Bosch Industrial Spark Plugs

Bosch Industrial Spark Plugs

Double Iridium Overview Introducing the new Double Ir Spark Plugs We tested the new Bosch Double Ir spark plug against the current competition in our CAT 50C engines and were very pleased with the results. The plugs lasted over 4500 hours which is 50% longer than the plugs we had been using and consistently achieved their change interval. Longer life, less downtime, and fewer engine fault codes resulted in one very happy customer. Warren Landfill Power Plant Manager Pin to pin design improves ignitability of air fuel mixture improving eiciency Nickel plated threads reduce likelihood of seizing Longer Graphite Resistor for improved durability in high voltage applications Applications Two M8 and two M4 designs to fit the most common applications Electrodes.4mm high content Iridium center and ground electrode for long life even in biogas/landfilll applications Continuous laser welding ensures precious metal stays in place. Full length brass terminal nut for improved connection to ignition leads M8 M4 705 75 708 7 Test Results Over 4,500 hours in a Cat 50C running ~5% CH4 landfill gas, 00% load,.6mw generator. 50% longer than the current plug used. Heat Removal Properties (higher number indicates more heat being removed) The Nickel Yttrium (NiY) alloy used on the ground electrode of the Bosch Industrial Series spark plugs dissipates heat much better than competitor materials. This results in lower temperatures of the ground electrode and longer run times. New packaging of all Bosch Industrial spark plus is significantly stronger than previous packaging ensuring plugs arrive to the engine well protected and ready for service. A security sticker over the opening of M8 plugs is now used to ensure the plugs you receive are authentic Bosch spark plugs. Conclusion: Long life performance for your landfill, biogas, or natural gas applications.

Competitive Comparison Bosch 705 Competitor A Competitor B Competitor C Bosch Competitor A Competitor B Competitor C.4mm Iridium center electrode continuous laser welded.0mm Iridium center electrode continuous laser welded.4mm Iridium center electrode pulse laser welded with cross grooves.0 Iridium center electrode pulse laser welded.4mm Iridium pad projected from ground electrode continous laser welded and resistance welded.mm Iridium pad projected from ground electrode, continous laser welded.4mm Iridium pad flush with ground electrode, pulse laser welded.4mm Iridium pad flush with ground electrode, pulse laser welded 4 Ground electrode profile.8mm x.7mm Ground electrode profile.8mm x.7mm Ground electrode profile 4.mm x.6mm Ground electrode profile 4.mm x.6mm 5 Full Length Terminal Stud with Brass Terminal Nut: Terminal Stud increases spark plug strength and the brass terminal nut reduces corrosion ensuring the spark plug has a clean connection to the ignition lead. Ribbed Pyranite Insulator: 95% aluminum oxide reduces likelihood of dielectric punctures in high voltage applications. Ribbed profile reduces possibility of flashover. Graphite Metal Glass Resistor: Increased length improves reliability of the resistor in high voltage applications reducing resistor failures. Bosch Advantage: With a larger center electrode it yields a 44% larger wear area over.0mm electrodes increasing longevity. Cross grooves remove ~0% of surface area from electrode increasing gap erosion, but reduce ignition voltage. Bosch Advantage: Projected precious metal improves access to air fuel mixture reducing quenching and improving ignitability, laser and resistance welding reduces likelihood of precious metal separation. Bosch Advantage: Smaller width of ground electrode reduces quenching and eases ability to gap. 4 Nickel Plated Steel Shell: Specially designed for high mechanical strength to prevent breakage during removal. The housing is also nickel coated to prevent seizing in the engine. 5 See electrode comparisons on the next page. 4 5

