PRATT & WHITNEY CANADA

MAINTENANCE MANUAL
MANUAL PART NO. 3034342

LIST OF EFFECTIVE PAGES

CHAPTER
SECTION PAGE DATE
LEP 1 Apr 11/2008
2 blank Apr 11/2008

Contents 1 Apr 11/2008

2 blank Apr 11/2008

74-20-00 1 Feb 06/2004

Description and 2 Feb 06/2004
Operation

74-20-00 201 Apr 11/2008

Maintenance 202 Apr 11/2008
Practices 203 Apr 11/2008
204 Apr 11/2008
205 Apr 11/2008
206 Apr 11/2008
207 Apr 11/2008
208 Apr 11/2008
209 Apr 11/2008
210 Apr 11/2008
211 Apr 11/2008
212 Apr 11/2008

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MAINTENANCE MANUAL
MANUAL PART NO. 3034342

TABLE OF CONTENTS
SUBJECT PAGE

IGNITION CABLES AND SPARK IGNITERS - DESCRIPTION AND

OPERATION 74-20-00

1. General 1
A. Ignition Cables 1

B. Spark Igniters 1
CABLES & SPARK IGNITERS - MAINT. PRACTICES 74-20-00

1. General 201
2. Consumable Materials 201

3. Special Tools 201

4. Fixtures, Equipment and Supplier Tools 201
5. Removal/Installation 201

A. Removal of the Ignition Cables 201

B. Removal of Spark Igniters 205
C. Installation of the Ignition Cables 205

D. Installation of Spark Igniters 207

6. Cleaning/Painting 208
A. Spark Igniters 208
7. Inspection/Check 208
A. Spark Igniters 208

8. Approved Repairs 208

A. Cable Braiding Minor Damage 208

B. Cable Braiding Major Damage 210

9. Adjustment/Test 212
A. Ignition Cables 212

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MAINTENANCE MANUAL
MANUAL PART NO. 3034342

IGNITION CABLES AND SPARK IGNITERS - DESCRIPTION AND OPERATION

1. General

A. Ignition Cables

Two individual ignition cables carry the electrical energy output from the ignition exciter
to the engine mounted spark igniters. Each cable assembly consists of an electrical
lead contained in a flexible metal braiding. Coupling nuts at each end facilitate connection
to respective connectors on ignition exciter and spark igniter. Mounting flanges for
attachment to the engine fireseal mount rings are free to move on the flexible braiding.

B. Spark Igniters (Ref. Fig. 1)

The air-cooled spark igniters, located at the 4 and 9 o’clock positions on the gas
generator case adjacent to the fuel manifold, are in the form of a double-ended, threaded
plug with a central positive electrode, enclosed in an annular semi-conducting material.
The electrical potential developed by the ignition exciter is applied across the gap
between the central conductor and the igniter shell (ground). As this potential increases,
a small current passes across the semi-conducting material. This current increases
until the air between the central conductor and the shell ionizes. When ionization occurs,
high energy discharges between the electrodes. The spark always occurs somewhere
in the annular space between the central conductor and shell.

Spark igniters are procured under a single part number which covers several parts
obtained from different sources. Although individual parts may thus differ in detail
appearance, the function is identical and they are fully interchangeable.

74-20-00
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IGNITION CABLES AND SPARK IGNITERS - DESCRIPTION AND OPERATION Feb 06/2004
 PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3034342

POWER TURBINE STATOR HOUSING

COMBUSTION CHAMBER LINER

SPARK IGNITER

C13695

Spark Igniter Installation

Figure 1

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 PRATT & WHITNEY CANADA
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MANUAL PART NO. 3034342

CABLES & SPARK IGNITERS - MAINT. PRACTICES

1. General

A. Maintenance personnel should make reference to the INTRODUCTION section and

Chapter 70-00-00 STANDARD PRACTICES of this manual to familiarize themselves
with general procedures.

B. Install suitable protective caps/covers over all disconnected tubes/lines and component
openings.

C. Lockwire used, unless otherwise specified, shall comply with specification AMS5687,
heat and corrosion resistant steel wire MS9226-03, 0.025 inch diameter, and will not
be specified in instructions.

2. Consumable Materials

The consumable materials listed below are used in the following procedures.

