Teledyne D-3000 Series Technical specifications

4PTELEDYNE
NEWAL MOTORS
Arc Products
P.O. Box 90
MOBILE, ALABAMA 36601
Service Support Manual
HIGH TENSION
IGNITION HARNESSES
OTELEDYNEINDUSTRIES, INC. 1989
MaintenanceInstructions
&
IllustratedParts List
F.A.A. APPROVED
OCTOBER,l 989
~43001

WARN
(Please notethe followingstatementsfrom FAA Advisory Circular 20Ii2C entitled TLIGIBILITY, QUALITY, AND IDENTlFlCATlON
OFAPPROVED REPLACEMENTPARTS"):
3.
BAGKGR8 U N D. An increasingamountofreplacementparts(includingstandardparts),materials,
appliances, and instrumentsare offeredfor sale as beingof aircraft qualitywhen actuallythe qualityand
originoftheseunitsareunknown.Usersofsuchunitsareusuallynotawareof thepotentialhazardsinvolved
with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are
deceptively advertised or presentedas "unused," "likenew," or "remanufactured." This impliesthat the
qualityof such unitsisequaltoan originalor appropriately repairedor overhauledunit.
The performancerulesfor replacementof partsand materialsused inthe maintenanceand alteration of
U.S. certificatedaircraft are specifiedinFederalAviation Regulations (FAR) 43.13 and FAR 145.57. The
responsibilityforthecontinuedairworthinessoftheaircraft,whichindudesthereplacement
of parts, isthe
responsibilityof the ownerloperator as outlined inFAR
91.163, FAR 121.363, FAR 123.45, FAR 127.131
and FAR 135.143 (a).
IDENTIFICATION OF THE APPROVED PARTS. Approved serviceable replacement
partsare identifiedasfollows:
a. By an FAA Form
81 30-3 (FormerlyFAA Form 186), AirworthinessApproval Tag. An Airworthiness
Approval Tag identifies a part or group of parts that have been approved by authoriied
FAA
representatives.
b.
Byan FAATechnicalStandardOrder (TSO)numberandidentificationmark that indicatesthe partor
appliancehas beenmanufactured underthe requirementsof FAR
37.
c. Byan FWMAsymbol, togetherwiththe manufacturer's name, trademarkor symbol,part number,
andthe makeand modelof the
type certificatedproductonwhichthe partiseligiblefor installation,
stamped onthe
part An FAA Patts ManufacturerApproval (FAAIPMA) isissued under FAR 21.305.
The makeand modelidomtationmay beonatagattachedtothe part.
d. Byshippingticket, invoice, or otherdocumentwhich
provides evidencethat the partwas produced
bya manufacturerhddingan
FAA Approved ProductionInspectionSystem issuedunder FAR 21,
SubpartF, orby a manufacturerhddingan FAA ProductionCertificateissuedunderFAR 21, Subpart
G.
e. By a certificateof airworthiness for export issued by a foreign government under the provisionsof
FAR 21, Subpart
N.
KNOW YOUR SUPPLIER. It has come to our attention that many reproduced parts and
components, particulaiiyinstrumentswhich have been manufactured bypersonsotherthanthe original
manufacturer,areavailableforpurchaseandinstallationon
U.S. certificatedaircraft. Often, anoriginalpart
isusedasasampletoproduceduplicates.The reproducedpartsappearto
be asgoodastheoriginalpart;
however, there are many unknown factors to be considered that may not
be readily apparent to the
purchaser,i.e., heattreating, plating, inspections,testsand calibrations. Alltoooftenthe faulty part is not
discovereduntila malfunctionor anaccident occurs.
SUMMARY. In accordancewithFAR'S,certificationofmaterials, parts, andappliancesforreturn
tosewice,
for useonaircraft, istheresponsibEIity of theperson or agencywho signsthe approval.
The ownerlopetator,
as denotedinparagraph3 of thisadvisorycircular, is responsiblefor the continued
aiworthiness of theaircraft. Toassurecontinuedsafetyinaircraftoperation, itisessentialthat greatcare
be usedwhen inspecting, testing, and determiningtheacceptabifiof all partsand materials. Particular
cautionshould
be exercisedwhenthe identity of material& parts, and appliances cannotbeestablished
orwhentheir originisindoubt

System Support Manual
HIGH TENSION IGNITION HARNESSES
TO:
Holdersof Installation&Maintenancelnstmctions with ServicePartsList,L-2039-1and Installation
Instructions
JP00336
SUBJECT: SystemSupport ManualX43001
ThisSystemSupport ManualsupersedesL-2039-1andJPO0336andallpertinentsupplements.
Initialissue.
Highlights
Page
1
October, 1989

