
rubber insert.
Use a magnetic spark plug socket and
continue to back out the spark plug until
the threads are no longer engaged.
Lift the spark plug out with the socket,
being careful not to drop the plug.
Mark or tag the spark plug with the
cylinder number from which it was
removed.
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Spark Plugs (Non Shielded)
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For L10G Applications:
Any time the spark plugs are removed or
coolant is found in the oil, the copper
sleeves in the cylinder head must be
checked for leaks. This inspection can be
performed by viewing the top of the piston
through the spark plug hole for indications
of an extra clean combustion bowl on any
of the pistons.
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for
use. Wear goggles and protective
clothing to reduce the possibility of
personal injury.
WARNING
Some solvents are flammable and toxic.
Read the manufacturer's instructions
before using.
CAUTION
Spark plug life is largely dependent on
cleanliness of the plug's porcelain. Dirt,
oil, and fingerprints reduce the seal
strength between the spark plug boot
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Spark Plugs (Non Shielded)
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and the porcelain causing reduced
spark plug life. Do not touch the
porcelain area on the spark plug. Use
rubbing alcohol and a lint-free cloth to
clean the spark plug porcelain and
rubber boot before installing the spark
plugs.
CAUTION
Do not clean boots on C8.3G, C Gas
Plus, L Gas Plus, or ISL G applications.
These boots are pre-greased.
A convenient option is an alcohol prep pad
that does not contain any moisturizers or
other cleaners. Compliant alcohol prep
pads are available at many department
stores, drug stores, and industrial supply
centers.
Use rubbing alcohol and a lint-free cloth to
clean the spark plug porcelain and rubber
boot.
Table 2: Final Gap Specification
Engines
Maximum Re-Use Gap
mm
in
B5.9 G-150 and 195 hp and B5.9 LPG
0.66
0.026
B Gas Plus 195 hp
0.66
0.026
B5.9 G 230hp
0.771
0.028
B Gas Plus -200 and 230hp
0.771
0.028
B LPG+
0.66
0.026
B Gas International 150 and 195 hp
0.66
0.026
B Gas International 230 hp
0.771
0.028
ISB 5.9G 230 hp
0.66
0.026
ISB 5.9G less than 230 hp
0.66
0.026
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Spark Plugs (Non Shielded)
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C8.3 G and C Gas Plus
0.635
0.025
L10G Automatic Transmission
N/A
N/A
L10G Manual Transmission
N/A
N/A
CNGE (Prime Power)
N/A
N/A
ISL G and L Gas Plus
0.635
0.025
Use the following to determine if the spark
plug meets reuse guidelines. Refer to
Spark Plug Reuse Guidelines, Bulletin
4383578.
Inspect the spark plugs for the following
issues:
1.
2.
3.
4.
5.
Insulator flashover
Electrode deposits or fouling
Missing electrode
Corrosion (not shown)
Electrode beading (not shown).
A worn electrode does not mean that the
spark plug should be replaced. However,
if the electrode gap is less than the
minimum starting gap, reference Table 1. If
the electrode gap is greater than the
maximum reuse gap, reference Table 2 to
replace the spark plug.
NOTE: Spark plugs should not be
replaced due to corona staining (3).
Corona staining does not affect spark
plug or ignition system performance.
1. Cracked insulator
2. Electrode misalignment
3. Corona staining.
NOTE: If a spark plug exhibits electrode
beading, check the electrode gap
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Spark Plugs (Non Shielded)
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before discarding the plug. Replace the
plug only if the gap is less than the
minimum gap shown in Table 1, in the
Initial Check section above.
A damaged spark plug showing traces of
aluminum can indicate piston damage.
Inspect the piston for damage. Use the
following procedure in the ISL G CM2180
Service Manual, Bulletin 4021649. Refer
to Procedure 001-043 in Section 1 or
contact a Cummins® Authorized Repair
Location.
Remove the old spark plug boot:
Twist the spark plug boot on the extension
one full turn, then remove the spark plug
boot by pulling and twisting at the same
time.
