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Service Manual - AeroElectric Connection

1. Old Part No Superseded By Old Part No Superseded By Old Part No Superseded By 10 382555 10 Discontinued 10 382910 10 Discontinued 10 384601 126 Discontinued 10 382555 1 1 10 682555 11 Discontinued 10 384601 128 Discontinued 10 382555 12 10 682555 12 10 682910 18 10 384602 302 Discontinued 10 382555 13 10 682555 13 10 682910 13 10 384602 303 10 821614 6 10 382555 14 10 682555 14 Discontinued 10 384602 306 Discontinued 10 382555 15 10 682555 15 Discontinued 10 384602 307 10 821624 6 10 382555 16 10 682555 16 Discontinued 10 384602 323 Discontinued 10 382555 131 Discontinued 10 382910 17 10 682910 13 10 384602 327 Discontinued 10 382555 141 10 682555 141 10 382910 18 10 682910 18 10 384602 502 Discontinued 10 382555 151 10 682555 151 10 382910 53 10 682910 13 10 384603 302 Discontinued 10 382555 161 Discontinued 10 382910 58 Discontinued 10 384603 502 Discontinued 10 382560 10 Discontinued 10 382910 101 Discontinued 10 384604 103 10 821615 4 10 382560 11 10 682560 11 10 382910 161 Discontinued 10 384604 106 Discontinued 10 382560 12 Discontinued 10 382910 531 Discontinued 10 384604 109 10 821635 4 10 382560 13 10 682560 13 10 382920 11 10 682920 11 10 384604 126 10 821625 4 10 382560 53 10 682560 13 10 382920 12 Discontinued 10 384605 106 Discontinued 10 382560 111 Discontinued 10 382920 51 10 682920 11 10 384605 126 Discontinued 10 382560 131 10 682560 131 10 382
2. BS aj aja 10 682610 11 10 682610 13 10 682610 131 N mN Sy o je lo N o o a N IN IN oo oo co 21212 Oo jo jo je 111 112 2 1 a aj oy f 10 682910 18 10 682920 11 11 11 Illustrated Parts List Table 11 6 D 3000 Series Magnetos Figure 1 Index Description Part No 53 Bushing Roller Bearing 10 382969 54 Screw W Lock washer 10 682024 55 Plate Coil Retaining 10 382935 56 Spring 10 382931 57 Strip Paper 10 382568 58 Coil 6 3 8 CYL 10 382588 1 Coil 4 CYL 10 382790 1 59 Plug Ventilator 10 157134 60 Plug Solid Nylon 10 157135 61 Bushing Threaded 10 382815 62 Orifice Threaded 10 382861 63 Plug Solid Aluminum 10 51391 64 Plate Identification 10 400006 65 Housing Magneto 10 682000 1 Housing Magneto 10 682000 2 Housing Magneto 10 682000 4 11 12 10 682555 11 10 682555 12 10 682555 13 21 S gt 710 682555 14 gt gt 710 682555 15 gt gt 110 682555 16 Po n5 Po n5 10 682555 141 10 682555 151 10 682560 11 gt
3. Torques Cam Screw 21 to 25 in Ibs Capacitor Nuts 60 70 in Ibs Contact Screws Coil Screws 20 to 25 in Ibs rive Shaft Nu 0 in Ibs Cover Screws unpressurized magnetos 30 to 35 in Ibs pressurized magnetos 40 to 45 in Ibs Distributor Block Screws 25 to 30 in Ibs Bearing Retaining Plate Screws 15 to 20 in Ibs Aluminum Plug Bushing or Orifice 60 to 80 in Ibs Nylon Plug Ventilator Plug 10 to 15 in Ibs Switch and Retard Stud Nuts 15 to 17 in Ibs 1 CAUTION If self locking screw is removed or loosened at any time always replace with a new self locking screw and apply torque to the specified value 1 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation Section 2 Description and Operation 2 1 General D 2000 and D 3000 Series Magnetos are designed to provide ignition for four six and eight cylinder aircraft engines Each magneto system consists of a dual magneto and a harness assembly These magnetos generate high voltage which is distributed through radio shielded harness leads to the spark plugs To obtain the retard spark necessary for starting D 3000 Series Magneto Ignition systems employ an impulse coupling and D 3200 Magneto Ignition Systems include an additional contact assembly used in conjunction with a starting vibrator Figure 2 1 shows the components used in a typical D 3200 Ignition System incorporating a starting vibrato
4. sessi 4 5 4 2 6 A RA t ce reete tue inte e ence cues 4 5 4 2 7 Spur Gear and Bearing Bushing Removal see 4 6 Harness Disassembly ciar ninia pe van arce 4 7 Cleaning er D M 5 1 Detailed Magneto Cleaning Procedures eee 5 1 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 xi xii 5 3 6 6 1 6 2 7 7 1 7 2 7 3 8 8 1 8 2 9 9 1 Ignition Harness Cleaner ria 5 2 Periodic Maintenance Contra sarita a a 6 1 Detailed Maintenance Procedures iei ere is 6 2 6 2 1 Contact Assembly Inspection enhn 6 2 6 2 2 Impulse Coupling Inspection oooonnncnncnnonconnonnnonconnnanonononcnononononn con nonnconn cano nccnnono 6 4 6 2 3 500 Hour A A nete ot PO De EEE Trs E 6 8 General Overhaul Generalia enuen p a ana a a nS 7 1 Detailed Overhaul Procedures 5e sero eee dria de eoe tia 7 1 7 2 1 Magneto Disassembly eese eene eene nene nnne enne enne enne enne 7 1 7 2 2 Distributor Gear Inspection sicoiir snieter enne nennen 7 2 7 2 3 Breaker Cam Inspection eren eren non nennen nennen 7 3 7 2 4 Distributor Block Inspecti0N ononnononnonnnonnccnncnnonnnnncononononacon non corno conc nennen nennen 7 3 4 2 5 Capacitor Inspection oz oco IRE Rp UE RE dees tent 7 7 7 2 6 Coil and Clamp Inspection eere rere 7 8 7 2 7 Impulse Coupling
5. 11 17 D 3000 Series Magneto Harness Assembly Exploded View 11 18 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 NG Introduction and Specifications Section 1 Introduction and Specifications 1 1 General This manual provides complete maintenance and overhaul instructions with illustrated parts list for D 2000 and D 3000 Series Magnetos and harnesses manufactured by Continental Motors D 2000 and D 3000 Series Magnetos convert mechanical energy into a sequenced series of high voltage pulses for reciprocating engine ignition The ignition harness conducts the high voltage pulses from the magneto to the spark plugs Grounded coaxial braided shielding provides attenuation of radio frequency interference Revision service is available by subscription to Form X40000 Service Bulletins included in the Master Service Manual Subscription or by visiting the Continental Motors web site This manual may be inserted as Chapter 74 10 and 74 20 of applicable GAMA format publications Instructions in the manual do not cover all details or variations in equipment nor do they provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or particular problems arise which are not covered sufficiently for purchaser s purpose refer to Continental Motors Customer Service Maintenance instructions in this manual have been shop ver
6. Assembl the distributor gear resulting in magneto failure and subsequent engine failure personal injury or death 3 As required assemble Terminal Kits for each magneto as shown in Figure 9 28 Install switch and applicable retard and or tachometer wiring by securing terminal nut s onto magneto Tighten terminals finger tight 4 Dress spark plug leads to the engine in accordance with engine manufacturer s instructions Dress leads away from sharp edges and hot spots When clamps are tightened ensure leads will not be crushed Leads must be supported at short intervals to prevent chafing damage and not drawn so taut as to produce strain on the parts 5 Apply MS 122AD dry lubricant spray to the terminal insulating sleeves Figure 2 4 in the location shown in Figure 9 27 to prevent heat from causing sleeve to stick to spark plug barrel B NUT COAT FERRULE Ili Figure 9 27 Lubricate Insulating Sleeve 6 After harness is dressed to the engine recheck clamp securing screws for tightness For 3 4 20 B nuts apply 110 120 in Ibs torque For 5 8 24 B nuts apply 90 95 in Ibs torque Do not allow the ferrule Figure 1 8 to twist while tightening nut 9 32 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl STRIP INSULATION 0 125 1 031 IF SHIELDED CABLE IS 7 USED STRIP AND SOLDER STRIP METALLIC SHIELDING 0 672 0 031 eel I
7. Breaker Felt Lubricant Part No 10 86527 Distributor Block Bushing Felt Washer Distributor Block Lubricant Part No 10 391200 Impulse Coupling Spring Clean Aviation Engine Oil Magneto Shaft Taper Anti Seize Lubricant Part No 646943 Grommets Sleeves TFE Release Agent Miller Stephenson Part No MS 122AD Distributor Block Buna Rubber Distributor Block Coating Part No 10 391400 Testing Coming in speed 150 RPM Spark gap setting 0 157 in 4 mm Drive Speed D4 and D8 Magnetos equal to crankshaft speed D6 Magnetos 3 4 crankshaft speed Tolerances Cam Washer Thickness 0 095x0 010 in Capacitor 10 400574 4 Cyl 0 12 0 18 utarads 10 400576 6 Cyl amp 10 400578 0 32 0 43 yfarads All Feed through resistance 004 ohm maximum All Leakage 0 4 pA max at 400VDC Coil Resistance 68 F 20 C 10 382790 1 4 Cyl Secondary Winding 13100 to 15900 ohms 10 38258801 6 and 8 Cyl Secondary Winding 5900 to 7500 ohms All Primary Winding 1 ohm Contact Point Clearance Left Main 0 016 x 0 002 in Right Main Retard amp Tachometer Contacts 0 016 x 0 004 in Contact Synchronization within T E Gap 8 22 Retard Angle As marked on date plate 2 7 0 Pressurized Magneto Leakage 2 410 11 8 SCFH at 29 10 3 1 psig Ground Return from capacitor case to magneto 3 m ohms maximum
8. CAUTION Ensure roller bearing does not become contaminated with debris prior to or during assembly NOTE Springs pre lubricated roller bearing and felt strips are pre assembled into spare distributor blocks Distributor gear bushings are supplied pre lubricated Installation of distributor block kits part numbers 10 682054 10 682056 or 10 682058 or installation of roller bearing P N 10 382971 according to the following procedures ensures compliance with Service Bulletin 600 Part 2 paragraph F or H as applicable 1 If new tower springs Figure 1 29 are to be installed refer to Figure 9 5 and use the 11 8627 Spring Seating Kit Insert the Spring Insertion Guide in the block 27 tower outlet hole as shown Place contact spring 29 large end down in top of the Guide Position the Plunger Assembly with the Handle attached over the small end of spring With a firm counter clockwise pushing motion seat spring in the recess of block tower 27 Spring is properly installed when the bottom turn is caught in the bushing of block and top turn is approximately centered in the tower outlet Check spring height according to instructions in Section 7 2 4 step 8 Install the bearing 30 in the distributor block 27 a Position the distributor block Figure 1 27 tower side up on the solid end of the 11 9999 bearing pressing support Figure 10 5 so the block insert rests on the support b Using 11 9998 bearing pressi
9. Check magneto to engine timing according to the Engine Maintenance Manual prior to magneto removal or disassembly Disassemble the magneto according to instructions in Section 4 2 1 Remove and inspect the contact assemblies 11 12 amp 13 according to instructions in Section 6 zc Inspect and treat the distributor block 27 according to the instructions in all the steps of Section 7 2 4 except step 3 Inspect the distributor gear assemblies 21 and carbon brushes 24 a Wipe distributor gears and axles 21 free of all oil film and other contaminants Inspect for damage or unusual wear replace as necessary b Remove carbon brush and spring 24 from the hole in the gear axle 21 Clean each hole with a pipe cleaner Check carbon brush for side loading or unusual wear Measure the carbon brush from the spring shoulder to working end of the brush Overall length shall be 0 375 in minimum Replace worn brushes as necessary with a new brush and spring assembly 24 Seat the new brush and spring 24 in the gear 21 axle hole and compress brush to within 1 8 in of gear then release slowly Brush shall move freely within the hole in the axle c Generously apply MS 122AD dry lubricant spray to the distributor gear teeth d Ensure washers 23 amp 25 are in place on the gear axle and in good condition Ensure the nylon washer 25 is positioned against the distributor gear Inspect the housing 66 for physica
10. Return the switch key or lever to the BOTH position and shut down the engine using normal procedures 5 If problems persist replace the magneto with a known serviceable unit and send the suspect unit to the overhaul shop for test and repair D 2000 D 3000 Series High Tension Magneto Service Support Manual 3 1 31 August 2011 Testing amp Troubleshootin 6 If a replacement unit is not readily available inspect the following to isolate the cause of the malfunction a Remove harness securing screws and separate the cover from the magneto Inspect for presence of moisture and foreign matter on rubber grommets and high tension outlet side of the distributor block Check for broken or burned outlet towers If either is present remove magneto and replace as necessary b Check block tower springs for proper height End of spring shall not be more than 0 422 inch from top of tower Replace burned or otherwise short springs according to the instructions in Section 9 2 4 Check for broken leads or damaged lead insulation If either is present replace magneto c Inspect contact assemblies according to the Contact Assembly Inspection in Section 6 2 1 3 2 Post Overhaul Testing 1 Mount the magneto on a 11 10500 test stand Connect the high voltage outlet to spark gaps on test stand using a standard harness assembly Set spark gaps at 0 157 in 4 mm as shown in Figure 3 1 CAUTION Do not operate the magneto on a
11. S S 7110 682560 13 gt S S 710 682560 131 f S S gt gt 110 682605 13 Po n5 Po Po 10 682610 11 10 682610 13 cK NM IN co cO TA run c cO c o o Sr N je Zz O S dq o o N N IN QIN oO 09 09 CO cO PIP L L IP c o oO o o SSS lS l 1 4 4 M 4 4 la 4 4 l 2 2 2 2 2 2 2 2 1 1 2 1 1 1 1 10 682920 11 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 7 Spare Elbow Leads and 4 Cylinder D 2000 and D 3000 Gold Seal Harnesses FEB e REE EE be 3 34 10 89 00 0 SERRE dq Figure 2 SNS sssesassgss Index Description Part No seeleseeeereers 1 Lead Kit 3 4 20 48 in 10 400401 48 18 4 4 6 3 5 6 6 4 Lead Kit 3 4 20 78 in 10 400401 78 4 4 2 2 4 Lead Kit 5 8 24 48 in 10 400402 48 2 Spring 10 32326 8 3 Terminal Wire 10 320467 8 8 10 320468 4 Sleeve Insulating 10 4
12. blue in color and include the word REBUILT Magnetos and Ignition systems marked with a BL prefix part number are FAA PMA for all applications approved for the corresponding 10 prefix units Units marked with a BL prefix are fully interchangeable with the corresponding units marked with a 10 prefix To maintain BL prefix magnetos and ignition systems use the corresponding 10 prefix service and parts list data When ordering rebuilt units specify BL prefix part numbers 10 prefix applies to new units only D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 2 9 Description and Operation 2 7 2 8 2 10 D 2000 Series Magneto Difference Data The D 2000 Series Magneto was the predecessor to the D 3000 Series units Most parts are interchangeable between the two model series In terms of fit and function D 2000 and D 3000 units are fully interchangeable between the superseding and superseded part numbers D 2000 Series to D 3000 Series Model conversion is listed in Table 2 3 Table 2 3 D 2000 Supersedure Legacy D 2000 Magneto Replacement with D4LN 2021 D4LN 3000 D4RN 2021 D4RN 3000 D4LN 2200 D4LN 3200 D6LN 2031 D6LN 3000 D6LN 2230 D6LN 3200 D6RN 2230 D6RN 3200 D8LN 2200 D8LN 3200 Part number supersedure A detailed list of superseded D 2000 Series System part numbers and D 2000 Series Magneto part numbers is provided in the Superseded D
13. depending upon the extent of change Service Documents may supplement or replace technical information contained in one publication or an entire series of publications Such Service Documents represent a change to the published ICA until the individual publications incorporate the latest technical information Document updates are available via the Continental Motors web site upon notification of FAA document approval Printed publication subscribers receive printed changes and revisions as they are released Document revisions are released if the update changes more than 50 of the contents of a publication Revisions replace the previous version of a publication from cover to cover Minor corrections are released as change pages to the original publication identified with a change number and effective change date in the page footer Information on the page that changed from the previous edition is identified by a vertical six point black line Figure B referred to as a change bar in the outside margin of the page A change page replaces only the previous edition of the affected page D 2000 D 3000 Series High Tension Magneto Service Support Manual V 31 August 2011 7 2 3 Flight Check and Break In An Operational Check and a normal preflight ground run up in accordance with the Airplane Flight Manual or Pilot s Operating Handbook AFM POH must be completed before the A amp P mechanic can approve the airplane for a Flight Check A Fl
14. eee 9 2 Position Plate with Recess Facing Up esses 9 3 Kit Parts Installed in D 2000 Magneto eese 9 4 Spur Gear Alignment on Shaft sse 9 6 Contact Spring Installation eene 9 9 Distributor Block Timing esee 9 11 Dial Indicator Mounted on Housing sees 9 11 Shims Positioned Around the Rotating Magnet 9 13 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 XV xvi Figure 9 9 Figure 9 10 Figure 9 11 Figure 9 12 Figure 9 13 Figure 9 14 Figure 9 15 Figure 9 16 Figure 9 17 Figure 9 18 Figure 9 19 Figure 9 20 Figure 9 21 Figure 9 22 Figure 9 23 Figure 9 24 Figure 9 25 Figure 9 26 Figure 9 27 Figure 9 28 Figure 9 29 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 10 9 Figure 11 1 Figure 1 Figure 2 Distributor Block Secured and Centered 9 13 Cam End View of Magneto ccscc scccescceascecsanacavsnccasdersvcnsteenbed cave 9 15 11 8465 Rotor Holding Tool in Position 9 16 Timing Marks on Rotating Magnet seen 9 17 Rotor Timing Marks Aligned with Pointer 9 17 Painted Tooth Centered in Window ess 9 17 Che
15. 10 400325 Coupling Impulse CCW 10 10 400326 Body Impulse Coupling 10 382747 10 382768 10 382748 B 10 382767 10 382952 10 382961 41 Spring Flat Spiral 10 51324 10 400042 Cam Assembly Impulse 10 400167 9 10 400166 7 10 400167 7 us 10 400167 8 10 400167 13 10 400167 12 43 Ring Retaining MS16624 2062 1 44 Washer Plain 10 349328 1 45 Washer Bowed 10 349249 1 46 Screw Socket Head Locking 10 382789 4 47 Washer Plain 10 382788 4 48 Magnet Rotating 10 382799 1 1 10 382799 2 49 Slinger Cil 10 349248 1 50 jBearing Ball 10 400567 1 51 Plate Bearing Retainer 10 382787 1 52 Gear Spur 4 amp 8 CYL 10 382573 1 Gear Spur 6 CYL 10 382575 11 8 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 5 D 2000 Series Magnetos Illustrated Parts List 10 382555 151 10 382560 11 CN co om M O M O tO O NAN oo co c9 c eco em 10 382560 13 Ir i i A eo e e 10 382610 131 10 382610 221 10 382620 11 54a Screw Cap Figure 1 Index Description Part No 53 Bushing Roller Bearing 10 382969 Kit Coil Securing 10 382939 NAS1352 08 24P 54b Washer 10 382788 54c Nut Self Locking 10 382936 lt 1 s i e co e e T 1 1 4 4 4 4 4 2 SEPP ALA 5 7 710 382555 15 SN S S S S 7 7110 382555 141 SEPA A 5 5 7 710 382605
16. 13 SEPA A 5 10 382610 11 mm A 10382610 13 Mm A 10 382910 13 mm 5 A A AL 10 382910 18 PEPER A S 2 10 382920 11 M m 55 Plate Coil Retaining 10 382935 56 Spring 10 382931 57 Strip Paper 10 382568 58 Coil 6 amp 8 CYL 10 382588 1 Coil 6 amp 8 CYL 10 382790 1 59 Plug Ventilator 10 157134 60 Plug Solid Nylon 10 157135 61 Bushing Threaded 10 382815 62 Orifice Threaded 10 382861 63 Plug Solid Aluminum 10 51391 64 Plate Identification 10 400006 65 Housing Magneto NP P a m 2 1 No Parts Available For housing replacement convert magneto to D 3000 configuration D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 6 D 3000 Series Magnetos SS sees aaa LWO LO LO LO LO LO O S O O O c o O S o o pS Figure 1 TERE RE ERE EEEE Index Description Part No l l l l lo fo fo lo la la la lo lo fo lo je jo 1 Screw Socket NAS1351 3 32P 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 NAS1351 3LB32P 4141 4 2 Washer Spring Lock MS35338 43 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 3 Washer Plain 10 5550
17. 3 Apply lengths of heat shrink tubing over the lead and terminal assembly Crimp 10 400506 sleeve in place as shown in Figure 8 1 4 Using a heat gun position the heat shrink tubing in place and apply heat to the tubing to shrink the tubing into place as shown in Figure 8 1 using the lowest heat setting capable of melting the heat shrink tubing 8 2 2 Threaded Hole Repair Threaded holes in the housing Figure 1 66 may be repaired as shown in Figure 8 2 using threaded insert part numbers shown in Figure 8 2 according to the latest instruction from the supplier Emhart Fastening Teknologies See Table 10 1 USE 10 32 HELICOIL MS124695 OR MS1247358 8 PLACES USE 8 32 HELICOIL MS122119 OR MS122159 4 PLACES Figure 8 2 Helical Coil Repair 8 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Section 9 Assembly 9 1 General Refer to Figure 10 1 for a list of materials and tools required during assembly Refer to Figure in Section 11 for magneto exploded view Refer to Figure 2 in Section 11 for harness exploded view Numbers in parenthesis following part names correspond to the index numbers in the exploded view WARNING Adhere to the fastener torque specifications in the assembly instructions Failure to properly torque fasteners places the Aiworthiness of the entire assembly in question NOTE The following parts must be replaced 100 with new parts follo
18. 6 10 821625 4 10 821625 34 10 821635 4 Lead Kit 3 4 20 48 in 10 400401 48 n5 A a Lead Kit 3 4 20 78 in 10 400401 78 n o oc Y Mm M n M Cover 6 CYL Tach Ret Cover 6 CYL Tach Cover 8 CYL Retard Kit Elbow Clamp 4 CYL Kit Elbow Clamp 6 CYL Clamp Primary Clamp Secondary Screw w Lock washer Nut Tie Cable Clamp 1 wire Clamp 2 3 wire Clamp 4 wire Clamp 6 wire Bracket Twist Screw Lock nut 2 Spring 10 32326 3 Terminal Wire 10 320467 4 Sleeve Insulating 10 400099 5 Eyelet Compression 10 400097 6 Spring Compression 10 400195 7 Eyelet Retention 10 400093 8 Ferrule 10 400137 9 Nut Hex Coupling 10 400187 10 Clamp 5mm 100 ft 10 400062 1 11 Grommet 10 320777 12 Eyelet 10 163012 16 Cover 6 CYL Plain 10 400126 1 Cover 6 CYL Retard 10 400126 2 10 400126 3 10 400126 4 10 400128 2 10 400112 8 10 400112 12 10 400105 10 400107 10 35936 6 MS35649 282 10 620013 MS21333 98 MS21333 102 MS21919WCG10 MS21919WCG12 10 400060 2 10 400060 3 10 400060 7 10 35937 10 MS21044N3 A za al al m Po Mm po pol A em Po n5 po pol 77 00 N D C3 het wo O O al al O A oe a A Poy poy M ine ine NT 30 Plate Cable Supp
19. AL 36601 Copyright 2011 Continental Motors Inc All rights reserved This material may not be reprinted republished broadcast or otherwise altered without the publisher s written permission This manual is provided without express statutory or implied warranties The publisher will not be held liable for any damages caused by or alleged to be caused by use misuse abuse or misinterpretation of the contents Content is subject to change without notice Other products and companies mentioned herein may be trademarks of the respective owners A D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Service Document and Technical References Relevant technical content of the service documents which apply to D 2000 and D 3000 Series Magneto Ignition Systems listed below have been incorporated in this manual Active Continental Motors service documents are available on the Continental Motors web site http continentalmotors aero Refer to Contact Information on page vii for Continental Motors web site details Due to the continuing nature of FAA Airworthiness Directives and the Service Bulletins associated with them some Service Bulletins issued prior to the issuance of this manual are still considered active Consult the most recent revision of Continental Motors Ignition Systems Master Service Manual Index Form X41005 for a complete listing of active magneto Service Bulletins Service Bulletins
20. D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 9 4 10 10 1 10 2 11 11 1 11 2 11 3 11 4 11 5 9 2 0 Plug Installation RN 9 19 9 2 9 1 Non Pressurized Magneto Plug Installation 9 19 9 2 9 2 Pressurized Magneto Plug Installation eese 9 19 9 2 10 Impulse Coupling Assembly sese ener 9 20 9 2 11 Impulse Coupling and Drive Plate Installation see 9 22 9 2 12 Data Plate Installation ot ert te rectae 9 24 9 2 13 Post Overhaul Test oooonocnnnninnnnnnncnncnconocononnconccnnocnnonnnnnnnnn cnn cnn non n raro ene nennen 9 24 Harness Assembly co id ihe eas dade deca Rede d 9 24 9 3 Parts Supersedure a csch etes rp eR PE de He SEE 9 24 9 3 2 Lead Assembly Replacement nennen 9 24 9 3 3 3 4 20 Straight Spark Plug Terminal Assembly see 9 28 9 3 4 5 8 24 Straight Spark Plug Terminal Assembly sees 9 28 9 3 5 3 4 20 Elbow Spark Plug Terminal Assembly sese 9 28 Harness to Magneto Installation eene 9 30 Magneto Installation on Engine ocoooccnoncccnoncccnoncnononanononanonnnnconnnnonancninnnos 9 3 Special Tools Equipment and Supplies Special Tool and Consumable Supply List esses 10 1 Illustrated Special Tools and Fixtures eere
21. Inspection in Section 6 2 1 Pressurized Ignition Systems must be tested for integrity of the pressurization system at intervals not to exceed 100 hours in service in accordance with Textron Lycoming Service Instruction 1308D or later revision Inspect magnetos equipped with snap ring impulse couplings 39 at the first 500 hours in service and every 500 hours thereafter according to the Impulse Coupling Inspection in Section 6 2 2 Inspect magnetos equipped with riveted impulse couplings 39 at the first 100 hours in service and every 100 hours thereafter according to the Impulse Coupling Inspection in Section 6 2 2 Inspect all magnetos according to the 500 Hour Inspection in Section 6 2 3 at the first 500 hours in service and every 500 hours thereafter If the magneto has more than 500 hours inspection as outlined above must take place within the next 100 hours or at the next scheduled inspection period whichever occurs first and at 500 hour intervals thereafter Make an appropriate logbook entry signifying compliance with this paragraph and referencing the magneto serial numbers involved after completing the inspections Ignition systems are subject to the same environmental conditions and wear as the engine Therefore overhaul the magnetos and replace the ignition harnesses at the same time as the engine Engine overspeed sudden stoppage or other unusual circumstances may require engine overhaul prior to engine manu
