CONTENTSIntroduction 2Altronic FLASHGUARD® Industrial Spark Plugs

Features and Benefits 3Types and Part Numbers 4Application List 5

Altronic Spark Plug LeadsFeatures and Benefits 6Universal FLASHGUARD® Leads 7Assembled FLASHGUARD® Leads 8CSA Certified Spark Plug Leads 9

Accessories

From the manufacturers of industry standard ignition systems…

ALTRONIC INDUSTRIAL SPARK PLUGSAND IGNITION ACCESSORIES Designs based on more than 30 years of industrial natural gas engine

accessory experience

Engineered for heavy duty industrial applications

Promotes improved engine and electronic performance

For more than a quarter century, Girard, Ohio-based Altronic, Inc. has designedand produced ignition, instrumentation, and control systems for natural gas-fueled engines. Now, the pioneers of capacitor-discharge and digital ignitionsystems introduce high quality spark plugs and ignition accessories for heavyduty gas engine applications.

Engineered for the gas compression, power generation, cogeneration, andpumping industries, Altronic industrial spark plugs and ignition accessorieshave been introduced to promote more efficient engine operation and reducemaintenance. The incorporation of integral high ohmic resistors into the AltronicFLASHGUARD spark plug and resistor spark plug lead designs reduces theemission of RFI (radio frequency interference — electrical “noise”) and thusimproves the overall operation and reliability of engine-based electronic systemssuch as ignition, speed control, monitoring, and safety shutdown.

Sales/Service Contacts

ALTRONIC INDUSTRIAL SPARK PLUGSAND IGNITION ACCESSORIES

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1210-11

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Altronic, Inc. (Girard, Ohio)Certificate #006688

REMOVABLE THREADED BRASS

TERMINAL (NICKEL PLATED)

SWAGED AND HEAT SHRUNK FITTING

INNER GASKET

ELECTRICAL CONDUCTIVE GLASS

MELT OF PROPRIETARY RESISTANCE

CENTER ELECTRODE COPPER CORED FOR

EFFECTIVE ELECTRODE COOLING

PROPRIETARY NOSE CONE DESIGN TO RESIST INTERNAL

FLASHOVER

SAFETY RESTRAINED INSULATOR

FIVE-FOLD FLASHOVER BARRIER WITH A

GROOVE PROFILE

EXTRA-LONG DOUBLE GLAZED ALUMINA

CERAMIC INSULATOR; RESISTS FLASHOVER

UP TO 40kV

NICKEL PLATED STEEL TERMINAL CONDUCTOR

FLASHGUARD

SPARK PLUGCUT-AWAY DIAGRAM

ALTRONIC FLASHGUARD INDUSTRIAL SPARK PLUGS

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FLASHGUARD industrial spark plugs are designedto increase effective spark plug service life byreducing flashover and electrode erosion whileoptimizing combustion and minimizing radiofrequency interference (RFI).

Here are a few items that set FLASHGUARD sparkplugs apart:

Double-glazed alumina ceramic insulators withgrooved profiles resist flashover up to 40,000 volts

A variety of electrode configurations and reaches toprecisely match the spark plug to the application

FLASHGUARD spark plugs feature a proprietaryspark plug nose cone designed to minimize internalflashover-related misfire – often referred to as“cone discharge”

Reduced radio frequency interference (RFI) andelectrode erosion due to the integration of a highohmic internal resistor

Electrode designs and large internal nose coneclearances allow for superior scavenging andcirculation of the combustible mixture between theelectrodes which ultimately leads to improvedcombustion stability

Most Altronic FLASHGUARD spark plugs areconstructed for use with the tight-fitting, AltronicFLASHGUARD secondary leads for furtherreduction in flashover and improved spark plugservice life

Modern spark-ignited gas engines, particularly highperformance, lean-burn configurations, demand thatincreasingly higher voltage levels be delivered to thespark plug to insure a strong spark at the plugelectrodes. The FLASHGUARD family of productshas been developed by Altronic to meet the industryneed for high-quality secondary leads and spark plugsto complement its high performance digital ignitionsystems, such as the DISN, CPU-95, and CPU-2000.

The ignition system is only as good as its weakest link,which traditionally has been the delivery of the highvoltage spark energy between the ignition coil andspark plug electrodes. FLASHGUARD productsprovide an effective solution, even in demandingapplications, and offer engine users reducedoperating and fuel costs, as well as less frequentspark plug changes. Whether in search of longerspark plug life in conventional engines, or reliablecombustion in lean-burn applications, the featuresand capabilities of the FLASHGUARD secondaryleads and spark plugs make them a logical choice foruse on any industrial engine application.