Item No. Name

PWC05-058 Solder, Tin-Alloy
PWC06-005B Lubricant, Spray
PWC06-009 DELETED
PWC06-023 Compound, Anti-seize
PWC11-014 Alcohol, Isopropyl
PWC11-027 Solvent, Petroleum
PWC11-031 Cleaner, Engine
PWC11-032 Solvent, Degreaser
PWC06-036 Compound, Anti-seize
PWC06-036A Compound, Anti-seize

3. Special Tools

Not Applicable

4. Fixtures, Equipment and Supplier Tools

Not Applicable

5. Removal/Installation

WARNING: MAKE SURE IGNITION IS SWITCHED OFF AND SYSTEM HAS BEEN
INOPERATIVE FOR AT LEAST SIX MINUTES BEFORE REMOVING ANY
IGNITION COMPONENTS.

A. Removal of the Ignition Cables (Ref. Fig. 201)

(1) Isolate the power from the ignition system.

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MANUAL PART NO. 3034342

3 A B C D 1 E

4 F G H 2 I J
DETAIL G PRESSURE
2 OIL TUBE

6 7

5 PRESSURE
OIL TUBE
2
2
DETAIL F

NO. 2 BEARING DETAIL H 5

SCAVENGE OIL
TUBE
FUEL
2 TUBE
2

7
REAR FIRESEAL DETAIL I
DETAIL J

C13242

Removal/Installation of the Ignition Cables

Figure 201 (Sheet 1 of 2)

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MANUAL PART NO. 3034342

Key to Figure 201

1. Left Ignition Cable

2. Right Ignition Cable
3. Left Spark Igniter
4. Right Spark Igniter
5. Loop Clamp
6. Bracket
7. Ignition Cable Flange

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MANUAL PART NO. 3034342

3 1
A B C D E

4 F G H 2 I J
6
DETAIL A
NO. 2 BEARING
SCAVENGE OIL
TUBE
CENTER FIRESEAL 5
5
DETAIL E
DETAIL B
1
7
5

2 6 1
NO. 2 BEARING
1 SCAVENGE OIL
5 TUBE

DETAIL D 5

DETAIL C

NO. 2 BEARING
SCAVENGE OIL 1
TUBE

C13241

Removal/Installation of the Ignition Cables

Figure 201 (Sheet 2)

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MANUAL PART NO. 3034342

WARNING: DISCONNECT COUPLING NUTS AT IGNITION EXCITER FIRST. USE

INSULATED TOOLS TO REMOVE CABLE COUPLING NUTS. DO NOT
TOUCH OUTPUT CONNECTORS OR COUPLING NUTS WITH BARE
HANDS.
CAUTION: WHEN LOOSENING/TIGHTENING COUPLING NUTS, DO NOT LET
BRAIDING, FERRULES OR IGNITER PLUGS TURN.

(2) Remove the left and right ignition cables (1) and (2) from the ignition exciter and
respective spark igniters (3) and (4). Cap/cover cable connections.

(3) Remove the loop clamps (5) that attach the ignition cables to the brackets (6) on
the center fireseal mount ring. (Ref. Details A, B, and F).

NOTE: Remaining loop clamps are detached at the removal of No. 2 bearing
scavenge oil tube, fuel tube and compressor delivery pneumatic tube.

(4) Remove the self locking nuts and bolts and the cable flanges (7) from the center
and the rear mount rings. (Ref. Details B, F, and I).

(5) Remove the ignition cables (1 and 2) through the mount rings.

B. Removal of Spark Igniters

(1) Isolate power from ignition system.

CAUTION: WHEN LOOSENING/TIGHTENING COUPLING NUTS, DO NOT LET

BRAIDING, FERRULES OR IGNITER PLUGS TURN.
(2) Remove coupling nut of ignition cable from respective spark igniter (Ref. 74-20-00,
Removal/Installation).

(3) Remove spark igniters (2, Fig. 202) from gas generator case.

(4) Remove copper gasket (1) from each spark igniter.

C. Installation of the Ignition Cables (Ref. Fig. 201)

(1) Install ignition cables (1) and (2) between the center and rear fireseals, passing
cable ends outward through the respective holes in the fireseals.

CAUTION: BOLTS MUST BE INSTALLED WITH HEADS ON AIR INLET SIDE OF

MOUNT RINGS.
(2) Install cable flanges (7) on the fireseals with bolts and self-locking nuts. Install
brackets (6) with one flange securing bolt. (Ref. Details B and F).

