APPLICATION GUIDE For CATERPILLAR G3400 Series

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APPLICATION GUIDE For CATERPILLAR G3400 Series GAS ENGINE TECHNOLOGY reliable efficient worldwide

Ignition Controllers MIC3+ Series Ignition Controllers High energy ignition controller for retrofits Plug & play solution Patented technology (Patent No. US 8,893,692 BS) For use with G3406, G3408 P/N 66.00.356-8 CATERPILLAR P/N 163-6164 High energy ignition controller for retrofits Plug & play solution Patented technology (Patent No. US 8,893,692 BS) For use with G3412 P/N 66.00.357-12 CATERPILLAR P/N 163-6108 CATERPILLAR Digital Ignition Controllers Refurbished MOTORTECH refurbished ignition controllers Come with a 1 year warranty Always consult factory for availability P/N 163-6164-R CATERPILLAR P/N 163-6164 As good as new! MOTORTECH Repair and Overhaul Service Based on years of technical experience MOTORTECH offers a comprehensive repair and overhaul service for almost all popular ignition controllers. Our economically remanufacturing process covers intensive inspections, parts replacement, extensive reconditioning and full operational test procedures. Within an average of four weeks (depends on customer location) we return a fully functional product that looks as good as new. Flatrate Overhaul of: CATERPILLAR ignition controllers for G3300/G3400 series gas engines ALTRONIC DISN series All MOTORTECH ignition controllers 2

Ignition Coils Ignition Coils ALTRONIC Style For unshielded applications P/N 06.50.054 CATERPILLAR P/N 4W-5439 ALTRONIC P/N 591010 ALTRONIC Style For unshielded applications P/N 06.50.055 CATERPILLAR P/N 2W-3747 ALTRONIC P/N 501061 CATERPILLAR Style For unshielded applications P/N 06.50.141 P/N 06.50.143 CATERPILLAR P/N 437-4049, 232-6348, 165-1591, 131-3277, 129-8802, 108-0615 CATERPILLAR P/N 232-6352, 213-7443 CATERPILLAR Style For shielded applications P/N 06.50.142 P/N 06.50.144 CATERPILLAR P/N 232-6349, 165-1592, 122-8070 CATERPILLAR P/N 232-6353, 213-7444 3

Ignition Coils Ignition Coil Extension Overhaul Kits Extension overhaul kits include: Teflon extension and spark plug seal Extension seal (CSA applications) Lip seal Secondary terminal (Patent No. US 7,455,536 B2, EP 1 653 571 A3) Fits Ignition Coil: P/N 06.80.741 MOTORTECH P/N 06.50.141 P/N 06.80.742 MOTORTECH P/N 06.50.142 P/N 06.80.743 MOTORTECH P/N 06.50.143 P/N 06.80.744 MOTORTECH P/N 06.50.144 Integral Ignition Coils Slim Design 6 in. length 13/16-20 UNEF inner thread 3 pole primary connector P/N 95.09.222-6 CATERPILLAR P/N 107-2400 ALTRONIC P/N 591011A 12 in. length 13/16-20 UNEF inner thread 3 pole primary connector P/N 95.09.222-12 CATERPILLAR P/N 215-2434 ALTRONIC P/N 591011B, 591011C 6 in. length 13/16-20 UNEF inner thread, 1-20 UNEF outer thread 3 pole primary connector P/N 95.09.223-6 CATERPILLAR P/N 4W-4959 ALTRONIC P/N 591007 4