Clean the coil extension.
Use a clean, lint-free cloth to remove any
deposits from the outside and inside of the
coil extension.
Refer to Procedure 013-012 in Section 13
in the appropriate service manual.
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Install
Install the spark plug boot onto the coil
extension.
Install the new boot onto the end of the
coil extension by pushing and twisting the
boot at the same time until it is fully seated
on the extension.
NOTE: Do not over apply the dielectric
grease.
Verify that dielectric grease is inside the
opening of the spark plug boot.
If there is no dielectric grease in the new
boot, apply a pea-sized amount of
dielectric grease, Dupont® Krytox 205,
Cummins® Part Number 3164956, or
equivalent, to the inside of the boot.
Spread it around the inner diameter to
ease assembly on the spark plug.
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for
use. Wear goggles and protective
clothing to reduce the possibility of
personal injury.
WARNING
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Spark Plugs (Non Shielded)
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Some solvents are flammable and toxic.
Read the manufacturer's instructions
before using.
CAUTION
Spark plug life is largely dependent on
cleanliness of the plug's porcelain. Dirt,
oil, and fingerprints reduce the seal
strength between the spark plug boot
and the porcelain causing reduced
spark plug life. Do not touch the
porcelain area on the spark plug. Use
rubbing alcohol and a lint-free cloth to
clean the spark plug porcelain and
rubber boot before installing the spark
plugs.
CAUTION
Do not clean boots on C8.3G, C Gas
Plus, L Gas Plus, or ISL G applications.
These boots are pre-greased.
A convenient option is an alcohol prep pad
that does not contain any moisturizers or
other cleaners. Compliant alcohol prep
pads are available at many department
stores, drug stores, and industrial supply
centers.
Clean the magnetic spark plug socket and
spark plug.
CAUTION
Mechanical over-tightening can
damage the spark plug and cylinder
head or adapter.
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Spark Plugs (Non Shielded)
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CAUTION
Proper spark plug torque is required for
heat transfer from the spark plug to the
cylinder head. Improper torque will lead
to spark plug failure, disconnected
spark plug wires, and possible engine
damage.
Inspect the cylinder head plug cavity for
debris. Clean as required.
Install the spark plug. Use a magnetic
spark plug socket, Part Number 3824876,
and thread the plug in by hand to make
sure that the threads are smooth and the
plug is not cross-threaded. Tighten the
spark plug.
NOTE: The use of anti-seize compound
on spark plug threads is not approved
by Cummins Inc.
Torque Value: 38 n.m [28 ft-lb]
Check the ignition coil.
Refer to Procedure 013-012 in Section 13
in the appropriate service manual.
For B5.9G, B5.9LPG, B Gas Plus, B LPG
Plus, B Gas International, ISB5.9 G
Applications:
Clean, add dielectric grease, and install
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Spark Plugs (Non Shielded)
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the spark plug wires.
Refer to Procedure 013-014 in Section 13
in the appropriate service manual.
WARNING
Do not remove the coil extension or
engine damage could possibly result.
CAUTION
Do not clean boots on C8.3G, C Gas
Plus, L Gas Plus, or ISL G applications.
These boots are pre-greased.
For C8.3G, C Gas Plus, L Gas Plus, and
ISL G Applications:
Clean the spark plug, replace the boot,
and install the coil.
Install the ignition coil.
NOTE: For an angled coil, clean/remove
the grease deposits from the end of the
coil spring at each plug change interval
prior to installing a new plug boot onto
the coil.
Refer to Procedure 013-012 in Section 13
in the appropriate service manual.
Torque Value: 9 n.m [80 in-lb]
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For L10 G Applications:
Clean, replace the boot, add dielectric
grease,and install the spark plug wires.
Refer to Procedure 013-014 in Section 13
in the appropriate service manual.
Last Modified: 25-Mar-2015
Copyright © 2000-2010 Cummins Inc. All rights reserved.
https://qsol2.cummins.com/qs3/pubsys2/xml/en/procedures/107/107-013-016.html
7/6/2015