Home

Service Support Manual

1. 2 S 8 3 3 3 Sg S3 3 F 3 3 32105 a 2 wo wo wo wo wo S alal S alal S a alal Sl 8 e ao 5 5 o 5 5l S 6 Bb 6 S BS S BS Index Description Part No e 222 2222 21 Nut Cap 10 163177 1 22 Disk Neoprene 10 163384 1 25 Screw Fillister Head 10 35937 12 4 4 4 4 4 44 4 4 4 4 4 4 4 4 A4 33 Screw Hex Head 10 682025 1 MENU i UNMIUENMUESM 1 34 Gasket 10 357520 1 35 Spring 10 102090 1 d d di 1 1 NT UI 1 1 37 Washer Plain 10 14268 1 SOOS O I EMINUS HMM 39 Contact Assembly 10 382585 1 10 357173 1 1 10 357174 1 d dd 1 lp 1 1 41 Screw wilock washer 10 35935 5 2 10 35936 7 3 BREE BSG Bee am 42 Capacitor 10 51676 1 NEMUS a ee hu 1 10 400572 1 44 Plug Solid 10 157135 1 manna aaa aa i 10 51391 1 45 Bushing P Lead NLA 1 1 46 Plug Ventilator 10 157134 1 CO O I DMIMSM MU 10 50732 1 47 Screw 10 157158 5 GCS IE Games HE 48 Housing Distributor NLA 1 i see ee 1 NLA 1 1 10 400551 7 1 NLA 1 49 Gasket 10 52320 1 50 Housing Magneto 10 400549 1 1 m 1 1 1 1 1 10 400549 2 I 1 1 1 10 400549 4 1 1 1 NLA 1 52 Plate Data 10 400012 1 E m a 53 Key Woodruff 10 90788 5 2 AAA IRIS CEDA BH 54 Magnet Rotating Rotor 10 52945 1 10 52946 1 1 10 52947 1 1 RR 1 1 10 52948 1 1 1 1 1 55 Slinger Oil 10 51678 1 NEMUS MINIM i
2. Table 11 16 Numerical Parts List Table 11 16 Numerical Parts List Part No Description Index Part No Description Index 2 161 1 thru7 Washer Lock 71 10 52945 Magnet Rotating Rotor 54 2 199 1 thru6 Washer Shim 65 10 52946 Magnet Rotating Rotor 54 2 202 Bearing Ball 64 10 52947 Magnet Rotating Rotor 54 10 3505 Washer Plain 66 10 52948 Magnet Rotating Rotor 54 10 3793 Washer Lock 3 10 56513 Pin Stop 60 10 4093 Washer Plain 4 10 70371 Body Impulse Coupling 9 10 14268 Washer Plain 26 10 76232 Body Impulse Coupling 9 10 16092 Washer Plain 26 10 79011 Pin Stop 60 10 25788 Bearing Sleeve 69 10 81806 Bearing Ball 70 10 35935 5 Screw w lock washer 41 10 90751 18 Pin Cotter 1 10 35935 6 Screw w lock washer 41 10 90751 19 Pin Cotter 1 10 35936 7 Screw w lock washer 41 10 90788 5 Key Wooduf 53 10 35937 8 Screw w lock washer 56 10 102083 Screw w plain amp lock washer 78 10 35937 12 Screw w lock washer 25 10 102090 Spring 35 10 50732 Plug Ventilator 44 10 102092 Spring 35 10 50737 Spring Tower 80 10 116860 Washer Plain 4 10 50752 Washer Felt 82 10 125996 Bushing Insulating 27 10 50757Y Housing Distributor 48 10 157120Y Gear Pinion 67 10 50765 Clamp Coil Core 57 10 157134 Plug Ventilator 46 10 50772 1 Cam Breaker 63 10 157135 Plug Solid 44 10 50772 4 Cam Breaker 63 10 157158 Screw w lock washer 47 10 50772 5
3. LA mai aim eee C ee oe oe ms om dii qt ad ch 374 Insulated Ta Figure 1 S 20 S 200 Series Magneto Exploded View S 20 S 200 Series High Tension Magneto Service Support Manual 11 39 Reverse Blank 31 August 2011 H A H Continental Motors Inc www continentalmotors aero
4. ele xle 95s 2 552258 amp 8 2 222 2 2 2 2 9 8 8 8 I 2222232228583 s35555 o uo uo uo uo 1o ig io io Ho 2 2 Index Description Part No o 2c 9o 2 2 2 2 22 22 22 e2 18 Sleeving 654742 2 50 1 19 Grommet Tach 10 400103 1 25 Screw wllock washer 10 35937 12 4 4 4 4 4 4 M 28 Nut MS35650 302 1 1 1 IEEE Fa 34 Gasket 10 357520 i 4 1 36 Packing 10 349263 1 Rene Bane Bee B 37 Washer Plain 10 14268 1 EMEN 1 BNMBMMNMNM 1 ee 2 NAS620 8L 1 38 Bushing Tach 10 361639 2 39 Contact Assembly 10 382585 1 BENI 1 1 1 1 10 382584 mi Mm 1 1 1 Tachometer 10 400507 1 40 Plate Insulating Tach 10 361624 1 41 Screw wlock washer 10 35935 7 2 Mm 2 ne mm 2 MM I 4 41a Screw w lock washer 10 35935 6 2 ENENEPM 2 EPNEPNEPNM 2 RR RR 2 E 42 Capacitor 10 400615 1 BEBE 1 ee BEBNEEN Bl 44 Plug Solid 10 157135 1 Bee 1 ee 1 ee Ni 46 Plug Ventilator 10 157134 1 BEBNEBE ane i BE 1 46a _ Orifice Air Bleed 10 382861 14 47 Screw wlock washer 10 157158 5 Mm MR 5 BEER 5 ES 48 Housing Distributor 10 400551 7 141371 1 1 1 1 10 400551 8 EE 1 EMI 1 1 1 49 Gasket 10 357533 1 1 1 50 Housing Magneto 10 400549 1 1 1 1 1 10 400549 2 EE 1 EMI 10 400552 1 1 11 10 400552 2 1 1 10 400552 5 1 52 Plate Data 10 400012 1 n e 1 eee GE y BN 53 Key Woodruff 10 90788 5 3 RARER NEMENSEM NSMESENM 54 Magnet Rotating Rotor 10 52946 1 10 52947 1 1 1 10 52
5. Degrees Applicable Magneto Part Number Model Number Lag Retard Use Terminal Kit Part No Parts List 10 79020 119 S6RN 25P 30 10 382814 Table 11 5 10 163005 2 S4LN 200 25 10 157208 amp 10 157209 Table 11 6 10 163005 3 S4LN 200 25 10 157208 amp 10 157209 Table 11 6 10 163005 11 S4LN 200 15 10 157208 amp 10 157209 Table 11 6 10 163010 1 S6RN 200 30 10 157208 amp 10 157209 Table 11 7 10 163010 2 S6LN 200 30 10 157208 amp 10 157209 Table 11 7 10 163010 10 S6LN 200 37 5 10 157208 amp 10 157209 Table 11 7 10 163010 11 S6LN 200 30 10 157208 amp 10 175209 Table 11 7 10 163010 15 S6RN 200 25 10 157208 amp 10 157209 Table 11 7 10 163015 3 S4RN 201 20 10 157208 amp 10 157209 Table 11 6 10 163020 3 S6RN 201 30 10 157208 amp 10 157209 Table 11 7 10 163020 4 S6LN 201 30 10 157208 amp 10 157209 Table 11 7 10 163045 1 S4LN 204 10 157209 Table 11 6 10 163045 3 S4LN 204 10 157209 Table 11 6 10 163045 6 S4LN 204 00 10 157209 Table 11 6 10 163050 1 S6LN 204 10 157209 Table 11 7 10 163050 2 S6LN 204 10 157209 Table 11 7 10 163050 7 S6RN 204 11 10 157209 Table 11 7 10 163050 9 S6LN 204 11 10 157209 Table 11 7 10 163050 12 S6LN 204 11 10 157209 Table 11 7 10 163055 1 S4RN 205 11 10 157209 Table 11 6 10 163060 1 S6RN 205 11 10 157209 Table 11 7 10 163060 2 S6LN 205 11 10 157209 Table 11 7 10 500514 1 S4LSC 21 25 Table 11 8 10 500514 2 S4LSC 21 15 Table 11 8 10 500514 3 S4RSC 21 25 Table 11 8 10 500514 4 S4RS