Ignition Coils Integral Coil/Spark Plug Adaptor Seal Silicone seal For use with integral ignition coils 5 P/N 06.84.026 4 3 2 1 Seal, spark plug adaptor to valve cover P/N 06.84.090 Z CATERPILLAR P/N 7E-0079 Z 6 5 4 3 2 1 Z Z The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. D C B 6 5 toleranceclass m (middle) 0,5 till 3 ` 0,1 4 Technical ref. A. Mohr Material (acc. TL 301) Technical Created byref. A. Mohr A. Mohr Date 27.07.2016 Material Title, (acc. Supplementary TL 301) title Created by A. Mohr Date 27.07.2016 3 Title, Supplementary title CAT 7E0079 Seal 2 A CAT 7E0079 Seal General tolerance DIN ISO 2768-mK (in mm) tolerance- 0,5 over 3 over 6 over 30 over 120 over 400 over 1000 over 2000 CAT 7E0079 class till 3 till 6 till 30 till 120 till 400 till 1000 till 2000 till 4000 MOTORTECH GmbH, Hogrevestr. 21-23, 29223 Celle, Germany m (middle) ` 0,1 ` 0,1 ` 0,2 ` 0,3 ` 0,5 ` 0,8 ` 1,2 ` 2,0 Rev. - Date Changed by Approved by Sheet 1 / 1 General tolerance DIN ISO 2768-mK (in mm) 5 4 3 2 1 over 3 over 6 over 30 over 120 over 400 over 1000 over 2000 CAT 7E0079 till 6 till 30 till 120 till 400 till 1000 till 2000 till 4000 MOTORTECH GmbH, Hogrevestr. 21-23, 29223 Celle, Germany ` 0,1 ` 0,2 ` 0,3 ` 0,5 ` 0,8 ` 1,2 ` 2,0 Rev. - Date Changed by Approved by S 5 1

Pickups Pickups Hall effect pickup - Active Low Thread size 5/8 in.-18 UNF 2.5 in. length For unshielded and shielded applications P/N 95.70.002-250 CATERPILLAR P/N 116-6806 ALTRONIC P/N 791050-2 6

Primary Leads Primary Leads for shielded Applications Available as Conventional Style and Ignition coil connector 3 pole, socket, 90 2 wire conductor 1/2-14 NPT outlet box adaptor P/N 95.01.020-60 P/N 95.01.120-60 CATERPILLAR P/N 1N-3735 ALTRONIC P/N 593027-60 P/N 95.01.020-72 P/N 95.01.120-72 CATERPILLAR P/N 1N-3736 ALTRONIC P/N 593027-72 Conventional Style P/N 95.01.020-84 P/N 95.01.120-84 CATERPILLAR P/N 1N-3738 ALTRONIC P/N 593027-84 P/N 95.01.020-96 P/N 95.01.120-96 CATERPILLAR P/N 1N-3739 ALTRONIC P/N 593027-96 P/N 95.01.020-108 P/N 95.01.120-108 CATERPILLAR P/N 1N-3740 ALTRONIC P/N 593027-108 7

Primary Leads P/N 95.01.020-120 P/N 95.01.120-120 CATERPILLAR P/N 1N-3741 ALTRONIC P/N 593027-120 P/N 95.01.020-48 P/N 95.01.120-48 CATERPILLAR P/N 4W-5467 ALTRONIC P/N 593027-48 P/N 95.01.020-12 P/N 95.01.120-12 CATERPILLAR P/N 4W-6741 ALTRONIC P/N 593027-12 Conventional Style P/N 95.01.020-24 P/N 95.01.120-24 CATERPILLAR P/N 4W-6742 ALTRONIC P/N 593027-24 P/N 95.01.020-42 P/N 95.01.120-42 CATERPILLAR P/N 4W-6743 ALTRONIC P/N 593027-42 8

Primary Leads P/N 95.01.020-54 P/N 95.01.120-54 CATERPILLAR P/N 4W-6744 ALTRONIC P/N 593027-54 P/N 95.01.020-132 P/N 95.01.120-132 P/N 95.01.020-138 P/N 95.01.120-138 CATERPILLAR P/N 4W-6745 ALTRONIC P/N 593027-132 CATERPILLAR P/N 4W-6746 ALTRONIC P/N 593027-138 P/N 95.01.020-150 P/N 95.01.020-150 CATERPILLAR P/N 4W-6747 ALTRONIC P/N 593027-150 9