FLASHGUARD ®

Massive Electrode Spark PlugsDeveloped for use on medium and large- borenatural gas-fueled engines, these plugs are suitablefor stoichiometric and lean-burn applications (open-chamber or pre-chamber). This design is particularlyhelpful for applications in which air/fuel mixing andscavenging is irregular or voltage demand (due tolean operation or high compression ratio) is high.The massive designs are available in both 18mmand 7/8"-18 thread sizes and with various reaches.

FLASHGUARD ®

Precious Metal Spark PlugsLean-burn engines, which require a spark in excessof 30,000 volts, and expose the spark plug toelevated temperatures, require more frequent sparkplug maintenance and replacement. Precious-metalAltronic spark plugs, due to their intrinsically highresistance to erosion, offer substantially improved lifeand performance. Altronic platinum (DP) designsshould be used only in open-chamber engines.Iridium-platinum plugs (IP) may be used in both openand pre-combustion chamber engines. Both typesprovide very long operating life in conventional engines.

DP Series Two-Wire Platinum Electrodes:Offer moderate price and enhanced performance foropen-chamber, lean-burn applications. DP-seriesplugs are available in 14mm, 18mm, and 7/8"-18sizes and unshielded and integral versions.

IP Series Iridium-Platinum Electrodes:The L1863IP model fits many popular engines suchas the Caterpillar G3500 , G3600, and Waukesha ATand VHP-GL-series engines. The iridium centerelectrode assures long life in open-chamber or pre-chamber lean-burn engines.

ALTRONIC FLASHGUARD INDUSTRIAL SPARK PLUGSTYPES AND CONFIGURATIONS

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ALTRONIC FLASHGUARD® SPARK PLUGCONFIGURATIONS

N SHELLL SHELLJ SHELL

NOTES:1. Standard gap is .012" (0.30 mm) for L1863IP and .014" (0.35 mm) for all other types..2. Recommended installation torque is 24 ft-lbs. for 14mm, 35 ft-lbs. for 18mm, 50 ft-lbs. for 7/8"-18 type.3. “B” suffix plug replaces former “A” suffix model; “DP” suffix plug replaces former “P” suffix model.

Short service life

Open-chamber engine only: good service life

Open or pre-chamber engines: best service life

Which Flashguard® spark plug electrode type is right for my application?

Electrode Type

Massive (-B)

Platinum (-P, -DP)

Iridium-Platinum (-IP)

Lowest

Medium

Highest

Cost Factor

Good service life

Very long service life

Very long service life

Conventional Engine Lean-Burn Engine

Spark Plug Types:

ThreadSize

ThreadReach

14MM

1/2"

HexSize

13/16"

Part No.

J1443DP

18MM

3/4"

1/2" 7/8"L1843BL1843PN1843B

5/8" 15/16" L2252BL2252DP

L2272B7/8"-18 0.86" 15/16"

1" 15/16" L2282B

Description

Unshielded, platinum

13/16" J1463DP Unshielded, platinum

N1463DP Integral, platinum

Unshielded, massive nickelUnshielded, platinumIntegral, massive nickel

13/16" 7/8"

L1863BL1863DPL1863IPN1863DP

Unshielded, massive nickelUnshielded, platinumUnshielded, iridium-platinumIntegral, platinum

Unshielded, massive nickelUnshielded, platinum

Unshielded, massive nickel

Unshielded, massive nickel

7/8"

ElectrodeTypeB = massive nickel 3-prongDP = platinumIP = iridium center/ platinum groundP = platinum

Spark Plug Part Number Designation:L

PlugTypeJ = Unshielded, std. insulatorL = Unshielded, long insulatorN = Integral coil, 13/16"-20

ThreadDiameter14 = 14mm18 = 18mm22 = 7/8"

22

ThreadReach4 = 1/2"5 = 5/8"6 = 3/4" (14mm)6 = 13/16" (18mm)7 = 0.86"8 = 1.00"