6. lal E 5 Sl ex xi uie Sl sla 2 2 2 2 28 amp amp 2 2 23 2 2 2 2 2812 2 2 2 2 232 2S 2 a Index Description Part No 3 S 3 S 3 S 3 S 3 S S 3 S 3 50 Housing Magneto 10 400549 4 1 BEEN TEE ma 10 400552 4 11 111 52 Plate Data 10 400012 1 1 14 i BENENEN i mhil i E 53 Key Woodruff 10 90788 5 2 EHE 3 ENENENM 3 ENEXNES 54 Magnet Rotating Rotor 10 52945 111 1 1 1 10 52947 1 1 1 il at 10 52948 1 4 111 55 Slinger Oil 10 51678 1 BENNMEN U ELI 1 L 56 Screw wilock washer 10 35937 8 2 EMEN NM o PECETE 2 MR BR 2 I 57 Clamp Coil Core 10 50765 2 ENHEPNEPN ENEPNENSo Rarer 2 P 58 Coil 10 357165 1 imENBEBEE 1 ie 1 BEBEBN Ni 59 Seal Oil 10 400554 1 inte 1 Rane 1 aaa 1 Ei 61 Screw w lock washer 10 391213 1 Be 1 ee 61 ie 1 62 Washer Plain 10 513541 1 Bee BENMENEN rig E 63 Cam 10 50772 4 1 1 1 1 1 10 50772 5 1 fd fa io 1 1 1 1 64 Bearing Ball 2 202 1 Be ENMEEMBNM BMEBNEBEN 1 T 65 Washer Shim 0 002 in thick 2 199 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 199 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 199 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 199 4 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 010 in thick 2 199 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 199 6 AR AR AR AR AR AR AR AR A
7. 9 20 Impulse Coupling Spring Orientation esses 9 21 Lift Inner End of S pneus eoa Aa ap eave Mee ae 9 2 Apply Anti seize to Magneto Shaft sess 9 22 Proper Cotter Pin Installation 2 2 tenido docet pretenden 9 23 Typical Impulse Coupling Crack sess 9 23 Lead Preparation 523 3 n stia rede Ire deis ko Ren ee tops anc URS 9 25 Lead Assembly Detail 5 555 5 c or te teca est ee ko ees euo SiS 9 25 Dura Blue Lead Assembly 345 2 5 5 dene eor NER EER 9 26 Eyelet Crimping Toolse a ub aetas aie added ted n de 9 27 Ignition Harness Assembly Tool eese 9 29 Formed Capacitor Leads 1 tct teorie eite 9 30 Lubricate Insulating Sleeve 12 eese eren etti iere etae eras 9 32 Terminal Kit Assembly t edet erae o tease 9 33 Elbow Kit Assembly sc teen nsiirgae teen i ISDN E Ne UN 9 33 Eyelet Pressing Tool sse uet soa od Rd ee Pe Mass 10 3 Harness Assembly Tool edendi traditae its cu end 10 3 11 147 T DOC cose qtu a tq iom 10 3 11 9998 Bearing Pressing Tool eese 10 4 11 9999 Bearing Pressing Support sese 10 4 Support Bar DITICBSTORS 53 sep pir IR oeil le eise indi iusatadeos 10 5 Small Gear Support Bar Dimensions eese 10 5 Wood Support Block Dimensions eene 10 6 Dial Indicator Mounting Plate sees 10 6 Terminal Kit Sp
8. 56 Screw w lock washer 10 35937 8 222 2 2 j2 2 2 2 2 2 2 2 2 2 sa 57 Clamp Coil Core 10 50765 2 2 22222221 2212 22522 58 Coil 10 357165 20S 1 d 1 d Y hM d ht hd 1d 4 1 10 357165 1 1 59 Seal Oil 10 400554 1 ENEMIES m a EMI 11 12 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 4 S6LN S6RN 20 21 and 23 Magnetos Illustrated Parts List 28 8 3 2 23 S SF F S FSi Ss 5 8 2 wo wo wo Q Q 9 150 wo 15 10 S 8 8 8 8 8 8 8 8 8 8 8 59529 8 iD bb bl ID IO ID IO IO IO ID I D S S Index Description Part No e g g g gg gegggglg 60 Pin Stop 10 56513 1 2 2m2 i ft 2 2 1 1 P Pin Stop 0 0005 AO 10 400602 1 2 2222 HH 2 2 1 1 2 61 Screw w lock washer 10 391213 1 Pi Pe DEMUESUES ie 62 Washer Plain 10 51354 1 PP Pie mu MUI 63 Cam 10 50772 1 1 ith tnt tit MUN 10 50772 5 1 64 Bearing Ball 2 202 1 Ph Tinh RHI HUMUM 65 Washer Shim 0 002 in thick 2 199 1 AR AR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR JAR IAR 0 004 in thick 2 199 2 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR JAR IAR 0 005 in thick 2 199 3 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 0 008 in thick 2 199 4 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 0 010 in thick 2 199 5 AR AR AR
9. 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 on com Birmingham AL 888 451 8665 CAN 01536 413877 UK 1800 811 480 AU Slaughter 28105 N Keith Drive 847 932 3665 hipot com Lake Forest IL 60045 800 504 0055 Thomas amp Betts 8155 T amp B Boulevard 901 252 8000 tnb com Memphis TN 38125 800 816 7809 Waldes TruArc Division Waldes Truarc 908 859 4266 truarc com Lon Island City NY 11101 800 526 7055 10 2 Illustrated Special Tools and Fixtures ee e ism ln EN 0 625 9 000 1 000 4 000 Figure 10 1 Small Gear Support Bar Dimensions 10 2 S 20 S 200 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 Degrees Applicable Magneto Part Number Model Number Lag Retard Use Terminal Kit Part No Parts List 10 51360 27 S4RN 20 10 52305 Table 11 3 10 51360 28 S4RN 21 25 10 52305 Table 11 3 10 51360 29 S4LN 20 10 52305 Table 11 3 10 51360 37 S4LN 21 25 10 52305 Table 11 3 10 51360 40 S4RN 20 10 52305 Table 11 3 10 51360 41 S4RN 21 25 10 52305 Table 11 3 10 51360 45 S4LN 21 25 10 157209 Table 11 3 10 51360 46 S4RN 21 2
