R E C I P R O C A T I N G E N G I N E S A ® ® 1 R E C I P R O C A T I N G E N G I N E S Purpose Spark Plugs ................................................................................... 2-18 Product Features ............................................................................................. 3 This service manual presents recom- Design Features .............................................................................................. 3 mended service, handling and recondi- Spark Plug Type Designation System ............................................................... 4 tioning practices to assure economic, Typical Types of Electrode Construction .................................................. 4 satisfactory operation from Champion Operating Period ................................................................................... 4 Aerospace spark plugs and oil filters. Selection Criteria ............................................................................................. 5 Proper service and handling can help Reach .................................................................................................... 5 lengthen the time between replacement Heat Rating............................................................................................ 5 Shielded Terminal Designs ...................................................................... 5 periods, while reducing unscheduled or Electrode Conditions .................................................................................... 6-9 emergency replacements. Electrode Wear Patterns ...................................................................... 6-7 Included are ways to analyze spark plug Carbon Fouling...................................................................................... 8 performance through examples of Oil Fouling............................................................................................. 8 adverse effects from certain engine Lead Fouling....................................................................................... 8-9 operating conditions. You will also find Bridged Electrode Gaps ......................................................................... 9 Cracked Core Nose ................................................................................ 9 application information and spark plug Operating Data ............................................................................................ 10 type selection criteria, as well as useful Preignition ........................................................................................... 10 references to supplemental Champion Detonation .......................................................................................... 10 publications. Connector Well Flashover .................................................................... 10 Improper Gaskets ................................................................................. 10 FAA/PMA Approved Installation Procedures ............................................................................. 11-12 Preinstallation....................................................................................... 11 Champion Aerospace products are manu- Outside Gaskets ................................................................................... 11 factured in accordance with standards Anti-Seize Compound ........................................................................... 11 established by the Federal Aviation Installation ...................................................................................... 11-12 Administration. 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 ........................................................................... 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............................................................. 22 Lycoming Replacement Filters .............................................................. 22 Semi-Depth Type Filters ........................................................................ 23 Element Removal and Installation Procedures ................................................ 23 Housing Removal ................................................................................. 23 Cleaning and Lubrication ..................................................................... 23 Assembly ........................................................................................ 23-24 By-Pass Filter System ............................................................................. 24 Full-Flow Filter System .......................................................................... 25 Oil Filter Sludge Inspection ............................................................................ 25 Over Pressurized Lube Oil Filter ..................................................................... 26 Supplemental Information ............................................................................. 27 2 R E C I P R O C A T I N G E N G I N E S ® 3 S P A R K P L U G S Spark Plug Type Designation System All Champion Aerospace spark plugs are Typical Spark Plug Number with Symbol Explanation identified by type designations as indicated on the following spark plug number and symbol chart. The symbol is composed of a rating position number, together with prefix and suffix numbers to indicate major plug design characteristics. RHB37E Typical Types of Electrode Construction Resistor Electrode Design None — No Resistor None — Conventional Single R — Mil Spec. E — Two Electrode Massive Resistor — Erosion N — Four Electrode Massive Two-Prong E Protection Ground Electrodes S — Single Electrode (Iridium) B — Twin Electrodes R — Push-wire - 90' to Center Y — Projected Core Nose Fine Wire Barrel Style Heat Rating Position None — Unshielded Low Number — Cold E —Shielded 5/8" - 24 Thread High Number — Hot H — Shielded 3/4" - 20 Thread