AIR PUBLICATION 113L-0301-1 PLESSEY IGNITION HARNESS FOR GIPSY MAJOR | MK. 8 ENGINE | GENERAL AND TECHNICAL INFORMATION DSGAviation vor dsgviation co.uk mail@dsgavitoneoule BY COMMAND OF THE DEFENCE COUNCIL Zi [Bunn Ministry of Defence FOR USE IN THE ROYAL NAVY ROYAL AIR FORCE (Prepared by the Ministry of Technology Pret Insued July 68 eetRESTRICTED AMENDMENT RECORD SHEET ‘To record the incorporation of an Amendment List fn this publication, sign against the appropriate ALL. No. and insert the date of incorporation, Prelim Page 2 RESTRICTED [AL.No. AMENDED BY DATE AL. No] AMENDED BY | DATE a z F 2 | Ea | 3 | x6 | | | ” | i |e ‘ I » 7 | «| 8 | 7 “ 2 a » | : ° : | a “ | - a | oo” w | i | i “ | «| | is | 6 ” DSGAviati " so | Miksewatonca ie | a | » 2 | | » =| | 2 “| mo 2 | | s | al | 0 r uw | 7 a i =| t 26 | * Tt w | oO 2 a | 2. © | i | eo) | a | el | 2 ~| ‘5 | 3 I wo |ADANSL-0301-1 LIST OF CHAPTERS 1 Plessey ignition harness for Gipsy Major Mk. 8 engine Chapter 1 PLESSEY IGNITION HARNESS FOR GIPSY MAJOR Mk. 8 ENGINE ‘CONTENTS Page Page 1 Painting. 2 - ~ 1 Special ols... 2 “ 1 Make-up of fitings 2 . 1 Replacement of conductor 2 1 Testing 3 2 TABLES No. Page 1 Lengo of conductors 2 2 Provisioning schedule right-hand 3 DSGAviation pene 3 Provisioning schedule left-hand 3 mai@éegaratoncouk ILLUSTRATIONS Fi Page 1 Ignition harness, righthand 4 2 Ieniton harness, lefthand 5 3 Special tol. - 6 Introduction SERVICING 1. The Plessey ignition harnesses Ref, No. 37B 3009 Prestesting Kighs Hand and 378 3010 Left Hand ate ted © Comma op the De-Havilland Gipsy Major Mk. § engine DESCRIPTION General 2. Bach harness, fg. 1 ot fig. 2, comprises a mani- fi ‘ely magne cand ‘see yan ts spark. plug conduit assemblies. The left-hand har ‘ess incorporates four spark piug elbow assemblies and the righthand harness one, Details of these assemblies are given in Para, 8 10 11. awed July 68 3. Test each complete cable for continuity, using a Multimeter Type 12889 from plug terminal to ‘magneto terminal Inada resistance tes 4, Using Tester Ignition Type HT. Mk. 2 (Ref: No, 56/39) te intron eer ce eae Re the contact stud of eac conductor must be hotles than 2 megohms, 1 Page 1Cleaning 3. _Allparts should be cleaned with Trichlorethylene Ref, No. 330547. Painting 6 Paint used is Grey Cellulose to D-T-D. 7724. Special Tools 7. The only sperial tool is C spanner see fg. 3. ‘TABLE 1 Length of Conductors Cable cutting length Length Make-up of Fittings ‘Spark plug elbows assembly 8. A spark plag elbow is silver soldered at one end 1 a threaded union. A coupling unit is slid on to the other end of the elbow and is retained by the shoul er of a ferrule silver soldered to the end of the elbow. A spring and washer located in the ferrule are retained by an insert swaged into the ferrule reves. Spark ing conduit asiembly 9, Each end of the spark plug conduit assembly is ‘identical. The flexible conduit has a cap ferrule ‘waged to cach end. A coupling nat is retained by the shoulder of a spring ferrule assembly fitted over the end of the conduit and soft soldered. A spring ‘and washer located in the ferule are retained by an insert swaged into the ferrule recess. On the left- ‘hand harness the four spak plag elbow assemblies fir on to the spark plug conduit ends. To make up ‘the plug terminal a ceramic insulator fits over the ‘end of the cable on to the copper washer and the end is sealed by a cup washer and contact stud. The length of the conduit is covered by a neoprene sleeve secured by rwo clamp rings Magneto conduit assembly 10. The 0 magneto conduit assemblies are ident cal except that the right-hand assembly is} in longer, ‘The flexible conduit has a cap ferrule swaged to each