10. Old Part No For Part No Type No Part No Type No 10 51360 1 10 51360 26 10 51360 37 ALN 21 10 500514 1 ALSC 21 10 51360 3 10 51360 29 10 51360 29 S4LN 20 10 600644 1 S4LSC 204 10 51360 4 10 51360 27 10 51360 27 S4RN 20 10 600644 3 S4RSC 204 10 51360 6 10 51360 28 10 51360 28 S4RN 21 10 500514 3 S4RSC 21 10 51360 8 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 10 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 11 10 51360 29 10 51360 29 S4LN 20 10 600644 1 S4LSC 204 10 51360 12 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 23 10 51360 29 10 51360 29 S4LN 20 10 600644 1 S4LSC 204 10 51360 24 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 25 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 26 10 51360 26 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 27 10 51360 27 10 51360 27 S4RN 20 10 600644 3 S4RSC 204 10 51360 28 10 51360 28 10 51360 28 S4RN 21 10 500514 3 S4RSC 21 10 51360 29 10 51360 29 10 51360 29 S4LN 20 10 600644 1 S4LSC 204 10 51360 30 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 31 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 33 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 37 10 51360 37 10 51360 37 S4LN 21 10 500514 1 S4LSC 21 10 51360 40 10 51360 40 10 51360 40 S4RN 20 10 600644 5 S4RSC 204 10 51360 41 10 51360 41 10 51360 41 S4RN 21 10 500514 5 S4RSC 21 10 51360 45 10 51360 45 10 51360 45 S4LN 21 10 5005
11. General Overhaul will not glide easily and material will be removed Discard impulse coupling cams with soft flyweight s and replace with a cam with flyweights marked according to the NOTE following step a c Make an appropriate log book entry indicating compliance with this step mark the heel of the flyweights with yellow Dykem or lacquer if numbers are not stamped and stamp a 0 0625 inch high letter F in the upper right hand corner of the data plate 52 5 Visually inspect flyweight securing washers snap rings and flyweights particularly in area around the axle bore for cracks Grip the washer with fingers as shown in Figure 7 15 and exert a turning force in each direction attempting to move the washer If the washer moves or any cracks are discovered discard and replace the cam assembly NOTE Never attempt to repair any part of a rejected cam and flyweight assembly 11 Figure 7 15 Inspect Flyweight Washers Procedure continues on next page S 20 S 200 Series High Tension Magneto Service Support Manual 7 13 31 August 2011 General Overhaul 6 Inspect the impulse coupling body drive lugs Figure 7 16 If wear is noted measure difference between worn and unworn areas of drive lug surface If difference exceeds 0 015 in replace the impulse coupling body 9 5 Figure 7 16 Worn Drive Lug 7 Inspect impulse coupling trip dogs 9 for grooves worn by the tail of flyweight or wear at the t
12. 10 50752 FELT WASHER 10 163374 FELT STRIP IN GROOVE Figure 7 5 Distributor Block Cutaway 1 Inspect brown polyester distributor blocks for batch code Replace distributor blocks with batch code 8601 or lower 2 Measure the distributor block bushing for an inside diameter 0 376 0 377 over the entire length of the bushing with a three point micrometer If the bushing inside diameter exceeds 0 377 discard and replace the distributor block S 20 S 200 Series High Tension Magneto Service Support Manual 7 5 31 August 2011 General Overhaul 3 Examine the distributor block 79 for cracks particularly around high tension terminal towers mounting holes and the nose in the center of electrode side 4 Clean the distributor block according to instructions in Section 5 2 step 4 5 After cleaning inspect the distributor block for carbon tracking which appears as a thin wavy line across the dielectric surface If suspicious areas are noted check with the E 5 High Voltage Cable Tester a Connect the tester ground lead to a distributor block electrode with a No 2 alligator clip b Attach the tester high voltage lead Figure 7 6 to one of the electrodes adjacent to the grounded one 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 79 in the housing 48 and test for carbon tracking between