(3) Install the flange on the rear fireseal to the bracket on the No. 2 bearing scavenge
oil tube. (Ref. Detail I). Torque the nuts 36 to 40 [Link].

(4) Make sure that all flange securing bolt heads are on the compressor air inlet side of
the fireseals.

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MANUAL PART NO. 3034342

SPARK IGNITER

1
SPARK IGNITER
VIEW FROM REAR OF ENGINE

C63B

Removal/Installation of Spark Igniters

Figure 202

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MANUAL PART NO. 3034342

Key to Figure 202

1. Gasket
2. Spark Igniter

CAUTION: UNDER NO CIRCUMSTANCES IS ANY LUBRICANT CONTAINING

GREASE OR SILICONE, OR ANY LUBRICANTS SUCH AS PETROLATUM
TO BE USED ON ANY IGNITION COMPONENT.

CAUTION: DO NOT LET ANY LUBRICANT CONTACT CENTRAL CONDUCTORS OF

CABLES. CONTACT MAY RESULT IN A HIGH RESISTANCE PATH
WHICH COULD GENERATE HEAT AND OXIDATION.

CAUTION: DO NOT APPLY LUBRICANT ON ANY CABLES HAVING TEFLON

INSULATED SLEEVES.
(5) Lightly spray the insulated ends of the cable conductors with fluorocarbon dry-spray
lubricant (PWC06-005B).

CAUTION: WHEN LOOSENING/TIGHTENING COUPLING NUTS, DO NOT LET

BRAIDING, FERRULES OR IGNITER PLUGS TURN.
(6) Connect the ignition cables (1) and (2) to the respective spark igniters (3) and (4)
and to the connectors on ignition exciter. Install the couplings into mating threads
by hand. Make sure that there is no binding between the coupling nuts and the cable.
Tighten coupling nuts fingertight plus 45 degrees. Lockwire the coupling nuts at
the ignition exciter.

(7) Install the remaining bracket (6) to the center fireseal with bolt and self locking nut.
(Ref. Details A through I). Torque the nut 36 to 40 [Link].

(8) Install the nine loop clamps (5) on the ignition cables (1) and (2) to the respective
mating clamps and brackets with self locking nuts and bolts. (Ref. Details A through
I). Torque the nut 36 to 40 [Link].

D. Installation of Spark Igniters

(1) Install new copper gasket (1, Fig. 202) on each spark igniter (2).

(2) If necessary, chase igniter boss threads (Ref. 72-30-04, Approved Repairs).

CAUTION: APPLY COMPOUND TO IGNITER THREADS OR IGNITER BOSS

THREADS ONLY.
(3) Apply a thin coat of anti-seize compound (PWC06-023 or PWC06-036 or
PWC06-036A) to spark igniter threads.

NOTE: Spark igniter threads must not be lubricated with oil.

(4) Install spark igniters in bosses at 4 o’clock and 9 o’clock positions on gas generator
case. Tighten igniters 300 [Link]., loosen to zero, and retighten 200 to 240 [Link].

(5) Insert central conductor of ignition cable into respective spark igniter.

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MANUAL PART NO. 3034342

6. Cleaning/Painting

A. Spark Igniters

CAUTION: DO NOT CLEAN THE NOSE (FIRING) END OF THE IGNITERS. DO NOT
REMOVE CARBON FROM THE ELECTRODES OR FROM ANNULAR GAP
AREAS. CARBON DEPOSITS IN THE GAP AREA ACT AS AN AID IN IGNITER
OPERATION.
(1) Use a felt swab soaked in alcohol (PWC11-014) or (PWC11-031) to clean the inside
surface of the terminal well and contact pin.

(2) Dry using clean, dry compressed air.

7. Inspection/Check

A. Spark Igniters

(1) Examine exterior cylindrical area of firing end of igniter shell for chafing wear.

NOTE: Wear is acceptable to a depth of 0.015 inch.

(2) Inspect igniter shell and electrode for erosion (Ref. Fig. 203 and Table 201). If
erosion equals or exceeds amount shown, reject spark igniter.

(3) Check air cooling holes are clear and unobstructed.

(4) Inspect igniter plug contact pin for erosion/burning. Replace plug if such condition is
apparent.

(5) Positive retention must exist between the igniter pin and the ignition cable terminal.

(6) Test spark igniters (Ref. 74-00-00, Adjustment/Test).