5

HeatRange0 = coldest9 = hottest

2 B

ALTRONIC FLASHGUARD INDUSTRIAL SPARK PLUGSAPPLICATION LIST

5

SUPERIOR2400 Series **R

R G825, GT825, GTL, SGT – 18mm plugsG825, GT825, GTL, SGT – 7/8"-18 plugs

Manufacturer/Model MassiveElectrode

PlatinumElectrode

AJAXR LE models (precombustion chamber)R All other models

L2252BL2252B

—L2252DP

CLARKR Models with precombustion chamber **R All other models

L2252BL2252B

—L2252DP

DE LAVALHV, HVA series L2282B —

MEPR MEP – 6, 8, 10, 12 ** L1843B, N1843B —

INGERSOLL RANDModels with precombustion chamberAll models replacing RW83F

L2282BL2272B

——

COOPER/BESSEMERR 5/8" reach, precombustion chamber **R 5/8" reach, open chamber

1" reach, precombustion chamber ** 1" reach, open chamber

L2252BL2252B

L2282B, L2272BL2282B, L2272B

—L2252DP

——

CATERPILLARG342, G379, G398, G3993300 series – 1/2" reach3300 series – 3/4" reach3400 series3500 series **3600 series **

————

L1863B *L1863B

J1443DPJ1443DP

J1463DP, N1463DPJ1463DP, N1463DPL1863DP*, L1863IP*

L1863IP

* Requires longer spark plug terminal 510726 when used with Caterpillar EIS ignition system.** On lean-combustion engines, it is advisable to set plug gap to .011"–.012" prior to installation.

R = revision to listing in previous (2001) Spark Plug Catalog.Note: “B” suffix plug replaces former “A” suffix model; “DP” suffix plug replaces former “P” suffix model.

WORTHINGTON All models L2252B L2252DP

WAUKESHAR AT series – 1/2" reach heads **R AT series – 13/16" reach heads **R VGF series **R VGF series ** (shielded)R VHP-G, VHP–GSI seriesR VHP-GL series – 1/2" reach heads **R VHP-GL series – 13/16" reach heads **

L1843B, N1843B L1863B L1863B

—L1843B, N1843BL1843B, N1843B

L1863B

—L1863IP

L1863DP/L1863IP N1863DPL1843P

—L1863IP

L1843B, N1843BL2252B

L1863IPL1843P

L2252DP

L1863B

RRRRRR

ELECTRODETYPE

B

DP/P

IP

ALTRONIC STANDARD AND FLASHGUARD LEADSFEATURES AND BENEFITS

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Description and features: High quality, corrosion-resistant components for

heavy duty industrial applications

Wide variety of ignition coil and spark plugtermination options

Shielded and unshielded configurations available

FLASHGUARD boot and lead assemblies, withintegral 5,000 ohm resistor and high quality bootconstruction, improve flashover resistance, plugperformance, and reduce RFI

Altronic has developed a complete line of ignitionspark plug leads for use on standard applications aswell as for applications operating in areas requiringClass I, Division 2, Group D compliance. These highquality industrial leads are available with a widevariety of primary and secondary terminations foruse with unshielded and shielded coils as well asstandard and shielded spark plugs.

FLASHGUARD secondary lead assemblies, whichincorporate an integral 5,000 ohm resistor and tight-fitting silicone or Teflon boots, offer a number offunctional advantages including longer spark pluglife and durability. Engine-related digital controls andinstrumentation also benefit from the reduction inRFI (electrical “noise”) brought about by the built-inresistor. FLASHGUARD spark plug lead modelsare also available with special extensions for deepwell applications.

FLASHGUARD®Spark PlugBoot Design and MaterialsThe basic function of a spark plug boot is to insurethat the energy generated by the ignition system tobring about an arc at the firing end of the plug isefficiently delivered and does not flashover theinsulator. Altronic spark plug boots are available in anumber of tight-fitting silicone configurations as wellas in Teflon with integral, flashover-resistant O-rings.

Altronic silicone boots provide exceptional sealing tothe plug. This raises the “flashover” voltage of theassembly and helps insure that the likely place forthe discharge of electrical energy is not along theoutside of the insulator but at the spark plugelectrodes. Silicone boots are ideal for moststandard, rich-burn applications.*

Teflon boot construction is preferable for severetemperature applications, such as those operatingwith precombustion chambers. Since lean burnapplications often require over 20,000 volts toinitiate an arc between the center and groundelectrodes, the integral O-rings standard on theAltronic Teflon boots help to suppress flashover onthe outside of the spark plug insulator.

*NOTE: Silicone boots should be lubricated with a high-temperature,high-dielectric compound, such as ChristoLube MCG147 orPermatex Dielectric Tune-up Grease, prior to use.