Spark Plug Extensions Spark Plug Leads PolyMot spark plug lead (Patent No. 19611283) Fits spark plug P/N 2N2839 Fits ignition coil P/N 4W5439, 2W3747 P/N 06.85.751-18 P/N 06.85.1054-18 CATERPILLAR P/N 7W-8542, 262-4855, 250-2149 Fits spark plug B4321 Ignition Coil Extension Overhaul Kits & Accessories For MOTORTECH or original CATERPILLAR ignition coils Extension overhaul kits include: Teflon extension and spark plug seal Extension seal (CSA applications) Lip seal Secondary terminal (Patent No. US 7,455,536 B2, EP 1 653 571 A3) Fits Ignition Coil: P/N 06.80.419H CATERPILLAR P/N 232-6348, 165-1591, 131-3277, 129-8802, 108-0615 P/N 06.80.741 MOTORTECH P/N 06.50.141 P/N 06.80.742 MOT/CAT P/N 06.50.142, 232-6349, 165-1592, 122-8070 P/N 06.80.420H CATERPILLAR P/N 232-6352, 213-7443 P/N 06.80.743 MOTORTECH P/N 06.50.143 P/N 06.80.744 MOT/CAT P/N 06.50.144, 232-6353, 213-7444 Lip seal For use with MOTORTECH and original CATERPILLAR ignition coils P/N 06.81.051 CATERPILLAR P/N 135-2651 10

Ignition Wiring Rails & Hardware Ignition Upgrade Kits to replace Magneto Ignition Systems For unshielded applications Incl. MIC3+ ignition controller Ignition Upgrade Kit for In-line Engine CATERPILLAR G3406 Kit contains: MIC3+ series ignition controller 1 Input and output harnesses 2 AlphaRail wiring rail with high energy ignition coils and brackets 3 PolyMot TM spark plug leads 4 Pickup 5 Mechanical trigger conversion kit with trigger disc, spacer, gaskets 6 Magneto flange cover kit 7 2 1 5 6 7 4 3 P/N 75.00.538 Ignition upgrade kit for CATERPILLAR G3406 Ignition Upgrade Kit for V-Engines CATERPILLAR G3408/ G3412 Kit contains: MIC3+ series ignition controller 1 Input and output harnesses 2 AlphaRail wiring rails with high energy ignition coils and brackets 3 PolyMot TM spark plug leads 4 Pickup 5 TriDev trigger device to replace ALTRONIC III magneto 6 2 1 5 6 4 3 3 4 P/N 75.00.539 P/N 75.00.540 Ignition upgrade kit for CATERPILLAR G3408 Ignition upgrade kit for CATERPILLAR G3412 11

Spark Plugs & Accessories Spark Plugs (M14x1.25 Thread Size 0.750 in. Thread Reach) Fine wire electrode (Au/Pd) Recommended for natural gas P/N RN79G (CHAMPION ) CATERPILLAR P/N 2N-2839 J-type electrode (Ir/Pt) Recommended for natural gas P/N GE3-1 (DENSO ) J-type electrode (Ir/Ir) Recommended for special gas P/N GE3-5 (DENSO ) MHP Spark Plug J-type electrode (Ir/Ir) Recommended for natural/special gas Double insulator length for best flashover protection 1) P/N B4321 (MOTORTECH) 1) Due to longer isulator of B4321, spark plug lead P/N 06.85.1054-18 needs to be used. For use with integral ignition coils Fine wire electrode (Au/Pd) Recommended for natural gas P/N RTN79G (CHAMPION ) CATERPILLAR P/N 4W-2256 J-type electrode (Ir/Ir) Recommended for natural/special gas P/N ICPB432 (MOTORTECH) 12