13. AR AR AR 0 008 in thick 2 199 4 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 010 in thick 2 199 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 199 6 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 66 Washer Plain 10 3503 1 1 1 1 1 1 1 1 1 1 1 1 1 1 67 Gear Pinion 10 157120Y 1 1 1 1 1 1 1 1 1 1 1 1 1 1 69 Bearing Sleeve 10 25788 1 BEEMNEEMENM BMEMEBNMENM BNBMEBESBSB K SN 70 Bearing Ball 10 81806 1 1 1 1 1 1 1 1 1 1 1 1 1 1 71 Washer Shim 0 002 in thick 2 161 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 161 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 161 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 161 4 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 010 in thick 2 161 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 161 6 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 0015 in thick 2 161 7 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 72 Kit Distributor Gear 10 357586 1 1 1 1 1 1 1 1 1 1 1 1 1 1 73 Brush Carbon 10 160844 1 1 1 1 1 1 1 1 1 1 1 1 1 1 74 Ring Retaining MS16624 2037 1 1 1 1 1 1 1 1 1 1 1 1 1 1 75 Washer 0 750 OD 10 349511 1 1 1 1 1 1 1 1 1 1 1 1 1 1 76 Washer 0 562 OD 10 606505 1 1 1 1 1 1 1 1 1 1 1 1
14. 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 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 Pad Repair 1 Place a piece of phenolic or metal between the terminal pad and the coil to prevent damage to the coil Drill a 0 125 0 016 0 000 inch diameter hole Figure 8 1 through the center of the high tension terminal pad DRILL 0 125 0 016 pia 0 000 10 76257 CONTACT Figure 8 1 Coil Pad Repair 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 2 Lightly abrade the surface of the terminal and clean with isopropyl alcohol Tin the surface of the coil terminal and the protruding side of the 10 76257 contact with solder and flux 3 Position the contact so the protrusion extends through the 0 125 inch hole in the terminal pad Flow solder between the coil pad terminal and the 10 76257contact with a soldering iron Check the finished joint for good electrical bonding the soldered joint between the coil terminal pad and the contact should be smooth and even S 20 S
15. 44 STRIP INSULATION 0 125 0 031 STRIP SHIELDING 0 672 0 031 SLEEVE U IF SHIELDED CABLE IS USED SECURE SHIELDING HERE Figure 9 23 Terminal Assembly Kit 10 52305 or 10 52305 1 S 20 S 200 Series High Tension Magneto Service Support Manual 9 23 31 August 2011 Assembl Intentionally Left Blank 9 24 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Special Tools Equipment and Supplies Section 10 Special Tools Equipment and Supplies Refer to Table 10 1 for a list of special tools fixtures equipment and consumable supplies Figure 10 1 provides fabrication instructions for a fixture required for magneto service All linear dimensions are in inches unless specified otherwise NOTE Tools specified in this manual are listed 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 as 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 Part Number and Description Application Source Special Tools 11 6924 1 Pressing Tool To install press fit parts Kell Strom 11 8150 1 Timing Kit Check magneto internal timing Ke
16. 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 556C Shouldered Magneto Drive Shaft Bushing Change from Sintered Iron to Machined Steel 7 75 583 Ignition Switches Rotary Action Key or Lever Actuated Twist to Start Push to Start Twist to Start 4 76 Push to Prime Types 623A Inspection of Impulse Coupling Cam Assemblies 8 94 631 Recommended Lubricant for Tapered Drive on TCM magnetos 9 89 634 Replacement of P N 10 357173 Breaker Assemblies Exhibiting Batch Code 0690 and P N 10 357174 12 90 Breaker Assemblies Exhibiting Batch Code 4289 through 1790 or Subject Breakers P N s with Illegible Batch Codes 635 Gold Seal Harnesses 5 91 639 Proper Installation of Impulse Couplings 3 93 640 New Service Document Format 2 1 94 CSB641 Possible Open Condition of SC 20 SC 200 and S 1200 Series Magneto Capacitor P N 10 349276 2 1 94 SIL642 Manufacturing Number Serial Number Interpreting 2 1 94 SB643 Maintenance Intervals for all TCM and Bendix Aircraft Magneto and Related Equipment 2 8 94 MSB644 Replacement of Magneto Coils and Rotating Magnets 4 4 94 MSB645 Inspection of Riveted Impulse Couplings and Stop Pins 4 4 94 SIL646 History of the Requirements to Replace Magneto Coils and Rotating Magnets 9 14 94 SIL647 SC 20 and
17. Inspect the steel sleeve bearing 69 for scratches pits or scoring that might allow oil to enter magneto If sealing surface of the steel sleeve bearing is worn bearing can be reversed when reinstalled to provide an unused surface If sleeve bearing is worn at both locations replace it with a new sleeve bearing 7 2 11 Contact Assembly Inspection WIRE STRANDS AND INSULATION MUST BE VISIBLE IN THIS AREA BELL MOUTH MUST BE 1 For magnetos equipped with tachometer contacts inspect the condition of the insulating bushings 38 Current production bushings are constructed of phenolic material with annular circular laminations Replace the bushing if laminate layers are parallel or if the bushing is cracked crushed or otherwise damaged 2 Inspect the condition of the contact point flag terminals using the criteria in Figure 7 21 Replace the affected lead assembly if flag terminals do not meet the conditions depicted in Figure 7 21 NO LOOSE NICKED SCRAPED OR CUT STRANDS THIS AREA WIRE BARREL SEAM CLOSED WITH NO 7 CONDUCTOR STRANDS PO SHOWING CONDUCTOR ENDS FLUSH WITH OR SLIGHTLY BEYOND END OF WIRE BARREL NO DAMAGE TO No EXCESS WIRE MATING AREA BARREL FLASH Figure 7 21 Flag Terminal Inspection Criteria S 20 S 200 Series High Tension Magneto Service Support Manual 7 19 31 August 2011 General Overhaul Intentionally Left Blank 7 20 S 20 S 200 Series High Tension Magneto Service Support Manual