7mm SILICONEJACKETED

HIGH TENSIONCABLE WITHOR WITHOUTADDITIONAL

SILICONEHOSE OVER

ONE-WAYPOSITIVE

LEADCONNECTION

PREVENTSLEAD

PULL-OUT

INTEGRAL5000Ω

RESISTORREDUCESRFI AND

ELECTRODEEROSION

SPARK PLUGTERMINATION

WITH SNAPACTION BALLCONNECTION

FLASHOVERRESISTANT

TEFLON BOOTWITH TWO HIGHTEMPERATURE

FLUOROSILICONEO-RINGS

FLASHOVERRESISTANT

HIGHTEMPERATURESILICONE BOOT(REPLACEABLE)

TEFLON BOOT(with O-Rings)

SILICONE BOOT(Tight Fitting)

UNIVERSAL FLASHGUARD SPARK PLUG LEADSAND PARTS BREAKDOWN

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Universal FLASHGUARD ® Spark Plug LeadsUniversal lead assemblies can be made into specific types by adding one of 3 optional spark plug boots and one of 3 optional coil termination packages:

Spark Plug Coil Type

All All

Description

Lead Ass'y. - 4" extension(complete leads on pg. 8)

Item No.

1

Part No.

593200-30

All All Lead Ass'y. - 9" extension(complete leads on pg. 8)

1 593250-35

2b2a

2c

1

3a3b, 3c

Hose,seepg. 11

Ignition Coil End (choose one)

Coil Type Description

Coil terminal, 180°Coil boot, 180° Coil terminal, 90°Coil boot, 90°

Item No.

3a

Qty.

11 11

Part No.

504040502122 504207504180

Shielded Coil secondary kit 3b 1 510480

Coil kit w/silicone hose 3c 1 510714

Unshielded

Spark Plug End (choose one)

UnshieldedSpark Plug Description

14mm Spark plug boot, silicone

Item No.

2a

Qty.

1

Part No.

504235-1

Spark plug boot, Teflon (1) 2b 1 504276 (1)

2c 1

18mm,7/8"-18

Spark plug boot, Teflon (3) 1 504280 (3)

Spark plug boot, Teflon (4) 2b 1 504313 (4)

Spark plug boot, silicone

Spark plug boot, Teflon (3)

Spark plug boot, Teflon (2)

2a

2b

2c

1

1

1

504235-2

504280 (3)

504254 (2)

(1) Boot designed to fit Champion RC78PYP and RX85PYP spark plugs only.(2) Long boot only fits spark plugs with an exposed insulator of 1.5" or longer.(3) Short boot for use with Champion spark plugs with an exposed insulator of

less than 1.5".(4) Short boot for use with Altronic 14mm spark plugs.

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ASSEMBLED FLASHGUARD SPARK PLUG LEADS

FLASHGUARD® Spark Plug Leads

FLASHGUARD® Spark Plug Leads forCaterpillar 6-1/4" Bore EnginesThe Altronic FLASHGUARD spark plug lead for the CATERPILLAR G342,G379, G398, and G399 engines is for use with unshielded ignition coils andutilizes a 5,000 ohm resistor lead assembly in conjunction with a tight-fitting14mm spark plug boot.

L L

Typical -unshieldedcoil end

Typical -shieldedcoil end

Part No. Length

593207-18 18"

593209-30 30" universal version

CSA-Certified Shielded Spark Plug Leads forClass I, Division 2, Group D Hazardous AreasIn order to comply with requirements for Class I, Division 2, Group Dhazardous areas, Altronic manufactures a stainless steel-jacketed sparkplug lead with a Teflon inner liner and shielded terminations. This lead iscompatible with shielded Altronic ignition coils and shielded (aircraft-style) spark plugs with 3/4"-20 connections.

OTHER ALTRONIC SPARK PLUG LEADS

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Part No.

593020-L

593030-L

SparkPlugEnd

CoilEnd

Lengths “L”

180°

180°

180°

180°

10", 13", 16", 18"

10", 13", 16", 18"

1"

2"

SparkPlugWell

Part No.

593121-L

593122-L

SparkPlugEnd

CoilEnd

Lengths “L”

180°

180°

180° 14", 18", 22"

14", 18", 22"

1"

SparkPlugWell

593123-L 90°

90°

180° 14", 18", 22"

1"

1"

593131-L 180° 14", 18", 22"

593132-L 180°

180°

90° 14", 18", 22"

2"

2"

593133-L 90° 14", 18", 22"180°2"

593134-L 90° 14", 19"90°2"

CSA-Certified Safe-T-Lead™ Spark Plug Leadsfor Class I, Division 2, Group D Hazardous AreasThe Altronic Safe-T-Lead™ is a patented spark plug lead design for usein Division 2 hazardous area applications. Using a proprietary, semi-conductive jacket over the high-tension cable instead of the traditionalstainless steel braid, the Division 2 certified Safe-T-Lead™ enables theoperator to use conventional troubleshooting tools such as timinglights, neon firing indicators, and scope probes. The reduction in cap-acitive loading, brought about by the elimination of the metallic jacket,also contributes to an increase of available voltage at the spark plug.