Electrode Comparison Center Electrode Surface Area Product Cross Reference Guide 5 4.5 4.5.5.5 0.5 0 +44% Center +00% Bosch 705 GI-5 8GZ6-77- 94-858 The larger surface area of the center electrode helps increase longevity. The increased precious metal available reduces gap expansion resulting in longer run times. Bosch Part# Denso Part# Champion Part# Beru 70 RB75N / RB75PP* 8GZ0 70 RM77N / RM77PP 8GZ 705 GI-5 8GZ6-77- 706 GI- / GI- RB77WPCC / KB77WPCC / RB77CC / RB77WPC 8GZ6-77 707 GL- / GL- RB75WPCC 8GZ5-77 708 GL-5 8GZ5-77- 7 GE- RN79G 4R-4CDP 7 RN5C 75 GE-5 4R-4CIU- 7 (FRKII) GK-/GK- RC78PYP / RC78PYP5 / RC78WYP 4FR-4DPU0 7 GK-5 4FR-4DIU Bosch 705 Competitor A Competitor C *Ceramic length dierent from RB75PP, adapter may be required Double Platinum vs. Double Iridium Full Weld of Pad Weld Zone No Weld No Weld Weld Zone Full Weld of Pad Weld Zone No Weld Weld Zone No Weld In these cross sections of the electrodes, note that the welding of the Bosch spark plug supports the entire iridium pad. In the other plugs, the welded zone is only on the edges of the precious metal pins. This complete weld, ensures the precious metal pin has the strongest connection possible to the base material and will not separate even in the most demanding applications. Bosch 706 Bosch 705.0mm platinum iridium center electrode: surface area =.4mm 0.6mm x.8mm platinum iridium pin: surface area =.68mm Continuous laser welding on center and ground.4mm high content iridium center electrode: surface area = 4.5mm 44% larger than 706.4mm x.8mm high content iridium ground electrode: surface area = 4.5mm 69% larger than 706 Continuous laser welding on center and ground with additional resistance weld on ground for added strength 6 7

Industrial Spark Plugs 70 70 705 706 707 708 7 7 75 7/FRKII 7 Specifications Double Ir Double Ir Double Ir Double Ir Hex: ⅞" (.mm) ⅞" (.mm) ⅞" (.mm) ⅞" (.mm) 6" (0.8mm) 6" (0.8mm) 6" (0.6mm) 6" (0.6mm) 6" (0.6mm) ⅝" (6mm) ⅝" (.mm) Thread: 8mm 8mm 8mm 8mm 8mm 8mm 4mm 4mm 4mm 4mm 4mm Reach: 6" (0.6mm) ½" (.7mm) 6" (0.6mm) 6" (0.6mm) 6" (0.6mm) 6" (0.6mm) ¾" (9mm) ¾" (9mm) ¾" (9mm) ¾" (9mm) ¾" (9mm) Heat Range: 7 Electrode Material (c/g): Fine Wire Pt/Pt Fine Wire Pt/Pt Ir/Ir Pt/Pt Ir/Pt Ir/Ir Pt/Pt Copper/Yttrium enhanced Nickel Ir/Ir Ir/PtIr blend Ir/Ir Gap: 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0.00" (0.5mm) 0.0" (0.mm) 0.0" (0.mm) 0.0" (0.mm) 0-Digit Part# 0 4 56 50 0 4 56 50 0 4 56 50 0 4 56 504 0 4 56 507 0 4 56 508 0 4 55 5 0 4 6 580 0 4 55 59 0 4 55 5 0 4 55 58 8 9

