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Service Manual Spark Plugs/Oil Filters

1R E C I P R O C A T I N G E N G I N E SAV6-R$ November 2004 AviationServiceManualSpark Plugs/Oil Filters Bringing Power To Flight 2R E C I P R O C A T I N G E N G I N E SPurposeThis Service Manual presents recom-mended Service , handling and recondi-tioning practices to assure economic,satisfactory operation from ChampionAerospace Spark plugs and oil Service and handling can helplengthen the time between replacementperiods, while reducing unscheduled oremergency are ways to analyze Spark plugperformance through examples ofadverse effects from certain engineoperating conditions.

Fine Wire Projected Core Nose. 5 S P A R K P L U G S Heat Rating The heat rating of a spark plug is the measure of its ability to transfer heat re-ceived from the combustion chamber to the cylinder and engine cooling system. The correct heat rating for the engine ...

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Transcription of Service Manual Spark Plugs/Oil Filters

1 1R E C I P R O C A T I N G E N G I N E SAV6-R$ November 2004 AviationServiceManualSpark Plugs/Oil Filters Bringing Power To Flight 2R E C I P R O C A T I N G E N G I N E SPurposeThis Service Manual presents recom-mended Service , handling and recondi-tioning practices to assure economic,satisfactory operation from ChampionAerospace Spark plugs and oil Service and handling can helplengthen the time between replacementperiods, while reducing unscheduled oremergency are ways to analyze Spark plugperformance through examples ofadverse effects from certain engineoperating conditions.

2 You will also findapplication information and Spark plugtype selection criteria, as well as usefulreferences to supplemental ApprovedChampion Aerospace products are manu-factured in accordance with standardsestablished by the Federal plugs .. 2-18 Product Features .. 3 Design Features .. 3 Spark Plug Type Designation System .. 4 Typical Types of Electrode Construction .. 4 Operating Period .. 4 Selection Criteria .. 5 Reach .. 5 Heat Rating .. 5 Shielded Terminal Designs .. 5 Electrode Conditions .. 6-9 Electrode Wear Patterns .. 6-7 Carbon Fouling .. 8 Oil Fouling .. 8 Lead Fouling .. 8-9 Bridged Electrode Gaps .. 9 Cracked Core Nose .. 9 Operating Data .. 10 Preignition .. 10 Detonation.

3 10 Connector Well Flashover .. 10 Improper Gaskets .. 10 Installation Procedures .. 11-12 Preinstallation .. 11 Outside Gaskets .. 11 Anti-Seize Compound .. 11 Installation .. 11-12 Correct Socket Tools .. 11 Spark Plug Connector Installation .. 11-12 Dow Corning Compound Application .. 12 Removal Procedures .. 12-13 Shielded Terminal Connectors .. 12 Unshielded Terminal Connectors .. 12 Spark Plug Handling .. 12 Reconditioning Service .. 13-18 Preliminary Visual Inspection .. 13 Degreasing .. 13 Cleaning the Firing End .. 13-14 Model 2600A Vibrator/Cleaner .. 13 Model CT-475AV Cleaner/Tester .. 14 Cleaning the Barrel End .. 14 Cleaning the Terminal Wall .. 14 Cleaning Connector Seats .. 15 Firing End Inspection.

4 15 Cleaning the Threads .. 15 Gap-Setting Tools and Procedure .. 16 Model CT-482 Erosion Gauge .. 16 Model 2500A Gap-Setting Tool .. 16 Model CT-415 Gap-Setting Tool .. 17 Model CT-457 GAP-SETTING TOOL .. 17 Model CT-408 Gap-Setting Tool .. 17 Testing Tools and Procedures .. 18 Model CT-475AV Cleaner/Tester .. 18 Tester Calibration .. 18 Preservation and Storage .. 18 Oil Filters .. 19-26 Product Features .. 19 Aircraft Engine Oil Filters .. 20 Benefits of Efficient Engine Oil Filtration .. 20 Oil filter and Efficient Element Design .. 20-21 Champion Replacement Elements .. 20 filter Media .. 21 Dirt-Holding Capability .. 21 Resistance to Collapse .. 21 Champion Full-Flow Spin-On Filters .. 21 Champion Aviation Engine Oil Filters .

5 22 Lycoming Replacement Filters .. 22 Semi-Depth Type Filters .. 23 Element Removal and Installation Procedures .. 23 Housing Removal .. 23 Cleaning and Lubrication .. 23 Assembly .. 23-24By-Pass filter System .. 24 Full-Flow filter System .. 25 Oil filter Sludge Inspection .. 25 Over Pressurized Lube Oil filter .. 26 Supplemental Information .. 273R E C I P R O C A T I N G E N G I N E SProduct FeaturesPlated threads prevent glass seal provides positiveretention of center wire andprevents gas threads prevent ChampionAerospace Spark plugs are designed forthe critical difference in performance, farbeyond the ordinary.