22. STOP TOE dal APPROX 4 1 8 IN AXLE HEEL TRIGGER RAMP ROTATING MAGNET SHAFT Figure 6 3 Flyweight Terminology 1 Rotate the impulse coupling so the flyweight axles are next to the stop pins Position flyweight as shown in Figure 6 4 and check flyweights and axles for wear WARNING A polished area on the heel Figure 6 4 of the flyweight is an indication of severe wear and cause for immediate rejection of the cam assembly WARNING Lock the rotor on drive shaft end only Do not use gear lock devices which could cause gear tooth damage and subsequent magneto failure 6 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance a Inspect the heels of the flyweights for wear indicated by what appears to be a polished surface in the area depicted in Figure 6 4 Figure 6 4 Flyweight Heel Inspection b Lock rotor in place using an 11 8465 rotor holding tool Figure 6 5 D 2000 D 3000 Series High Tension Magneto Service Support Manual 6 5 31 August 2011 Periodic Maintenance ROTOR HOLDING TOOL Figure 6 5 Inspection Setup c Form a piece of wire into hook as shown in Figure 6 6 Reach between the cam and the flyweight with the wire hook as near as possible to the stop pin Pull outward on the flyweight as shown in Figure 6 7 NOTE All dimensions in Figure 6 6 are approximate p 0 125 in Maximum Figure 6 6 Wire Hook Configuration
23. Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance Section 6 Periodic Maintenance 6 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified Refer to Table 10 1 for a list of special tools and materials required during Periodic Maintenance 1 Use a 4X 5X magnifying glass for all visual inspections 2 The following parts must be replaced 100 with new parts following their disassembly from the magneto regardless of whether disassembly is for the purpose of inspection replacement of a part or overhaul lock washers Figure 1 2 33 screws 9 14 18 46 54 retaining ring 22 43 washers 3 47 bearings 30 50 felt strip 28 identification plate 65 bearing retainer 51 springs 56 pin 7 spring 41 and gasket 8 The following parts may be re used after maintenance inspections according to instructions in Section 6 2 1 and Section 6 2 2 but must be replaced during Magneto Overhaul Main and retard contact assemblies 11 12 13 felt washer 26 carbon brushes 24 and capacitors 6 3 Periodic Maintenance Intervals a At each magneto inspection or maintenance inspect the ignition harness components particularly the terminal sleeves Figure 2 4 grommets 11 and springs 2 for tears cracks contamination arci
24. Using a multimeter measure DC resistance in series Replace the capacitor if it does not meet Table 7 1 specifications Table 7 1 Capacitor Test Values 4 Cylinder 6 or 8 Cylinder Capacitor Part No 10 382807 10 382681 or 10 382681 1 Capacitance at 70 F microfarads 0 12 0 18 0 32 0 43 DC series resistance ohms 1 0 max 1 0 max Leakage current 400 VDC 190 10 F 0 4 yA max 0 4 pA max D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 7 31 August 2011 General Overhaul 7 2 6 Coil and Clamp Inspection 1 Inspect coils Figure 1 58 for cracks in molding frayed or damaged lead insulation corrosion or looseness of flag terminal and for damaged or corroded coil laminations Corroded laminations may be wire brushed Coil leads and terminals may be repaired according to instructions in Section 8 2 1 Inspect high tension tab for wear caused by carbon brush 73 indicated by a visible depression in the tab If tab is worn more than 0 015 inch or exhibits an irregular surface replace the coil 2 Using a Fluke 8840A Digital Multimeter or equivalent measure primary resistance from flag terminal to coil core between coil leads Primary resistance must be less than one ohm Measure secondary resistance between the coil core and high tension tab Four cylinder secondary coil resistance must be between 13 100 and 15 900 ohms Secondary coil resistance for six and eight cylinder must be betw
25. affecting D 2000 and D 3000 Series Magnetos and or applicable Gold Seal Harnesses issued subsequent to issuance of this manual shall be considered to supplement or supersede applicable information in this manual Bulletin Bulletin Title Issue Date Number 584B Coil Retaining Devices for D 2200 Series Magnetos 04 78 587 Inspection of D 2000 Series Magneto Capacitors and Capacitor Lead Crimp Terminals 02 77 588 Stress Relief Lines in Distributor Blocks of D 200 D 2200 Series Magnetos 05 78 590A Rotating Magnet to Housing Clearance D 2000 D 2200 Series Magnetos 05 78 597A Cleaning Bendix Lightweight Ignition Harness Spark Plug Ends 10 79 600 10 353110 Bearing in D 2000 D 2200 Series Magneto 05 78 603 Aircraft Noise in Aircraft Communication Equipment 11 78 605A Inspection of D 2000 D 2200 Series Magnetos etc 11 79 606 D 2000 D 2200 Series Magnetos using Green Distributor Blocks 04 79 608 Self Locking Cam Retaining Screws P N 10 391213 and 10 352959 11 79 610 10 652014 and 10 652016 Insulated Distributor Gear Kits for D 2000 D 2200 Series Magnetos 6 80 617B Inspection and or Replacement of Distributor Gears in D 2000 D2200 Series Magnetos 07 89 618 Replacement or Inspection of Distributor Gears in D 3200 Series Pressurized BLUE Magnetos 08 81 619 Replacement of Distributor Gears in D 3200 Series Pressurized BLUE Magnetos 07 89 623A Inspection of Impulse Coupling Cam
26. and Related Component Inspection essss 7 8 7 2 8 Magneto Housings and Cover Inspection sessseeeee 7 1 7 2 9 Rotating Magnet Inspection sees eee 7 12 7 2 10 Drive Bushing Drive Plate and Washer Inspection eese 7 12 7 2 11 Magneto Assembly scini en e a E aa E tentent nee nent nnne en 7 12 7 2 12 Magneto Post Overhaul Testing rennen 7 12 Harness Overall lios 7 12 Repair A e TE 8 1 Detailed Repair Procedures A Rines 8 1 8 21 Coil head Replica o Gin winded ERE 8 1 8 2 2 Threaded Hole Repair ohhe neenon inrer epe 8 2 Assembly GEHL ME E 9 1 Detailed Assembly Procedures eee tte tee tette tte e eto dpn 9 2 9 2 Coll InstallatiOnzs oie tte RC ERE con euis iiti Ln 9 2 9 2 1 D 3000 Series Magneto Coil Installation eene 9 2 9 2 1 2 D 2000 Series Magneto Coil Installation eene 9 4 9 2 2 Assemble Gear and Bushing on Rotation Magnet 9 6 9 2 3 Install Bearing and Magnet in Housing eseseeeeeeeeeneen 9 7 9 2 4 Distributor Block Assembly seen 9 8 9 2 5 Distributor Block and Gear Assembly see 9 9 9 2 6 Distributor Block and Gear Installation eee 9 10 9 2 7 Contact Assembly Installation eese 9 14 9 2 8 Magneto Internal Timing esee enne en eker EEE eoe 9 16 D 2000
27. assembly terminals 11 12 amp 13 Remove the plug 59 60 amp 63 bushing 61 and orifice 62 from the housing 66 Remove screws 18 Disconnect the coil 58 primary leads from contacts 11 12 amp 13 Loosen the cam securing screw 14 and turn screw halfway out Place the ends of two screwdrivers between the bottom of the main contact cam 16 and the surface of the distributor block Apply even pressure to both screwdrivers to pry the main contact cam 16 loose from the taper on the rotating magnet shaft 48 Remove the cam securing screw 14 washer 15 retard cam 17 and main contact cam 16 discard the screw 14 Remove the distributor block 27 from the housing 66 CAUTION Do not allow the two housings to turn in relation to each other as damage to coil or carbon brush may result Using No 2 retaining ring pliers remove retaining rings 22 securing the gear 21 to the distributor block 27 and discard the ring 22 Remove washer 23 and slide gear 21 from the distributor block 27 Remove washers 25 amp 33 Using a pointed tool remove felt washer 26 and felt strips 28 from the distributor block 27 Remove the carbon brushes 24 from distributor gear 21 D 2000 D 3000 Series High Tension Magneto Service Support Manual 4 1 31 August 2011 Disassembl 4 2 2 General Overhaul Disassembly 1 Remove contact assemblies Figure 1 11 12 amp 13 from the distributor blo
28. blocks made of phenolic black material may remain in service in unpressurized applications if they pass tests outlined in this section For pressurized magnetos and eight cylinder applications use only brown polyester blocks Green distributor blocks must not be used see the Illustrated Parts Breakdown for a suitable replacement for green distributor blocks found on some D 2000 applications Visually inspect the distributor block Figure 1 27 for damage Inspect threaded inserts for stripped or mutilated threads Brown blocks must have 0 427 inch diameter counterbore at locations shown in Figure 7 6 Reject brown blocks with 0 359 inch counterbore in these positions Inspect bronze oilite bushings both must be tight in the block the inner diameters of both bushings must measure 0 376 0 377 inches Discard blocks with any oversize bushing D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 3 31 August 2011 General Overhaul 3 Inspect bearing bore for roller bearing bore must measure 0 9982 0 9987 inches Discard blocks with oversize bearing bore 4 Inspect brown polyester blocks for batch code replace polyester blocks with batch code 8552 or lower 5 Examine distributor block 27 for cracks particularly around high tension terminal towers mounting ears bushings in center of distributor wells Figure 7 3 illustrates a permissible material flow line which may appear as a crack This line is a res
29. high lobe s is are under the cam followers of the contact assemblies Adjust the left main contact to obtain 0 016 0 002 inch opening Check the retard contacts for 0 016 0 004 inch clearance CAUTION Bend the contact assembly frame carefully It requires very little movement of the bracket to change the contact opening clearance If the bracket is bent too much do not attempt to bend it back as this will weaken the bracket Use another new contact assembly If proper retard contact clearance cannot be obtained loosen the contact assembly securing screws 9 move the contact assembly away from the cams and retighten the screws If the clearance was over 0 020 inch bend the steel upright frame of the contact assembly away from the cam If the clearance was under 0 012 inch bend the frame toward the cam Readjust the left main contact assembly for the 0 016 0 002 inch clearance and recheck the retard clearance Support the drive end of the rotating magnet 48 shaft on a non metallic surface and install woodruff key s 35 Apply a thin film of P N 646943 anti seize lubricant to the taper on the rotating magnet 48 and install a drive plate 37 amp 38 or cam assembly 42 over the taper Install bushing 34 and nut 32 do not tighten the nut at this time D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 15 31 August 2011 Assembl 9 2 8 Magneto Internal Timing 9 16 NOTE The timin
30. is evident and nut torque reduces immediately If the cam cracks replace it with a new cam Figure 9 20 Typical Impulse Coupling Crack 4 Inspect the impulse coupling according to instructions in Section 6 2 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 23 31 August 2011 Assembl 9 2 12 Data Plate Installation 1 Type applicable magneto data on the new data plate Apply a protective coating of clear enamel to the label and allow to dry 2 Clean data plate attachment surface of housing Figure 1 66 by wiping with cloth moistened with isopropyl alcohol Apply Permabond 910 Adhesive to the back side of the data plate 3 Align the data plate 65 with the housing 66 and apply firm pressure across entire surface of the label 9 2 13 Post Overhaul Test Perform the applicable Post Overhaul Testing according to instructions in Section 3 2 9 3 Harness Assembly 9 3 1 Parts Supersedure Spare piece parts for Gold Seal Harnesses may be used to maintain Bendix Blue and Dura Blue Harnesses and vice versa with the following exceptions 1 Sleeve P N 10 320466 out of production for 3 4 20 terminals cannot be used with Gold Seal Eyelet Figure 2 5 When using Gold Seal Eyelet 5 use Gold Seal Sleeve 4 2 For 3 4 20 applications the Spring Assembly P N 10 94225 2 out of production cannot be used with current Gold Seal Low Profile Outer Ferrules Figure 2 8 Use Gold
31. is weak or missing install new vibrator If this does not correct trouble remove magneto and check for improper internal timing or improperly timed distributor gears Magneto improperly timed to engine Check magneto to engine timing according to the Engine Manufacturer s instructions Inspect contact assemblies according to instructions in Section 6 2 1 and adjust and replace parts as necessary Main contact assembly out of adjustment internal timing off Check magneto internal timing according to instructions in Section 9 2 8 Retard points opening too late Check timing of retard points according to instructions in Section 9 2 8 3 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 N ER V See Testing amp Troubleshootin Table 3 1 Troubleshooting Chart Symptom Probable Cause Test Engine Roughness Worn or fouled spark plugs Install new spark plugs Worn ignition leads Check plug leads for continuity and breakdown Worn or fouled magneto contact assemblies Check magneto contact assemblies for burning melting or contamination according to instructions in Section 6 2 1 Carbon tracked distributor block Replace distributor block Magneto Drop off Magneto to engine timing incorrect Check magneto to engine timing according to the Check Out of Limits Engine Manufacturer s instruc
32. materials Particular caution should be exercised when the identity of materials parts and appliances cannot be established or when their origin is in doubt Advisories This manual utilizes three types of advisories defined as follows WARNING A warning emphasizes information which if disregarded could result in severe injury to personnel or equipment failure CAUTION Emphasizes certain information or instructions which if disregarded may result in damage to the engine or accessories NOTE Provides special interest information which may facilitate performance of a procedure or operation of equipment Warnings and cautions precede the steps to which they apply notes are placed in the manner which provides the greatest clarity Warnings cautions and notes do not impose undue restrictions Failure to heed advisories will likely result in the undesirable or unsafe conditions the advisory was intended to prevent Advisories are inserted to ensure maximum safety efficiency and performance Abuse misuse or neglect of equipment can cause eventual engine malfunction or failure D 2000 D 3000 Series High Tension Magneto Service Support Manual ix 31 August 2011 Intentionally Left Blank D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 31 August 2011 1 1 1 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 1 3 2 3 3 3 4 3 5 4 1 4 2 4 3 5 5 1 5 2 TABL
33. obtain the desired fit Place each lead between the post and block tower Figure 9 10 14 Remove the rotor holding tool from the rotor shaft 9 2 9 Plug Installation 9 2 9 1 Non Pressurized Magneto Plug Installation 1 Install ventilated plugs Figure 1 59 in the windows at each end of the magneto 2 Install solid plugs 60 in the top timing hole and bottom window 3 Torque the plugs 59 or 60 to 5 10 in Ibs 9 2 9 2 Pressurized Magneto Plug Installation 1 Install a threaded plug Figure 1 61 in the window at the end of the housing nearest the data plate 65 Install and orifice plug 62 in the bottom hole in the housing 3 Install the solid plugs 63 in the remaining two holes Tighten all aluminum plugs to 60 80 in lbs D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 19 31 August 2011 Assembl 9 2 10 Impulse Coupling Assembly If the magneto features impulse couplings Figure 1 39 assemble the impulse coupling according to these instructions NOTE Induced magnetism from engine parts not thoroughly degaussed following magnetic particle inspection will result in a magnetized body 40 Ensure all engine parts are properly degaussed before reinstalling a body requiring degaussing 1 Check cam assembly 42 and body 40 for magnetization which would prevent flyweights from engaging Hold assembly as shown in Figure 9 15 and push upper position flyweigh
34. of capacitor mounting area with a clean fresh nylon scouring pad only b Using a different clean fresh nylon scouring pad remove contamination and corrosion from mounting area on capacitors Figure 1 6 A good electrical connection between the capacitor housing and ground is essential for proper magneto operation Form capacitor leads as shown in Figure 9 26 Figure 9 26 Formed Capacitor Leads Install the two capacitors Figure 1 6 in their respective places in the harness cover Figure 2 16 Secure each capacitor with lock washer Figure 1 5 and nut 4 centering the wire nipple between the silicone grommets Figure 2 11 Torque each nut Figure 1 4 to 60 70 in Ibs NOTE Spray grommets with a film of MS 122AD dry lubricant Do not spray the distributor block Harness is secured to both D 2000 and D 3000 magnetos with four screws and four washers Original D 2000 harness covers with eight screw holes which have not been previously modified to fill in four center holes must be replaced with a new cover Ensure the Harness Cover and housing mating surface are free of corrosion paint and sealing materials Use only a clean fresh nylon scouring pad to brighten these surfaces Ensure threads in housing are free of corrosion and thread locking compounds Use a 10 32 tapered tap followed by a clean fresh nylon brush and air blast to clean the threads D 2000 D 3000 Series High Tension Magneto Service Supp
35. of engine cranking speed The retard ignition is in the form of a shower of sparks instead of a single spark as obtained from an impulse coupling NOTE Reference only for actual engine schematic see Airframe Service Manual DUAL MAGNETO DISTRIBUTOR START SWITCH SWITCH L Q Q Q MAN CONTACT ASSEMBLY ALR RETARD O RETARD CONTACT ASSEMBLY STARTING VIBRATOR 24V ONLY e SPARK PLUG SWITCH Q K STARTER SOLENOID JUMPER TERMINAL P N 10 126656 INSTALLED BETWEEN ADJACENT R TERMINALS ON SWITCH Figure 2 3 Sample Magneto Circuit with Starting Vibrator Schematic D 2000 D 3000 Series High Tension Magneto Service Support Manual 2 3 31 August 2011 Description and Operation D 2000 Series and D 3000 Series Magnetos offer an optional set of tachometer contacts above the right main contact assembly These contacts are actuated by a cam above the main contact assembly cam Pressurized D 2230 and D 3200 Series Magneto Systems are configured for attachment of engine induction system pressure air hoses Increasing the pressure of the air inside the magneto above ambient pressure has the effect of increasing the insulation strength of the air per unit volume thus improving high altitude performance D 3000 Gold Seal Harnesses also for D 2000 Series Magnetos are assembled with 5 mm shielded ignition cable This cable Figure 2 6 with stranded stainless st
36. stock so the exposed ends come out between the cover attaching holes in the housing Figure 9 8 h If step g cannot be accomplished disassemble and discard housing Convert the magneto housing to the D 3000 configuration Otherwise leave the shims in position and assemble distributor block and gears in position as described in step 1 through step 5 When seating the distributor block to the housing ensure none of the shims are caught between the block and the housing Figure 9 9 1 Install the two connector strips 20 distributor block securing screws 18 and washers 31 taking care to align the holes in the connector strips with the contact assembly securing holes in the block contact assemblies may be temporarily installed on the block to help align the strips Tighten screws to 25 30 in Ibs One at a time carefully pull the four shims from the assembly Ensure no part of the shims remains inside the magneto assembly If magneto must be disassembled to remove debris repeat step g through step i to ensure proper centering of rotating magnet 8 Turn the rotating magnet in the normal direction of rotation until the L or R align with the built in timing pointer in the center of the timing window on the top side of the magneto This is the E Gap position of the rotating magnet 8 past neutral With the magnet in this position the red painted tooth of each distributor gear must be approximately centered in each t
37. the Item 1 Lead Assembly Kits 22 TCM GOLD SEAL 3 4 31 SPARK PLUG TERMINAL 0 eS SHOWN FOR REFERENCE _9 Figure 2 D 3000 Series Magneto Harness Assembly Exploded View 11 18 Reverse Blank E A E Continental Motors Inc www continentalmotors aero
38. 000 RPM Perform high speed test run at 3500 RPM minimum Do not exceed 5000 RPM Magneto shall fire all gaps consistently and operate smoothly throughout its operating range Ensure the magneto ceases to fire when grounding leads are connected to ground 5 Test magnetos equipped with impulse couplings Couplings must engage fully at speeds up to 150 RPM minimum Four cylinder impulse couplings must engage fully at speeds up to 100 RPM minimum Six cylinder impulse couplings must engage fully at speeds up to 75 RPM minimum Intermittent engagement is permissible up to 450 RPM at which point the coupling must be fully disengaged Remove and replace any couplings which do not meet this test 6 After testing check rotating magnet for 0 002 to 0 005 in end axial play and no perceptible radial play If end play or radial play is out of limits replace parts as necessary and re test 7 For pressurized ignition systems pressurized magnetos and pressurized harnesses only a If ignition system is already installed on engine test pressurization system according to Textron Lycoming Service Instruction No 1308D or later revision NOTE Magneto and harness must be fully assembled together as an Ignition System according to instruction in Section 9 4 If magneto or harness is to be tested separately a slave harness or magneto respectively must be assembled to the unit under test to complete the pressure vessel Cap retard bushing or assemble s
39. 00099 8 8 10 320473 110 400101 5 Eyelet Compression 10 400097 8 8 6 Spring Compression 10 400195 8 8 7 Eyelet Retention 10 400093 16 16 TA Ferrule Inner 10 620109 8 Ferrule 10 400137 8 8 10 400081 9 Nut Hex Coupling 10 400187 10 400186 10 Cable 5mm 100 ft 10 400062 1 11 Grommet 10 320777 8 8 12 Eyelet 10 163012 8 8 13 Ferrule Outer 10 620024 14 1 10 620011 Ferrule Inner 15 Elbow 110 NP 16 Cover 4 CYL Plain 10 400124 1 Cover 4 CYL Retard 10 400124 2 1 Cover 4 CYL Tach 10 400124 4 1 17 Kit Elbow Clamp 4 CYL 10 400112 8 1 18 Clamp Primary 10 400105 8 19 Clamp Secondary 10 400107 8 20 Screw w Lock washer 10 35936 6 8 21 Nut MS35649 282 8 22 Tie Cable 10 620013 18 16 23 Clamp 1 wire MS21333 98 1 5 24 Clamp 2 3 wire MS21333 102 313 25 Clamp 4 wire MS21919WCG10 2 2 26 Clamp 6 wire MS21919WCG12 1 27 Bracket Twist 10 400060 2 10 400060 3 2 28 Screw 10 35937 10 2 29 Lock nut MS21044N3 2 30 Plate Cable Support 10 620039 2 10 620039 3 10 620039 4 2 10 620039 5 4 2 31 Grommet 10 320163 MS35489 9 1 Elbow leads available only until supply on hand is exhausted 2 No Parts Available D 2000 D 3000 Series High Tension Magneto Service Support Manual 11 13 31 August 2011 Illustrated Parts List Table 11 8 6 amp 8 Cylinder D 2000 and D 3000 Gold Seal Harnesses Index Figure 2 Description Part No 10 821614 6 10 821614 36 10 821615 4 10 821615 20 10 821624
40. 1 4 41 4 4 Nut Hex 10 382618 2 222 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 5 Washer Lock 10 17050 DN 2 2 2 PAR 2 2 2 PME 2 2 2 2 6 Capacitor 6 CYL 10 400576 2 2 Capacitor 8 CYL 10 400578 2 2 Capacitor 4 CYL 10 400574 A 2 2 2 EN 2 7 Pin Cotter 10 90751 18 II 11111 AROS 11111 UN 8 Gasket Cover 10 382811 1 BEN 9 Screw w Lock washer 10 35936 7 414 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 10 Washer Plain 10 14268 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 11 Contact Assembly 10 382585 PZA 2 2 2 NENNEN 2 1 1 NN 111 SES 12 Contact Assembly Main amp Tach 10 400183 JN 1 111 13 Contact Assembly Main amp Retard 10 400184 1 MI 1 1 1 NNI 14 Screw w Lock washer 10 382959 1 1 111 Bae 11111 EMI 10 391213 11 1 1111 111 15 Washer Plain 10 51354 II 11111 NAO 11111 HNOS JN 16 Cam Breaker 2 lobe 10 382544 II UN 1 Cam Breaker 4 lobe 10 382543 EE 1 1 II BM 17 Cam Retard Tach 4 lobe 10 382739 1 II BM Cam Retard Tach 2 lobe 10 382741 3 ea 1 NEENNEN 1 NN 18 Screw w Lock washer 10 35937 20 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 19 DELETED 20 Connector Strip 10 382785 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 21 2 21 Gear Kit 4 amp 8 CYL 10 682014 2 2 2 2 21 2 2 2 2 2 2 Gear Kit 6 CYL 10 682016 2 2 2 DENCNE R 2 2 2 22 Ring Retaining MS16624 2037 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 23 Washer Flat 10 349511 414144 4 14 4 4 4 4 4 4 4 4 4 4 4 4 4 4 24 Brush Car
41. 10 3 Illustrated Parts List Equipment Covered fos uu ea oe Sa cadet aeta tend sait dada fos 11 1 Superseded Discontinued amp Interchangeable Items 11 2 o estos i a a uda deti a ce tins 11 6 Illustrated Parts by Magneto Series eee 11 7 Numerical Parts Lit tetona aid 11 15 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 xiii Xiv Table 1 1 Table 1 2 Table 2 1 Table 2 2 Table 2 3 Table 3 1 Table 7 1 Table 10 1 Table 10 2 Table 11 1 Table 11 2 Table 11 3 Table 11 4 Table 11 5 Table 11 6 Table 11 7 Table 11 8 Table 11 9 JADDEeVIHLIDESI ae ced O Ge son essit bera 1 1 Table of beading Partculars io oque cer abiisse dti oes 1 2 Legacy Magneto Serial Number Code sess 2 8 Current Magneto Serial Number Code since Jan 2001 2 9 D 2000 SUDGESOdULG di 2 10 Troubleshooting Chart iia ias 3 6 Capacitor Test Maltes o ds danos 7 7 Special Tools and Consumable Supplies 10 1 Supplier Contact Information eee 10 2 Equipment Covered ita 11 1 Superseded Discontinued amp Interchangeable Items 11 2 Switch Terminal P Lead Kits eese 11 6 Terminal A 245 acy A ea pue A 11 6 D 2000 Series Magnets saepe te na roe dy i 11 7 D 3000 Series Magnetos tds 11 10 Spare Elbow Leads and 4 Cylinder
42. 10 685124 107 Discontinued 10 684402 106 Discontinued Discontinued 10 685124 108 Discontinued 10 684402 306 Discontinued 10 821614 36 10 685124 109 Discontinued 10 684402 307 Discontinued Discontinued 10 685124 110 10 785124 110 10 684403 303 Discontinued 10 821625 34 10 685124 111 10 785124 111 10 684403 306 Discontinued Discontinued 10 685124 112 10 785124 112 10 684403 307 Discontinued Discontinued 10 685124 113 10 785124 113 10 684404 303 Discontinued Discontinued 10 685124 114 Discontinued 10 684405 303 10 821414 8 Discontinued 10 685124 115 10 785124 115 10 684405 305 Discontinued Discontinued 10 685124 116 10 785124 116 10 684405 307 Discontinued Discontinued 10 685124 117 Discontinued 10 684406 103 10 821414 4 Discontinued 10 685124 118 10 785124 118 10 684406 303 10 821414 4 Discontinued 10 685124 120 Discontinued 10 684407 303 10 821414 10 Discontinued 10 685124 122 10 785124 115 10 684408 302 10 821414 18 10 684800 107 10 821825 2 10 685124 123 10 785124 123 10 684409 102 10 821415 12 10 684800 127 10 821825 2 10 685124 124 10 785124 124 10 684409 106 10 821425 12 10 684801 107 10 821825 2 10 685124 126 Discontinued 10 684410 104 Discontinued 10 684841 127 Discontinued 10 685124 129 10 785124 129 10 684410 124 Discontinued 10 685026 107 Discontinued 10 685124 130 10 785124 130 10 684411 402 10 821414 14 10 685046 102 Discontinued 10 685124 701 Discontinued 10 684412 106 10 821425 12 10 685046 103 Discontinued 10 685124 702 Discontinued 10 6