System Support Manual
HIGH TENSION IGNITION HARNESSES
RECORD OF REVISIONS
Record of Revisions
Page 1
October, 1989

System Support Manual
HIGH TENSION IGNITION HARNESSES
RECORD OF TEMPORARY REVISIONS
Record of Temporary Revisions
Page 1
October, 1989

System Support Manual
HIGH TENSION IGNITION HARNESSES
SERVICE BULLETINLIST
The following is a list of service bulletinswhich have been incorporatedintothis manual.
Service Bulletin Date Incorporated
597A October 1989
603 October 1989
Service Bulletin List
Page 1
October, 1989

Subject
System Support Manual
HIGH TENSION IGNITION HARNESSES
LIST OF EFFECTIVEPAGES
Vitle
Highlights
Recordof Revisions
Recordof TemporaryRevisions
ServiceBulletin
List
Listof EffectivePages
Tableof Contents
Introductionand Specifications
DescriptionandOperation
Testing andFault Isolation
Disassembly
Cleaning
Assembly
SpecialTools, Fixturesand Equipment
IllustratedParts
Llsts
Page Date
October 1989
October 1989
October 1989
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List of EffectivePages
Page 1
October, 1989

System Support Manual
Section
1
2
HIGH TENSION IGNITION HARNESSES
TABLE OF CONTENTS
Paragraph ntle Page
IntroductionandSpwlfications ................... 1-1
General
................................. 1-1
Des~riptionand Operation ...................... 2-1
........................... GeneralDescription 2-1
RecommendedMaintenanceand
OvemaulPractices ......... 2-6
...................... TestingandFaultIsolation 3-1
.................................
General 3-1
DetailedTestingProcedures ...................... 3-1
FaultIsolation
.............................. 3-2
Disassembly .............................. 4-1
..................................
General 4-1
DetailedDisassemblyProcedures
................... 4-1
Cleaning ................................ 5-1
General
................................. 5-1
DetailedHarnessCleaningProcedures
................ 5-1
PeriodicMaintenance ......................... N/A
GeneralOverhaul ........................... N/A
Repair .................................. N/A
Assembly ................................ 9-1
................................. General 9-1
HarnessAssemblyProcedures
..................... 9-1
LeadAssembly Replacement(currentindividualgrommets)
..... 9-2
LeadAssemblyReplacement
(out
of ProductionandCompetitive Outlet Arrangements) ..... 94
AssembleSparkPlugTerminals .................... 9-6
installationonEngine
.......................... 9-8
Special Tools. FixturesandEquipmen .............. .10.1
.........................
llluaratedPartstist -11-1
EquipmentCovered ........................... 11-1
..................
Superseded & DisccrntinuedHems
.1 1.5
10-720095-5thtu10-720410-3 .................... -1 1-6
10-720420-2tht~l0-720510-4 ..................... 118
....................
10-720515-lthtul0-726814-1 11-1 0
......................... 10-721 XM-X Series
1 1-12
............ 10-WW-XSeries and 10-72064X-XX Series
1 1-1 3
..........................
NumericalParts List
1 1-1 4
HarnessEixplodedView ........................ 11-1 5
Table of mMents
Page t
October.1989

