CIVIL AVIATION AUTHORITY CIVIL AIRCRAFT INSPECTION PROCEDURES EL/5-2 Issue 3. December, 1979 AIRCRAFT ENGINES PISTON ENGINE IGNITION CABLES AND HARNESSES ' INTRODUCTION 1.1 ‘The procedure outlined in this Leaflet gives general guidance on the installation and ‘maintenance of fully screened high-tension ignition cables and cable harnesses. The information should be read in conjunction with the Maintenance Manual for the type of engine concerned. 1.2. To maintain efficient functioning, the cables and harnesses should be inspected, serviced and tested at the periods which are given in the Approved Maintenance Schedule. It is essential that the test equipment recommended by the manufacturer is used, 1.3, The following Leaflets contain information associated with the subject covered by this Leaflet and reference should be made to these as appropriate. EL/3-9 Piston Engines—Magnetos EL/S-1 Sparking Plugs 2 GENERAL 2.1 The low of high tension current along the ignition cables from the magnetos to the sparking plugs results in unwanted electrical radiation which could, if not checked, result in interference with the aircraft radio equipment. Avoidance of interference is achieved by ‘screening’ the ignition cables by covering them with a metallic braiding Which is connected to ground potential. It is also nevessary to provide protection against mechanical damage, deterioration and contact with liquids; this is normally achieved either by enclosing the cables in a prefabricated ‘ignition harness’ (see Figure 1) ‘or by providing an outer covering of neoprene or plastic tubing (see Figure 2) 211 All types of harness are basically the same in principle, but because of the proprietary nature of the manufacture, both the materials used and the arrangement of details may vary. The three main parts of a typical harness are as follows:— (a) The body of the harness comprises a rigid metal duct which may be in several parts ‘and may be joined by means of threaded joints. Materials commonly used for these ducts are brass, aluminium alloy, or corrosion resisting steel. The harness assembly is often attached to the engine by means of brackets soldered or brazed to the rigid duct.Figure 1 IGNITION HARNESS FOR A TYPICAL SIX CYLINDER, IN-LINE ENGINE InsuLarion ‘OUTER COVER (NEOPRENE OR PLASTIC TUBING) Figure 2 IGNITION CABLE WITH PROTECTIVE COVERING 2omy 3 EL/5-2 (b) From the rigid duct, large diameter flexible ducts house the cables between the duct and the magneto distributors. These flexible ducts are usually made from a close mesh metallic braiding often of tinned copper or tinned phosphor bronze (©) The individual ignition cables, which are routed through individual apertures in the rigid duct, are covered with a similar braiding to that described in (b). The cable ends are fitted with metallic connectors for attachment to the sparking plugs ‘and magneto distributors. IGNITION HARNESSES 3.1 Dismantling. When a harness is removed from an engine and is awaiting dis- ‘mantling, it should be properly stored so that it is not damaged either physically or by contact with oils or other liquids. The harness should be secured by its attachment brackets to a suitable stand so as to avoid distortion of the subsidiary conduits and ducts, which can easily result from the unsupported weight of the assembly. The sequence of dismantling should be as recommended in the manufacturer's publication, and will vary according to the type of harness. 3.2. Inspection of the Dismantled Harness 3.2.1 Every magneto distributor-block or harness connector assembly should be ‘examined for freedom from cracks or signs of tracking. Where fitted, the carbon brush should be free from chips and excessive wear and should move freely in the guide under spring pressure. 3.2.2. The body of the harness should be free from cracks and dents, especially around the apertures and attachment brackets, which should also be in good condition. The threads of the couplings should be undamaged, and the nuts should be correctly fitted. 323 All flexible ducts and subsidiary conduits should be free from internal damage ‘and wear caused by abrasion. 3.2.4 Alll ignition cable connections and plug terminal sleeves should be in good condition. These parts must be renewed if there are any signs of burning or tracking. 3.2.5 Any neoprene seals should be free from deformation and cracks. 3.2.6 Rubber sleeves and bushes which have deteriorated should be rejected and new ‘ones should be fitted. 32.7 All sharp corners or irregularities liable to damage the covering of the cables should be removed, and all vents should be clear so that air may circulate freely. 3.28 The ducts of waterproof type harnesses may require pressure testing. This is usually carried out by blanking off all the outlet connections except the one to which fan air pressure supply is connected. ‘The pressure is then raised to the specified figure. “Precise details of this test will be found in the manufacturer's Maintenance Manual. 33 Assembly 3.3.1 Before assembly, ducts and subsidiary conduits should be checked for obstruc- tions, and all-parts including cables and detail fittings should be clean, 3