Spark plug replacement interval extended by 50%! 5 key tips for industrial equipment maintenance

1. Five key tips for maintaining industrial spark plugs

Frequent replacement of industrial spark plugs not only increases costs, but also affects the operating efficiency of equipment. Mastering scientific maintenance methods can significantly extend the life of the spark plug and reduce downtime.

 

• Tips 1: Choose a spark plug material suitable for working conditions

Problem: Ordinary spark plugs are easily dissipated in high temperature and high corrosion environments.

Solution:

High-load equipment (such as generator sets, construction machinery) → iridium/platinum spark plugs (high temperature resistance and corrosion resistance).

High sulfur fuel environment (such as ships, oilfield equipment) → Special coating spark plugs (anti-chemical corrosion).

Effect: Increase the life span by 30%-50%, reducing electrode ablation.

 

• Tips 2: Clean the carbon deposits regularly to maintain the best gap

Problem: Carbon deposits lead to poor ignition, and gap changes affect the spark intensity.

Solution:

Remove carbon deposits every 200 hours with a dedicated spark plug cleaner (or ultrasonic cleaning).

Check the electrode gap (refer to the equipment manual, usually 0.7-1.1mm), and adjust with a feeler gauge.

Effect: Avoid ignition failure and extend service life by more than 20%.

 

• Tips 3: Optimize the air-fuel ratio and reduce incomplete combustion

Problem: Too thick or too thin the mixture will accelerate the loss of the spark plug.

Solution:

Use a exhaust analyzer to ensure that the air-fuel ratio is within the ideal range (gasoline engine 14.7:1, diesel engine varies by model).

Check the oxygen sensor and fuel injector to avoid poor fuel atomization.

Effect: Reduce carbon deposits and electrode corrosion, and improve combustion efficiency.

 

• Tips 4: Avoid frequent short-term operation of "cold start"

Problem: Frequent start and stop cause the spark plug temperature to suddenly change, which is prone to cracking and carbon accumulation.

Solution:

Industrial equipment should be continuously operated as much as possible (avoid short start and stop <30 minutes).

Use preheating devices in cold environments to reduce cold start impact.

Effect: Reduce thermal stress damage and extend the life of the spark plug by 30%.

 

• Tip 5: Use high-quality spark plugs and install them correctly

Problem: Low quality spark plugs or improper installation lead to early failure.

Solution:

Choose the original spark plug.

Use a torque wrench during installation (avoid excessive tightness/looseness resulting in air leakage or thread damage).

Apply anti-blocking agent (to prevent spark plugs from sticking in high temperatures).

Effect: Avoid abnormal losses and ensure stable ignition.

 

2. Maintenance Guide for Industrial Spark Plugs

Analysis of common problems and causes of industrial spark plugs

Electrode ablation or corrosion

Phenomenon: The central electrode becomes round, the side electrode becomes thinner, and even breaks.

reason:

High temperature operation (more than 1000°C) causes metal oxidation.

High sulfur content of fuel oil (such as heavy oil, inferior diesel) leads to chemical corrosion.

 

Severe carbon deposits

Phenomenon: The electrodes and ceramic insulators cover black carbon deposits.

reason:

The air-fuel ratio is too rich (inadequate combustion).

Long-term low load operation (spark plug temperature is insufficient and cannot be self-cleaned).

 

Cracked or leakage of ceramic body

Phenomenon: The spark plug has flashover and poor ignition.

reason:

Overtighten during installation (overt torque).

Hot and cold shock (frequent start and stop or cooling system failure).

 

Ignition performance deteriorates

Phenomenon: Difficulty in starting the engine, insufficient power, and increased fuel consumption.

reason:

The electrode gap is too large or too small (the standard value is usually 0.7-1.1mm).

Spark plug aging (over recommended service life).

Five major maintenance tips for industrial spark plugs

Clean the carbon deposits regularly to maintain the best gap

Operation steps:

Remove the spark plug for inspection every 200-300 hours of operation.

Use a spark plug cleaner or ultrasonic cleaner to remove carbon deposits.

Adjust the electrode gap with a feeler gauge (see the equipment manual).

Effect: Restore ignition efficiency and reduce fuel waste.

 

Choose spark plug material suitable for working conditions

Recommended choices:

Working conditions	Recommended spark plug types	Lifespan improvement
High temperature and high load (generator set)	Iridium/platinum spark plug	30%-50%
High sulfur fuel (ships, oil fields)	Special coating spark plug	40%-60%
Frequent start and stop (construction machinery)	Copper core resistive spark plug	20%-30%

 

Optimize the air-fuel ratio and reduce incomplete combustion

Inspection method:

Use a exhaust analyzer to detect CO and HC emissions.

Adjust the fuel injection system or carburetor to ensure that the air-fuel ratio is within 14.7:1 (gasoline) or reasonable range (diesel).

Effect: Reduce carbon deposits and reduce spark plug losses.

 

Avoid frequent short-term operation of "cold start"

Solution:

Try to keep the equipment running continuously (avoid short start and stop <30 minutes).

Use preheating devices (such as glow plugs or intake heating) in cold environments.

Effect: Reduce thermal stress damage and extend life by 30%.

 

Proper installation to prevent mechanical damage

Installation points:

Use a torque wrench (refer to the manufacturer's recommended value, usually 15-25N·m).

Apply anti-jamming agent before installation (to avoid difficult to remove after high temperature sintering).

Check the spark plug gasket to ensure no air leakage. Effect: Avoid thread damage and air leakage, ensuring stable combustion.