Spark Plugs & Accessories Tools Spark plug gap setting tool For easy setting of spark plug gaps Basic kit includes M14x1.25 thread adaptor P/N 07.98.120-14 Accessory kit for J-type spark plugs Including base insert and feeler gauge P/N 07.98.122-A P/N 07.98.037 P/N 07.98.059 P/N 07.98.034 P/N 07.98.035 P/N 07.98.036 Feeler gauge clamp Feeler gauge, gap 0.008 in./0.20 mm Feeler gauge, gap 0.010 in./0.25 mm Feeler gauge, gap 0.012 in./0.30 mm Feeler gauge, gap 0.014 in./0.35 mm Spark plug cleaning kit Removes oil residues and deposits in the electrode area by high pressure Special blasting grit for gentle cleaning of the electrode and thread area P/N 44.01.023 Extended barrel magnetic spark plug sockets 1/2 in. drive 12 in. length P/N 07.99.022-2-12 hex 15/16 in. for use with 4W-2256 P/N 07.99.022-4-12 hex 13/16 in. for use with 2N-2839 P/N 07.99.022-5-12 hex 5/8 in. - for use with B4321 Torque wrench 1/2 in. drive P/N 07.98.065 13

Spark Plugs & Accessories Seat & thread reconditioners M14x1.25 thread size 3/4 in. thread reach P/N 07.98.114-34 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, spark plug lead or ignition controller) Faulty compression of a cylinder P/N 06.90.099-100 Accessories Spark plug gaskets For M14x1.25 thread size Pack of 100 pcs. P/N 02.85.015-100 Gaskets for integral ignition coil spark plugs Copper Pack of 100 pcs. P/N 75.90.295-100 Thread lubricant Can 4 oz/115 g P/N 07.98.718 14

Gas Engine Control Systems Throttle Bodies Throttle body, series 100 68 mm inner diamater P/N 30.40.101-68AT2-7 IMPCO P/N AT2-7 To replace: CATERPILLAR P/N 7C-1147 Throttle body, series 140 94 mm inner diamater P/N 30.40.141-94AT2-9 IMPCO P/N AT2-9 To replace: CATERPILLAR P/N 7W-1501 on G3408/G3412 CATERPILLAR P/N 7W-1513 on G3408/G3412 15

Sensor Systems Oxygen Sensors Oxygen sensor For unshielded applications P/N 19.60.027 CATERPILLAR P/N 196-5391 Oxygen sensor For shielded applications P/N 19.60.029 CATERPILLAR P/N 141-2494 Heat shield P/N 19.60.022 Weld hub P/N 19.60.023 16

Gas Engine Accessories Coolant Filtration Bypass filters with stainless steel filter elements Cleans and maintains coolant system from rust and contaminants Increases water pump life and cylinder head efficiency Easy to install and to service P/N 25.00.009-50 P/N 25.00.009-50-30 Features: 9 in. element length 50 micron element Flow indicator Features: 9 in. element length 50 micron element Flow indicator 30 in. stand Lube Oil Filtration Lube filter conversion kit for CATERPILLAR G3406/08 including reusable stainless steel filter element, housing, end caps and o-rings P/N 25.00.303-1-CA CATERPILLAR P/N 1R-0716, 2P-4005, 4W-6000, 272-1788, 3I-1284, 1W-2660, 2Y-8097 17