43. 30 10 382910 13 11 10 821625 4 10 785046 110 D6RN 3200 10 682910 18 D6RN 2230 10 382910 18 11 10 821625 4 10 785046 118 D6LN 3200 10 682910 13 D6LN 2230 10 382910 13 11 10 821625 34 10 785046 119 D6RN 3200 10 682910 18 D6RN 2230 10 382910 18 11 10 821625 34 10 785048 101 D8LN 3200 10 682920 11 D8LN 2200 10 382920 11 15 10 821825 2 10 785124 106 D4LN 3000 10 682555 11 D4LN 2021 10 382555 11 25 10 821414 6 10 785124 110 D4LN 3000 10 682555 11 D4LN 2021 10 382555 11 25 10 821414 8 10 785124 111 D4LN 3000 10 682555 13 D4LN 2021 10 382555 13 15 10 821414 6 10 785124 112 D4RN 3000 10 682555 14 D4RN 2021 10 382555 14 20 10 821414 6 10 785124 113 D4LN 3000 10 682555 15 D4LN 2021 10 382555 15 20 10 821414 6 10 785124 115 D4RN 3000 10 682555 14 D4RN 2021 10 382555 14 20 10 821414 4 10 785124 116 D4LN 3000 10 682555 13 D4LN 2021 10 382555 13 15 10 821414 8 10 785124 118 D4LN 3000 10 682555 13 D4LN 2021 10 382555 13 15 10 821414 10 10 785124 121 D4LN 3000 10 682555 15 DA4LN 2021 10 382555 15 20 10 821414 4 10 785124 123 D4LN 3000 10 682555 11 D4LN 2021 10 382555 11 25 10 821414 18 10 785124 124 D4LN 3000 10 682555 13 DALN 2021 10 382555 13 15 10 821415 12 10 785124 129 D4RN 3000 10 682555 16 15 110821414234 10 785124 130 D4LN 3000 10 682555 13 D4LN 2021 10 382555 13 15 10 821414 14 10 785124 704 D4RN 3000 10 682555 12 D4RN 2021 10 382
44. 31 Grade B Compound Seal between bearing and housing and bearing and Loctite shaft Dykem Stain Red DNC Mark distributor gears Dykem MS 122AD Teflon Dry Lubricant Distributor Gear Teeth Miller Stephenson Permabond 910 Industrial Grade Adhesive Bond Data Plate to Housing Permabond Table 10 2 Supplier Contact Information Company Address Telephone Internet site Dykem ITW Dykem 800 443 9536 buydykem com 805 E Old 56 Highway Olathe KS 66061 Eastern Technology 42 Nelson St 860 528 9821 easterntech com Corporation East Hartford CT Emhart Fastening Teknologies Industrial Division 203 924 9341 emhart com 50 Shelton Technology Center products P O Box 859 Shelton CT 06484 Ideal Industries Becker PI 800 435 0705 idealindustries com Sycamore IL 60178 Kell Strom Tool Company 214 Church Street 800 851 6851 kell strom com Wethersfield CT 06109 860 529 6851 Loctite 1201 Trout Brook Crossing 800 567 8483 henkelna com Rocky Hill CT 06067 Miller Stephenson Chemical 6348 Oakton St 847 966 2022 miller Company Morton Grove IL 60053 800 992 2424 stephenson com Permabond International Englewood NJ 07631 732 868 1372 800 714 0170 Sencore 3200 Sencore Drive 800 736 2673 sencore com Sioux Falls SD 57107 Snap On Tools 2611 Commerce Blvd 877 762 7664 US snap com Birmingham AL 888 451 8665 CAN 01536 413877 UK 1800 811 480 AU Thomas amp Betts 8155 T amp B
45. 385046 115 10 785046 109 10 382610 131 10 682610 131 10 384406 307 Discontinued 10 385046 116 Discontinued 10 382610 161 Discontinued 10 384407 303 10 821414 10 10 385046 117 Discontinued 11 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 2 Superseded Discontinued amp Interchangeable Items Illustrated Parts List Old Part No Superseded By Old Part No Superseded By Old Part No Superseded By 10 382610 221 10 682610 221 10 384408 302 10 821414 18 10 385046 209 10 785046 109 10 382620 10 Discontinued 10 384409 102 10 821415 12 10 385046 216 Discontinued 10 382610 11 10 682610 11 Discontinued 10 385046 217 Discontinued 10 382610 51 10 682610 11 Discontinued 10 385048 101 10 785048 101 10 382650 1 1 Discontinued Discontinued 10 385048 201 10 785048 101 10 382650 111 Discontinued 10 821412 93 10 385048 701 Discontinued 10 382650 121 Discontinued Discontinued 10 385064 114 Discontinued 10 382650 141 Discontinued Discontinued 10 385064 115 Discontinued 10 382725 10 Discontinued Discontinued 10 385086 102 Discontinued 10 385086 103 Discontinued 10 385144 104 Discontinued 10 385246 402 Discontinued 10 385086 108 Discontinued 10 385144 105 Discontinued 10 385256 401 Discontinued 10 385086 209 Discontinued 10 385144 106 Discontinued 10 385286 401 Disco
46. 4602 307 10 821624 6 10 785046 119 10 685126 114 Discontinued 10 684602 323 Discontinued 10 785048 101 10 685144 101 Discontinued 10 684602 327 Discontinued Discontinued 10 685144 102 Discontinued 10 684603 502 Discontinued Discontinued 10 685144 103 Discontinued 10 684604 103 10 821615 4 Discontinued 10 685144 104 Discontinued 10 684604 106 Discontinued Discontinued 10 685144 105 Discontinued 10 684604 109 10 821635 4 Discontinued 10 685144 106 Discontinued 10 684604 126 10 821625 4 Discontinued 10 685144 107 Discontinued 10 684605 106 Discontinued Discontinued 10 685144 108 Discontinued 10 684605 126 Discontinued Discontinued 10 685144 109 Discontinued 10 684606 106 Discontinued Discontinued 10 685144 110 Discontinued 10 685144 111 Discontinued Discontinued 10 685186 108 Discontinued 10 685144 112 10 785144 114 Discontinued 10 685186 109 10 785186 109 10 685144 113 Discontinued Discontinued 10 685224 701 Discontinued 10 685144 114 10 785144 114 Discontinued 10 685226 401 Discontinued 10 685146 101 Discontinued 10 785148 102 10 685236 401 Discontinued 10 685146 102 Discontinued 10 785148 102 10 685242 701 Discontinued 10 685146 103 Discontinued Discontinued 10 685246 401 Discontinued 10 685146 104 Discontinued 10 785164 112 10 685256 401 Discontinued 10 685146 105 Discontinued 10 785164 113 10 685286 402 10 785286 402 10 685146 106 10 785146 106 Discontinued 10 685296 401 Discontinued 10 685146 107 Discontinued 10 685164 115 Discontinued 10 68
47. 5 is restricted Remove the orifice clean the hole of obstructing material reinstall the orifice and retest IGNITION SYSTEM ELBOW P N MS20822 4 REGULATED OUTPUT FITTING REGULATED PRESSURE GAUGE G1 AIR INPUT FITTING OUTPUT 100 PSI MAX PRESSURE REGULATOR TUBE ASSY 11210087 CAP AIR VALVE LEVER UP OPEN TESTER Figure 3 2 Pressurized Magneto Test Stand Block Diagram 3 3 Harness Testing 1 Using continuity circuit of 11 8950 2 lead tester test for continuity between each spark plug terminal spring Figure 2 2 and its respective eyelet 12 Proper assembly may be confirmed by comparing engine manufacturer s recommendations for lead routing and firing order with spark plug numbers marked on identifier tags on each lead and arrangement of leads in the cover 16 Continuity must be observed between each outer ferrule 8 or 13 and elbow Figure 2 15 to the cover 16 Check for continuity between the threaded portion of each capacitor Figure 1 6 and the cover Figure 2 16 3 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Sw Testing amp Troubleshootin 2 Using 11 8950 2 high tension lead tester check harness leads for high voltage breakdown as follows a Connect red high voltage test lead to spark plug terminal spring Figure 2 2 Connect black ground lead of tester to the ferrule 8 elbow 15 or cover 16 b Depress PUSH TO TE
48. 5296 402 Discontinued 10 685146 108 Discontinued 10 685166 102 Discontinued 10 685296 403 Discontinued 10 685146 109 Discontinued 10 685166 104 Discontinued 10 785124 131 10 785124 106 10 685146 110 Discontinued 10 685166 107 10 785166 107 10 820414 6 10 821414 6 10 685146 111 10 785146 111 10 685184 101 Discontinued 10 685146 112 Discontinued 10 685186 102 Discontinued D 2000 D 3000 Series High Tension Magneto Service Support Manual 11 5 31 August 2011 Illustrated Parts List 11 3 Switch Terminal Kits Table 11 3 Switch Terminal P Lead Kits Kit Number Description Application Code One each for pressurized magnetos with 10 382813 retard contacts Kit Pressurized Retard Terminal Table 11 4 Terminal Kit Spares Figure 11 1 Quantity Index Part Number Description Use Code Required 10 157212 Bushing Insulated B C 1 10 157213 Bushing Shouldered All 1 10 157211 Nut Coupling 0 4375 28 AC 1 4 1 5 Figure 11 1 Terminal Kit Spares 11 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List 11 4 Illustrated Parts by Magneto Series Table 11 5 D 2000 Series Magnetos coses enla LO f LO LO LO LO LO CD O LN C O O O JO lO O O 2 lS e S ig 8 EE EE d eag Figure 1 Sis
49. 555 12 25 10 821412 93 10 785126 105 D6LN 3000 10 682560 11 D6LN 2031 10 382560 11 15 10 821614 6 10 785126 107 D6LN 3000 10 682560 13 D6LN 2031 10 382560 13 10 10 821614 6 10 785126 109 D6LN 3000 10 682560 13 D6LN 2031 10 382560 13 10 10 821615 4 10 785126 111 D6LN 3000 10 682560 13 D6LN 2031 10 382560 13 10 10 821615 20 10 785126 112 D6LN 3000 10 682560 11 D6LN 2031 10 382560 11 15 10 821614 36 10 785144 114 D4LN 3200 10 682605 13 D4LN 2200 10 382605 13 20 10 821425 12 10 785146 106 D6LN 3200 10 682610 11 D6LN 2230 10 382610 11 15 10 821624 6 10 785146 111 D6LN 3200 10 682610 13 D6LN 2230 10 382610 13 11 10 821624 6 10 785148 102 D8LN 3200 10 682620 11 D8LN 2200 10 382620 11 15 10 821825 2 10 785164 112 D4RN 3000 10 682555 141 D4RN 2021 10 382555 141 20 10 821444 6 10 785164 113 D4LN 3000 10 682555 151 D4LN 2021 10 382555 151 20 10 821444 6 10 785166 107 D6LN 3000 10 682560 131 10 10 821644 6 10 785186 109 D6LN 3200 10 682610 131 D6LN 2230 10 382610 131 11 10 821635 4 10 785286 402 D6RN 3200 10 682610 221 D6RN 2230 10 382610 221 19 10 821635 11 1 Available only until current supply is exhausted D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List 11 2 Superseded Discontinued amp Interchangeable Items Table 11 2 Superseded Discontinued amp Interchangeable Items
50. 6 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance d Insert a feeler gauge between the stop pin and flyweight to determine clearance X of Figure 6 7 while the flyweight is forced outward Maintain constant outward force on the flyweight while measuring clearance to ensure accuracy e Remove the wire to relax the flyweight Add 0 014 feeler gauge to the X value Figure 6 8 Attempt to pass an X plus 0 014 feeler gauge between the flyweight and stop pin If the feeler gauge passes remove and discard the worn cam assembly STOP e PIN hs o BODY TRIP DOG EAR Figure 6 7 Flyweight to Axle Wear Check X PLUS 0 014 NOT PERMISSIBLE 27 t STOP M p Figure 6 8 X Value Measurement 2 If the impulse coupling fails to successfully pass any of the preceding checks replace the entire impulse coupling assembly or worn parts Replace the spring Figure 1 41 whenever the impulse coupling is disassembled 3 Inspect the stop pins in the magneto flange or housing A shiny spot at the point of flyweight contact is acceptable a step catch at this point is unacceptable A damaged or worn stop pin is cause for replacement of the magneto stop pin or flange depending on extent of damage or wear D 2000 D 3000 Series High Tension Magneto Service Support Manual 6 7 31 August 2011 Periodic Maintenance 6 2 3 500 Hour Inspection 6 8 l
51. 789 Screw Socket Head 1 46 10 382790 1 Coil Magneto 1 58 10 382799 1 Magnet Rotating 1 48 10 382799 2 Magnet Rotating 1 48 10 382811 Gasket 1 8 11 15 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 9 Numerical Parts List Part No Description Fig Ind 10 382861 Orifice Threaded 1 62 10 382881 Screw 1 1 10 382935 Plate Coil Retaining 1 55 10 382937 Screw 1 54a 10 382939 Kit Coil Securing 1 10 382969 Bushing 1 53 10 391309 Washer Nylon 1 25 10 400042 Spring Flat Spiral 1 4 10 400053 2 Clamp 2 3 wire 2 24 10 400056 1 Clamp 6 wire 2 26 10 400060 2 Bracket 2 27 10 400060 7 Bracket 2 27 11 16 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 lllustrasted Parts List D 3000 MAGNETO EXPLODED VIEW gt gt Z N Of z A Item 21 Gear Kit includes circled items B Item 27 Block Kit includes under lined items Figure 1 D 3000 Series Magneto Exploded View D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 11 17 Reverse Blank D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrasted Parts List 3 4 20 TERMINAL 3 4 6 g 9 ne 5 We 10 ies REL y 16 7 lt TA 9 4 CB pr a op AU He Pe Ay us d 7 11 12 Items 7 11 12 are included in
52. 84441 603 Discontinued 10 685046 104 Discontinued 10 685124 703 Discontinued 10 684442 603 Discontinued 10 685046 105 Discontinued 10 685124 704 10 785124 704 10 684443 603 Discontinued 10 685046 106 Discontinued 10 685124 705 Discontinued 10 684444 602 10 821412 93 10 685046 107 Discontinued 10 685126 101 Discontinued 11 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 2 Superseded Discontinued amp Interchangeable Items Old Part No Superseded By Old Part No Superseded By Old Part No Superseded By 10 684445 602 Discontinued 10 685046 108 Discontinued 10 685126 102 Discontinued 10 684600 106 Discontinued 10 785046 109 10 685126 103 Discontinued 10 684601 106 Discontinued 10 785046 110 10 685126 104 Discontinued 10 684601 108 Discontinued Discontinued 10 685126 105 10 785126 105 10 684601 126 Discontinued Discontinued 10 685126 106 Discontinued 10 684601 128 Discontinued Discontinued 10 685126 107 10 785126 107 10 684602 302 Discontinued 10 785046 110 10 685126 108 10 785126 107 10 684602 303 10 821614 6 10 785046 109 10 685126 109 10 785126 109 10 684602 304 Discontinued Discontinued 10 685126 111 10 785126 111 10 684602 305 10 821644 6 Discontinued 10 685126 112 10 785126 112 10 684602 306 Discontinued 10 785046 118 10 685126 113 Discontinued 10 68
53. 85124 119 Discontinued 10 385146 112 Discontinued 10 682610 10 Discontinued 10 385124 120 Discontinued 10 385146 113 Discontinued 10 682610 12 Discontinued 10 385124 121 10 785124 121 10 385146 114 Discontinued 10 682610 14 Discontinued 10 385124 122 10 785124 115 10 385146 115 Discontinued 10 682610 15 Discontinued 10 385124 123 10 785124 123 10 385146 116 Discontinued 10 682610 16 Discontinued 10 385124 124 10 785124 124 10 385146 117 Discontinued 10 682610 18 Discontinued 10 385124 126 Discontinued 10 385147 701 Discontinued 10 682610 20 Discontinued 10 385124 127 Discontinued 10 385148 101 10 785148 102 10 682610 101 Discontinued 10 385124 128 Discontinued 10 385148 102 10 785148 102 10 682610 161 Discontinued 10 385124 701 Discontinued 10 385148 201 10 785148 102 10 682620 10 Discontinued 10 385124 702 Discontinued 10 385148 202 10 785148 102 10 682650 11 Discontinued 10 385124 703 Discontinued 10 385164 112 10 785148 102 10 682650 111 Discontinued 10 385124 704 10 785124 704 10 385164 113 10 785148 102 10 682650 121 Discontinued D 2000 D 3000 Series High Tension Magneto Service Support Manual 11 3 31 August 2011 Illustrated Parts List Table 11 2 Superseded Discontinued amp Interchangeable Items Old Part No Superseded By Old Part No Superseded By Old Part No Superseded By 10 385124 705 Discontinue
54. 90751 18 Pin Cotter 1 7 10 90788 5 Key Woodruff i amp 10 91431 8 Screw 2 28 10 92815 37 Ring Retaining 1 22 10 92815 62 Ring Retaining 1 43 10 92879 43 Washer Lock 1 2 10 116860 Washer Plain 1 36 10 157134 Plug Ventilator 1 59 10 157135 Plug Solid 1 60 10 160844 Brush Carbon 1 24 10 163012 Eyelet 2 12 10 163048 Bushing Drive 1 34 10 163178 Nut Cap 1 32 10 163194 Paper Retard 1 24 10 163374 Strip Felt 1 28 Part No Description Fig Ind 10 320163 Grommet 2 31 10 320467 Terminal 2 3 10 320468 Terminal 2 3 10 320473 Sleeve 2 4 10 320573 3 X Elbow Assembly 110 2 15 10 320777 Grommet 2 11 10 349248 Slinger Oil 1 49 10 349249 Washer Bowed 1 45 10 349328 Washer Plain 1 44 10 349932 3 Driveplate 1 37 10 349932 4 Driveplate 1 37 10 349932 9 Driveplate 1 38 10 382543 Cam Breaker 4 lobe 1 16 10 382544 Cam Breaker 2 lobe 1 16 10 382568 Strip i 57 10 382573 Gear Spur 1 52 10 382575 Gear Spur ES 10 382585 Contact Assembly 1 11 10 382588 1 Coil Magneto 1 58 10 382618 Nut 1 4 10 382739 Cam 4 Lobe Retard 1 17 10 382741 Cam 2 Lobe Retard 1 17 10 382747 Body Impulse Coupling 1 40 10 382748 Body Impulse Coupling 1 40 10 382749 Body Impulse Coupling 1 40 10 382767 Body Impulse Coupling 1 40 10 382768 Body Impulse Coupling 1 40 10 382785 Strip Connector 1 20 10 382787 Plate Bearing Retainer 1 a 10 382788 Washer Plain 1 47 1 54b 10 382
55. 940 131 Discontinued 10 384606 303 10 821614 6 10 382590 11 Discontinued 10 382940 161 Discontinued 10 384606 307 Discontinued 10 382605 10 Discontinued 10 382960 13 Discontinued 10 384670 102 Discontinued 10 382605 11 Discontinued 10 384241 106 Discontinued 10 384670 106 Discontinued 10 382605 12 Discontinued 10 384242 106 Discontinued 10 384670 108 Discontinued 10 382605 13 10 682605 13 Discontinued 10 384671 106 Discontinued 10 382605 14 Discontinued 10 821414 6 10 384671 108 Discontinued 10 382605 17 10 682605 13 Discontinued 10 384700 607 Discontinued 10 382605 18 Discontinued Discontinued 10 384800 107 10 821825 4 10 382605 151 Discontinued Discontinued 10 385026 107 Discontinued 10 382610 10 Discontinued Discontinued 10 385046 102 Discontinued 10 382610 11 10 682610 11 Discontinued 10 385046 103 Discontinued 10 382610 12 Discontinued Discontinued 10 385046 104 Discontinued 10 382610 13 10 682610 13 Discontinued 10 385046 107 Discontinued 10 382610 14 Discontinued Discontinued 10 385046 108 Discontinued 10 382610 15 Discontinued Discontinued 10 385046 109 10 785046 109 10 382610 16 Discontinued Discontinued 10 385046 110 10 785046 110 10 382610 18 Discontinued Discontinued 10 385046 111 Discontinued 10 382610 20 Discontinued 10 821414 8 10 385046 112 Discontinued 10 382610 22 Discontinued Discontinued 10 385046 113 Discontinued 10 382610 101 Discontinued 10 821414 4 10 385046 114 10 785046 110 10 382610 121 Discontinued 10 384406 303 10 821414 4 10
56. Assemblies 08 94 627 Distributor Block Kit Part Number 10 682056 6 Cylinder Dual Magneto Series 06 85 628 Replace of impulse Coupling Main Spring P N 10 382941 05 85 629 Inspection and replacement of Certain Bendix Aircraft magneto Brown Distributor Blocks as Used on 07 89 Turbocharged Six 6 Cylinder Engines 631 Recommended Lubricant for Tapered Drive on TCM Magnetos 09 89 635 Gold Seal Harnesses 05 91 639 Proper Installation of Impulse Couplings 03 93 640 New Service Document Format 02 94 SIL642A Manufacturing Number Serial Number Interpreting 02 94 SB643B Maintenance Intervals for all TCM and Bendix Aircraft Magneto and Related Equipment 04 05 MSB644 Replacement of Magneto Coils and Rotating Magnets 04 94 MSB645 Inspection of Riveted Impulse Couplings and Stop Pins 04 94 SIL648 Optional Conversion to Shower of Sparks Ignition 10 94 D 2000 D 3000 Series High Tension Magneto Service Support Manual i 31 August 2011 Bulletin Bulletin Title Issue Date Number SB651 Capacitor information and Installation D 2000 and D 3000 Series Magnetos 03 95 SB652 Impulse Coupling Configuration and maintenance for All Type D6LN 2031 Magnetos 03 95 SB653 Hot Magneto Test 05 95 SB655 Improved Ball Bearing P N 10 400605 for Pressurized S 1200 D 2000 AND D 3000 Magnetos Formerly using Standard Bearing P N 10 353056 12 95 SB658 Distributor Gear Maintenance 08 96 SB661 BL Prefix marking on Rebuilt Magnet
57. Bearing Kit 8 CYL 10 682058 28 Strip Felt 10 163374 29 Spring Helical 10 50737 30 Bearing Roller 10 400553 31 Washer Plain 10 685548 D 2000 D 3000 Series High Tension Magneto Service Support Manual 11 7 31 August 2011 Illustrated Parts List Table 11 5 D 2000 Series Magnetos SS eee Sele eee ee 5555552259222 amp 8228 amp Cd SA ed A N fet A ed Cd lew ew lew ed EM lew AA A Figure 1 e e leo leo leo leo leo lea ea lea le e9 eo e leo e le eo index Description PartNo l l l el l l elel elelee 32 Nut Castellated 10 51643 10 163178 1 33 Washer Lock 10 3793 34 Bushing Drive 10 163048 1 35 Key Woodruff 10 90788 5 2 Washer Plain 10 4093 36 10 52307 10 116860 37 Driveplate 10 349932 2 1 10 349932 3 38 Driveplate 10 349933 9 Coupling Impulse CCW 25 10 400323 Coupling Impulse CW 20 10 400311 39 Coupling Impulse CCW 15 10 400322 Coupling Impulse CCW 20 10 400324 Coupling Impulse CCW 15
58. Block and Gear Assembly 1 Mark gears Figure 1 21 to identify magneto rotation according to instructions in Section 7 2 2 Generously apply an even coating of MS 122AD dry lubricant to the gear teeth Repeat for second gear This procedure will provide sufficient lubrication for the gears Excess lubricant will be thrown off during magneto operation which may lead to service difficulty due to contamination Install one insulating washer 25 onto each gear axle Install one plain steel washer 23 on top of each insulating washer Slide the clean and dry gear axle in to the distributor block bushing Install one plain steel washer 23 over the protruding axle end and reservoir felt washer 26 Repeat for the second gear 21 Using No 2 retaining ring pliers install new retaining rings 22 with sharp side facing out into the axle grooves Check for freedom of gear rotation by turning each gear through several complete revolutions Install new carbon brush and spring assemblies 24 in each gear axle by rotating carbon brush clockwise Brushes must move freely up and down in the axle hole after assembly D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 9 31 August 2011 Assembl 9 2 6 Distributor Block and Gear Installation 9 10 1 Using the appropriate view in Figure 9 6 as a guide align the proper red dot of each distributor gear with the timing mark dot on the distribut
59. Boulevard 901 252 8000 tnb com Memphis TN 38125 800 816 7809 10 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Special Tools Equipment and Supplies Table 10 2 Supplier Contact Information Telephone Internet site 908 859 4266 truarc com 800 526 7055 Company Address Waldes Tru Arc Division Waldes Kohinoor Inc Long Island City NY 11101 10 2 Illustrated Special Tools and Fixtures FLAT FACE 210 ry 250 500 DIA MIN Figure 10 1 Eyelet Pressing Tool 3 0 IN MIN DRILL NO 47 TO 0 25 IN DEEP TAP 3 48 BLEND O D TO I D POLISH O D 25 IN 3 0 IN MIN MATERIAL NO 30 DRILL ROD OR EQ Figure 10 2 Harness Assembly Tool 000 1 312 005 qd i a 0 id 69 01 Dia Figure 10 3 11 1471 Drift D 2000 D 3000 Series High Tension Magneto Service Support Manual 10 3 31 August 2011 Special Tools Equipment and Supplies 000 625 DIA 997 031x 45 031x45 747DIA 985DIA 1 109 DIA 001 002 1 000 375 015 x45 506 MATERIAL 001 STEEL AMS 5062 Figure 10 4 11 9998 Bearing Pressing Tool 250 250 BREAK SHARP EDGE 003 005 1 010 DIA 031x 45 1 040 DIA 002 1 375 DIA 000 625 1138 DIA SUUS 000 DRILL POINT 1 188 DIA 005 PERMISSIBLE MATERIAL STEEL AMS 5062 Figure 10 5 11 9999 Bearing Pre
60. Crimp terminal only once to produce a joint capable of withstanding 15 lb pull test Avoid damage to the threaded portion of the terminal 5 Crimp the terminal 3 on the conductor using the modified WT 111M Crimping Tool 6 Place outer ferrule 13 over terminal 3 past insulation and onto shielding of cable 7 Place inner ferrule 14 over terminal 3 past the insulation and under the cable shielding 8 Feed terminal 3 through elbow 15 9 Tighten the elbow nut 15 on the outer ferrule 13 to seat ferrule 14 Remove excess jacket material and loosen the nut until the harness is installed on engine 10 Slide sleeve 4 over insertion tool as shown in Figure 9 25 Slide the eyelet Figure 2 5 and spring 6 over sleeve 4 The tapered side of eyelet 5 must rest against the taper on the sleeve 4 SPRING RETAINER ASSEMBLY SLEEVE Figure 9 25 Ignition Harness Assembly Tool 11 Assemble spring Figure 2 2 and terminal 3 with a clockwise twisting motion 12 Clean the spark plug terminal according to the instructions in Section 5 3 13 Test the ignition lead according to instructions in Section 3 3 D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 29 31 August 2011 Assembl 9 4 Harness to Magneto Installation 9 30 1 Install capacitors in housing a Ensure capacitor mounting area in cover Figure 1 16 is clean and free of corrosion Brighten inside and outside
61. D 2000 D 3000 Series High Tension Magneto CONTINENTAL IGNITION SYSTEMS SERVICE SUPPORT MANUAL po o E m was Technical Portions Approved by the FAA Publication X42003 3 92011 CONTINENTAL MOTORS INC AUG 2011 Supersedure Notice This manual is a revision of the service instructions contained in X42003 2 published in July 2010 Upon FAA approval and release of this document all previous versions of X42003 are superseded and should not be used for Continental Motors D 2000 D 3000 magneto service maintenance or overhaul Effective Changes for this Manual Ova dies 31 August 2011 List of Effective Pages Document Title D 2000 D 3000 Series High Tension Magneto Service Support Manual Publication Number X42003 3 Initial Publication Date 31 August 2011 Page Change Page Change Page Change Page Change COVOF spissa 0 caos 0 DV 0 1 1 thru 1 2 0 2 1 thru 2 10 0 3 1 thru 8 8 0 4 1 thru 4 8 0 5 1 thru 5 2 0 6 1 thru 6 10 0 7 1 thru 7 12 0 8 1 thru 8 2 0 9 1 thru 9 34 0 10 1 thru 10 6 0 11 1 thru 11 18 0 Published and printed in the U S A by Continental Motors Inc Available exclusively from the publisher P O Box 90 Mobile
62. D 2000 and D 3000 Gold Seal Harnesses sendos 11 13 6 amp 8 Cylinder D 2000 and D 3000 Gold Seal Harnesses 11 14 Numerical Parts VASE aos 11 15 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 Figure 7 11 Figure 8 1 Figure 8 2 Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 LIST OF ILLUSTRATIONS D 3200 Magneto and Associated Components 2 1 Magneto Model Number Elements esee 2 2 Sample Magneto Circuit with Starting Vibrator Schematic 2 3 Lead Termination Detail 1 aee een 2 4 Harness Outlet Cover Configuration sees 2 5 Gold Seal Cable iiec e eet ea 2 5 NIaeneto Data PIA socrus aa 2 8 5mm Spark Gap Setting nct PRU Pond ee isse a eR RS UR 3 2 Pressurized Magneto Test Stand Block Diagram 3 4 Spring Engaged with Cam cccssscsessscsessscsenscceensecesneccesneees 4 3 Coupling Cam Removal 0 5 scssssisendcacascec
63. E Tighten the adjusting knob of the 11 8465 Rotor Holding Tool only enough to hold magnet shaft firmly in desired position Over tightening the adjusting knob may cause damage to the drive end bearing If equipped adjust the tachometer contact point gap to 0 019 0 003 in at the highest point on the cam lobe Inspect the magneto cover 16 for damage Check capacitors 1 6 for security of flag terminal boot and threaded tip Inspect the capacitor lead for chafed insulation Using clean dry compressed air clean as necessary and replace any damaged component s See appropriate procedures in Section 4 2 2 and Section 9 4 if capacitor replacement is necessary CAUTION When utilizing compressed air wear OSHA approved protective eye wear Never exceed 30 psi when using compressed gases for cleaning purposes OSHA 1910 242 b Clean and inspect the harness lead wires spark plug terminal ends clamps and related fasteners for damage or wear Replace damaged or worn parts according to Section 9 3 Replace missing terminal eyelets Figure 2 12 on the harness wires before reinstalling the ignition harness onto the magneto Check the harness grommets 11 for signs of tears or burns Replace as necessary according to instructions in Section 9 3 Test the capacitor according to instructions in Section 7 2 5 Form capacitor and coil leads and install the magneto cover 16 with a new gasket 8 if installed on the housing 66 accordi