Failure Modes High Transversal Forces Damage caused by socket Socket with supports (not recommended) Over Torquing: During installation and removal, if the socket is not fully seated on the plug or is applied at an angle, the side force can cause cracks Use a torque wrench with a wide bore. Wrenches with supports, as seen to the right, are more likely to damage the ceramic. Cracks in the threads Corona Discharge in the ceramic between the housing and insulator. Deposits Normal operating conditions High Electrode Wear M8 plugs should be torqued to 5-45 Nm (6- Lb-ft) M4 plugs should be torqued to 8 Nm ( Lb-ft) Over torquing is the most common cause of problems with industrial spark plugs. Over torquing can cause the seal between the ceramic and housing to break and cause cracks in the housing allowing combustion gases to escape. If the ceramic is not loose, the discoloration on the ceramic is called corona discharge and is normal when high voltages are present. If using anti seize lubricant, 000 C metal free lubricant must be used. Hot metal lubricants can cause spark plugs to seize in the cylinder head. Bosch recommends when installing spark plugs to use a torque wrench and the correct torque in ft.-lbs. As a general guideline, if a torque wrench is not available, hand tighten the plug until it is seated in the cylinder head. Spark plugs with gaskets should be tightened an additional 90. *Note: Avoid overtightening or undertightening as spark plug or engine damage may result. Always follow the manufacturer recommended torque specifications. Spark Plug with gasket 90º Plugs are covered with normal oil ash. Engine is operating as desired. Excessive Engine Oil Engine is operating as desired, but plugs have reached the end of their life. Replace plugs. Iron Deposits Ignition Lead Maintenance It is critical to avoid contamination in the ignition leads. The brownish green buildup is contamination and can cause flashover resulting in misfires. This contamination can be dirt, oil, or ozone. The dirt and oil can accumulate with time if the lead is placed over a dirty spark plug. The ozone forms when a poor connection between the lead and the spark plug terminal nut is present. The poor connection forms ozone which builds up on the walls of the lead. As this contamination builds, it increases the chances of flashover resulting in misfires. Always check the o-rings at the bottom of the ignition lead. A proper fitting o-ring reduces the likelihood of flashover and misfires. If misfires are occurring, changing the o-rings may solve the problem and save money. Plugs are coated with oil indicating high oil consumption. This could lead to a spark plug failure such as cracked insulator or oil fouling resulting in diiculty starting. The red coating is iron. The conductive iron leads to misfires as the spark travels from the center electrode to the housing instead of jumping between the electrodes (note white lines on the ceramic). The engine is not operating as desired. Valves may not be seating correctly. Ceramic Failures Ceramic Puncture: Punctures in the ceramic caused by high ignition voltages Flashover: Spark is traveling over ceramic from the terminal stud to the housing. Check insulator boots for proper fit and replace if necessary Mishandling or Impact Plug was damaged during installation or impacted during use. Use caution when installing new plugs. Do not drop plugs into cylinder head during installation. Excessive heat A melted ground electrode indicates pre-ignition. Ensure proper heat range of the plug is used and check ignition timing. 0

Industrial Spark Plug Application Guide For Natural Gas and LPG Applications Only Not recommended for landfill or biogas at this time. Engine Make Model Double Ir Long Life Standard Caterpillar G06, G /4" Reach 75 7 G4 75 7 G04 75 7 G400 Series 75 7 G500 Series (except C and E series with prechamber plugs) 705 706 70 G600 Series 705 706 70 Cooper Bessemer ENG, CNG 70 GDJ, GMA, GMB, GMC, w/g40 reducing Bushing 70 GDT, GFB, GFE, GFK, w/g40 reducing Bushing 70 Cummins L-0 7 7 QSV 8G 705 706 70 QSV 9G 705 706 70 QSK 9G 705 706 QSK 45G 705 706 QSK 60G 705 706 QSK 8G 705 706 QSK 50G 705 706 Deutz G60 V-8, TBG66 V-8, TBG66 V- 708 707 TBG66K V-8K, TBG66K V-, TBG66K V-6K 708 707 TBG60 V-8, TBG60 V, TBG60 V-6 708 707 TBG60K V-K TBG60K V-6K 708 707 Dresser Clark TLA6 7 7 Dorman DAG, 4DAG, 6DAG 75 7 6QG 75 7 6PG, PG 70 6SEG, 8SEG, SEG 75 7 6SETCWG Min Nox 75 7 SG 70 S, STCWG, STCAG 70 DATG-4 75 7 General Motors 05, 5, 40, 478, 70 Gasoline and LPG 75 7 Guascor FG80, FGLD80 705 706 70 FG40, FGLD40 705 706 70 FGLD60 705 706 70 FGLD480 705 706 70 John Deere 00 Series 75 7 400 Series (Nat. Gas and LPG) 70 500 Series (Nat. Gas and LPG) 70 Liebherr G 94T, G 94TC 75 7 Engine Make Model Double Ir Long Life Standard G 96T, G 96TC, G 96TC 40 75 7 G 9408 TC, G 9408 TC 40 7 7 MAN E 084 E0, E084 E0 75 7 E 086 E0, E086 E0 75 7 E 84, E84 LE 75 7 E 84 LN 75 7 E 876 75 7 E 084 7 7 E 086 7 7 Perkins G4-0 75 7 G4-6 75 7 900 Series 75 7 4000 Series 705 706 Superior 706G 705 706 70 7G 705 706 70 400 G Series 705 706 70 Wartsila W0V 705 706 W5SG 705 706 70 W8SG 705 706 70 W4SG 705 706 70 4SG 705 706 W0SG 7 7 Waukesha ATGL Series AT7GL Series - /" Rch Heads 70 AT7GL Series - /6" Rch Heads 705 706 70 VGF Series P48 705 706 70 L6 705 706 70 H4 705 706 70 F8 705 706 70 VHP Series P990GSI 70 P990GL - /" Rch Heads 70 P990GL - /6 Rch Heads 705 706 70 L7044GSI - /6" Rch Heads 705 706 L704GSI 70 L704G 70 704GL - /" Rch Heads 70 704GL - /6" Rch Heads 705 706 70