System Support Manual
HIGH TENSION IGNITION HARNESSES
SECTlON 1. INTRODUCTIONAND SPECIFICATIONS
1.1 GENERAL
A. This manual provides complete maintenance and
overhaulinstructionswith illustratedpartslistfor High
Tension Ignition Harnesses, manufactured by
Teledyne ContinentalMotors, Aircraft Products,
Me
bile, Alabama 36601. TCM high tension harnesses
conducthighvoltagepulsesfromthe magnetostothe
spark plugsfor reciprocatingengine ignition.
B. Thismanualissubdividedwithsub-headsas listed in
theTable of Contents. Revisionservice may be pro-
videdbyorderingFormX40000. This manualmay
be
includedinChapter74-20of applicableGAMA format
publications.
C. Theseinstructions do notcoveralldetailsorvariations
inequipment nor do they providefor every possible
contingencyto be met inconnectionwithinstallation,
operation,ormaintenance.Shouldfurtherinformation
be desiredor particularproblemsarisewhich are not
coveredsufficientlyforpurchaser's purpose,the mat-
tershould
be referredtoTeledyneContinentalMotors,
AircraftProducts,Mobile,Alabama36601.
D. Goodstandardshoppracticesandsafetyprecautions
should
be observedat alltimes to avoiddamage to
equipment and/orinjurytopersonnel.
TABLE101 : ABBREVlAnONS
DegreesFahrenheit
lnch
PoundInches
PoundFource
Pound(Mass)
PoundsperSquare
Inch,Absolute
PoundsperSquare
lnchGage
Feet
Gallons
Ounces
' F
in.
Ib. in.
Ibf
Ib
psia
E. All maintenanceinstructionsinthismanualhavebeen
shopverified. Shopverified proceduresare those by
which the manufacturerhas accomplishedall Disas-
sembly, Assembly, TestingandFautt Isolationbyper-
forming
the functions described in this manual on
equipmentidenticalinconfigurationtothatdescribed.
F. DimensionsaregiveninUSStandardUnits.Forrefer-
ence, abbreviationsusedare
listed inTable 101.
G. Numbersinparenthesesfollowing part nomenclature
refertoitemnumbersinIllustratedPartsListFire
1
unlessotherwisespecified.
Table1 02
Table of Leading Particulars
Grommet
(43) and MS122FluorocarbonSpray
Sleeves (33,46,47) Miller Stephenson
ChemicalCompany
P.
0. Box 950
Danbury,CT06813
IilSm!J
Continuity and Use 1 1-8950-2
Insulationstrength HighTensionLeadTester
IQ5xs.
Spark PIug Coupling
Nut
('B' Nut):
5/8-24
90 - 95 b. in.
3/4-20
110 - 920 lb. in.
HarnessSecuring 17
- 19 Ib. in.
Nuts($1
200)
Harnesssecuring
25 - 35 Ib. in.
screws
(S20 and 5200)
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System Support Manual
HIGH TENSION IGNITION HARNESSES
SECTION
2. DESCRIPTIONAND OPERATION
A. TCM HighTension IgnitionHarnesses, manufac-
turedbyTeledyne ContinetalMotors, Mobile,
Ala-
bama 36601 are designed to conduct ignition
energythroughradiishielded leadsfrommagne-
tosto spark plugsaridfour, six andeight cylinder
engines
utilizing TCMS-20,S-200andS-3200Se-
riesMagnetos.
NOTE:
Hamesses usedon TCM D-3000 and 0-2000
Series Magnetosare coveredinthe latest revi-
sion of D-3000 Series High Tension Ignition
Systems,FormX42003.
B. Harnessdesigndepends onthefollowingfactors.
(1) Lead length, lead muting, magneto rotation
andenginefiringorder.
(2) Degreeof pre-assembly.Seeparagraph C.
(3) Spark plug terminal type: 5/8-24, 3/4-20
straightor 3/4-20elbow.SeeparagraphD.
(4) Typeof magnetodeterminestheshapeofthe
outlet plle: S4-20 or
-200, S6-20 or -200, I
C.
TCM HighTensionIgnitionHamessesaresupplied
inone of the followingforms:
(1) Custom Dressed: Magneto
and spark plug
ends pre-assembled, all clamps and ties
dressed.SeeFigure201.
(2) Custom Hybrid: Magneto and spark plug
ends pre-assembled, only key clamps
dressed,. Mostclampsand ties supplied
as
bagparts. SeeFigure202.
(3) Custom Ready-to-Fa: Magneto and spatk
plugendspre-assembled,allclampsandties
suppliedasbagparts.See Figure203.
(4) Universal Harness Kits and Outlet Kits:
Spark plugends pre-assembled,' magneto
end must
be cut and assembled to outlet
plateinthefie@.SeeFigure204.
D.
Spareleadswithsparkplugendspre-assembled*
areavailableintwo lengthsforTCM-only
type kits
andinfive lengthsfor universaladapterkits. Part
number suffix equals lead length in inches. See
Figure205.
* For 3/4-20 &bow fp%s, &bQW (35). spring (45). spring assemMy (48) atd sleeve (33) not Wuded,
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System Support Manual
HIGH TENSION IGNFlON HARNESSES
AGURE 202: CUSTOMHYBRID

System Support Manual
HIGH TENSION IGNITION
HARNESSES
FIGURE 2CK1: CUSTOM READV-TO-FTT HARNESS
FIGURE M4: UNNf RSAL HARNESS WT AND O
IUT