64. E OF CONTENTS Introduction and Specifications Geral iii ais 1 1 Specifications sostenido D bblastsohtu ta sasique attendee E casa 1 2 Description and Operation General osi asd pog gabe none a egre tenes E geen Oe 2 1 Detaled DESeri pun sse to ee EET EUG A eanateng A 2 2 Maintenance and Overhaul Periods esee 2 6 D 2000 and D 3000 Magneto Operation eee 2 6 2 4 1 General Theory of Operation tesse e e ee E E E EE ER 2 6 2 4 2 Operation of D 3200 Magneto System with Starting Vibrator 2 7 Serial NUMDETS saccades a a dti A nia a E etate 2 8 Part N MDETS ahonnan n Ee E A EA 2 9 D 2000 Series Magneto Difference Data eene 2 10 cp C M HT 2 10 Testing amp Troubleshooting e lc e 3 1 Post Overbaul TESTIS 552553550698 dde 3 2 Harness Testing POP 3 4 Hot Magneto Tetuan ases 3 5 A A O E 3 5 Disassembly lr n 4 1 Detailed Disassembly Procedures seen 4 4 2 1 Initial Inspection Disassembly 0 0 0 eescescecsseeeseceeeeceseeencecencessecenceceeeecseeeseecnees 4 1 4 2 2 General Overhaul Disassembly essere 4 2 4 2 3 Drive Plate and Front End Hardware Disassembly sese 4 2 4 2 4 Impulse Coupling Disassembly sese 4 2 4 2 5 Rotating Magnet Disassembly
65. If not previously accomplished modify the housing to accommodate the coil securing kit a Prepare two lengths of 1 4 in steel rod approximately 3 5 in long and grind to a 45 point on both rods so they can be used as center punches b Position a coil Figure 1 58 in the housing 66 and insert both rods point down in each of the circular recesses between the coil core and the housing CAUTION Use only enough force in tapping the center punch rods to make an indent c Visually center the coil and hold it against the pole shoe extensions Tap each rod to produce a center punch indent on the housing inner surface 9 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl d e f Remove the coil and center punch rods and repeat steps b and c for the coil at the opposite end of the housing Using a No 14 0 182 in dia drill in a drill press drill through the housing at each of the center punch marks to produce clearance holes for an 8 32 UNEF 2A screw CAUTION Remove only enough material from the housing to produce a flat counterface Using a 5 16 in counterbore with a 0 182 in dia pilot counterface the outside of the housing to obtain a flat seating surface at each of the four screw hole locations Thoroughly clean the housing of all chips and foreign material then paint the newly machined counterface surfaces 2 Install and secure coils using 10 382939 k
66. NSULATING WIRE BUSHING 4 047 SOLDER SHOULDERED RETARD TACH BUSHING 609 010 Figure 9 28 Terminal Kit Assembly 7 If used secure elbow nuts Figure 2 15 to ferrule 13 in final position or assemble elbow clamps 17 as shown in Figure 9 29 8 For pressurized ignition systems only following ignition system installation or anytime magneto or magneto harness is removed or replaced check the integrity of the magneto pressurization system according to instructions in Textron Lycoming Service Instruction 1308D or later revision CLAMP IGNITION SECONDARY CLAMP CABLE 10 400107 SECONDARY CLAMP PRIMARY FERRULE CLAMP UE A PRIMARY SCREW NUT 10 400105 10 35936 6 10 90404 4 RETENTION SCREW amp NUT TCM GOLD SEAL 3 4 20 SPARK PLUG TERMINAL SHOWN FOR REFERENCE Figure 9 29 Elbow Kit Assembly D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 33 31 August 2011 Assembl Intentionally Left Blank 9 34 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Special Tools Equipment and Supplies Section 10 Special Tools Equipment and Supplies Refer to Figure 10 1 for a list of special tools fixtures equipment and consumable supplies Figure 10 3 through Figure 10 9 illustrate fabrication of special for disassembly assembly and adjustment All linear dimensions are in specified otherwise NOTE Tools specified in this manual are lis
67. Release Coupling CAUTION Do not strike the puller with a hammer If puller is struck with hammer magneto ball bearings must be replaced Do not tighten puller handle further after coupling cam releases from shaft This could damage a flyweight if flyweight is caught under woodruff key D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl 6 Remove puller Holding the toe of the flyweight inward lift the cam from rotating magnet shaft See Figure 6 3 for flyweight terminology 7 Remove the woodruff key s Figure 1 53 from the rotating magnet shaft and discard the woodruff key 4 2 5 Rotating Magnet Disassembly 1 Unseat retaining ring Figure 1 43 using No 2 pliers Remove and discard the ring 43 Remove flat washer 44 and bowed washer 45 Using two offset screwdrivers or similar small prying tools pry the oil slinger 49 evenly off the rotating magnet 48 2 Remove and discard the four front bearing retainer securing screws 46 and four sealing washers 47 Loosely install the nut 32 on the rotating magnet shaft to protect the threads Using arbor press press the rotating magnet 48 front bearing 50 and bearing retainer 51 from housing 66 ensuring housing has adequate support and shaft is not damaged when it falls free 4 2 6 Bearing Removal 1 Fabricate two support bars and a support plate similar to the ones shown in Figure 10 6 and Figure 4 4 r
68. ST switch c Verify the INDICATOR lamp flashes and GAP fires simultaneously as long as the switch is depressed If the INDICATOR lamp fires and GAP fails to fire the lead under test is malfunctioning and must be replaced 3 4 Hot Magneto Test 1 In addition to performing all magneto related operational checks as specified by engine and or airframe manufacturers prior to each engine shut down and prior to performing any maintenance on the engine perform the Magneto RPM drop off Test according to the AFM POH normally found under Preflight Engine Run Up Procedures 2 Ifno RPM drop is noted when a magneto is individually selected either the magneto selected is timed far in advance of the other magneto or the primary circuit between the alternate magneto and airframe ground is mis wired or faulty Either condition must be remedied before further flight and before moving the propeller by hand 3 Shut down the engine according to the instructions in the AFM POH 3 5 Troubleshooting WARNING Turn the Ignition Switch OFF disconnect engine electrical power and confirm continuity between the magneto capacitor and aircraft ground before commencing maintenance or inspections to avoid uncommanded engine starts during maintenance Do not stand or place equipment within the arc of the propeller If there is evidence of discontinuity in the magneto grounding circuit inspect circuit connections for cleanliness and tightness inspect wire an
69. Seal Eyelet 5 and Gold Seal Spring 6 only when using Gold Seal Outer Ferrule 8 3 Use P N 10 620109 7a inner ferrule only to service Bendix Blue and Dura Blue Harnesses with original outer ferrules and outlet plates Use Retention Eyelet 7 only to service Gold Seal Harnesses 9 3 2 Lead Assembly Replacement Except for 3 4 20 Elbow types spare lead kits Figure 2 1 are supplied with spark plug terminals fully assembled For replacement of 3 4 20 elbow leads salvage spring 6 eyelet 5 and elbow 15 purchase spring 2 and sleeve 4 separately 1 Disassemble the harness as necessary to remove the damaged lead Press the old ferrule 7 or 7a from the cover 16 using 0 25 inch drift Measure lead length and cut the new lead slightly longer 2 Insert 11 9596 nylon tube between shielding and insulation to approximately 1 5 inch depth as illustrated in Figure 9 21 9 24 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Braid Cut 11 9596 Insulation Figure 9 21 Lead Preparation 3 Assemble the Gold Seal eyelet 7 into Gold Seal Harness Cover 16 a With 11 9596 nylon tube acting as a protective sleeve cut off 7 8 in of shielding and scrape off 3 16 to 1 4 in of the silicone covering from the remaining shielding Remove the 11 9596 nylon tube b Cut and remove 5 16 in insulation from the conductor Figure 9 22 to facilitate crimping of
70. aft The gear must not move 4 Using an arbor press 11 1471 drift and wooden support press bushing 53 over the shaft until it seats against the gear 52 9 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 9 2 3 Install Bearing and Magnet in Housing CAUTION Use extreme care when working with the bearing to avoid disturbing lip of seals where they contact the inner race 1 Place the magnet assembly in the wooden support block Figure 10 8 with the gear resting on the block Place a new retainer plate recessed side toward the bearing over the magnet shaft Figure 1 48 Apply Loctite grade B compound to the bearing 50 inner diameter Using an arbor press and 11 1471 drift press the bearing 50 on to the shaft until it is firmly seated against the magnet shoulder Coat pole pieces of rotating magnet lightly with rust preventative or clean SAE 30W oil 2 Using a clean lint free cloth soaked with isopropyl alcohol and a pointed non metallic tool clean the Loctite residue from the bearing bore of the housing Allow alcohol to evaporate Apply a light coating of rust preventative or clean SAE 30W oil to the surfaces of the four pole shoes in the housing Place the housing assembly flange end down on the work block Install the rotating magnet assembly in the housing with the tabs of the bearing retainer plate 51 facing toward the coils Using hand pressure push on rotor asse
71. agnetize rotor Kell Strom 11 10900 Air Flow Tester Test magneto pressurization system Kell Strom 30 501 Crimping Tool Crimp lead splice eyelet strip wires Ideal Industries Fluke Test coil Commercial off the shelf CG240 Puller Remove drive plate or cam Snap On E 50 Timing Light or equivalent Check magneto to engine timing T chnolooy Corp LC 103 Capacitor Tester Test capacitor Sencore No 2 Retaining ring pliers Remove retaining ring Waldes Tru Arc e A MOI QE PCM Crimps eyelets and terminals onto cable Thomas amp Betts Consumable Supplies 646943 Anti seize Lubricant Prevent drive members from locking on rotating Continental magnet shaft taper Motors D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 10 1 ee Special Tools Equipment and Supplies i Table 10 1 Special Tools and Consumable Supplies Part Number and Description Application Source 10 400419 3 Coil Lead and Repair Kit Continental Motors 10 86527 High Temperature Lubricant Contact assemblies cam follower felt Continental Motors 10 70506 10S Protective Caps 4 required Protect bushing during coating of block Continental Motors 10 391200 Distributor Block Lubricant Distributor block bushings Continental Motors 10 391400 Distributor Block Coating Apply to Black distributor blocks to inhibit moisture Continental sheeting on dielectric Motors Loctite 85
72. bon 10 160844 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 25 Washer Nylon 10 391309 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 26 Washer Felt 10 50752 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 27 Block amp Bearing Kit 4 CYL 10 682054 II REGERE 1 Block amp Bearing Kit 6 CYL 10 682056 1 1 1 IERE 1 1 Block amp Bearing Kit 8 CYL 10 682058 1 1 28 Strip Felt 10 163374 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 29 Spring Helical 10 50737 8 8 8 8 8 8 8 8 12 12 12 8 12 12 12 12 16 12 12 16 30 Bearing Roller 10 400553 II i 1 1 HNOS 11111 HN 1 MN 31 Washer Plain 10 685548 414144 4 14 4 4 4 4 4 4 4 4 4 4 4 4 4 4 32 Nut Castellated 10 51643 1 10 163178 1 E 111 11 NIB 11111 MN 111 MN 33 Washer Lock 10 3793 1 1 11 10 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 6 D 3000 Series Magnetos Illustrated Parts List Figure 1 Index Description Part No 34 Bushing Drive 10 163048 35 Key Woodruff 10 90788 5 36 Washer Plain 10 4093 10 52307 10 116860 37 Driveplate 10 349932 2 10 349932 3 38 Driveplate 10 349933 9 39 Coupling Impulse CCW 252 10 400323 Coupling Impulse CW 20 10 400311 Coupling Impulse CCW 15 10 400322 Couplin
73. butor block and remove the protective caps from the bronze bushing 8 Treat the distributor block according to the instructions in Section 7 2 4 5 3 Ignition Harness Cleaning WARNING Isopropyl Alcohol IPA is Flammable Do not use near an ignition source Use only with adequate ventilation Use appropriate personal protective equipment to protect eyes skin and clothing from exposure Avoid breathing IPA vapors Store IPA only in approved containers CAUTION When utilizing compressed air wear OSHA approved protective eye wear Never exceed 30 psi when using compressed gases for cleaning purposes OSHA 1910 242 b Use of chlorinated solvents Ex Tuner Cleaner for cleaning any portion of the harness may result in a chemical reaction which will dissolve the insulating sleeves 4 grommets 11 or silicone portion of the cable 10 1 Wipe the insulating sleeves 4 and springs 2 with a clean lint free cloth moistened with isopropyl alcohol to remove dust dirt and debris CAUTION Do not immerse the harness in cleaning solution 2 Wipe the exterior of the harness with a clean lint free cloth moistened with isopropyl alcohol to remove dust dirt and debris CAUTION When utilizing compressed air wear OSHA approved protective eye wear Never exceed 30 psi when using compressed gases for cleaning purposes OSHA 1910 242 b 3 Dry the ignition harness parts with compressed air 5 2 D 2000 D 3000 Series High
74. ccessory drive adapter thro gi th lt Cas amp magneto pad opening 2 Remove the nuts 10 amp 11 lock washers 8 amp 9 and washers 6 amp f Remove the accessory drive assemblies from the rear of the c case Discard tye lock washers 8 amp 9 Remove and discard the gasket 1 and residue from th crankcase aid the face of the accessory adapter w 4 Repeat steps 1 through 3 for the second accessory drive adajXer 5 Disassemble the accessory drive adapters according to instructigns in Chapter 7 i Part References So by index numbers 14 15 16 AT Og AB Illustration Number Indexed Part Accessory Drive Assembly names Gasket 7 Plain Washer 3 Sleeve Assembly Adapter Lock Washer Gasket Bushing 9 Lock Washer 5 Cover Ol Seal 10 Nut 6 Plain Washer Stud 1 Nut 7 Lock Washer Plain Washer 2 Drive Gear Assembly Nut Figure A Figure and Index Reference D 2000 D 3000 Series High Tension Magneto Service Support Manual iii 31 August 2011 Publications Service Documents Continental Motors may issue Service Documents in one of six categories ranging from mandatory Category 1 to informational Category 6 Definitions of the categories are listed below NOTE Upon FAA approval Continental Motors publishes service documents for immediate availability on our web site http continentalmotors aero The service document cover page indicates the magnetos affected by the service document Service document
75. ce procedures and a functional hot magneto condition exists the engine may fire and cause injury to personnel a If necessary ensure the magneto impulse coupling flyweights are not engaged on the stop pins Connect the 11 9110 1 Timing Light or equivalent across the main contact assembly b Slowly rotate the crankshaft to position the piston of the No 1 cylinder on the compression stroke at the full advance firing position according to the instructions in the appropriate engine maintenance manual The timing light should indicate proper magneto to engine timing If the timing light does not indicate proper magneto to engine timing remove the magneto from the engine and perform internal timing check and inspection according to instructions in Section 6 2 3 D 2000 D 3000 Series High Tension Magneto Service Support Manual 6 3 31 August 2011 Periodic Maintenance 6 2 2 Impulse Coupling Inspection Inspect snap ring impulse couplings Figure 1 39 at the first 500 hours in service and every 500 hours thereafter Inspect riveted impulse couplings 39 at the first 100 hours in service and every 100 hours thereafter Snap ring cam assemblies may be distinguished by the S mark on both sides of the toe of each flyweight as shown in Figure 6 3 LETTER S ON BOTH SIDES OF FLYWEIGHT TOE FOR IDENTIFICATION OF SNAP RING CAM ASSEMBLY WITHOUT DISASSEMBLY FROM MAGNETO ALIGN APEX OF FLYWEIGHT SPRING WITH EDGE OF
76. ceptible groove or a ridge can be felt when fingernail is drawn across surface reject the impulse coupling body Figure 1 9 D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 9 31 August 2011 General Overhaul Figure 7 10 Worn Drive Lug US TRIGGERING RAMP CONTACT FLYWEIGHT TAIL CONTACT CAM STOP CONTACT Figure 7 11 Coupling Body Wear Points 7 10 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 7 2 8 Magneto Housings and Cover Inspection 1 Visually inspect the housing Figure 1 66 for cracks stripped threads or other damage Check bearing outer race seats in both housings for wear or peening due to operation with loose bearings 2 Perform a Fluorescent Penetrant Inspection on the cleaned non ferrous magneto housing and cover according to ASTM E1417 methods ASTM E1208 ASTM E1209 ASTM E1219 methods may be used Inspection must be performed by qualified technicians certified to perform the inspection a Look for cracks or indications of cracks especially in the areas adjacent to the mounting flange b Cracks in the magneto housing or cover is cause for rejection destroy cracked magneto housings or covers to prevent possible return to service c Look for indications which break into corners edges holes or fillets Identify parts that contain linear indications which cannot be reworked d Follow the fluorescent penetrant ma
77. ch produced in F S 1200 No letter D April G D 3000 for new E May month Begins H Ignition F June with 01 at the Switches G July startofeach J Ignition H August month Vibrators September K Ignition J October Harness K November L December 2 8 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation Table 2 2 Current Magneto Serial Number Code since Jan 2001 Example GO9EA005R restart G 09 E A005 R Y Y I I Component ID Year Month Manufactured Unit Number Condition D S 20 Manufactured A January Fifth unit Blank New E S 200 09 2009 B February producedin R Rebuilt F S 1200 C March month No letter G D 3000 E May Number resets for new H Ignition Switches F June to A001 each J Ignition Vibrators G July month After K Ignition Harness H August unit 999 alpha i P character October K November increments L December and numbers 2 6 Part Numbers Since May 28 1999 Continental Motors factory rebuilt magnetos and rebuilt D 3000 Ignition Systems harness and rebuilt magneto supplied assembled have been marked with part numbers beginning with BL Blue Label to distinguish them from new 10 prefix assemblies For example the data plate for a factory rebuilt magneto formerly marked 10 349350 4 is identified as BL 349350 4 Data plates for rebuilt units are
78. ck Impulse Coupling for Magnetism ss 9 20 Impulse Coupling Spring Orientation esss 9 2 Lift Inner End of Sprie nl gu 9 21 Apply Anti seize to Magneto Shaft sss 9 22 Proper Cotter Pin Installation 2 1 dp 9 23 Typical Impulse Coupling Crack essess 9 23 Lead Preparation 42 5 rare tn ca rhet eoe Sag eae Hi PUR RUE 9 25 Lead Assembly Detail brain o a e OP NERA 9 25 Dura Blue Lead Assembly aria 9 26 Eyelet Crimping Tool odes edis o Di a tussis a tue 9 27 Ignition Harness Assembly Tool sees 9 29 Formed Capacitor Leads sesionar recette taret 9 30 Lubricate Insulating ies Ve aeeectecee aperte sever ta iras 9 32 Terminal Kit Assembly eere eei rete tni 9 33 Elbow Kit Asset pa eeu Han eU E EON 9 33 Eyelet Pressing A qi ses oe pea tease eU ERAT eC I aires 10 3 Harness Assembly Tool a aO QE 10 3 Pei TL DET Seacrest piod v leet ptis 10 3 11 9998 Bearing Pressing Tool eee 10 4 11 9999 Bearing Pressing Support esses 10 4 Support Bar Dimensions casser th IER Re pido e pde ie 10 5 Small Gear Support Bar Dimensions eese 10 5 Wood Support Block Dimensions eee 10 6 Dial Indicator Mounting Plate eese 10 6 Terminal iPS Paves acid da are ruo Oe EUER 11 6 D 3000 Series Magneto Exploded View
79. ck by removing screws 9 and washers 10 discard the contact assemblies 11 12 amp 13 and screws 9 NOTE Tachometer contact assembly identified by smaller 0 125 in diameter silver contact points may be reused Loosen and remove the nuts 4 lock washers 5 and capacitors 6 from the cover Figure 2 16 Remove the two tapered fishpaper strips Figure 1 57 which retain the coil leads against the magneto housing 66 For D 3000 Series Magnetos remove and discard the four coil retaining screws 54 For D 2000 Series Magnetos remove and discard the four coil retaining screws 54a washers 54b and nuts 54c Remove the plates 55 Position the rotating magnet shaft 48 with timing mark K centered in the timing window Turn the housing 66 over and lightly tap the mating surface of the housing on the work stand The coil 58 and springs 56 will drop from the housing Repeat to remove the other coil and springs Discard the springs 56 4 2 3 Drive Plate and Front End Hardware Disassembly 1 2 3 4 Remove the cotter pin Figure 1 7 from the magnet shaft While holding the drive member with a crescent wrench remove the nut 32 Lift off the lock washer 33 and bushing 34 Protect the rotating magnet shaft threads by loosely threading the nut 32 on the shaft far enough to cover the cotter pin hole and all end threads CAUTION Do not strike puller with hammer If puller is stru
80. ck with hammer magneto ball bearings MUST be replaced If necessary apply soldering tip to drive plate 37 amp 38 Refer to Section 4 2 4 step 6 Remove the drive plate using a CG240 puller Remove Woodruff key s 35 as necessary 4 2 4 Impulse Coupling Disassembly I 4 2 WARNING Use of makeshift tools or tools and procedures other than those specified herein for impulse coupling removal may damage the magneto or magneto components NOTE Use of the specified anti seize compound during previous assembly will ease disassembly of the impulse coupling Remove the cotter pin Figure 1 7 from the rotor shaft While holding the impulse coupling body 40 drive dogs with a crescent wrench remove the nut 32 Lift off the lock washer 33 or bushing 34 discard the lock washer D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl 2 Using heavy gloves or a shop towel grasp coupling body 9 firmly to prevent the internal spring from unwinding suddenly Pull outward on the impulse coupling body only enough to release it from the cam assembly 11 Keep the impulse coupling body close against cam and allow the impulse coupling body to turn as the spring 10 unwinds After one or two turns spring coils will wedge against projections on body restraining spring from further unwinding 3 Look through the hole in the impulse coupling body and note the location of the inner ey
81. d 10 385164 114 Discontinued 10 682650 141 Discontinued 10 385126 101 Discontinued 10 385164 115 Discontinued 10 682725 10 Discontinued 10 385126 102 Discontinued 10 385166 101 Discontinued 10 682910 10 Discontinued 10 385126 103 Discontinued 10 385166 102 Discontinued 10 682910 11 Discontinued 10 385126 104 Discontinued 10 385166 103 Discontinued 10 682910 12 10 682910 18 10 385126 105 10 785126 105 10 385184 101 Discontinued 10 682910 14 Discontinued 10 385126 106 Discontinued 10 385186 102 Discontinued 10 682910 17 10 682910 13 10 385126 107 10 785126 107 10 385186 103 Discontinued 10 682910 18 Discontinued 10 385126 108 10 785126 107 10 385186 108 Discontinued 10 682910 101 Discontinued 10 385126 109 10 785126 109 10 385186 109 10 785186 109 10 682910 131 Discontinued 10 385126 110 Discontinued 10 385186 111 Discontinued 10 682910 181 Discontinued 10 385126 111 10 785126 111 10 385226 401 Discontinued 10 682960 13 Discontinued 10 385126 112 10 785126 112 10 385236 401 Discontinued 10 684241 106 Discontinued 10 385144 101 Discontinued 10 385242 701 Discontinued 10 684242 106 Discontinued 10 385144 102 Discontinued 10 385242 702 Discontinued 10 684400 303 10 821414 6 10 385144 103 Discontinued 10 385246 401 Discontinued 10 684400 305 Discontinued 10 684400 306 Discontinued 10 684606 307 Discontinued 10 685124 105 Discontinued 10 684400 307 Discontinued 10 684607 102 10 821615 20 10 685124 106 10 785124 106 10 684400 309 Discontinued Discontinued
82. d capacitors for continuity and inspect switch es for correct electrical operation Repair or replace malfunctioning parts as necessary according to the appropriate service manual CAUTION If the self locking cam securing screw is removed or loosened at any time always replace with a new self locking screw and apply 21 25 in lbs torque to the screw NOTE Do not use an ohmmeter or continuity tester to troubleshoot the magneto grounding circuit with the magneto connected false continuity to ground will be read through the points or coil primary windings Instead position the magneto shaft so that the points are open and use a magneto timing light to troubleshoot the magneto grounding circuit D 2000 D 3000 Series High Tension Magneto Service Support Manual 3 5 31 August 2011 Testing amp Troubleshootin Table 3 1 Troubleshooting Chart Symptom Probable Cause Test Hard Starting Worn or fouled spark plugs arcing ignition lead Inspect and replace or repair as necessary Impulse Coupling not operating properly Remove and check for binding worn or broken impulse coupling parts Ensure D6LN 2031 model magnetos incorporate latest Heavy Spring Impulse Coupling Assembly Impulse Coupling is magnetized Remove and demagnetize or replace impulse coupling Inspect engine for magnetized components and demagnetize all such components Low voltage at vibrator input Measure voltage between v