6 Champion sparkplugs stand up to high temperatures,pressures and lead deposits, with aperformance second to none. Whenyou re up in the air, count on qualityChampion Spark FeaturesThe # I Choice Worldwide - OEM forall Piston EnginesChampion Spark plugs are a product ofChampion Aerospace s commitment toquality and advanced technology, acommitment that has made Championspark plugs the #I choice of enginemanufacturers, maintenance techniciansand pilots around the lridium S Spark plugs forhigh-performance than platinum Spark plugs ,Iridium S plugs resist lead attack betterand provide better scavenging thanstandard platinum plug designs, resultingin exceptional performance, even underthe most demanding carbide resistor prevents wear fromvoltage drain for prolonged plug core assures efficient heat transferand maximum electrical oxide insulator has excellentthermal properties to resist alloy electrodes provideexcellent resistance to Spark andheat erosion.

7 3 Spark plugs 4S P A R K P L U G SSpark Plug TypeDesignation SystemAll Champion Aerospace Spark plugs areidentified by type designations asindicated on the following Spark plugnumber and symbol chart. The symbol iscomposed of a rating position number,together with prefix and suffix numbers toindicate major plug design Types ofElectrode ConstructionTwo-Prong B Tangentto CenterSingle-GroundElectrode AutomotiveGap ConfigurationTypical Spark Plug Number with Symbol ExplanationResistorNone No ResistorR Mil ErosionProtectionBarrel StyleNone UnshieldedE Shielded 5/8" - 24 ThreadH Shielded 3/4" - 20 Thread(All-weather Plug)Mounting ThreadReachHex SizeB - 18mm13/16" ( )7/8" ( )M - 18mm1/2" ( )7/8" ( )J - 14mm3/8" (.)

8 095cm)13/16" ( )L - 14mm1/2" ( )13/16" ( )U - 18mm1-1/8" ( )7/8" ( )N - 14mm3/4 ( )13/16 ( )Operating PeriodThe useful operating life of a Spark plugvaries greatly with operating conditions,engine models, ignition systems andspark plug types. Scheduled serviceintervals should be established by theindividual is normally recommended that sparkplug gaps and deposit conditions bechecked at 50-hour intervals. In addition,removal time specifications are usuallyavailable from the engine manufacturerand may be supplemented by past expe-rience with a particular engine Spark plug gaps and deposits atappropriate regular intervals is crucial topreventing engine misfires. Since plugdeterioration can vary with operatingconditions, the operating period couldincrease somewhat or be sharplyreduced, depending on manufacturergap width recommendations, increasedvoltage needed to fire the gap or deterio-ration of magneto components andignition DesignNone Conventional SingleE Two Electrode MassiveN Four Electrode MassiveS Single Electrode (Iridium)

9 B Twin ElectrodesR Push- wire - 90' to CenterY Projected Core NoseHeat Rating PositionLow Number ColdHigh Number HotTwo-Prong EGround ElectrodesFine WireProjected Core Nose5S P A R K P L U G SHeat RatingThe heat rating of a Spark plug is themeasure of its ability to transfer heat re-ceived from the combustion chamber tothe cylinder and engine cooling correct heat rating for the enginedesign ensures that the plug operatescool enough to prevent preignition butwarm enough to resist accumulation ofconductive, plug-fouling aviation Spark plugs areavailable in a wide range of heat ratingsto meet all engine and CriteriaChampion Aerospace Spark plugs are manu-factured within all military and commercialstandards established for aviation sparkplugs.

10 All plug types are designed to meetspecific engine and aircraft requirements forthread size, reach , heat rating, shieldingand terminal following Champion applicationcatalog and charts display in red printthe recommended Spark plugs by aircraftand engine model for the mostsatisfactory Service . Champion aviation catalog AV-12 Champion pocket size catalog AV-14 Champion wall chart AV-33 ReachThe reach of a Spark plug is the distancefrom the shell gasket seat to the end ofthe shell threads. A proper-reach plugensures that the electrodes are appropri-ately positioned in the combustion cham-ber to ignite the fuel-air mixture, basedon requirements of the cylinder "-20 All-weather Shielding Barrelwith ConnectorA hot-type Spark plug has a longer corenose and transfers heat more slowly thana cold-type TypeReachShell threads are furnished in 14mm- and18mm-diameter, long reach and short DiameterLong ReachShort Reach14mm1/2"3/8"18mm13/16"1/2"Shielded Terminal DesignsShielded terminal connections are usedon aviation Spark plugs to prevent radiointerference by the engine ignition current industry standard is the all-weather 3/4"-20 Spark plug.


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