18. Procedure continues on next page S 20 S 200 Series High Tension Magneto Service Support Manual 7 11 31 August 2011 General Overhaul 4 Inspect the impulse coupling components CAUTION Regardless of condition or appearance replace all obsolete design impulse coupling cam assemblies featuring riveted cam axles Figure 7 13 with current production parts featuring integral flyweight axles with a machined impulse coupling cam AXLES RIVETED INTO CAM BODY Figure 7 13 Riveted Impulse Coupling Cam Assembly a Ensure impulse coupling cam flyweights are properly heat treated NOTE This test does not apply to cam assemblies with yellow paint dykem or lacquer on the heel of the flyweight or with stamped numbers on flyweight Figure 7 15 or with more than 300 hours service Proceed to step b NOTE XXX in Figure 7 14 indicates the location of stamped numbers FILE THIS ARE b G TOE Y HEEL Figure 7 14 Soft Flyweight Check b Use finger pressure to push inward on the toe of a flyweight so the heel points outward Using a fine 1 double cut 0 50 inch wide file at least 0 09375 inch thick pass the file across the heel of the flyweight and attempt to remove material Repeat for the second flyweight The file should glide smoothly over the heel of the flyweight and remove no material If the flyweight is soft the file 7 12 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011
19. This system consists of a single contact assembly magneto a dual contact assembly 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 S 200 Magneto and Associated Components 1 The Short Cover SC style magnetos offer the following features e Feed thru capacitor on all magnetos e Capacitor interchangeable with S 1200 Series e Simplified stud type switch and retard connections no special kits necessary e Low profile short cover SC allows maximum installation flexibility e Consolidated parts usage e Familiar and versatile S 20 and S 200 technology SC magnetos are fully interchangeable with older S 20 and S 200 designs Refer to Superseded Discontinued and Interchangeable Magnetos in Section 11 2 S 20 S 200 Series High Tension Magneto Service Support Manual 2 1 31 August 2011 Description and Operation 2 Magneto model numbers are read as follows S 4 L N 204T Model Number T S 20 Serles Magneto Configuration Magneto Configuration 21 Dog Ear Mount Impulse Coupled S Single Type Magneto 25 Deep Flange Mount Impulse Coupled one drive one output distributor D Dual Type Magneto one drive two output distributors S 200 Serles 200 Dog Ear Mount With Retard Breaker 201 Deep Flange Mount With Retard Breaker 204 Dog Ear Mount 205 Deep Flange Mount Cylinders Fired Suffix S 20 and
20. Tower 10 50737 6 81 Strip Felt 10 163374 1 82 Washer Felt 10 50752 1 S 20 S 200 Series High Tension Magneto Service Support Manual 11 31 31 August 2011 Illustrated Parts List 11 4 Switch Terminal Kits See Table 11 1 for Application Figure 11 1 Kit 10 52305 amp 10 52305 1 Table 11 11 Terminal Kit Spares Figure 11 1 Quantity Index Part No Description Required 2 10 7030 Ferrule Outer Ground Wire 1 10 37668 Sleeve Insulating 10 52305 1 2 155 Washer Ground Wire Contact 1 11 32 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List uas F AL A Figure 11 2 Kit 10 157208 10 157209 amp 10 382814 Table 11 12 Terminal Kit Spares Figure 11 2 Quantity Index Part Number Description Use Code Required 10 157212 Bushing Insulated A amp B 1 10 157213 Bushing Shouldered A B amp C 10 157211 Nut Coupling 0 4375 28 10 157209 B amp C Table 11 13 Switch Terminal P Lead Kits Kit Number Description Application Code 10 157209 Kit Magneto Ground Terminal One each per magneto B S 20 S 200 Series High Tension Magneto Service Support Manual 11 33 31 August 2011 Illustrated Parts List 11 5 Short Cover Conversion Kits Table 11 14 Kit Applicability O
21. X S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 TABLE OF CONTENTS 1 Introduction and Specifications T General isin 1 1 2 PDE CITC all oHs ocio dece bidon tq buta ee spent tun cda bed a Ho ad Lo ese 1 2 2 Description and Operation sl General nnns ep Kost Ospiti delli epos Reditus god estan aed 2 1 22 Detailed Description scio nt OR ed IAE NOR QN Eq 2 2 2 3 Maintenance and Overhaul Periods eere 2 3 2 4 S 20 and S 200 Magneto Operation seen 2 4 2 4 General TROP oer Rte CU Rot lente be Mena 2 4 2 4 2 Operation of S 200 Magneto System with Starting Vibrator 2 4 2 35 Seral INURIDEDS ossa fe sari deo Qn utut eater eae 2 6 2 0 3SEDEB o o E o T OM AN Pus OR ades adu d esa Id I EE mais 2 6 3 Testing amp Troubleshooting ST General si oc uos noc Mesa eral nct agen se c ULLA te 3 1 3 2 Post Oyverhaul Test cte destituta Maud tiis d 3 2 3 X Hot Magneto T68L esce ene aus en den NES UR ORE n i Na 3 4 s DPoublesHOOU IE etate ires o ier ve eae eee Ba ee oa up RUE 3 4 4 Disassembly 4al NGO OLA E NS 4 4 2 Detailed Disassembly Procedures ecceeeeceeseeceeeeececeeeeeceneeeenteeeenaeeees 4 4 2 1 Initial Inspection Disassembly eese enne enne 4 1 4 2 2 General Overhaul Disassembly essere 4 2 4 2 3