83. e of spring where it engages with the mating recess Figure 4 1 in the cam hub Insert a screwdriver under the spring end and pry the spring eye out of the recess Remove the impulse coupling body and spring together Uncoil the spring from the body and pry the spring eye from the impulse coupling body recess to disengage spring remove and discard the spring Figure 1 10 Figure 4 1 Spring Engaged with Cam 4 Assemble nut Figure 1 2 to support cotter pin holes in end of shaft Engage puller over shaft and cam assembly with jaws of puller hooked under the cam assembly as shown in Figure 4 2 CAUTION Do not allow puller jaws to apply pressure to the flyweights resulting flyweight damage will require flyweight replacement D 2000 D 3000 Series High Tension Magneto Service Support Manual 4 3 31 August 2011 Disassembl Figure 4 2 Coupling Cam Removal 5 Tighten puller handle to remove the impulse coupling from shaft If cam assembly 11 does not release with maximum hand torque at puller handle apply penetrating thread release compound between the cam assembly 11 and the shaft While the puller is still fully tightened hold tip of hot heavy duty soldering iron in contact with the cam assembly Figure 4 3 hub Wetting the tip of the soldering iron at the point of contact with the cam hub will assist in heat transfer to the parts Retighten puller after about a minute of heat application Figure 4 3 Apply Heat to
84. e technical manual Figure C If change pages are issued for the manual the change will be identified with an effective date under the heading Effective Changes for This Manual on the inside front cover of the manual Page A The list of effective pages itemizes the pages in each section by change number Original pages are designated by a 0 in the List of Effective Pages Change column Suggestions and Corrections Continental Motors solicits and encourages user comments regarding suggested changes to this manual Direct recommended changes or questions to the attention of Publications at the address listed in Contact Information on this page or via email to CM techpubs continentaomotors aero vi D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 31 August 2011 Zo 7 Effective Manual UT 007 Mer 2005 Changes and chari er Engine In isiiston and Operst C ha nge Dates Fuzlkcston Number OF24 e Change Change Page Change Itemized List of Effective ob ip bb tp 7 15 Seu 7 16_ 8 747 they 7 54 2 A tes Abonono 8 1 fs 8 12 0 C1 ru 0 44 0 DEL C 10 they C 14 0 0 0 0 hos b o Figure C List of Effective Pages Contact Information Notify Customer Service immediately using our toll free number if you discover incorrect information which adversely affects saf
85. eaeacessintasstecavtancdaatesassaces 4 4 Apply Heat to Release Coupling eese 4 4 Rotor on Support Bars for Bearing Removal 4 5 Bearing Pressing Tool in Position eee 4 6 Rotor on Support Bars for Small Gear and Bushing Removal 4 7 Check Contact Point Security essen 6 2 Normal Contact Pote 6 2 Flyweight Terminology seen 6 4 Flyweight Heel Inspection rl et petierit 6 5 Inspection Setup oee n tee d cipue pfe tede 6 6 Wire Hook Configuration zoo doe eee od d De DNO NRI Sad US 6 6 Flyweight to Axle Wear Check eene 6 7 X Value Measurement viii ias 6 7 Distributor Gear Identification Marks sess 7 2 Check Electrode Security ciet ooo e tai eese 7 3 Stress Line in Distributor Block cie restet ees 7 4 Check Distributor Block for Carbon Tracking 7 5 Contact Spring Height i2 ense eter ten titre 7 5 Lubrication Identification Mark sees 7 6 Capacitor Date Code i iier rita cir 7 7 Soft Flyweight Check cts ee eee hie Bae idee 7 8 Inspect Flyweight WaslieEs eo des vs oh porque e Oase MUS 7 9 Won Di MB o esse utpat Retina NC 7 10 Coupling Body Wear Points eene 7 10 Coil Lead Repair siii nda ent cto e Qe ica c Exe ve 8 1 Helical Com Repat 5e oO Re bc te M 8 2 Position Springs in Magneto Housing
86. ee hours Remove distributor block and oil from oven and allow them to cool to room temperature together Oil is absorbed into bushing during cooling Carefully remove cork stopper and allow excess oil to drain from bushing CAUTION Do not lubricate the felt strip D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 11 Install a new dry felt strip Figure 1 26 in the groove on the electrode side of the distributor block When the strip is properly installed approximately 1 16 inch of the bushing shall be exposed above the strip 12 For all blocks before installing new felt washer 82 into the distributor block 79 saturate the washer with 10 391200 Distributor Block Lubricant Blot excess oil from the washer until flat surfaces take on a frosted appearance and seat the washer in the recess on the tower side of block 7 2 5 Capacitor Inspection NOTE The capacitor on all D 2000 and D 3000 magnetos must be replaced at the time of magneto overhaul 1 Inspect new capacitors for a date code Figure 7 7 of 9943 ore newer Figure 7 7 Capacitor Date Code 1 Visually inspect capacitor mounting brackets for cracks or looseness Check capacitor lead for damaged insulation and loose terminal connections If any damage is found discard capacitor Figure 1 42 2 Using a LC101 capacitor tester measure capacitance and leakage according to Table 7 1 specifications
87. eel con ductor silicone insulation tightly woven coaxial plated copper braid radio shield and abrasion resistant outer jacket is used to conduct high voltage pulses from the magneto to the spark plugs Positive sealing individual grommets and high altitude spark plug termi nals are attached to the cable ends Harness design depends on the following factors e Lead length lead routing magneto rotation and engine firing order e Spark plug terminal type 5 8 24 or 3 4 20 Figure 2 4 e Magneto type determines cover configuration Impulse Coupled Shower of Sparks Tachometer Spare leads with spark plug ends pre assembled are available in two lengths Dura Blue Harnesses may be repaired using Gold Seal Spare leads as each Gold Seal spare lead includes inner ferrules 2 7a for use in Dura Blue assemblies The part number suffix identifies the lead length in inches See Figure 2 4 10 400401 48 78 10 400402 48 72 2 4 2 8 2 4 2 10 Fh 2 7 3 4 20 STRAIGHT TERMINAL g 5 8 24 SPARK PLUG TERMINAL 2 7A 2 7 2 12 2 11 ITEMS INCLUDED WITH 10 40040X XX KITS Figure 2 4 Lead Termination Detail The Magneto Harness Cover is a machined magnesium alloy casting The first cylinder in the engine firing order is cylinder No 1 the corresponding No 1 spark position on the magneto is identified by the numeral 1 in the cover casting Depending on magneto rotation the leads to the remaining cylinders in
88. een 5900 and 7500 ohms Replace coils not within specifications 7 2 7 Impulse Coupling and Related Component Inspection WARNING Regardless of condition discard and replace impulse coupling springs after disassembly 1 During overhaul all type D6LN 2031 magnetos must incorporate current improved heavy spring design impulse coupling Compare impulse coupling body Figure 1 40 and cam assembly 42 part number markings to part numbers listed in Table 11 5 Replace components identified with part numbers other than those listed in Table 11 5 with the current part number components 2 Ensure impulse coupling cam flyweights have been properly heat treated NOTE Cam assemblies with yellow paint dykem or lacquer on the heel of each flyweight or with stamped numbers on flyweight as shown in Figure 7 8 or with more than 300 hours service are not subject to this test Proceed to step b XXX in Figure 7 8 indicates the location of stamped numbers FILE IN THIS AREA TOE 85 pe HEEL Figure 7 8 Soft Flyweight Check 7 8 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul a Use finger pressure to push inward on the toe of a flyweight so that the heel points outward Using a fine 1 double cut 1 2 in wide file at least 3 32 in thick pass the file across the heel of the flyweight and attempt to remove material Repeat for other flyweight File should glide s
89. espectively Position the rotating magnet assembly on the fabricated support bars and support plate as illustrated in Figure 4 4 Loosely install the nut Figure 1 32 on the rotating magnet shaft to protect the threads Press the rotating magnet shaft 48 out of the front bearing 50 and bearing retainer 51 Discard bearing 50 and bearing retainer 51 NUT 1 32 PRESSURE DIRECTION r3 IMEEM RETAINER STEEL PLATE a LOCALLY FABRICATED STEEL SUPPORT TUBE LOCALLY FABRICATED BEARING LL ARBOR PRESS BASE Figure 4 4 Rotor on Support Bars for Bearing Removal D 2000 D 3000 Series High Tension Magneto Service Support Manual 4 5 31 August 2011 Disassembl 2 Position the distributor block 27 distributor well side down on the hollow end of the 11 9999 bearing pressing support Figure 10 5 so the block insert rests on the support as illustrated in Figure 4 5 Using the 11 9998 bearing pressing tool Figure 10 4 press the bearing Figure 1 30 from the distributor block 27 and discard the bearing 30 Figure 4 5 Bearing Pressing Tool in Position 4 2 7 Spur Gear and Bearing Bushing Removal NOTE Remove the small gear 52 and rear bearing bushing 53 only if replacement is indicated by visual and dimensional inspection in Section 7 2 9 These parts become sized to the rotating magnet shaft 48 during assembly and must not be reu
90. ety Continental Motors is available to answer technical questions and encourages suggestions regarding products parts or service If customers have an inquiry or require technical assistance they should contact their local Continental Motors distributor or field representative To contact our factory customer service department refer to the contact information below Continental Motors Inc P O Box 90 Mobile AL 36601 Customer Service Department Toll free within the Continental United States 1 888 826 5465 International 1 251 438 8299 Internet http continentalmotors aero D 2000 D 3000 Series High Tension Magneto Service Support Manual vii 31 August 2011 PREFACE NOTE Please note the following statements from FAA Advisory Circular 20 62C entitled ELIGIBILITY QUALITY AND IDENTIFICATION OF APPROVED REPLACEMENT PARTS Background An increasing amount of replacement parts including standard parts materials appliances and instruments are offered for sale as being of aircraft quality when actually the quality and origin of these units are unknown Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certificated aircraft Frequently such units are deceptively advertised or presented as unused like new or remanufactured This implies the quality of such units is equal to an original or appropriately repaired or ove
91. eyelet Figure 2 12 c Insert a replacement lead through the cover 16 d Insert an eyelet 7 under the braiding to the depth specified in Figure 9 22 e Pull the cable with correctly positioned eyelet into the outlet and fully seat the eyelet in the cover using an Eyelet Pressing Tool Figure 10 1 IMPORTANT AREA END OF EYELET MUST BE POSITIONED AS SHOWN EYELET 10 400093 NOTE EYELET FLANGE WILL BE FORMED INSULATION FLAT AFTER BEING y FULLY SEATED GOLD SEAL SPARK PLUG OUTER FERRULE OR GOLD SEAL MAGNETO OUTLET PLATE COVER CAP BRAID CAN EXTEND PARTLY ONTO EYELET SHOULDER SILICONE JACKET 3 16 1 4 IN IMPORTANT AREA STRIP BRAID FREE OF SILICONE JACKET Figure 9 22 Lead Assembly Detail D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 25 31 August 2011 Assembl 4 Assemble Dura Blue ferrule Figure 2 7a in the Dura Blue Harness Cover a With 11 9596 nylon tube acting as a protective sleeve cut off 7 8 in of shielding and scrape off 3 8 in of gold silicone covering from remaining shielding Remove 11 9596 nylon tube b Cut and remove 5 16 insulation from conductor Figure 9 23 to facilitate eyelet Figure 2 12 crimping c Insert the replacement lead through the cover Insert a ferrule 32 over the insulation and slide the tapered end under the braid Cover approximately 3 4 of ferrule taper d Pull the lead and ferrule back into the cover 16 En
92. facturer s recommendations In such circumstances overhaul the magneto regardless of in service time with particular attention focused on rotating parts bearings and electrical components Inspect magnetos and harnesses for airworthiness at the expiration of four years without regard to the accumulated operating hours since new or last overhaul D 2000 and D 3000 Magneto Operation General Theory of Operation The rotating magnet is of a four pole design As the magnet is turned the polarity continually changes thereby producing flux reversals in the magneto coil core Four flux reversals occur during one complete revolution of the magneto With the contact assembly points closed the flux reversals cause a current to be generated in the primary winding of the magneto coil The flow of current through this coil produces a magnetic field around the coil When the cam pushes the contact assembly points open current ceases to flow and the magnetic field around the primary winding collapses causing a high voltage to be induced in the secondary winding of the coil The capacitor D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 ee YA O NEA Description and Operation 2 4 2 connected in parallel across the contacts to ground suppresses arcing across the opening contacts by providing a low impedance path to ground for the continuing induced primary voltage The high voltage induced in the c
93. g Impulse CCW 20 10 400324 Coupling Impulse CCW 15 _ 10 400325 Coupling Impulse CCW 10 10 400326 Coupling Impulse CW 15 10 400310 40 Body Impulse Coupling 10 382747 10 382768 10 382748 10 382767 10 382952 10 382961 10 382749 41 Spring Flat Spiral 10 51324 10 400042 42 Cam Assembly Impulse 10 400167 9 10 400166 7 10 400167 7 10 400167 8 10 400167 12 10 400167 13 10 400166 5 43 Ring Retaining MS16624 2062 44 Washer Plain 10 349328 45 Washer Bowed 10 349249 46 Screw Socket Head Locking 10 382789 47 Washer Plain 10 382788 48 Magnet Rotating 10 382799 1 10 382799 2 49 Slinger Oil 10 349248 50 Bearing Ball 10 400567 51 Plate Bearing Retainer 10 382787 52 Gear Spur 4 amp 8 CYL 10 382573 Gear Spur 6 CYL 10 382575 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 10 682555 11 10 682555 12 10 682555 13 ST i O NON NT M LO LO M LO LO wm LO 1 CM IN CN oo joo co 21212 ceo o mm v 111 1 2 12 12 a aj a a aj a af a f a 10 682555 141 10 682555 151 10 682560 11 MM mm uou NT OS ce O Oo o coc tO O co CM IN N oo joo co ceo o q mm 111 1 2 12 12
94. g marks on the rotating magnet have a width of two degrees 1 Turn rotating magnet to the No 1 neutral position For DALN 2200 and D4LN 3200 magnetos this position is with the C mark on the rotor centered in the timing window and the red gear teeth on the edges of the windows on the ends of the magneto For all other magnetos position K mark on the rotor in the center of the timing window and the red gear teeth on the edges of the windows on the ends of the magneto CAUTION When timing magneto do not use any gear holding timing device as hidden gear tooth damage may result Loosen drive shaft nut to position the 11 8465 rotor holding tool under the washer or bushing on the drive end of the rotor shaft with a clamp at the 4 o clock position so any shaft deflection caused by clamping action will be in a plane parallel to the contact assembly Check to ensure proper location of rotor before tightening the holding tool adjusting screw Figure 9 11 to lock the rotor in position Figure 9 11 11 8465 Rotor Holding Tool in Position 3 The magneto incorporates timing marks printed on the rotating magnet and a built in timing pointer The marks indicate magnetic neutral K A B C E gap L R and retard angle references of 10 15 20 and 25 degrees past E gap These marks are set up for clockwise R or counterclockwise L rotation as viewed from the magneto drive end Loosen the 11 8465 rotor holding tool to tur
95. g parts of the magneto except capacitor 6 distributor block 27 cams 16 amp 17 and coils 58 with isopropyl alcohol and dry with compressed air Blow out holes in ventilator plug 59 and orifice 62 with compressed air ensuring holes are clear of any blockage 3 Clean the capacitor 6 breaker cams 16 amp 17 and coils 58 with a clean dry lint free cloth 4 Install 10 70506 10S protector caps to cover both ends of the distributor block bronze bushing to prevent contamination of the bearing during the second stage of the cleaning operation 5 Clean distributor block 27 with a clean dry lint free cloth carefully wipe the internal and external surfaces of the distributor block clean and free of all contaminants If the dry lint free cloth is insufficient moisten the cloth with isopropyl alcohol and wipe the accessible surfaces of the distributor block free of contaminants Do not allow alcohol to contact the brass bushing or roller bearing 30 D 2000 D 3000 Series High Tension Magneto Service Support Manual 5 1 31 August 2011 Cleanin 6 Hold the distributor block 27 with the outlet towers in a vertical plane Using a 1 2 inch bristle brush dipped in isopropyl alcohol clean in and around the block outlet towers and the distributor block electrodes allowing the cleaning fluid to flush out any remaining contaminants from inside the distributor block 7 Use dry oil free compressed air to dry the distri
96. h vernier calipers or a micrometer Minimum thickness at any point is 0 040 in Replace any gear 21 exhibiting any of these conditions 3 Wipe gear 72 free of all oil film and other contaminants 4 Using Red Dykem paint timing marks on the gears Refer to marks on the carbon brush side of gear only For D4RN and D6RN magnetos paint tooth and dot shown by CW trace line For D4LN D6LN and D8LN magnetos paint tooth and dot shown by CCW trace line 7 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul Figure 7 2 Check Electrode Security 7 2 3 Breaker Cam Inspection 1 Inspect breaker cams Figure 1 16 17 for scratches or wear replace the cam if it exhibits scratches or wear Ensure outer surface is not contaminated with plastic or dried oil replace if any of these conditions are found Wipe the cam with a clean lint free cloth 3 Submerge cams completely in a vat of 10 391200 Distributor Block Lubricant heated to 200 F for 30 minutes While still submerged in oil allow cam and oil to cool to room temperature together After cooling remove cam from oil wipe with lint free cloth and put into service or store in a sealed plastic bag until needed 7 2 4 Distributor Block Inspection 1 NOTE Current design distributor blocks are made of brown polyester material and have a part number and batch code molded into the surface on the tower side Older
97. ibrator terminal marked in and the ground terminal while operating starter Must be at least 8 volts on 12 volt systems or 13 volts on 24 volt systems Inoperative vibrator If voltage is within specification listen for buzzing of vibrator during starting If no buzzing is heard either the vibrator is inoperative or the circuit from the Output terminal on the vibrator to the switch and magneto points is open Check both Switch and Retard circuits Check for continuity from the BO terminal through the switch and through both the main and retard magneto points Retard contact assembly in retard dual contact magneto not operating electrically Engine may kick back during cranking due to advance timing of ignition Retard points may not be closing due to improper adjustment or may not be electrically connected in the circuit due to a poor connection Inspect retard points to see if they close Check for proper contact at the SWITCH and RETARD terminals of retard dual contact assembly magneto and at the vibrator Check wiring Vibrator magneto combination not putting out electrically Turn engine in the normal direction of rotation until retard points just open on No 1 cylinder position Remove input connection from starter to prevent engine turning and while holding No 1 plug lead 3 16 inch from ground energize vibrator by turning switch to START Plug lead should throw a 3 16 inch spark If spark
98. ibutor blocks Bronze bushings in all types of distributor blocks must be oil impregnated at each 500 hour inspection and at each overhaul period The bronze bushing in the distributor block is impregnated with oil to provide proper lubrication for distributor shaft The phenolic dielectric surfaces are coated to inhibit moisture from sheeting and possibly causing electrical failure Care should be taken to keep coating away from bronze bushing and to keep oil from coated surfaces Install a 10 70506 105 protective cap over each end of bronze bushing in the distributor block Brushcoat all surfaces of the distributor block insulating material with 10 391400 Distributor Block Coating as illustrated in Figure 7 6 Do not apply the coating to any exposed surface of the bronze bushing Allow the distributor block coating to dry for a minimum of 30 minutes before continuing to the next step Remove 10 70506 10S protective caps from distributor block Insert a cork stopper in one end of the bushing and fill bushing with 10 391200 Distributor Block Lubricant NOT COATED IN SHADED AREA OR ON BEARING BORE SURFACE 7 4 in A 7 COUNTERBORE 427 in COUNTERBORE NOTE APPLY COATING TO BLACK BLOCKS ONLY INSPECT COUNTERBORE ONLY ON BROWN BLOCKS Figure 7 6 Lubrication Identification Mark Using care not to spill oil on coated surfaces place the distributor block in oven and bake the distributor block at 190 210 F 88 99 C for two to thr
99. ified Shop verified procedures are those by which the manufacturer has performed according to provided instructions on equipment identical in configuration to that described Good standard shop practices and safety precautions should be observed at all times to avoid damage to equipment and or injury to personnel For specific information regarding Continental Motors Ignition Harnesses Ignition Switches and Starting Vibrators used in conjunction with D 2000 and D 3000 Series Magnetos consult the applicable service manual and all applicable service bulletins Service Bulletins issued subsequent to the date of this manual may supersede or supplement the information contained in this manual Such bulletins must be complied with whenever equipment covered in this manual is inspected tested adjusted maintained or overhauled Dimensions are provided in U S Standard Units For reference abbreviations are listed in Table 1 1 Table 1 1 Abbreviations US Standard Unit Abbreviation Degrees Fahrenheit F Inch in Inch Pound in lbs Pound Mass lb Standard Cubic Feet Per Hour SCFH Pounds per Square Inch Gauge psig D 2000 D 3000 Series High Tension Magneto Service Support Manual 1 1 31 August 2011 Introduction and Specifications 1 2 Specifications Table 1 2 Table of Leading Particulars Subject Data Lubrication amp Compounds Cam Distributor Block Lubricant Part No 10 391200 Cam Follower Felt
100. ight Check is required after engin tallation inspection repairs or adjustments Follow these same parameters for t hours of operation to complete the recommended break in for TCM eng New and re shipped by TCM are calibrated in a test cell prior to shipment However the Wh c es the engine meets all operational parameters after installation an for normal service Refer to Engine Specifications and Operating Limits ic limits for your engine model Ch B CAUTION Higi ver ground operation resulting in cylinder and ange ar oil temperatur xceedi ia operating limits can be detrimental to cy es and rings l Start the engine according to on in Section 7 3 2 Engine Start 2 Conduct a normal take off ac g toy ions in Sections 7 3 3 Engine Run up before Takeoff 7 3 4 Taxi 7 3 5 Take Off 3 Monitor the following engine o Engine RPM FADEC HSA or ECP Fuel flow vo aA Oil pressure Oil temperature mon Cylinder Head Temperature g Turbine Inlet Temperature Exhaust Gas Temp the airframe manufacturer s AFM POH Maintain a shallow clim je optimum airspeed and cooling airflow 5 Atcruise altitude a Maintain level flight cruise at 75 power for the first hov b During second hour of flight alternate power settings between 65 and 75 power Figure B Change Page Identification Page A of this manual contains the original publication date and an itemized list of changes issued for th
101. iming window at the ends of the housing It is permissible for the red tooth to be on the incoming side of the window less than one tooth width from the center 9 12 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Figure 9 8 Shims Positioned Around the Rotating Magnet Figure 9 9 Distributor Block Secured and Centered D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 13 31 August 2011 Assembl 9 2 7 Contact Assembly Installation 9 14 NOTE The presence of oil on contact points will tend to attract and hold contaminating metallic particles This will adversely affect contact assembly performance Do not remove the new contact assemblies from the shipping containers until ready for installation At installation carefully blot any oil on contact point surfaces with a piece of clean hard cardboard such as a business card Ensure no paper particles are left between the contact surfaces Current design stacked contact assemblies include a relief in the steel support which allows them to be used with current replacement coil lead flag terminals as used only on reworked coils as well as with flag terminals used on new production coils Older design stacked contact assemblies cannot be used with reworked coils as the terminal will short to ground through the contact support Before installing new contact assemblies Figure 1 11 12 amp 13 check fol
102. iscontinued amp Interchangeable Items found in Table 11 2 Procedures for D 3000 Series magnetos and systems may be applied to superseded D 2000 magnetos and systems except in regard to 1 housings 2 coil securing hardware and 3 distributor block securing This information is included in the appropriate section of the main text Storage Magnetos may be stored up to five years following overhaul in an unsealed plastic bag Place the packaged magneto in climate controlled indoor storage between 50 80 F 10 26 C Inspect the magneto upon removal from storage for evidence of corrosion If no exposure is indicated continue with normal acceptance inspection and installation D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 1 Y gt O Y _ KSK Sw Testing amp Troubleshootin Section 3 Testing amp Troubleshooting 3 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified 1 If engine malfunctions develop which appear to be caused by the ignition system check the spark plugs and wiring first before working on the magnetos WARNING Turn the Ignition Switch OFF disconnect engine electrical power and confirm continuity between the magneto capacitor and aircraft ground before commencing maintenance or inspectio