TABLE 201, Spark Igniter Erosion Limits (Ref. Fig. 203)

Dim. A Dim. B
P&WC P/N Supplier and P/N (in.) (in.)
*3035102 Champion, CH34055 0.3000 Not applicable to
air cooled igniters
*3031213 Bendix, 10-390667-1 0.3000
* Parts obtained under ordering Part No. 3032096

8. Approved Repairs

A. Cable Braiding Minor Damage

(1) Examine damaged area. Make sure damage does not exceed 0.375 inch long,
edge of damage is at least 0.500 inch from nearest connector or flange and
there is no damage to underlying insulation.

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MANUAL PART NO. 3034342

CAUTION:
SHOULD AN IGNITER PLUG BE DROPPED, INTERNAL DAMAGE,
POSSIBLY NOT DETECTABLE BY TEST, CAN OCCUR.
RECOMMENDATION IS TO REPLACE THE IGNITER PLUG.

DIM. A

DIM. B

NEW IGNITER ACCEPTABLE WEAR WORN OUT

NOTE: FOR DIMENSIONS A AND B REFER TO TABLE 201.

C174
Spark Igniter Inspection
Figure 203

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WARNING: CLEAN CABLE ASSEMBLY IN A WELL-VENTILATED AREA. AVOID

PROLONGED INHALATION OF FUMES. WEAR PROTECTIVE (RUBBER)
GLOVES AND WASH HANDS AFTER EXPOSURE TO CLEANER.

WARNING: WEAR PROTECTIVE EQUIPMENT FOR EYES AND FACE WHEN USING
COMPRESSED AIR. AIR PRESSURE MUST NOT EXCEED 30 PSI.

(2) Clean damaged area of braiding with clean cloth dampened with solvent
(PWC11-014) or (PWC11-032), to remove all contaminants from ignition cable.

CAUTION: SOLDERING IRON MUST NOT EXCEED 250 WATTS. APPLY ONLY
ENOUGH HEAT TO FLOW SOLDER.

(3) Use a solder (PWC05-058) with suitable flux to solder damaged area. Overlap
damaged area by approximately 0.125 inch.

(4) Clean braiding with solvent (PWC11-014) or (PWC11-032), then dry repaired area
with filtered, compressed air not exceeding 30 psi.

(5) Smooth repaired area with abrasive cloth to blend with braided surface. Repeat
Step (4), as required.

(6) Check cable assembly for continuity and insulation resistance prior to installation
(Ref. Adjustment/Test).

B. Cable Braiding Major Damage (Ref. Fig. 204)

(1) Examine damaged area. Make sure damage, (Ref. Subpara. A.), does not exceed
1.00 inch long and is at least 0.500 inch from nearest connector, flange or existing
repair. Replace ignition cable assembly if damage exceeds these limits.

(2) Remove loose strands of braiding around damaged area.

(3) Wrap tape (PWC05-066A) around cable braiding, covering all of damaged area as
shown.

(4) Wrap repaired area with stainless steel wire as shown. Hold wrapping wire supply
along length of cable braid beginning from the left. Starting at opposite end, wrap
wire tightly and uniformly over cable braiding and repaired area.

NOTE: Make sure wire overlaps tape and contacts cable braiding at each end of
repair.

(5) When approximately two-thirds of wrapping is completed, allow short end of loop to
remain exposed. Continue wrapping wire to complete remaining distance, shown as
‘‘1/3X’’.

(6) After final turn of wrapping, insert wire ‘‘A’’ through loop as shown. Cut off surplus
end ‘‘B’’ of wire so that length is approximately one-third of repair length. Pull loop
and ‘‘C’’ until wire at ‘‘A’’ is snug and end ’’B‘‘ of wire has just disappeared
underneath final turn of wrapping. Cut wire and ’’C‘‘ flush.

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MANUAL PART NO. 3034342

INSULATING TAPE

B X
1/3 X
C

C4960C
Repair of Ignition Cable - Major Damage
Figure 204

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(7) Test cable assembly for continuity and insulation resistance prior to usage (Ref.
Adjustment/Test).

9. Adjustment/Test

A. Ignition Cables

(1) Check for continuity using an ohmmeter Model 260, or other low voltage continuity
device. Resistance from terminal to terminal must be 0.5 Ω max.

(2) Insulation resistance between metal braiding and inner cable must be 100 KΩ min.

NOTE: Return defective cables to authorized repair shop for inner cable
replacement.

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