Part No. Lengths “L”

593028-L 13", 17", 18", 21", 24"

Part No. Lengths “L”

593005-L 12", 16", 18", 22"

Standard Spark Plug Leads forUnshielded Spark Plug, Unshielded CoilThis non-resistor lead utilizes a standard silicone spark plug boot and is foruse with unshielded ignition coils and unshielded spark plugs.

Standard Spark Plug Leads forUnshielded Spark Plug, Shielded Altronic CoilFor applications operating with shielded Altronic ignition coils and unshieldedspark plugs, Altronic offers a lead with a shielded termination (coil side) and asilicone spark plug boot. It is available in a variety of lengths.

FLASHGUARD ® Spark Plug Replacement Parts

FLASHGUARD ® Spark Plug Installation and Maintenance Tools

FLASHGUARD® Spark Plug Installation and Removal SocketsThese high quality, industrial spark plug sockets, available in 7/8" and 15/16" hex sizes,are ideal for performing maintenance on FLASHGUARD series spark plugs. A spring-loaded design built into the socket “captures” the spark plug shell and assists inremoving the plug from the head and well.

FLASHGUARD® Massive Electrode Spark Plug Gapping ToolDesigned exclusively for use with FLASHGUARD spark plugs, these unique tools applyuniform, incremental pressure to the ground electrodes when they require re-gapping.This method of gapping minimizes the risk of damaging the ceramic insulator or distortingthe electrode configuration. Tools are available in 18mm and 7/8"-18 thread sizes.

Replacement Spark Plug Boots - FLASHGUARD ® and Standard

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FLASHGUARD SPARK PLUG ANDSPARK PLUG LEAD ACCESSORIES

ThreadSize

Spark PlugGasket

Spark PlugTerminal Nut

18MM 510721

7/8"-18

*510726 terminal required when used with Cat EIS ignition.

510722

510726*

510720

14MM 510749 510720

510720

ThreadSize

Spark PlugSocket

18MM 506010

7/8"-18 506011

506012

506013

Spark PlugGapping Tool

Part No. Material

501151 Silicone

504235-1 Silicone

Application

593005, 593028

593201, 593203, 593205, 593207

504235-2 Silicone 593202, 593204, 593206, 593251, 593253

504254 Teflon with O-Ring 504253 (qty. 2)

18mm and 7/8"-18 spark plugs with anexposed insulator length of 1.5" or longer.

504276 Teflon with O-Ring 504275

14mm spark plugs with 0.41" dia. insulatorChampion RC78PYP and RX85PYP

504280 Teflon with O-Ring 504281

18mm and 7/8"-18 spark plugs with anexposed insulator length of less than 1.5".

4

FLASHGUARD SPARK PLUG ANDSPARK PLUG LEAD ACCESSORIES

510480-S

None

None

510473

510472

510493

510474

510714

*None

510473

*None

510474

Item Description

1-6 Kit

Qty. UnshieldedLead

510480

Unshieldedw/silicone hose

ShieldedLead

1 Nut, 3/4"-20 1 504088

2 Ferrule 1 504098

3 Stud 1 510473

4 Insulator 1 510695

5 Washer 1 510493

6 Spring Unit 1 510474

* Available only in kit.

11

1

3

5

6

2

Altronic Spark Plug Lead Wire — 503186-100Available in 100 foot spools, Altronic spark plug wire has beenspecially designed for industrial gas engine applications. This highquality wire is composed of 19 strands of 16 AWG tinned copperwire encased in a firm black silicone jacket. It is capable ofwithstanding ambient temperatures to 500 degrees F. and is usedin all Altronic standard and FLASHGUARD spark plug leadassemblies.

Altronic Spark Plug Lead Hose — 503328-100Altronic spark plug lead hose is available for those applicationsrequiring an extra measure of mechanical and environmentalprotection. It assists in preventing lead abrasion caused byrepeated contact with a vibrating surface such as a cylinder head.This 5/16" silicone hose also reduces deterioration due toenvironmental effects such as rain and intense sunlight. Altronicspark plug lead hose is available in 100 foot spools.

Altronic Shielded CoilSecondary Lead Termination Kits

Form ASPIA-C 8-05 ©Altronic, Inc. 2005

SALES/SERVICE CONTACTS