103. it as follows a CAUTION Discard any springs that become deformed during installation Position coils 58 in housing with ends of high tension tabs pointed toward the center of the housing Hold spring 56 with Duck Bill pliers using care to avoid crushing or deforming the spring Apply pressure at points A and B illustrated in Figure 9 3 Insert spring with the B side towards the coil core Repeat for all springs Figure 1 56 Install a plate 55 with recessed side facing the spring 56 and pointed end turned toward the center of the housing Where appropriate ensure the plate 55 1s seated below the coil lead and against the coil core as shown in Figure 9 3 Insert a socket head screw Figure 1 54a with a flat washer 54b through the housing 66 spring 56 and plate 55 Install nut 54c on screw 54a While holding nut 54c with 11 32 thin wall socket wrench tighten the screw 54a with a 9 64 in hex wrench to 20 25 in lbs torque Repeat steps c d and e for the remaining three screws After coil retention parts have been installed ensure the magneto is free from any foreign particles 3 Route the coil leads to the outside corners of the housing and fully seat tapered fish paper strips 57 small end down 4 Place a straight edge along the long center line of the housing cover mating surface The coil tabs must be parallel to the straight edge within four deg
104. l damage Clean housing 66 with a clean dry lint free cloth Inspect the coils 58 as follows a Using a dry lint free cloth clean contaminants from accessible surfaces of coil b Ensure coil outlet tab is parallel with the housing to cover mating surface Bend tab with finger as necessary to straighten Inspect roller bearing 30 for evidence of side play or overheating If either is present replace the bearing 30 according to instructions in Section 9 2 4 WARNING Do not lubricate the roller bearing under any circumstance Assemble distributor block 27 and distributor gear 21 assemblies in the magneto housing 66 according to instructions in Section 9 2 5 and Section 9 2 6 Pay particular attention to proper distributor gear positioning Inspect contact assemblies 11 12 amp 13 and related components a The contact assembly area shall be free of moisture dirt oil or grease residue Clean as necessary b Ensure cam securing screw 61 is tightened to a torque value of 21 25 in lb D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 10 11 12 13 14 15 16 17 18 Periodic Maintenance c Check magneto internal timing according to instructions in Section 9 2 8 WARNING Rotor is to be locked on drive shaft end only Do not use gear lock devices Use of such devices may cause gear tooth damage and subsequent magneto failure NOT
105. lave pressurized retard terminal made with kit P N 10 382813 b For ignition systems spare magnetos and spare harnesses not installed on an engine perform the following air leakage rate test in the shop prior to installation 1 Install an MS20822 4 elbow in the bushing Figure 1 61 Install a cap on the open end of the tee Attach 11 10097 tube assembly to elbow 2 Place air valve lever in the open up position Turn pressure regulator knob fully counterclockwise for minimum pressure 3 Connect air source 100 psi maximum to air input fitting Adjust the pressure regulator for pressure at the gauge G1 of 10 psi 4 Install tube assembly in the regulated output fitting of tester Pressure on the gauge G1 will drop momentarily when the connection is made then return to 10 psi setting If necessary adjust the pressure regulator to maintain 10 psi reading on gage D 2000 D 3000 Series High Tension Magneto Service Support Manual 3 3 31 August 2011 Testing amp Troubleshootin 5 Snap air valve lever to the closed down position and measure the time required for pressure to drop to 1 psi Time interval must be between 9 and 45 seconds 6 If the leak down time is shorter than 9 seconds verify all connections are tight Use soapy water to detect excessive leakage source Tighten or replace parts as necessary and retest 7 If the leak down time is longer than 45 seconds the hole in the orifice fitting 6
106. lower felt for adequate lubrication by squeezing felt tightly between thumb and forefinger If fingers are moistened with oil felt is adequately lubricated and no more oil is needed If not apply three drops of Breaker Felt Lubricant 10 86527 to the felt pad Allow 30 minutes for the oil to penetrate the felt and for the thinner to evaporate Avoid getting oil on contact points blot excess oil with a clean cloth Install connector strip 20 new distributor block screws 18 and 0 396 in O D flat washer 31 at each side of the distributor block For D 2000 Series Magnetos these are the only screws to secure the distributor block Tighten but do not torque the screws 18 at this time Install new contact assemblies 11 12 amp 13 on top of connector strips 20 Loosely secure contact assemblies in position with new screws 18 lock washers 9 and flat washers 10 The flat washer 10 is used only at the elongated hole side of the contact assemblies On magnetos using main contact assemblies only the contact assemblies and their positions on the distributor block are interchangeable On magnetos using a stacked main and retard contact assembly 13 install the assembly on the side of the magneto opposite the identification plate Figure 9 10 On magnetos using a stacked main and tachometer contact assembly Figure 1 12 install the assembly on the side of the distributor block near the identification plate The si
107. lver cadmium tachometer contacts may be readily identified by their obviously smaller diameter than the main contacts After assembling the appropriate contact assemblies center distributor block and tighten all four distributor block securing screws D 2000 block securing screws should already be tight See Figure 9 2 6 step 7 sub step i Tighten in a crisscross pattern to seat the block evenly Apply final torque of 25 30 in lbs to each of the four screws Remove all surface oil from the main contact cam 16 and retard tachometer cam using a clean dry lint free cloth Install the main contact cam 16 on the rotating D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Y 10 11 Assembl magnet shaft Using No 2 lock ring pliers in the small cam holes position the cam 16 so the lobes are centered on the contact assembly cam followers Loosely secure the cam s to the magnet shaft with a screw and a new lock washer 14 and with flat washer 15 next to the cam Use the short screw for one cam use the long screw for two cams Identification Plate Top of Magneto Right Main amp Tachometer Breaker Contact Assembly A 09 OA am PE Ly I ONA 40 HAS is ac Left Magneto High Left Main amp Retard Right Magneto High Tension Outlets Breaker Contact Tension Outlets Assembly Figure 9 10 Cam End View of Magneto Rotate the cam s so the
108. main and retard contact assemblies of the Left magneto to ground The magnetic field built up in coil L1 causes vibrator points V1 to open Current flow ceases through coil L1 causing the magnetic field to collapse and the vibrator points to close This allows coil L1 and L2 where applicable to energize and vibrator points V1 to again open This interrupted battery current will be carried to ground through the main and retard contact assemblies so long as they remain closed When the engine reaches its normal advance firing position the main contact assembly opens However the vibrator current is still carried to ground through the retard contact assembly which does not open until the starting retard position of the engine is reached When the retard contact assembly opens main contact assembly is still open the vibrator current flows through the terminal at the main contact assembly and then through the primary of transformer T1 producing a magnetic field around the coil Each time vibrator points V1 open current flow through the primary of transformer T1 ceases This causes a high voltage to be induced in the secondary which fires the spark plug A shower of sparks is thus produced at the spark plug due to the opening and closing of vibrator points V1 while both the main and retard contact assemblies are open When the engine fires and begins to pick up speed the switch is released and returns to the BOTH position rendering the starter ci
109. mbly and bearing to seat bearing 50 If hand pressure is not sufficient to seat bearing 50 use an arbor press and soft brass or wood drift to lightly press the magnet assembly and bearing until the bearing is seated 3 Turn the housing over and tuck the coil leads inside the housing Place the housing coil side down on the work block and install new self locking retaining plate screws 46 with new aluminum sealing washers 47 in the housing Alternately tighten the screws in the bearing retainer plate to a final torque value of 15 20 in lbs CAUTION Do not press directly against the tapered end of the shaft to avoid damage to the taper 4 Install a new oil slinger 49 over the drive end of the rotating magnet shaft and using arbor press and 11 1471 drift press the slinger down until it seats against the front bearing inner race The oil slinger 49 must not rub against the magneto housing when the rotating magnet is turned replace the oil slinger if rubbing is encountered Place a bowed spring washer 45 concave side against oil slinger along with flat washer 44 and retaining ring 43 sharp side out on to shaft Support the tapered end of the shaft on a wood block and using an arbor press and 11 8822 drift press retaining ring 43 until it fully seats in the groove in the shaft D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 7 31 August 2011 Assembl 9 2 4 Distributor Block Assembly 9 8
110. moothly over the heel of the flyweight and remove no material removal of black oxide finish is to be expected If the flyweight is soft the file will not glide easily and material will be removed Impulse coupling cams with soft flyweight s must be discarded and replaced with a cam with flyweights marked as specified in above Note b Make an appropriate log book entry signifying compliance with this step mark heels of flyweights on good cam assembly with yellow dykem or yellow lacquer if numbers are not stamped and stamp a 1 16 in high letter F in the upper right hand corner of the identification plate Figure 1 65 Visually inspect riveted flyweight securing washers snap rings and flyweights for cracks For riveted cam assemblies grip washer as shown in Figure 7 9 and exert a turning force in each direction If washer moves or if any cracks are found reject and replace the cam assembly Figure 7 9 Inspect Flyweight Washers CAUTION Never attempt to repair any part of a rejected cam and flyweight assembly Inspect coupling body drive lugs Figure 1 40 If wear is noted measure difference between worn and unworn areas of the drive lug surface If the difference exceeds 0 015 inch replace the impulse coupling body 40 Inspect the impulse coupling body trip dogs 40 for grooves worn by the tail of the flyweight and wear at triggering ramp and cam stop contact areas Figure 7 11 If either ear shows a per
111. n the distributor block pilot bore of the housing WITNESS MARK MARKS ON WITNESS MARK BLOCK CCW il ON 4 CYL CCW MAGNETOS WITH RETARD BREAKER THE MARKED TOOTH OF GEAR MUST SPLIT THE MARK ON BLOCK AT ITS CENTER AS SHOWN r CCW WITNESS MARKS WITNESS MARKS cw ccw Go Pg z 2 Noa ccw dc TIMING MARKS Ccw 4 amp 8 CYLINDER ON BLOCK 6 CYLINDER COUNTER CLOCKWISE COUNTER CLOCKWISE WITNESS MARKS WITNESS MARKS ccw CCW cw ES cw A NS cw cw ccw ccw 4 CYLINDER 6 CYLINDER CLOCKWISE CLOCKWISE Figure 9 6 Distributor Block Timing N UN y N y N inoue Po Figure 9 7 Dial Indicator Mounted on Housing D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 11 31 August 2011 Assembl d Measure the block to housing clearance by observing the total indicator movement registered when the block is moved to the extreme shift limits e If the total movement is more than 0 008 in scrap the housing and convert the magneto to the D 3000 configuration If the total indicator movement is 0 008 in or less perform the following inspection f Prepare four pieces of non metallic 0 007 m shim stock in wide x 4 5 in long g Position the rotating magnet as described in step 2 Insert one piece of the shim stock between each pole piece of the housing and the rotating magnet Angle the shim
112. n the housing must be sealed with a stop pin to prevent engine oil from entering the magneto 7 Inspect D 2000 housings most readily identified by lack of threads for coil securing screw according to the special inspection instructions in Section 9 2 5 D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 11 31 August 2011 General Overhaul 7 2 9 Rotating Magnet Inspection 1 Visually inspect rotating magnet rotor assembly Figure 1 48 for damage to the threaded portion of the shaft Minor thread damage may be repaired by chasing the original threads with a 0 3750 24 die 2 Repair light scoring of the magnet section with a polishing stone or a fine wire brush in the affected area No projections or burrs are allowed above the surface of the laminations 3 Check the shaft at the front bearing seating position for presence of wear or score marks which would allow engine oil leakage between the shaft surface and inner race of the front bearing If scoring is noted replace the entire rotating magnet assembly 4 Inspect gear 52 and bearing bushing 53 for score marks or wear Replace the gear and bearing bushing if either part exhibits score marks or wear 7 2 10 Drive Bushing Drive Plate and Washer Inspection Inspect the drive bushing Figure 1 34 drive plate 37 amp 38 washers 36 amp 44 and bowed washer 45 for wear replace as required 7 2 11 Magneto Assembly Assemble the magneto acc
113. n the rotor in the normal direction from No 1 neutral position Align the adjacent applicable R or L mark Figure 9 13 with the pointer Lock the rotor in this position Both red painted gear teeth D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Figure 9 14 must be approximately centered or within one tooth width of center on the incoming side in the windows E GAP ANGLES RETARD ANGLES 8 8 25 KEY WAY LOCATION Figure 9 12 Timing Marks on Rotating Magnet Figure 9 13 Rotor Timing Marks Aligned with Pointer Red Painted Tooth I Figure 9 14 Painted Tooth Centered in Window D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 17 31 August 2011 Assembl 9 18 5 10 11 12 Connect the 11 9110 1 timing light to left and right main contact assembly terminals and to ground Loosen the cam securing screw Figure 1 14 and unseat main contact cam from taper Finish removing screw 14 and remove washer 15 and retard tachometer cam 17 if used Using No 2 Retaining ring pliers inserted in the two small holes in the cam 16 rotate the cam in the normal direction of rotation until the left main contacts just open Press cam onto taper Install retard tachometer cam 17 if used washer 15 and screw 14 Tighten screw 14 to seat main contact cam Loosen the rotor holding tool to turn
114. ness Category 4 Service Information Directive SID The manufacturer directs the owner operator mechanic in the use of a product to enhance safety maintenance or economy May contain updates to Instructions for Continued Airworthiness in the form of maintenance procedures or specifications Category 5 Service Information Letter SIL This category includes all information not included in categories through 4 that may be useful to the owner operator technician May contain updates to Instructions for Continued Airworthiness for optional component installations which are not covered in the Applicable Operator Maintenance or Overhaul Manuals Category 6 Special Service Instruction SSI This category is used to address an issue limited to specific model and or serial number engines Continental Motors will distribute SSI notification directly to the affected engine s owners SSIs will not be included in the general service document set but will be made available through Customer Service to owners of the affected engines only An SSI may update the applicable engine s Instructions for Continued Airworthiness D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 31 August 2011 Publication Access Continental Motors web site provides an array of benefits including access to electronic versions of Continental Motors technical publications manuals service documents and parts catalogs via the Internet I
115. ng distortion or chafing Replace ignition harness components exhibiting these conditions Inspect the integrity of the pressurization system any time the Ignition System Magneto or Harness is removed or replaced or at intervals not to exceed 100 hours in service according to Textron Lycoming Service Instruction 1308D or later revision Perform the procedure outlined in Section 6 2 1 any time magneto to engine timing is found to be outside the engine manufacturer s limits Follow the instructions in Section 6 2 2 at the first 500 hours in service and every 500 hours thereafter for magnetos with impulse couplings Figure 1 8 installed or at the first 100 hours in service and every 100 hours thereafter for magnetos with riveted impulse couplings installed Complete the inspection items in Section 6 2 3 for all magnetos at the first 500 hours in service and every 500 hours thereafter Make appropriate log book entries signifying compliance with Section 6 2 1 Section 6 2 2 or Section 6 2 3 referencing the magneto serial numbers on which the inspections were conducted D 2000 D 3000 Series High Tension Magneto Service Support Manual 6 1 31 August 2011 Periodic Maintenance 6 2 Detailed Maintenance Procedures 6 2 1 Contact Assembly Inspection If magneto timing is not within the engine manufacturer s specified magneto to engine timing limits inspect contact assemblies 1 Remove cover Figure 2 16 from housing Figu
116. ng to instructions in Section 9 4 Inspect pressurized ignition systems according to Textron Lycoming Service Instruction 1308D or later revision Install the magneto on the engine Check and adjust magneto to engine timing to comply with the engine manufacturer s specifications Reinstall the ignition harness adapter plate to the magneto Evenly torque four securing screws initially to 4 8 in Ib and then to 25 35 in Ib Complete installation by properly attaching the aircraft primary wiring and any other miscellaneous hardware items removed D 2000 D 3000 Series High Tension Magneto Service Support Manual 6 9 31 August 2011 Periodic Maintenance 6 10 Intentionally Left Blank D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul Section 7 General Overhaul 7 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified 1 Use a 4X 5X magnifying glass for all visual inspections 2 Replace the following parts with new parts regardless of condition following disassembly from the magneto at overhaul Main and retard contact assemblies Figure 1 11 12 13 lock washers 2 33 screws 9 14 18 46 54 retaining ring 22 43 washers 3 47 oil slinger 49 bearings 30 50 felt strip 28 felt washer 26 ide
117. ng tool Figure 10 4 place a new bearing Figure 1 30 over the large end of tool so press will be against the lettered side of the new bearing Using an arbor press press the bearing 30 in to the distributor block until the bearing seats against the support Test the bearing 30 to bushing 53 fit by temporarily positioning the distributor block assembly on the housing The new bearing 30 must slide freely over the rear bearing bushing 53 To check bearing fit position hand to catch distributor block 27 and invert the magneto housing 66 The distributor block 27 must fall free of the magneto shaft assembly Replace the bearing 30 if it fails this test Form felt strips 28 into rings and install them dry into the annular groove adjacent to gear bushings on distributor well side of the distributor block When strips are properly installed approximately 1 16 inch of the bushings must be exposed above the strips Saturate new felt washers 26 with P N 10 391200 distributor block lubricant Blot excess oil from washers 26 until flat surfaces take on a frosted appearance Seat washers in the recesses on the tower side of block 27 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl HANDLE PLUNGER ASSEMBLY SPRING NZX INSERTION GUIDE DISTRIBUTOR BLOCK NAA N Ja START FINISH Figure 9 5 Contact Spring Installation 9 2 5 Distributor
118. ns to avoid uncommanded engine starts during maintenance Do not stand or place equipment within the arc of the propeller 2 Perform a Magneto RPM drop off test according to the instructions in the applicable Airplane Flight Manual AFM Pilot s Operating Handbook POH to assess the ignition system operation A drop in RPM is expected when one magneto in a redundant ignition system is shut off Absence of an RPM drop may indicate The magneto timing has been advanced beyond setting specified or A Magneto primary lead is open Hot Magneto or The ignition switch is inoperative or The grounding circuit of the feed through capacitor is open or a combination of these factors 3 An engine which does not exhibit a normal drop off in RPM when the Magneto is checked must be shut down and the cause for the problem corrected before further flight The normal engine drop off is specified in the appropriate AFM POH the and Engine Maintenance and or Overhaul Manual 4 As a precautionary measure test the Magneto grounding circuit prior to shutting down the engine using the following procedure a With the engine at normal idle rotate the switch key or lever momentarily to the off position one magneto is still functioning If the grounding circuit is working as prescribed the engine should quit If the magneto did not ground out determine and correct the cause prior to continued operation of the engine and before the next flight
119. nternet Service memberships are free to Continental Motors engine owners Our Internet Service is available to Fixed Base Operators and Repair Stations with a paid subscription fee Contact an authorized Continental Motors distributor to discuss service subscription options and pricing or visit our web site See Contact Information on page vii Printed Continental Motors publications may be ordered through a Continental Motors authorized distributors or via our web site See Contact Information on page vii Publication Changes The instructions in this manual represent the best and most complete information available at the time of publication Product or process improvements may trigger changes to existing product design specifications or procedures contained in publications As new technical information becomes available Continental Motors will make the information available to the customer WARNING New information may be contained in Continental Motors service documents Service documents applicable to engines and accessories within the scope of this manual must be complied with as defined in these documents This manual and other related publications noted herein constitute the Instructions for Continued Airworthiness ICAs prepared by Continental Motors and approved by the Federal Aviation Administration FAA Continental Motors releases publication changes in the form of either change pages or complete publication revisions
120. ntification plate 65 carbon brushes 24 bearing retainer 51 springs 56 capacitors 6 and pin 7 Also if installed spring 41 and gasket 8 3 General Overhaul as specified in Section 7 2 must be performed at the same interval as engine overhaul or in the event of severe environmental effects engine overspeeds sudden stoppage or other unusual circumstances or at the expiration of four years without regard to accumulated engine operating hours since new or last overhaul 7 2 Detailed Overhaul Procedures 7 2 1 Magneto Disassembly Completely disassemble the magneto according to instructions in Section 4 Disassembly D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 1 31 August 2011 General Overhaul 7 2 2 Distributor Gear Inspection NOTE Gears may be marked with an X and no circle discard gears marked with only an X 1 Examine gears for markings shown in Figure 7 1 Discard gears without markings or markings other than those depicted in Figure 7 1 Stamp the nameplate Figure 1 65 with the letter X in the upper left hand corner to indicate compliance with this step This Figure 7 1 Distributor Gear Identification Marks 2 Inspect distributor gear 21 for evidence of damaged gear teeth gear cracking electrode looseness Figure 7 1 axle scoring or overheating Inspect electrode for spark erosion by measuring the entire length of the electrode wit
121. ntinued 10 385124 101 Discontinued 10 385144 107 Discontinued 10 385286 402 10 785286 402 10 385124 102 Discontinued 10 385144 108 Discontinued 10 385296 401 Discontinued 10 385124 103 Discontinued 10 385144 109 Discontinued 10 385296 402 Discontinued 10 385124 104 Discontinued 10 385144 110 Discontinued 10 385296 403 Discontinued 10 385124 105 Discontinued 10 385144 111 Discontinued 10 682555 10 Discontinued 10 385124 106 10 785124 106 10 385144 112 10 785144 114 10 682555 111 Discontinued 10 385124 107 Discontinued 10 385144 113 Discontinued 10 682555 131 Discontinued 10 385124 108 Discontinued 10 385146 101 Discontinued 10 682555 161 Discontinued 10 385124 109 Discontinued 10 385146 102 Discontinued 10 682560 10 Discontinued 10 385124 110 10 785124 110 10 385146 103 Discontinued 10 682560 12 Discontinued 10 385124 111 10 785124 111 10 385146 104 Discontinued 10 682560 111 Discontinued 10 385124 112 10 785124 112 10 385146 105 Discontinued 10 682590 11 Discontinued 10 385124 113 10 785124 113 10 385146 106 10 785146 106 10 682605 10 Discontinued 10 385124 114 Discontinued 10 385146 107 Discontinued 10 682605 11 Discontinued 10 385124 115 10 785124 115 10 385146 108 Discontinued 10 682605 12 Discontinued 10 385124 116 10 785124 116 10 385146 109 Discontinued 10 682605 14 Discontinued 10 385124 117 Discontinued 10 385146 110 Discontinued 10 682605 18 Discontinued 10 385124 118 10 785124 118 10 385146 111 10 785146 111 10 682605 151 Discontinued 10 3
122. nufacturer s instructions for the equipment and materials required to perform the inspection safety precautions and disposal of used inspection media e Label each part s inspection status and required action if any f Follow the fluorescent penetrant manufacturer s instructions to remove penetrant residue from the inspected serviceable parts WARNING Do not attempt to repair worn bearing bores by any means If bearing bores are oversize replace housing Do not reuse housings which have been staked punched or knurled 3 Measure each bearing bore at 90 intervals for a diameter of 1 5746 1 5751 inches If bearing bores are worn peened or exceed dimensional limits replace the housing Replace the housing if at the time of assembly of new bearing races an interference press fit condition is not obtained 4 Check housing pole shoe laminations for evidence of scoring No scoring of housing pole shoes in the rotor bore is allowed If scoring is evident replace the housing Minor corrosion of the pole shoes may be removed with 320 grit emery cloth followed by a thorough cleaning according to instructions in Section 5 2 5 Clean threads as necessary Stripped threads may be repaired by installation of the applicable size helical coil helicoil insert 6 Inspect impulse coupling stop pins If any stop pin is bent damaged loose or shows signs of wear replace the housing Stop pins are not replaceable Each stop pin hole i