nd. A flange and ferrule assembly is fied over one end of the conduit and is soft soldered. At che other end, 8 coupling nut is retained by the shoulder of ferrule fired over the end of the conduit and soft soldered. The length of the conduit is covered by a neoprene sleeve secured by two clamp rings Page 2 Manifoid Assembly 11, Manufactured from brass tube the manifold has four screwed lugs silver soldered to three extrit- sions and to the end of the tube on the right-hand hharness, and to four extrusions on the left-hand harness. These lugs connect the spark plug conduit assemblies to the manifold. On the right-hand har- ness cylinder No. 1 connection at the end of the tube is through a spark plug elbow assembly. A screwed coupling silver soldered to the other end of the tube connects the magneto conduit assembly t0 the manifold through a copper washer. Two brackets ‘wrapped around the tube are drilled for attachment bolts Replacement of Conductor 12, Remove old conductor (1). Strip off cap washer, contact stud and Insulator from spark plug conduit assembly. (2) Remove spark plug conduit assembly by coupling mut at manifold tube screwed lug. sing seca wolf. inconet ‘coupling nut securing ‘conduit assembly to manifold tube sewed coupling (4), Remove tag and cable marker from end of cable. (5), Withdraw conducts freeman end ‘oe degniaton tk 13. Fit new conductor. ete erdacoice (1) Cut cable wo length given in Table 1 2) Smear cable with grene MS.4 (DTD. 00 42985 3) Feed cable through manifold assembly the screwed lug, and feed through magneto conduit assembly, Note... Gradual rotate cable asi fedit condi. The cable must not be pulled through. (4) Treat all threads with an approved anti- seize compound, (3) Fit spark plug conduit assembly. (6)_ Fit insulator, contact stud and cap washer to cable end. (D_Using special tool connect and tighten rupling ut at magneto conduit fo manifold tube joint. (8) Fit cable marker (9) Refer to fig. 1 or fig. 2 as appropriate and stop ack cable an lig bi ened length from magneto adapter. aAP.usL-001-1 TABLE 2 Provisioning schedule, right-hand TT Feetty Ref. No, Description Per Set Requirement 378 /3069 ‘Manifold Assembly 378 3059 Lug 378 3070 Bracket 378 3890 Serial No. Plate 378 3889 Nameplate 3784353 Screwed coupling 378 3887 Label ‘NIV Lae ‘Screwed lug No. Z5 37B 3025 ‘Magneto Conduit 1 General Assembly 378 3022 Spark Plug Conduit 4 > om 378 3028 Spark Plug Elbow 1 ae 37B 3072 Protective Cap 4 soe 37B 2376 Cup Washer 4 5 378 565 Contact Stud 4 37B 3091 Tasulator 4 z 37B 4310 ‘Markers 1 7 378 3029 Washer 1 : SK Id Tag 4 = @ Uniplagsheath Cable No. + 15 > om DSGAviation TABLE 3 ‘mail@ssgaviation co.uk Provisioning Schedule, left-hand Ref, No, Description $e'se Requirement 378 3026 ‘Manifold Assembly 1 “Manifold Repair 378 3059 Lug 1 > on 37B 3067, Lug 3 > om 37B 3018 Bracket 2 > om 2338 3850 Label i 7 37B 3889 Nameplate 1 » 37B 4353 Screwed Coupling 1 a 37B 3887 Label i a 378 3024 ‘Magneto Conduit 1 General Assembly 378 3020 Spark Plug Conduit 3 _ 378 3021 Spark Plug Conduit 1 x a 378 3028 Spark Plug Elbow 4 SS 37B 3844 Protective Cap 4 : 37B 2376 Cup Washer 4 yon 378 565 Contact Stud 4 soe 378 3091 Insulator 4 a 37B 4310 ‘Markers 1 » OR 378 3029 Washer 1 sos 3K Ia ag 4 ae Uniplugsheath Cable No. 4 1S ft Testing Conti tt 14, Test each complete cable for continuity, sng 4 Multimeter ‘Type 12888, fom pg eral dragnet ternina Issued July 68 Insulation resistance test 45. Using Tester Ignition Type H.T. Mk. 2 (Ret, ‘No. 5/399) the insulation berween the conduit and the contact stud of each conductor must be not lessFig. 1. Ignition harness, right-handAPIISL-0301-1 Fig. 2, Ignition harness, left-hand 1 Iesced July 68