22. and Pin 1 If installed the Spring 10 and Gaskets 14 49 must also be replaced The following parts may be reused after maintenance inspections per Section 6 2 1 and Section 6 2 3 but must be replaced at overhaul Main and Retard Contact Assemblies 39 Felt Washer 82 and Carbon Brush 73 2 Periodic Maintenance Intervals a Perform a visual inspection of surrounding components whenever engine maintenance requires access to the magneto internal components a Perform the inspection detailed in Section 6 2 1 any time magneto to engine timing is found to be outside the engine manufacturer s limits b Perform the inspection detailed 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 c Perform the inspection detailed in Section 6 2 3 for all magnetos at the first 500 hours in service and every 500 hours thereafter d 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 on S 20 S 200 Series High Tension Magneto Service Support Manual 6 1 31 August 2011 Periodic Maintenance 6 2 Detailed Maintenance Procedures 6 2 1 Contact Assemblies Inspect contact assemblies Remove t
23. 1 1 NLA 1 1 NLA 1 17 Lead Assembly Tach 10 400141 2 18 Sleeving 654742 2 50 1 19 Grommet Tach 10 400103 1 21 Nut Cap 10 163177 1 1 22 Disk Neoprene 10 163384 1 1 25 Screw Fillister Head 10 35937 12 4 4 4 4 4 4 4 4 4 4 4 4 33 Screw Hex Head 10 682025 1 1 1 1 1 1 1 1 1 11 8 S 20 8 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 3 SALN S4RN 20 and 21 Magnetos Illustrated Parts List aN amp A SI S 9 SY 3 8 2 2 0 0 2 2 2 2 2 6 Index Description Part No e Se S 2 29 e 35 Spring 10 102090 1 1 1 1 1 1 3 Washer Plain 10 14268 1 1 1 1 1 1 1 1 1 2 1 1 37a Washer Plain NAS620 8L 1 38 Bushing Tach 10 361639 2 39 Contact Assembly 10 382585 1 1 1 10 357173 1 1 1 10 357174 1 1 1 1 1 1 Tachometer 10 400507 1 40 Plate Insulating 10 361624 1 41 Screw w lock washer 10 35935 5 2 2 2 10 35936 7 3 man 3 NENNEN o ma 42 Capacitor 10 51676 1 1 1 1 1 1 1 1 1 10 400572 1 1 1 44 Plug Solid 10 157135 1 1 1 1 1 1 1 1 1 1 1 1 45 Bushing NLA 1 1 1 46 Plug Ventilator 10 157134 1 1 1 1 1 1 1 1 1 1 1 1 47 Screw w ock washer 10 157158 5 5 5 S 5 amp 5 5 5 amp amp 48 Housing Distributor NLA 1 1 1 NLA EE 1 Ba 1 1 10 400551 7 1 1 1 50 Housing Magneto 10 40
24. 1 NEUEN 1 NUUS 1 d 1 111 10 90751 19 1 1 1 2 Nut Drive Shaft 10 163151 1 Il 1 1 10 51643 Il 1 TITES 1 1 1 111 10 51652Y 1 1 1 3 Washer Lock 10 3793 Il 1 UN EUR T 1 1 Il 4 Washer Plain 10 4093 m1 1 1 1 1 10 51370 1 4 1 1 1 10 400640 1 1 1 Washer Keyed 10 51613 1 1 1 5 Bushing 10 51651 1 1 1 10 163049 Il 1 ISE 1 1 1 1 6 Plate Drive 10 160850 1 7 Plate Drive 10 163003 1 1 10 163214 1 1 1 8 Coupling Impulse 25 Lag 10 400302 1 1 25 Lag 10 400313 1 Tia 25 Lag 10 400301 1 15 Lag 10 400321 1 9 Body Impulse Coupling 10 51333 1 1 10 51395 1 10 52903 Il 1 1 10 Spring Main 10 51324 1 ite 1 BENI 11 Cam 10 400166 2 EN 10 400167 4 1 1 1 10 400167 1 1 12 Screw w lock washer 10 157160 4 Mm ea A ha nm 4 LEID 4 eee 4 ee 15 Cover Contact 10 400160 3 1 11 1 41311 E 1 EMI 1 10 400160 7 1 1 10 400160 1 E 1 BM 10 400547 3 1 10 400547 5 1 16 Washer Lock MS35338 438 1 ma 1 ma 2 1525 17 Lead Assembly Tach 10 400141 2 2 18 Sleeving 654742 2 50 1 1 19 Grommet Tach 10 400103 1 1 23 Lead Assembly Retard 10 400050 Im 1 Bua 1 25 Screw wilock washer 10 35937 12 4 44 44 44 5 5 5 5 4 4 4 4 4 4 4 26 Washer Insulating 10 16092 UE 1 BI 1 27 Bushing Insulating 10 125996 e i 1 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 11 23 Illustrated Parts List Table 11 8 SALSC S4RSC 21 21T 200 2
25. 1 S6RSC 25 10 79020 10 10 79020 10 10 79020 10 S6RN 25 10 500556 1 S6RSC 25 10 79020 11 10 79020 11 10 79020 11 S6LN 25 10 500556 203 S6LSC 25T 10 79020 13 Discontinued 10 79020 14 Discontinued 10 79020 16 10 79020 16 10 79020 16 S6LN 25 10 500556 3 S6LSC 25 10 79020 17 10 79020 17 10 79020 17 S6LN 25 10 500556 203 S6LSC 25T 10 79020 18 10 79020 18 10 79020 18 S6LN 25 10 500556 3 S6LSC 25 10 79020 19 10 79020 19 10 79020 19 S6RN 25 10 500556 1 S6RSC 25 10 79020 118 10 79020 118 10 79020 118 S6LN 25P 10 500556 103 S6LSC 25P 10 79020 119 10 79020 119 10 79020 119 S6RN 25P 10 500556 101 1S6RSC 25P 10 85290 2 Discontinued 10 85290 3 Discontinued 10 163005 1 10 163005 2 10 163005 2 S4LN 200 10 600614 1 S4LSC 200 10 163005 2 10 163005 2 10 163005 2 S4LN 200 10 600614 1 S4LSC 200 10 163005 3 10 163005 3 10 163005 3 S4LN 200 10 600614 3 S4LSC 200 10 163005 4 Discontinued 10 163005 5 Discontinued 10 163005 7 Discontinued 10 163005 10 Discontinued 10 163005 11 10 163005 11 10 163005 11 S4LN 200 10 600614 2 S4LSC 200 10 163010 1 10 163010 1 10 163010 1 S6RN 200 10 600616 4 S6RSC 200 10 163010 2 10 163010 2 10 163010 2 S6LN 200 10 600616 5 S6LSC 200 10 163010 3 Discontinued 10 163010 4 Discontinued 10 163010 5 Discontinued 10 163010 6 Discontinued 10 163010 7 Discontinued 10 163010 8 Discontinued 10 163010 9 10 600616 9 10 600616 9 10 600616 9 S6LSC 200 10 163010 10 10 163010 10 10 163010 10 S6LN 200 10 600616 3 S6L