123. oil secondary winding is conducted to the distributor gear electrode by means of a carbon brush When the high voltage is applied to the distributor gear traveling electrode it ionizes the gap to one of the terminals in the distributor block jumps the gap and is conducted through the contact springs and through a lead to a spark plug Operation of D 3200 Magneto System with Starting Vibrator A schematic diagram of the magneto with a starting vibrator is shown in Figure 2 3 The starting vibrator supplies interrupted battery current to the left magneto This type of vibrator is often used with one of the Continental Motors combination ignition and starter switches which controls the vibrator current flowing to the retard contact assembly and main contact assembly in the Left magneto and grounds the Right magneto during start In Figure 2 3 all switches are shown in their normal OFF position Figure 2 3 must only be used for following the electrical operation of the magneto circuit and not for installation purposes With the combination ignition and starter switch in its START position the Right magneto is grounded refer to Figure 2 3 Starter solenoid relay K1 is energized closing the contact points to allow current to flow through the starter to rotate the engine Battery current flows through vibrator points V1 coil L1 and L2 in 24 volt models through the BO Booster Output terminal to the switch where it is split and flows to both the
124. ondary tabs For D 3000 Series Magnetos with brown distributor blocks install a new screw with new lock washer Figure 1 18 and 0 396 in O D flat washer 31 in each of the two counterbored holes in the distributor block Tighten the screws but do not torque at this time D 3000 Series magnetos with black distributor blocks require washers 31 with an outer diameter of 0 328 in the counterbored distributor block holes These washers P N 10 4987 are no longer available In the event that more than two of the 0 328 in O D washers must be replaced replace the black distributor block with a current production distributor block D 2000 Series Magnetos require only two screws 18 and two of either size flat washer to secure the distributor block in place For D 3000 Series Magnetos proceed to step 8 7 Inspect D 2000 Series Magneto Housing a Attach the Dial Indicator Mounting Plate Figure 10 9 to the magneto housing as shown in Figure 9 7 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl b If not previously disassembled loosen the two distributor block securing screws Figure 1 18 just enough to release the lock washer compression CAUTION Force applied in either direction must not exceed 2 5 pounds c Steady the magneto housing with one hand at the indicator end With the other hand and with finger force only attempt to shift the distributor block laterally i
125. or block Be certain to align the gears for the correct rotation of the magneto The CW or CCW markings on the gears refer to the direction of magneto shaft rotation as viewed from the drive end of the magneto and correspond with the R or L appearing in the magneto Type number Position rotating magnet a For DALN 2200 and DALN 3200 magnetos position rotating magnet so the C mark is centered in the timing window on the top data plate side of the magneto This positions the keyway at the three o clock position as viewed from the drive end b All other magnetos are timed with the keyway at the 12 o clock position Turn the rotating magnet so the K mark is centered in the timing window on the top data plate side of the magneto Position the distributor block and gear assembly so the witness marks on the block align with the witness marks on the top outside edge of the housing Lower the distributor block carefully over the rotating magnet 48 until the gears mesh and the distributor block seats squarely against the housing The two distributor gears should easily mesh with the spur gear If gears do not mesh recheck the magnet keyway position and the alignment of the gears with the marks on the distributor block Correct alignment and reassemble as necessary Look through each of the timing windows at the ends of the housing to ensure that both carbon brushes are seated against the coil sec
126. ording to instructions in Section 9 7 2 12 Magneto Post Overhaul Testing Test the magneto according to the instructions in Section 3 2 7 3 Harness Overhaul Remove and replace the ignition harness at overhaul 7 12 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Repair Section 8 Repair 8 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified Refer to Table 10 2 for a list of tools and materials required for magneto repair 8 2 Detailed Repair Procedures 8 2 1 Coil Lead Repair 1 Coil leads and flag terminals may be repaired with a 10 400419 3 kit if the damaged area is more than one inch from the coil plastic molded surface If damage to the lead is less than one inch from the coil plastic mold surface discard the coil 6 70 7 10 LEAD LENGTH WIRE amp TERMINAL ASSEMBLY HEAT SHRINK 1 00 LENGTH CENTER OVER JOINT AND SHRINK HEAT SHRINK TUBING 5 20 LONG BUTT AGAINST COIL AND SHRINK 0 03 0 06 BOTH WIRES MUST PROTRUDE THROUGH CRIMP SLEEVE TYPICAL 10 400506 CRIMP SLEEVE Figure 8 1 Coil Lead Repair 2 Using wire cutters and strippers trim the coil lead as shown in Figure 8 1 Discard the existing tubing D 2000 D 3000 Series High Tension Magneto Service Support Manual 8 1 31 August 2011 Repair
127. ort 10 620039 1 10 620039 2 10 620039 3 10 620039 4 31 Bracket 10 78916 32 Clamp 8 wire MS21919WCG14 11 14 lo In i gt lo o A KS o co a CN a 2 eee m RE 4 79 8 9 12 16 12 16 12 16 12 16 12 16 24 32 12 16 12 16 AR AR 12 16 12 16 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 11 5 Numerical Parts List Table 11 9 Numerical Parts List Illustrated Parts List Table 11 9 Numerical Parts List Part No Description Fig Ind 10 3793 Washer Lock i 33 10 4093 Washer Plain 1 36 10 13799 Nut Elastic Stop Nut 2 29 10 14268 Washer Plain 1 10 10 17050 Washer Lock 1 5 10 32326 Spring 2 2 10 35936 6 Screw w lock washer 2 20 10 35936 7 Screw w lock washer 1 9 2 19 10 35937 10 Screw w lock washer 2 28 10 35937 20 Screw w lock washer 1 18 10 50737 Spring Helical 1 29 10 50752 Washer Felt 1 26 10 51324 Spring Impulse Coupling 1 41 10 51354 Washer Plain 1 15 10 51391 Plug Ventilator 1 63 10 51643 Nut Drive Shaft amp 10 52307 Washer Plain 1 36 10 55501 Washer Plain 1 3 10 78916 Bracket 2 32 10 90404 4 Nut 2 20 10
128. ort Manual 31 August 2011 cm Assembl 2 If used position gasket Figure 1 8 on the magneto mating surface Position harness cover Figure 2 16 so that witness marks align with witness marks on magneto housing Figure 1 66 3 Install capacitor lead flag terminal onto the inside spade terminal of the corresponding contact assembly LEFT capacitor lead to contacts farthest from witness marks and data plate RIGHT capacitor lead to contacts nearest to witness marks and data plate Fully seat flag terminals straight onto spade terminals 4 Position cover onto magneto ensuring each grommet slides into its corresponding distributor block outlet tower 5 Install screws Figure 1 1 with new lock washer 2 for un pressurized magnetos or crush washer 3 for pressurized magnetos at the four corners of the cover Tighten screws evenly ensuring gasket is positioned properly if applicable Do not use any thread locking compound on these screws as the capacitor ground return path requires a tight electrical connection between the cover Figure 2 16 and the housing Figure 1 66 For un pressurized magnetos torque the screws to 30 35 in lbs For pressurized magnetos torque the screws to 40 45 in Ibs 9 5 Magneto Installation on Engine NOTE Comply with all engine manufacturer s installation instructions and parts lists regarding drive adapters spacers gaskets mounting hardware torque values and related specifica
129. os and Rebuilt D 2000 Ignition Systems 09 99 CSB662A TCM D 2000 AND D 3000 Series magneto Capacitors P N 10 382807 10 382681 AND 10 382681 1 01 00 Service Documents Released After Publication Continental Motors strives to provide clear concise and accurate information and instructions based on best known engineering data at the time of publication Ongoing process improvements may change a specification or procedure after a manual is released Service documents defined on Chapter 1 expedite customer notification and serve as the prevailing instruction over conflicting information until the new information is incorporated in the manual text As service documents are received note the service document number release date title and applicable section affected by the service document in the blank cells below and insert a copy of the service document behind the last page of this section Make pen amp ink corrections where appropriate to the original text in the manual with a citation to the service document i e see SB9X 1 For paragraphs or entire sections draw an X through the affected information in the manual and reference the service document containing the correction Service Bulletins Release After This Manual Bulletin Number Title Release Date Affected Sections Bulletin Number Title Release Date Affected Sections Bulletin Number Title Release Date Affec
130. r This system consists of a dual magneto item 1 an ignition harness item 2 a combination ignition and starter switch item 3 and a starting vibrator item 4 Figure 2 1 D 3200 Magneto and Associated Components D 2000 D 3000 Series High Tension Magneto Service Support Manual 2 1 31 August 2011 Description and Operation Magneto model numbers contain information regarding design configuration Magneto model numbers are defined in Figure 2 2 D6 L N 3200 Magneto Configuration S Single Type Magneto one drive one output distributor D Dual Type Magneto one drive two output distributors Cylinders Fired Designator 4 Four Cylinders N Scintilla Design 6 Six Cylinders SC Short Cover 8 Eight Cylinders Rotatlon Model Number Viewed Looking in to Drive End D 3000 Serles L Left counterclockwise 3000 Impulse Coupled 3200 With Retard Breaker R Right clockwise 2 2 2 2 Figure 2 2 Magneto Model Number Elements D 2000 Series Magnetos predecessors to the D 3000 Series Magnetos differ from their superseding part numbers in housing coil securing and distributor block fastening method See Section 2 7 D 2000 Series Magneto Difference Data for detailed difference data Detailed Description The D 2000 and D 3000 Series Magnetos feature two electrically independent ignition circuits in a single magnesium alloy housing The single four pole rotating magnet turn
131. rcuit vibrator circuit and retard contact assembly circuit inoperative The single contact assembly Right magneto is no longer grounded therefore both magnetos are simultaneously firing in full advance D 2000 D 3000 Series High Tension Magneto Service Support Manual 2 7 31 August 2011 wa Description and Operation MNA 2 5 Serial Numbers Manufacturing numbers commonly referred to as serial numbers are used to identify Continental Motors magnetos These manufacturing numbers employ a coding system illustrated in Figure 2 7 Table 2 1 and Table 2 2 The build date derived from this code rather than the magnitude of the numbers determines the recency of manufacture For Service Bulletin compliance all magnetos manufactured rebuilt or overhauled by Continental Motors may be considered to have a higher serial number than magnetos manufactured or remanufactured by the Bendix corporation SYSTEM P N MAGNETO P N HARNESS P N LAG RTD ANGLE MAG TYPE SERIAL NO GO9EA005R STOCK NO 4 4 TELEDYNE CONTINENTAL MOTORS FAA PMA MOBILE ALABAMA Figure 2 7 Magneto Data Plate Table 2 1 Legacy Magneto Serial Number Code Example B138901GR B 13 89 01 G R il I j Month Manufactured Day of Month Year Sequence Product ID Condition A January Manufactured Manufactured number for D S 20 Blank New B February 89 1989 unit First unit E S 200 R Rebuilt C Mar
132. rdware and or failure to utilize the approved lubricants during magneto assembly will produce inaccurate torque values and increased stress on the impulse coupling during assembly Ensure woodruff key s are in place Apply anti seize as shown in Figure 9 18 Do not apply anti seize lubricant to the shaft threads or nut threads Install the impulse coupling assembly Figure 1 39 and washer 36 or drive plate 37 amp 38 If applicable install bushing 34 or lock washer 33 LUBRICATE Figure 9 18 Apply Anti seize to Magneto Shaft D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl WARNING Do not exceed 300 in Ibs torque on the castellated nut If the nut will not align with the cotter pin holes within the torque specification replace the nut Exceeding the torque specification may damage the impulse coupling and require impulse coupling replacement 3 Using a calibrated torque wrench tighten the nut to 180 in Ibs Install and secure a new cotter pin 7 as shown in Figure 9 19 If the slots in the nut do not align with the cotter pin hole gradually increase fastener torque to align the cotter pin hole with the first available slot in the castellated nut Do not exceed 300 in lbs torque under any circumstances Figure 9 19 Proper Cotter Pin Installation CAUTION CAUTION If the impulse coupling cam cracks Figure 9 20 during this procedure an audible cracking noise
133. re 2 66 according to instructions in Section 4 2 1 2 Turn magneto drive shaft until the cam follower rests on a high lobe of the cam holding the contact points in their open position Use a fiber or plastic rod with a screwdriver shaped end prod contact points as indicated in Figure 6 1 If looseness is noted replace contact assembly A soe ie ee Figure 6 1 Check Contact Point Security NOTE Do not attempt to burnish or dress contact points Do not clean contact points with emery cloth Should contact assembly have bad points replace the contact assembly SERVICEABLE CONTACT POINTS ARE SMOOTH AND FLAT WITH A DULL GRAY SANDBLASTED APPEARANCE Figure 6 2 Normal Contact Point 3 Examine contact points for wear or burning Replace contact assemblies Figure 2 11 12 amp 13 with deeply pitted or burned contact points Figure 6 2 shows how the 6 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance average contact point will look when surfaces are separated for inspection Desired contact surfaces have a dull gray sandblasted almost rough or frosted appearance over the contact surface indicating the points are worn in and mated to each other thereby providing the best possible electrical contact and highest efficiency of performance Replace burned pitted peaked or otherwise damaged contact assemblies 4 Inspect nylon cam follo
134. rees If required carefully bend the coil tab to meet this dimension D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 5 31 August 2011 Assembl 9 2 2 Assemble Gear and Bushing on Rotation Magnet CAUTION If the gear and bushing have been removed they must both be discarded and replaced with new parts 1 If spur gear Figure 1 52 was removed fabricate a wood support block as shown in Figure 10 8 to support the rotating magnet shaft while pressing the new spur gear Figure 1 52 and bushing 53 CAUTION Failure to use the support block to hold the rotating magnet during pressing operations will likely result in damage to the rotating magnet 2 Position the gear 52 on the rotating magnet shaft 48 Referring to Figure 9 4 use a No 41 drill bit between two gear teeth to obtain the proper alignment Using an arbor press 11 1471 drift Figure 10 3 and wooden support press the gear down onto the shaft until it is seated against the shaft shoulder Ensure gear teeth are aligned as illustrated in Figure 9 4 90 REF 4 amp 8 CYLINDER 6 CYLINDER Figure 9 4 Spur Gear Alignment on Shaft CAUTION Do not twist gear on shaft to correct alignment If alignment is not correct after the gear is pressed on it must be removed and a new gear installed 3 Ensure correct press fit of the gear is obtained by wrapping the gear Figure 1 52 in a shop towel and attempt to turn it by hand on the sh
135. rhauled unit The performance rules for replacement of parts and materials used in the maintenance and alteration of U S certified aircraft are specified in Federal Aviation Regulations FAR 43 13 and FAR 145 205 The responsibility for the continued airworthiness of the aircraft which includes the replacement of parts is the responsibility of the owner operator as outlined in FAR 91 7 FAR 121 363 and FAR 135 419 Identification of Approved Parts Approved serviceable replacement parts are identified as follows e By an FAA Form 8130 3 Formerly FAA Form 186 Airworthiness Approval Tag An Airworthiness Approval Tag identifies a part or group of parts that have been approved by authorized FAA representatives e By an FAA Technical Standard Order TSO number and identification mark that indicates the part or appliance has been manufactured under FAR 37 requirements e By an FAA PMA symbol together with the manufacturer s name trademark or symbol part number and the make and model of the type certificated product on which the part is eligible for installation stamped on the part An FAA Parts Manufacturer Approval FAA PMA is issued under FAR 21 305 The make and model information may be on a tag attached to the part e By shipping ticket invoice or other document which provides evidence that the part was produced by a manufacturer holding an FAA Approved Production Inspection System issued under FAR 21 Subpart F or by a manufact
136. ring Figure 9 1 Position Springs in Magneto Housing 3 Install the plates 55 with recessed sides facing springs 56 and pointed ends turned toward the center of the housing Where appropriate ensure that plates 55 are seated below the coil lead and against the coil core as shown in Figure 9 2 9 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Figure 9 2 Position Plate with Recess Facing Up 4 Insert new screws Figure 1 54 down through the plates 55 and springs 56 Tighten screws evenly to a final tightening torque value of 20 to 25 in lbs 5 Route coil leads to outside corners of the housing and fully seat tapered fish paper strips 57 small end down 6 Place a straight edge along the long center line of the housing cover mating surface The coil tabs must be parallel to the straight edge within four degrees If required carefully bend coil tab to meet this dimension D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 3 31 August 2011 Assembl 9 2 1 2 D 2000 Series Magneto Coil Installation Coil securing kit P N 10 382939 contains a quantity of four of each item identified in Figure 9 3 This hardware is the only acceptable to secure the coil in the D 2000 Series Magnetos amp ZA ur VE Nowe Rb PLATE AA A SPRING gt SS WASHER SCREW La i E Figure 9 3 Kit Parts Installed in D 2000 Magneto 1
137. s on two bearings one roller bearing located at the contact assembly end and the other a ball bearing at the drive end A two or four lobe cam is secured to the contact assembly end of the rotating magnet shaft In a six cylinder magneto the rotating magnet turns 3 4 times engine speed Thus 6 sparks are produced through 720 degrees of engine rotation In a four or eight cylinder magneto the rotating magnet turns at the engine speed Therefore four or eight sparks are produced through 720 degrees of engine rotation D 2021 D 2031 and D 3000 Type four and six cylinder magnetos incorporate impulse couplings The purpose of the impulse coupling is to 1 rotate the magnet between impulse trips faster than engine cranking speed thus generating a better spark for starting the engine 2 automatically retard the spark during engine cranking and 3 act as a drive coupling for the magneto D 2200 D 2230 and D 3200 Type Magnetos incorporate a retard contact assembly mechanically linked to the left main contact assembly See Figure 2 3 This contact assembly is actuated by a cam above the main contact assembly It is positioned so that its points open a predetermined number of degrees after the main contact points open A D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation battery operated starting vibrator used with this magneto provides electrical energy for starting regardless
138. s in hub on the cam assembly Figure 1 42 with the eye at the inner end of the spring With the eye engaged rotate the cam assembly slightly in the direction to unwind spring to permit hub of the cam to slip into the inner loop of the spring Rotate the cam in the opposite direction winding spring slightly until trip dogs on the edge of the cam 42 clear the projections from the impulse coupling body 40 Push the cam assembly down in the impulse coupling body while removing the screwdriver from the assembly D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 21 31 August 2011 Assembl 7 For four cylinder applications only insert a spare rotor with woodruff key installed in the tapered portion of the cam assembly Turn the magnet slightly in the direction of coupling rotation to wind spring Lift the rotor with the cam only enough to clear the impulse coupling trip dogs Wind spring one half turn and re engage the cam assembly into the impulse coupling body Six cylinder applications must utilize current heavy spring and compatible body and cam assembly as specified in the Illustrated Parts List in Section 11 This arrangement does not require the extra spring tensioning procedure detailed above 9 2 11 Impulse Coupling and Drive Plate Installation 9 22 1 Apply a light coating of 10 27165 Magneto Grease to the impulse coupling stop pins at the flyweight contact points WARNING Use of unapproved ha
139. s may alter or replace the manufacturer s Instructions for Continued Airworthiness Insert a copy of applicable Service Documents in affected manuals until the service document instructions are incorporated in the manual or the service document is cancelled or superseded Category 1 Mandatory Service Bulletin MSB Used to identify and correct a known or suspected safety hazard which has been incorporated in whole or in part into an Airworthiness Directive AD issued by the FAA or have been issued at the direction of the FAA by the manufacturer requiring compliance with an already issued AD or an equivalent issued by another country s airworthiness authority May contain updates to Instructions for Continued Airworthiness to address a safety issue Category 2 Critical Service Bulletin CSB This category identifies a condition that threatens continued safe operation of an aircraft persons or property on the ground unless some specific action inspection repair replacement etc is taken by the owner or operator Documents in this category are candidates for incorporation into an FAA Airworthiness Directive May contain updates to Instructions for Continued Airworthiness to address a safety issue Category 3 Service Bulletin SB Information which the product manufacturer believes may improve the inherent safety of an aircraft or aircraft component this category includes the most recent updates to Instructions for Continued Airworthi
140. sed once they have been removed 1 Fabricate a set of support bars and plate matching the dimensions in Figure 10 6 and Figure 10 7 Thread a scrap screw into the cam securing hole in the rotating magnet shaft Figure 1 48 to protect the shaft taper during arbor press operation 2 Place a protective pad on arbor press base In arbor press set up support bars brass drift and support tube with rotating magnet shaft 48 as shown in Figure 4 6 Press gear Figure 1 52 and bushing 53 off of the rotating magnet 48 Discard the gear 52 and bushing 53 4 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl ai Us 4375 Dia Brass Drift Pressure Direction Steel Plate Locally Fabricated Arbor Press Base Figure 4 6 Rotor on Support Bars for Small Gear and Bushing Removal 4 3 Harness Disassembly Remove the inner ferrules Figure 2 7 7a or 14 from the outer ferrules 8 or 13 or cover 16 using 0 25 inch drift and arbor press Discard all used inner ferrules 7 7a or 14 2 All other harness hardware may be disassembled using standard shop practices Discard eyelets 12 and terminals 3 following disassembly D 2000 D 3000 Series High Tension Magneto Service Support Manual 4 7 31 August 2011 Disassembl 4 8 Intentionally Left Blank D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Cleanin Sec
141. semble spring 6 eyelet 5 and sleeve 4 onto lead The tapered side of eyelet 5 must rest against the taper on the sleeve 31 using the assembly tool shown in Figure 9 25 Assemble spring Figure 2 2 and terminal 3 with a clockwise twisting motion Clean the spark plug terminal according to the instructions in Section 5 3 Test the ignition lead according to instructions in Section 3 3 9 3 4 5 8 24 Straight Spark Plug Terminal Assembly l Ze 3 4 Complete step 1 through step 8 of Section 9 3 3 Assemble sleeve Figure 2 4 and terminal with a clockwise twisting motion using the Harness Assembly Tool Figure 9 25 Assemble spring Figure 2 2 and terminal 3 with a clockwise twisting motion Clean the spark plug terminal according to the instructions in Section 5 3 Test the ignition lead according to instructions in Section 3 3 9 3 5 3 4 20 Elbow Spark Plug Terminal Assembly 1 2 9 28 Insert 11 9596 nylon tube between shielding and insulation to approximately 4 inch depth Figure 9 21 With 11 9596 nylon tube acting as a protective sleeve cut off 4 inches of shielding and scrape off 3 8 in of gold silicone covering from remaining shielding D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 3 Remove 11 9596 nylon tube 4 Cut and remove 3 8 in insulation from the conductor to facilitate crimping the terminal Figure 2 3 NOTE