Index P/N Page P/N Page P/N Page 02.85.015-100... 14 06.50.054... 3 06.50.055... 3 06.50.141...3, 4, 10 06.50.142...3, 4, 10 06.50.143...3, 4, 10 06.50.144...3, 4, 10 06.80.419H... 10 06.80.420H... 10 06.80.741...4, 10 06.80.742...4, 10 06.80.743...4, 10 06.80.744...4, 10 06.81.051... 10 06.84.026... 5 06.84.090... 5 06.85.751-18... 10 06.85.1054-18... 10 06.90.099-100... 14 07.98.034... 13 07.98.035... 13 07.98.036... 13 07.98.037... 13 07.98.059... 13 07.98.065... 13 07.98.114-34... 14 07.98.120-14... 13 07.98.122-A... 13 07.98.718... 14 07.99.022-2-12... 13 07.99.022-4-12... 13 07.99.022-5-12... 13 19.60.022... 16 19.60.023... 16 19.60.027... 16 19.60.029... 16 25.00.009-50... 17 25.00.009-50-30... 17 25.00.303-1-CA... 17 30.40.101-68AT2-7... 15 30.40.141-94AT2-9... 15 44.01.023... 13 66.00.356-8... 2 66.00.357-12... 2 75.00.538... 11 75.00.539... 11 75.00.540... 11 75.90.295-100... 14 95.01.020-12... 8 95.01.020-24... 8 95.01.020-42... 8 95.01.020-48... 8 95.01.020-54... 8 95.01.020-60... 7 95.01.020-72... 7 95.01.020-84... 7 95.01.020-96... 7 95.01.020-108... 7 95.01.020-120... 7 95.01.020-132... 8 95.01.020-138... 9 95.01.020-150... 9 95.01.120-12... 8 95.01.120-24... 8 95.01.120-42... 8 95.01.120-48... 8 95.01.120-54... 8 95.01.120-60... 7 95.01.120-72... 7 95.01.120-84... 7 95.01.120-96... 7 95.01.120-108... 7 95.01.120-120... 7 95.01.120-132... 8 95.01.120-138... 9 95.09.022-6... 4 95.09.022-12... 4 95.09.023-6... 4 95.70.002-250... 6 107-2400... 4 108-0615... 3, 10 116-6806... 6 122-8070...3, 10 129-8802...3, 10 131-3277...3, 10 135-2651... 10 141-2494... 16 163-6108... 2 163-6164... 2 163-6164-R... 2 165-1591...3, 10 165-1592...3, 10 196-5391... 16 1N-3735... 7 1N-3736... 7 1N-3738... 7 1N-3739... 7 1N-3740... 7 1N-3741... 7 1R-0716... 17 1W-2660... 17 213-7443... 10 18

Index P/N Page P/N Page 213-7444...3, 10 215-2434... 4 232-6348...3, 10 232-6349...3, 10 232-6352... 10 232-6353...3, 10 250-2149... 10 262-4855... 10 272-1788... 17 2N-2839... 12 2P-4005... 17 2W-3747... 3 2Y-8097... 17 3I-1284... 17 437-4049... 3 4W-4959... 4 4W-5439... 3 4W-5467... 8 4W-6000... 17 4W-6741... 8 4W-6742... 8 4W-6743... 8 4W-6744... 8 4W-6745... 8 4W-6746... 9 4W-6747... 9 501061... 3 593027-24... 8 593027-42... 8 593027-48... 8 593027-54... 8 593027-60... 7 593027-72... 7 593027-84... 7 593027-96... 7 593027-108... 7 593027-120... 7 593027-132... 8 593027-138... 9 593027-150... 9 791050-2... 6 7C-1147... 15 7E-0079... 5 7W-1501... 15 7W-1513... 15 7W-8542... 10 AT2-7... 15 AT2-9... 15 B4321...10, 12 GE3-1... 12 GE3-5... 12 ICPB432... 12 RN79G... 12 RTN79G... 12 591007... 4 591010... 3 591011A... 4 591011B... 4 591011C... 4 593027-12... 8 19

Headquarter Office Sales Partner MOTORTECH GmbH Hogrevestr. 21-23 29223 Celle Germany Phone: +49 (5141) 93 99 0 Fax: +49 (5141) 93 99 99 www.motortech.de sales@motortech.de MOTORTECH Americas, LLC 1400 Dealers Avenue, Suite A New Orleans, LA 70123 USA Phone: +1 (504) 355 4212 Fax: +1 (504) 355 4217 www.motortechamericas.com info@motortechamericas.com MOTORTECH Shanghai Co. Ldt. Room 1018 Enterprise Square, No. 228 Meiyuan Road, Zhabei District, 200070 Shanghai China Phone: +86 (21) 6380 7338 www.motortechshanghai.com info@motortechshanghai.com Distribution partner for DENSO spark plugs P/N 01.00.010-EN Rev.07/2016 Copyright The copyright for all materials used in this MOTORTECH publication is reserved. Any kind of duplication or use of objects such as pictures or texts in other electronic or printed publications without approval by MOTORTECH is not permitted. Trademark Information MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of MOTORTECH GmbH. All OEM names and part numbers shown are for reference purposes only. All trademarks, logos and symbols used or shown in this MOTORTECH publication are exclusive objects to the right of their owners and are used for reference purposes only. Distribution:

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