26. 10 51365 48 10 51365 48 S6RN 21 10 500516 9 S6RSC 21 10 52350 6 10 52350 20 10 51365 43 S6LN 21 10 500516 3 S6LSC 21 10 52350 7 Discontinued 10 52350 8 Discontinued 10 52350 14 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 52350 15 10 51365 34 10 51365 34 S6RN 21 10 500516 5 S6RSC 21 10 52350 17 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 52350 18 10 51365 34 10 51365 34 S6RN 21 10 500516 5 S6RSC 21 10 52350 19 10 51365 48 10 51365 48 S6RN 21 10 500516 9 S6RSC 21 10 52350 20 10 52350 20 10 51365 43 S6LN 21 10 500516 3 S6LSC 21 10 52350 21 Discontinued 10 52350 22 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 52350 23 10 51365 34 10 51365 34 S6RN 21 10 500516 5 S6RSC 21 10 52350 24 Discontinued 10 52350 25 Discontinued S 20 S 200 Series High Tension Magneto Service Support Manual 11 5 31 August 2011 Illustrated Parts List Table 11 2 Superseded Discontinued and Interchangeable Magnetos For Maintenance or Overhaul Follow Parts List For Replacement Use Old Part No Part No Type No Part No Type No 10 79020 2 10 79020 104 10 79020 10 S6RN 25 10 500556 1 S6RSC 25 10 79020 5 10 79020 10 10 79020 10 S6RN 25 10 500556 1 S6RSC 25 10 79020 6 10 79020 6 10 79020 6 S6LN 25 10 500556 3 S6LSC 25 10 79020 8 10 79020 104 10 79020 10 S6RN 25 10 500556
27. 204 10 163050 2 10 163050 2 10 163050 2 S6LN 204 10 600646 3 S6LSC 204 10 163050 3 Discontinued 10 163050 4 10 163050 9 10 163050 9 S6LN 204 10 600646 1 S6LSC 204 10 163050 5 Discontinued 10 163050 6 Discontinued 10 163050 7 10 163050 7 10 163050 7 S6RN 204 10 600646 4 S6RSC 204 10 163050 8 Discontinued 10 163050 9 10 163050 9 10 163050 9 S6LN 204 10 600646 1 S6LSC 204 10 163050 12 10 163050 12 10 163050 12 S6LN 204 10 600646 201 S6LSC 204T 10 163055 1 10 163055 1 10 163055 1 S4RN 205 10 600654 1 S4RC 205 10 163055 2 Discontinued 10 163060 1 10 163060 1 10 163060 1 S6RN 205 10 600656 1 S6RSC 205 10 163060 2 10 163060 2 10 163060 2 S6LN 205 10 600656 3 S6LSC 205 10 163060 101 Discontinued 10 163070 1 Discontinued 10 163070 3 Discontinued shown in E Series Parts Catalog Publication No X30017 use Magneto Part Nos 10 51365 43 or 10 500516 3 en configuration magneto part numbers shown af Magnetos should be updated as a matching pair Continental Motors TSIOL 550 A engines originally equipped with indicated magnetos should be retrofitted to an S 1200 Magneto System Contact Continental Motors Customer Service Department for details S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Magnetos Part No 10 10 51365 44 and 10 51365 45 may be factory rebuilt only if a serviceable Bushing P N Upon exhaustion of special parts for radi
28. 48 according to instructions in Section 9 2 9 Install the magneto on the engine and adjust the Magneto to Engine timing according to the engine manufacturer s instructions 10 Replace any missing terminal eyelets on the harness wires before reinstalling the ignition harness on the magneto Check the harness grommets for signs of carbon tracking replace harness components according to instructions in the High Tension Ignition Harness Service Manual X43001 11 Reinstall the ignition harness adapter plate to the magneto Tighten the four screws evenly and torque 12 15 in lbs 12 Complete installation by properly attaching the aircraft primary wiring and any other miscellaneous hardware items removed S 20 S 200 Series High Tension Magneto Service Support Manual 6 9 31 August 2011 Periodic Maintenance 6 10 Intentionally Left Blank S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 7 1 General NOTE Index numbers in parentheses refer to the exploded view of the magneto in Figure 1 and the Illustrated Parts List in Section 11 unless otherwise specified Special Tools Required e 10 70506 10S Protective Caps e 10 391200 Distributor Block Lubricant e 10 391400 Distributor Block Coating e 11 8465 Rotor Holding Tool e 11 8150 1 Timing Kit e E 5 High Voltage Cable Tester e E 50 Timing Light or equivalent e Fluke 8840A Digital Multimeter e LC103 Capacitor Tester 1 Use a 4