142. sisssssssssssssss Index Description Part No el ille gelle 2lo SS 2122292 1 Screw Socket NAS1351 3 32P 4 14 4 4 4 4 NAS1351 3LB32P 2 Washer Spring Lock MS35338 43 3 Washer Plain 10 55501 4 Nut Hex 10 382618 5 Washer Lock 10 17050 Capacitor 6 CYL 10 400576 6 Capacitor 8 CYL 10 400578 Capacitor 4 CYL 10 400574 7 Pin Cotter 10 90751 18 8 Gasket Cover 10 382811 9 Screw w Lock washer 10 35936 7 10 Washer Plain 10 14268 11 Contact Assembly 10 382585 12 Contact Assembly Main amp Tach 10 400183 13 Contact Assembly Main amp Retard 10 400184 14 Screw w Lock washer 10 382959 10 391213 15 Washer Plain 10 51354 16 Cam Breaker 2 lobe 10 382544 Cam Breaker 4 lobe 10 382543 17 Cam Retard 4 lobe 10 382739 Cam Retard 2 lobe 10 382741 18 Screw w Lock washer 10 35937 20 19 DELETED 20 Connector Strip 10 382785 21 Gear Kit 4 amp 8 CYL 10 682014 Gear Kit 6 CYL 10 682016 22 Ring Retaining MS16624 2037 23 Washer Flat 10 349511 24 Brush Carbon 10 160844 25 Washer Nylon 10 391309 26 Washer Felt 10 50752 Block amp Bearing Kit 4 CYL 10 682054 27 Block amp Bearing Kit 6 CYL 10 682056 Block amp
143. ss otherwise specified Complete disassembly of magneto is not necessary in all instances Disassemble the magneto only to the extent required for maintenance procedures involved Refer to Table 10 1 for a list of tools and materials required for magneto disassembly Capacitors Figure 1 6 are part of the magneto assembly and are essential to magneto operation When replacing the magneto replace the capacitors as well Detailed Disassembly Procedures NOTE The following parts must be replaced 100 with new parts following their disassembly from the magneto regardless of whether disassembly is for the purpose of inspection replacement of a part or overhaul Lock washers 2 amp 33 Screws 9 14 18 46 amp 54 Retaining ring 22 amp 43 Washers 3 amp 47 Bearings 30 amp 50 felt strip 28 identification plate 65 Bearing retainer 51 Springs 56 Pin 7 Spring 41 and Gasket 8 The following parts may be re used after maintenance inspection according to Section 6 2 1 and Section 6 2 3 but must be replaced at overhaul Main Retard amp Tachometer assemblies 11 12 amp 13 felt washer 26 carbon brush 24 and capacitors 6 4 2 1 Initial Inspection Disassembly 1 Remove the cover retention screws Figure 1 1 and washers 2 or 3 from cover 16 Carefully remove the cover 16 away from housing 66 Remove and discard the gasket 8 if installed Pry capacitor 6 lead terminals from the contact
144. ssing Support 10 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Special Tools Equipment and Supplies gerd 1 87 Dia e Figure 10 6 Support Bar Dimensions 2 000 s 0 250 P ja 0 625 0 015 1 000 lt i M 4 000 Figure 10 7 Small Gear Support Bar Dimensions D 2000 D 3000 Series High Tension Magneto Service Support Manual 10 5 31 August 2011 Special Tools Equipment and Supplies 3 500 3 500 9 Figure 10 8 Wood Support Block Dimensions 0 250 Dia 2 Places Figure 10 9 Dial Indicator Mounting Plate 10 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Section 11 Illustrated Parts List 11 1 Equipment Covered Table 11 1 Equipment Covered Includes Supersedes Includes Harness Magneto Supersedes Magneto Part Part No System Part Magneto Type Part No Magneto Type Number Degrees Lag See Table 11 7 and Number Number See Table 11 6 Number See Table 11 5 Retard Table 11 8 10 720633 49 Spare elbow style lead to maintain Dura Blue Harnesses ONLY See Table 11 7 10 720633 78 Spare elbow style lead to maintain Dura Blue Harnesses ONLY See Table 11 7 10 785046 109 D6LN 3200 10 682910 13 D6LN 22
145. sure the braid is flush with cover e Fully seat the ferrule 7a using an arbor press and seating tool shown in Figure 10 1 The ferrule Figure 2 7a must seat flush to 0 031 in below the adjacent surface of the cover MAGNETO FERRULE EYELET 2 11 1 F AREA TO BE SCRAPED Figure 9 23 Dura Blue Lead Assembly 5 Using 11 9596 tube remove any jacket shavings and or stray shielding strands from the seating area Use care not to nick insulation 6 Install a grommet 11 over the insulation 7 Using a WT 111M crimping tool modified according to Figure 9 24 crimp eyelet Figure 2 12 9 26 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl CONTOUR INDICATED EDGES ROUND WITH A FILE TEST WITH A SPARE EYELET AND A SECTION OF SCRAP CABLE TO VERIFY SATISFACTORY CRIMP QUALITY Figure 9 24 Eyelet Crimping Tool a Seat eyelet 12 over inner conductor flush against grommet 11 b Crimp the eyelet to the lead as shown in Figure 9 24 step A c Rotate the lead and eyelet 90 degrees and crimp eyelet Figure 2 12 a second time as shown in Figure 9 24 step B Trim excess conductor flush d Crimp must have no breaks cracks voids or areas of distortion The crimped eyelet must withstand 15 Ib pull test If these conditions are not met remove and discard eyelet 12 8 Pull conductor from spark plug terminal end to seat the grommet 11 flush against cover 16 Milk o
146. t tail against body Figure 1 40 trip dog When released flyweight tail must drop down If flyweight tail sticks to body parts are magnetized and coupling may not function Perform test on both flyweights Figure 9 15 Check Impulse Coupling for Magnetism 2 If body is magnetized demagnetize it using a degaussing coil 3 Clamp one drive lug of body 40 in a soft jaw vise with the spring recess side up Orient new spring 41 with body 40 for correct rotation Figure 9 16 Insert eye of outer end of spring Figure 1 41 in the hole drilled in inner rim of body 40 4 Using heavy gloves to protect the hands wind the spring 41 in the impulse coupling body 40 manually lifting the spring coils one at a time over projections on the impulse coupling body Extreme care must be used to avoid scratching or nicking the spring After winding the spring brush a coating of light oil over spring coils 9 20 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl CW CCW Figure 9 16 Impulse Coupling Spring Orientation CAUTION Nicks or scratches in the impulse coupling spring will cause the spring to break 5 Using a small screwdriver with all sharp edges removed pry up one and one half turns at the inner end of the spring and support in the position shown in Figure 9 17 Do not allow the screwdriver to scratch the spring Figure 9 17 Lift Inner End of Spring 6 Engage the reces
147. ted Sections Bulletin Number Title Release Date Affected Sections Bulletin Number Title Release Date Affected Sections Bulletin Number Title Release Date Affected Sections Bulletin Number Title Release Date Affected Sections Bulletin Number Release Date sl Affected Sections D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 31 August 2011 Scope and Purpose of this Manual This manual provides installation operation maintenance and overhaul instructions applicable to D 2000 and D 3000 series magnetos manufactured by Continental Motors Instructions apply only to the Continental Motors magneto series listed for magnetos engines and accessories beyond the scope of this document refer to the appropriate instructions for continued airworthiness Exploded assembly illustrations accompany instructions throughout the manual Parts in illustrations Figure A are identified with numerical callouts indices Corresponding parts listings follow the illustrations for reference The first time instructions refer to an illustration the figure number is identified in parentheses followed by the callout In subsequent parts references only the callout will be specified unless the referenced illustration changes Referenced didnt d l Carefully slide the sleeve Figure 6 15 13 and drive gear assembly 3 out of the a
148. ted for the convenience of users wishing to purchase tools At the time of publication each tool listed is available from the corresponding supplier Use of alternate tools is acceptable so long as such tools are capable of equal or greater performance than the listed tool 10 1 Special Tool and Consumable Supply List Table 10 1 Special Tools and Consumable Supplies tools required inches unless 8840A Digital Multimeter or equivalent Part Number and Description Application Source Special Tools Fabricate Ignition Harness Assembly Tool Assemble Ignition Harness according to Figure 10 2 Fabricate Eyelet Pressing Tool Press Eyelet in to Cable Outlet Plate Figure 2 16 according to Figure 10 1 Fabricate 11 1471 Drift Seat bearing Figure 1 50 in flange according to Figure 10 3 11 8150 1 Timing Kit Check magneto internal timing Kell Strom 11 8465 Rotor Holding Tool Hold rotor to check magneto internal timing Kell Strom 11 8627 Spring Seating Kit Seat spring in distributor block Kell Strom 11 8822 Lock Ring Installation Drift Install retaining ring Kell Strom 11 8950 2 High Tension Lead Tester Test high tension lead insulation strength and continuity Kell Strom 11 9998 Bearing Pressing Tool Remove bearing Kell Strom 11 9999 Bearing Pressing Support Remove bearing Kell Strom 11 10500 Magneto Test Stand or equivalent For off engine magneto testing Kell Strom 11 10600 Magnet Charger M
149. test stand unless all high voltage leads are connected to spark gaps an open high voltage circuit would subject magneto parts to damage Do not operate magneto on test stand with oil seal installed for longer than five minutes as hidden damage may result MATERIAL TUNGSTEN BRASS OR STAINLESS STEEL A 0 008 in R max i 3 Places 4mm k 0 187 in orig AN IONIZING TEASER ELECTRODE Y m ASS 0 039 in NO ELECTRICAL CONNECTION DO NOT GROUND TO MAGNETO Figure 3 1 5mm Spark Gap Setting 2 Install magneto grounding leads fabricated using 10 382698 ground terminal lead kits to capacitors When applicable install a retard lead made with 10 157208 kit and or tachometer lead made with 10 157209 kit 3 Determine lowest speed at which rotating magnet can be turned and still spark all gaps without missing coming in speed Magnetos must spark consistently at 150 3 2 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Testing amp Troubleshootin RPM If coming in speed is greater than 150 RPM the trouble may be due to dirty contact points improperly adjusted contacts weak coil weak magnet damaged capacitor or improperly timed distributor gear Clean contact assembly try a new coil or capacitor recharge magnet recheck distributor gear recheck contact assembly adjustment and repeat test 4 Observe electrical and mechanical performance at 150 and 1
150. the firing order may be determined by the charts shown in Figure 2 5 Follow the Engine Manufacturer s instructions regarding lead routing cylinder numbering and engine firing order D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation Figure 2 5 Harness Outlet Cover Configuration High Tension cable Figure 2 5 is available in 100 foot rolls The cable is rated to withstand temperatures up to 400 F flexibility is retained to 65 F OUTER EXTRUDED SILICONE INSULATION SILICONE RUBBER STAINLESS STEEL BRAID CONDUCTOR WIRE Figure 2 6 Gold Seal Cable D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 2 5 Description and Operation 2 3 2 4 2 4 1 2 6 Maintenance and Overhaul Periods In addition to performing all magneto related operational checks as specified by engine and or airframe manufacturer prior to each engine shut down and prior to performing any maintenance on the engine perform the Magneto RPM drop off Test as detailed in the Pilot s Operating Handbook Normally found under Preflight Engine Run Up Procedures Refer to Hot Magneto Test in Section 3 4 in the event of adverse indications If magneto timing is found to be outside engine manufacturer s limits for magneto to engine timing check the contact assemblies 11 12 amp 13 according to the instructions in paragraph Contact Assembly
151. the rotating magnet back to the neutral position then turn rotor back in normal direction Timing light must go out when timing pointer is aligned with appropriate R or L E gap mark Lock the rotating magnet where the contacts just open Loosen the right main contact assembly securing screws to allow adjustment of the right main contacts Adjust right main contacts to just open Repeat step 7 this time ensuring that both sets of contacts open within one degree half the width of the R or L mark of one another If contacts are not properly synchronized reset the right contact assembly CAUTION The self locking screw 14 is a single use fastener If the self locking screw is removed or loosened at any time replace it with anew Self locking screw and apply 21 25 in lbs torque Check right main contacts for 0 016 0 004 inch opening at high lobe of cam If clearance is correct apply 21 25 in lbs torque to the right contact assembly securing screws 9 If clearance is out of limits repeat timing procedure setting left main contact as follows If right main contacts open more than 0 020 in set left contacts to 0 018 inch If right main contacts opened less than 0 012 in set left contacts to 0 014 inch Always torque the contact assembly retaining screws 9 before checking clearances If magneto does not use a retard and or tachometer contact assembly apply 21 25 in lbs torque to new cam sec
152. tion 5 Cleaning 5 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified Using a clean dry lint free cloth wipe accessible areas of the housing 66 cover 16 and other external surfaces free of grease oil film or other contaminants CAUTION Magneto 66 housing and harness cover 16 are made of magnesium alloy Use only fresh clean nylon scouring pads to brighten areas where oxidation may be present 5 2 Detailed Magneto Cleaning Procedures 1 Clean breaker points Figure 1 11 12 amp 13 using any hard finished paper i e a typical business card close contacts on cleaning paper then open breakers and remove paper Do not drag paper through closed contacts do not use emery cloth CAUTION Do not immerse cams 16 amp 17 or distributor block 27 in solvent Solvents will damage these items WARNING Isopropyl Alcohol IPA is flammable Do not use near an ignition source Use only with adequate ventilation Use appropriate personal protective equipment to protect eyes skin and clothing from exposure Avoid breathing IPA vapors Store IPA only in approved containers CAUTION When utilizing compressed air wear OSHA approved protective eye wear Never exceed 30 psi when using compressed gases for cleaning purposes OSHA 1910 242 b 2 Clean the remainin
153. tions WARNING When the P lead terminal is removed from the magneto the spring inside the capacitor DOES NOT ground the magneto Should the propeller be moved by hand during maintenance procedures and a functional hot magneto condition exists the engine may fire and cause injury to personnel 1 Remove plugs Figure 1 59 61 63 or 60 necessary to gain visual access to the distributor gear 21 and rotor 48 Turn rotating magnet to the No 1 neutral position For D4LN 2200 and D4LN 3200 magnetos this position is with the C mark of the rotor centered in the timing window and the red gear teeth on the edges of the windows on the ends of the magneto For all other magnetos position K mark of the rotor in the center of the timing window and the red gear teeth on the edges of the windows on the ends of the magneto Turn the rotor slightly in reverse direction of normal rotation and allow rotor to rest in magnetic neutral position The red tooth will appear off center in window 2 Using 11 9110 1 Timing Light and adapters made from P N 10 382698 terminal kits install and adjust magneto on engine according to the engine manufacturer s instructions WARNING Do not use any gear holding tool while performing magneto inspections maintenance adjustments or assembly Such tools are unnecessary and using them may cause hidden damage to D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 31 31 August 2011
154. tions Inspect contact assemblies according to instructions in Section 6 2 1 and adjust and replace parts as necessary Contact assemblies not opening properly Inspect contact assemblies for proper opening according to instructions in Section 9 2 8 Main contact assembly out of adjustment Check magneto internal timing according to internal timing off instructions in according to instructions in Section 9 2 8 Faulty plugs or leads Check plugs and leads No drop off noted open switch Check capacitor according to instructions in connection Section 7 2 5 Carbon tracked distributor block Replace distributor block Radio Noise Faulty spark plugs Replace spark plugs Frayed shielding at spark plug terminal magneto cover or intermediate point on harness lead Replace ignition lead Inadequate shielding ground at spark plug terminal or magneto cover Remove and replace inner ferrule according to instructions in Section 9 3 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 3 7 Testing amp Troubleshootin Intentionally Left Blank 3 8 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Y NAA Disassembl 4 1 4 2 Section 4 Disassembly General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure 1 or the harness in Figure 2 and the Illustrated Parts List in Section 11 unle
155. ult of a join point of material flow around the rear bearing liner insert during the molding process and may appear in any distributor block Replace the distributor block if a There is more than one material flow line extending or radiating out from the rear bearing liner b The material flow line extends beyond the permissible area shown in Figure 7 3 c The material flow line extends into the vertical area of the pilot skirt d The material flow line is apparent in the dielectric material on both the top and bottom sides of the block Material Flow Line Figure 7 3 Stress Line in Distributor Block 6 Clean the distributor block according to instructions in Section 5 2 step 5 7 After cleaning inspect for the distributor block carbon tracking which appears as a thin wavy line across the dielectric surface If suspicious areas are noted check with the 11 8950 2 High Tension Lead Tester Kit as follows a Connect the tester ground lead to a distributor block electrode with a medium alligator clip b Attach the tester high voltage lead Figure 7 4 to one of the electrodes adjacent to the grounded one 7 4 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul c Tester high voltage will follow a carbon track Test all inter electrode spaces Test between the grounded center bushing and all electrodes Temporarily assemble the distributor block Figure 1 27 in the ho
156. urer holding an FAA Production Certificate issued under FAR 21 Subpart G e By acertificate of airworthiness for export issued by a foreign government under the provisions of FAR 21 Subpart N Know Your Supplier It has come to our attention that many reproduced parts and components particularly instruments which have been manufactured by persons other than the original manufacturer are available for purchase and installation on U S certificated aircraft Often an original part is used as a sample to produce duplicates The reproduced parts appear to be as good as the original part however there are many unknown factors to be considered that may not be readily apparent to the purchaser i e viii D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 31 August 2011 heat treating plating inspections tests and calibrations All too often the faulty part is not discovered until a malfunction or an accident occurs Summary In accordance with FAR s certification of materials parts and appliances for return to service for use on aircraft is the responsibility of the person or agency who signs the approval The owner operator as denoted in paragraph 3 of this advisory circular is responsible for the continued airworthiness of the aircraft To assure continued safety in aircraft operation it is essential that great care be used when inspecting testing and determining the acceptability of all parts and
157. uring screw 14 at this time CAUTION If the upper cam operates tachometer contacts only cam position is immaterial apply 21 25 in lbs of torque to the cam securing screw On magnetos employing a retard contact assembly connect the 11 9110 1 timing light to the flexible tab terminal on the left contact assembly and to ground Turn the rotating magnet in the normal direction of rotation until the specified retard angle See Table 11 1 or identification plate Figure 1 65 is aligned with the timing pointer Lock the rotor in this position Carefully loosen the cam securing screw 14 enough to allow only the retard cam 17 to turn Turn the cam in the normal direction of rotation until the retard contacts just open Apply 21 25 in lbs torque to the cam securing screw 14 Using 11 9110 1 timing light recheck left and right magneto synchronization both points must open within half the width of the L or R timing mark Confirm retard D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 13 angle is set properly and or tachometer points make and break contact Recheck point clearances at high lobe of cam Left main 0 016 0 002 in all others 0 016 0 004 in Push coil lead flag terminals straight down over the outer spade terminal of each contact assembly The flag terminal must fit snugly to the spade terminal The flag terminal may be carefully pinched at each rolled edge to
158. using 66 and test for carbon tracking between electrodes and housing by connecting to housing and each electrode Reject the distributor block 27 if it exhibits carbon tracking Figure 7 4 Check Distributor Block for Carbon Tracking 8 Inspect contact springs 29 on the tower side of distributor block 27 If contact spring appear fuzzy or white or show evidence of burning rust or corrosion remove with needle nose pliers and discard Check springs for proper height by measuring down from the top of the tower If measurement exceeds the 0 422 inch Figure 7 5 the spring may be deformed or improperly installed Using a scribe or similar pointed instrument wiggle top of spring in a circular motion to ensure only bottom turn of spring is captive in groove of block insert Recheck spring height if measurement still exceeds 0 422 inch remove and replace the spring d 0 422 in MAX Figure 7 5 Contact Spring Height 9 Using a small scraper or knife clean distributor block 27 electrodes to remove any carbonized deposits Do not attempt to grind or machine electrodes D 2000 D 3000 Series High Tension Magneto Service Support Manual 7 5 31 August 2011 General Overhaul 10 Impregnate bronze bushing and coat distributor block as follows a e 7 6 NOTE Only black phenolic distributor blocks must be coated at each 500 hour inspection and at each overhaul period DO NOT COAT POLYESTER brown distr
159. uter braid for proper length Dress lead to harness and engine as necessary with clamps and cable ties 22 9 Clean the sleeve 4 and grommet 11 according to the instructions in Section 5 3 10 Test lead according to instructions in Section 3 3 D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 27 31 August 2011 Assembl 9 3 3 3 4 20 Straight Spark Plug Terminal Assembly 1 Insert 11 9596 nylon tube between the shielding and insulation to approximately 1 5 inch depth Figure 9 21 With 11 9596 nylon tube acting as a protective sleeve cut off 7 8 in of shielding and scrape off 1 4 to 3 8 in of gold silicone covering from the remaining shielding 3 Remove 11 9596 nylon tube 10 11 Cut and remove 1 2 in insulation from conductor to allow crimping of terminal Figure 2 3 Assemble the nut 9 and ferrule 8 on the cable 10 Place ferrule 7 or 7a over insulation and slide the tapered end under the braid to cover approximately 3 4 of the ferrule Position outer ferrule 8 snug against the inner ferrule 7 or 7a Seat parts together using arbor press and Eyelet Pressing Tool Figure 10 1 Remove excess jacket material NOTE NOTE Crimp terminal only once to provide joint capable of withstanding 15 lb pull test Avoid damage to the threaded portion of the terminal Crimp terminal Figure 2 3 onto conductor using modified WT 111M Crimping Tool As
160. wer where it bears against the breaker cam and where it bears against the point spring Each end is identical when the follower is new Gradual flattening of the radius against the cam is a normal wear condition Discoloration scoring and smearing of the nylon against the cam is cause for rejection of the contact assembly and calls for examination of the other contact assembly for similar damage as well as examination of the cam and needle bearing Replace the cam if it appears damaged or contaminated Replace the bearing if it exhibits signs of overheating such as discoloration or lack of lubrication If the end of the follower is deformed assuming the shape of the spring whether or not it is bulged or discolored adjacent to the spring replace the contact assembly and its associated capacitor 5 Check the condition of the cam follower felt Squeeze the felt tightly between thumb and forefinger If fingers are not moistened with oil re oil using 2 or 3 drops of 10 86527 Lubricant Allow approximately 30 minutes for felt to absorb the oil Blot off excess with a clean cloth Excess oil may foul contact points and cause excessive burning 6 Clean dirty breaker points according to instructions in Section 5 2 step 1 7 Check magneto to engine timing as follows WARNING When the P lead terminal is removed from the magneto the spring inside the capacitor DOES NOT ground the magneto Should the propeller be moved by hand during maintenan
161. wing their disassembly from the magneto regardless of whether disassembly is for the purpose of inspection replacement of a part or overhaul Lock washers 2 33 Screws 9 14 18 46 54 Retaining ring 22 43 Washers 3 47 Bearings 30 50 felt strip 28 identification plate 65 Bearing retainer 51 Springs 56 Pin 7 Spring 41 and gasket 8 The following parts may be re used after maintenance inspection according to Section 6 2 but must be replaced at overhaul Main Retard amp Tachometer assemblies 11 12 amp 13 felt washer 26 carbon brush 24 and capacitors 6 D 2000 D 3000 Series High Tension Magneto Service Support Manual 9 1 31 August 2011 Assembl 9 2 Detailed Assembly Procedures 9 2 1 Coil Installation Separate instructions are provided to install the D 2000 and D 3000 Coils Adhere to the appropriate instructions during assembly 9 2 1 1 D 3000 Series Magneto Coil Installation 1 Position coils Figure 1 58 in the housing with ends of the high tension terminals pointed toward the center of the housing CAUTION Discard any springs that become deformed during installation 2 Hold spring 56 with Duck Bill pliers using care to avoid crushing or deforming the spring Apply pressure at points Figure 9 1 A and B and insert spring with B side towards the coil core Repeat for all springs Figure 1 56 Magneto Housing Sori Coil Core p

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