Product Application Guide (cont.) Industrial Spark Plugs Engine Make Model Double Ir Long Life Standard Waukesha (cont.) L5790G 70 L5790GL - /" Rch Heads 70 L5790GL - /6" Rch Heads 705 706 70 F5G 70 F5GL - /" Rch Heads 70 F5GL - /6 Rch Heads 705 706 70 Other L508G, L508GSI 70 L508GL - /" Rch Heads 70 L508GL - /6" Rch Heads 705 706 70 L55GL 705 706 70 F905GR 70 FG, FGSI/GSID 75 7 F97GRSI 70 F905GRSI 70 F894G, F894GRSI 70 F895G, F895GSI 70 F895GL - /" Rch Heads 70 F895GL - /6 Rch Heads 705 706 70 F50G 70 L500GR, L500GRSI 70 L5788GR, L5788GRSI 70 L7040G 70 6BZ, 6LRZ, 6LRZB, 6MZA, 6MZR 70 6NK, 6WAK, 6WAKB 70 40GK, 45GK 70 80G, 80GB, 80GKB, 85GLB 70 90, 90GLB, 95G, 95GK 70 Other Natural and LP Gas (4mm Heads) P54G, P54GSI 75 7 H077G, H077GSI 75 7 L66G, L66GSI 75 7 VRG0, VRG0 75 7 VRN65, VRN8, VRN0 75 7 Bosch - the Facts The Bosch Group is a global leader in automotive, industrial and household technology. It has more than 50 subsidiaries and regional companies in some 60 countries and employs over 00,000 associates. In 0, Bosch spent more than 4 billion euros for research and development and applied for over 4,00 patents worldwide. 4 5

With over one hundred years of experience in spark plug development, Bosch is uniquely placed to supply a range of spark plugs that meet the extreme demands of industrial applications. Bosch combines its engineering experience with robust construction methods and the highest quality, heavy-duty components to produce the Industrial Series of spark plugs. The use of precious metals in both centre and ground electrodes provides exceptional resistance to wear, unsurpassed reliability and greatly extended service life in natural gas applications. Robert Bosch (Australia) Pty. Ltd. Cnr Centre and McNaughton Roads Clayton Vic 68 For further information please contact your local automotive distributor or call the Bosch Customer Service Line on: Australia 00 07 040 www.bosch.com.au New Zealand 0800 45 896 www.bosch.co.nz ADV05A Whilst every care has been taken in the preparation of this publication, Bosch does not warrant the accuracy or completeness of the information in this publication and Bosch reserves the right to alter specifications without notice. To the extent permitted by law, Bosch excludes all liability, including negligence, for any loss incurred in the reliance on the contents of this publication.