System Support Manual
FIGURE 205: SPARE LEAD KITS
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System Support Manual
HIGH TENSION IGNITION
HARNESSES
.- - ---
S4-20 AND -200
SERIES S6-1200 SERIES
FIGURE 206: OUTLET ADAPTER PLATE%
E.. MagnetolHamessOutletAdapter Plates: Thefirst
cylinder in the firing order of a given engine is
cylinder number one. Lead to this cylinder is al-
ways
in upper leftportionof outlet plate,identidied
with numeral 1. Dependingon magneto rotation,
the leadto the second cylinder inthe
firing order
may
be detehinedbythe chartsshowninFigure
206. FollowEngineManufacturer'sInstructionsre-
gardingleadrouting., cylindernumberingand en-
ginefiringorder.
F. Dura-Blue
High Tension cable (53), used on all
TCM HighTension Harnesses& available in100
footrolls.Darkbluesiliconecoatingprovidesmax-
imum abrasion resistance. Tightly woven tinned
copper braidinsures minimum
radii interference
radiation.Sixteenstrands
of braidedstainlesssteel
wire
form the durable conductor. Flexibility is re-
tainedupto
-65'F. The cablecanwithstand tem-
peraturesupto +400°F. Referto Figure
207.
BRAIDED STAINLESS -
SILICONE OUTER EXTRUDED
STEEt CONDUCTOR RUBBER ,JACKET SILICONE RUB,BER
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System Support Manual
HIGH TENSION IGNITION HARNESSES
2.2 RECOMMENDEDMAINTENANCEAND OVER-
'HAUL PRACTICES
A.
Harnesscomponentsshould be visuallyinspected
whenever maintenance allows access. Remove
andreplacedamagedcomponentsas necessary.
B.
Whenever replacement of pancake style outlet
grommetandlorthreadedstyleoutletplateisnec-
essary,retrofittoindividualgrommets (43, current
ferrule
(55), eyelet (54) and current outlet plate
(42).
C,
Harnessshould be discardedandreplacedat en-
gineoverhaul.
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3.1 GENERAL
System Support Manual
HIGH TENSION IGNITION HARNESSES
SECTION 3. TESVlNG AND FAULT ISOLAVlON
RefertoILLUSTRATEDPARTSLISTFigure 1 forHarnessExplodedView.
Table 30
Testing and Fautt laation mate-& and tools
Usedtotest insulationstrengthand
HighTensionLeadTester
Kit
continuityof harness leads
3.2 DETAILEDTESTINGPROCEDURES
A.
Using continuity circuit of 118950-2leadtester,
test forcontinuitybetweeneachsparkplugtermi-
nal spring
(45) and its respective eyelet (54).
Properassembly may be confirmed bycomparing
engine manufacturer'srecommendationsfor lead
routingand firing order with spark plugnumbers
markedon
"B" nuts(35,52)1 and outlet plate (42)
wiring arrangement. Continuity must also be ob-
servedfrom each outer ferrule (50,50A,50B) and
elbow
(35) tocommngroundatoutletplates (42).
B.
Check harnessleadsforhighvoltagebreakdown
usingthe 11-8950-2 hightension lead tester as
follows:
(1) Connect redhighvoltage test leadto spark
plugterminalspring
(45). Connectblacklead
oftestertofermle(50,50A,50B) orelbow
(35)
of the same leadassembly.
(2) Depresspush-to-testswitch
(3) Observethat indicatorlampflashes andgap
firessimo&amouslyas
long as switchisde-
pressed. Whenever indicator lamp flashes
andgapfailsto
fire, leadundertest isdefec-
tiveand must
be replaced.
NOTE:
High tensionbreakdowntest maybeperformed
fmm either spark-plug terminal end or outlet
plateendof agivenlead. Ensureoppositeend
is notadjacentto ground.
5 Only fatmy assembled harnesses feahtre spark plug numbers stamped on nuts @5,52).
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System Support Manual
HIGH TENSION IGNITION HARNESSES
A. A fault isolation charl is provided as an aid for
batingtroubles thought to be inthe ignition sys-
tem.
SYMPTOM PROBABLECAUSE
conespondiwspark plug.
Frayedshieldingat spark Remveandreplacelead
(44)
plugterminal, outlet
plate
(42) or intermediate
chafingpoint on harness lead
Inadequateshieidingground Removeand replaceinnerferrules
(55)
TEST
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System Support Manual
HIGHTENSION IGNITION HARNESSES
SECTION 4. DISASSEMBLY
4.1 GENERAL I
A. Refer to ILLUSTRATED PARTS UST Figure
1 for
Harness
Exploded View.
B.
RefertoTaMe401 fortoolsrequiredfordisassem-
MY.
C.
Disassembleharness only toextend necessaryto
effect adequate repair.
Table 401
Disassembly
Tools
11-1 0386 FerrulePressing Tod
Used toremoveinnerferrules (49,55) from
outer ferrules
(50,50A,508) and outlet
plates
(42)
4.2 DETAILEDDISASSEMBLY
A. Innerferrules
(49,55) may be removedfromouter
ferrules
(50,50AS58B) andloroutletplate (42) using
.25 inchdiameter drift andarborpressor 1 1-1 0386
ferrule seating tod. (See Special Tools, Fiures
and Equipment, Figure1003). See Figure 401.
B.
All other harnesshardwaremay be disassembled
usingstandardshop practices.
C. Discardferrules (49,55,62), eyelets (54) andterrni-
nals (5131A) fdlowingdisassembly. All other parts
may be re-usedonan onconditionbasis.
Figlure401
le (55) from Adapter Plate (42)
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