29. 8 Table 2 2 Current Magneto Serial Number Code since Jan 2001 2 9 Table 2 3 D 2000 Supersedure sitat tse nans idees tuti edid 2 10 Table 3 1 Troubleshooting Chart eeeeeeenrersrrerrrrrrnrensrensnernsrrsrsesnssssnssnns 3 6 hable 721 Capacitor Test Vales oo oen dU tipa t tUa ae e UE 7 7 Table 10 1 Special Tools and Consumable Supplies 10 1 Table 10 2 Supplier Contact Information eee 10 2 Table 11 1 Equipment Covered 5 50 cccesare gods enr esce b Yin tr ahve pore vein asd 11 1 Table 11 2 Superseded Discontinued amp Interchangeable Items 11 2 Table 11 3 Switch Terminal P Lead Kits sseeeeeeee 11 6 Table 11 4 Terminal Kit Spares 1553 ede ennt ote eoa aue been dpdein e aua e gg debe 11 6 Table 11 5 D 2000 Series Magnetos 22 espe pectet ensuite err tpocbr tees 11 7 Table 11 6 D 3000 Series Magnetos eeeeeeesrrrrrrrreseeesrensrrrrrrreernnreessesnsa 11 10 Table 11 7 Spare Elbow Leads and 4 Cylinder D 2000 and D 3000 Gold Sea 09 Harnesses ooi ecteteiuiece yita en cod rebate oce iain 11 13 Table 11 8 6 amp 8 Cylinder D 2000 and D 3000 Gold Seal Harnesses 11 14 Table LT 9 Numerical Parts hist 2isictoctos c qetetetio eterna e St MO RC SEK 11 15 S 20 S 200 Series High Tension Magneto Service Support Manual xiii 31 August 2011 Xiv Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Fig
30. 8149 Pointer on the cam securing screw aligned with the 0 mark on the Timing Plate S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl PINS INSERT IN COVER SCREW HOLES Figure 9 21 Timing Plate Installed on Housing CAUTION Tighten adjusting knob of holding tool only enough to hold magnet firmly in desired position Over tightening may cause damage to drive end bearing NOTE The main contact of a clockwise magneto is located on the left hand side of contact compartment looking into contact compartment The main contact of a counterclockwise magneto is on the right side of contact compartment 5 Loosen the adjusting knob of the 11 8465 Rotor Holding Tool and turn the rotor in the normal direction until the pointer indexes with the respective 10 E gap mark and tighten the adjusting knob of the 11 8465 Rotor Holding Tool Using the E 50 Timing Light or equivalent adjust the main contact points to just open at this position 6 Loosen rotor holding tool and turn the rotor until the cam follower of the main contact assembly aligns with the highest point of cam lobe Tighten the of the adjusting knob of the 11 8465 Rotor Holding Tool in this position and measure contact point clearance Clearance must be 0 018 0 006 inch If clearance is greater than 0 024 inch loosen the adjusting screw at the base of the contact assembly and adjust contact clearance to 0 024 inch opening If clea
31. 9 19 9 211 Plug Installation iiec eter re eic eerte eie 9 20 9 2 11 1 Non Pressurized Magneto Plug Installation 9 20 9 2 11 2 Pressurized Magneto Plug Installation sees 9 20 9 2 12 Data Plate Installation eee teet eire es 9 20 9 2 13 mal Assembly ceret rette et dee ipee ted 9 21 9 2 14 Post Overhaul Test iv ssc ose ceteri tte E enira 9 2 9 3 Magneto Installation on Engine eese 9 22 10 Special Tools Equipment and Supplies 10 1 Special Tool and Consumable Supply List ssesssss 10 1 xii S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 11 Illustrated Parts List 11 1 Equipment Covered 5 nte aberat teen Peine ette ena e Pee eR thane 11 1 11 2 Superseded Discontinued and Interchangeable Magnetos 11 4 11 3 Illustrated Parts Lists by Magneto Series eese 11 8 11 4 Switch Terminal Kits iii eo Ge o ep t Rb Gm onde M pe uui 11 32 11 5 Short Cover Conversion Kits 00 ceecceeesccecssececseececeeeeecseceeseeeenaeeeenas 11 34 T 1s6 Numetieal Parts Listasi iire docet reo be Loreto r ueri Torah Prev to sd ghe 11 36 Table Wed JABDEreviattOHs elann iea a a I NE ER TERI 1 1 Table 1 2 Table of Leading Particulars uo ocetoses tese den udo ee nte eis 1 2 Table 2 1 Legacy Magneto Serial Number Code esee 2
32. AR AR AR AR 0 010 in thick 2 199 5 AR IAR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 199 6 AR IAR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 66 Washer Plain 10 3503 1 ee mm ee ee 67 Gear Pinion 10 157120Y 1 EEBEENM a 1 BH 1 69 Bearing Sleeve 10 25788 1 BEIR NENNEN 1 NENNEN 70 Bearing Ball 10 81806 1 HH 1 NIME 1 EMEN 31 ENIMS 11 30 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 10 S6LSC S6RSC 200 200P 201 204 204P 204T and 205 Magnetos 75 Washer 0 750 OD 10 349511 76 Washer 0 562 OD 10 606505 222222222222222223g S S 5 5 2 o co Index Description Part No esjogogqegeggqgrigeing gagqsgcgegqee 71 Washer Shim i EN mW 1 B E 0 002 in thick 2 161 1 AR AR 0 004 in thick 2 161 2 AR AR 0 005 in thick 2 161 3 AR AR 0 008 in thick 2 161 4 AR 3 AR 0 010 in thick 2 161 5 AR ARIA i AR 0 012 in thick 2 161 6 AR AR 0 0015 in thick 2 161 7 AR AR 72 Kit Distributor Gear 10 357586 73 Brush Carbon 10 160844 74 Ring Retaining MS16624 2037 6 6 6 77 Washer Nylon 10 391309 78 Screw w plain amp lock 10 102083 3 washer 79 Block Distributor 10 357426 1 80 Spring
33. Ph a EI UNI 82 Washer Felt 10 50752 1 Pi Te mu mu NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly m conversion in the engine log book S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Magneto may be converted to a short cover model using the conversion chart in Table 11 14 and associated kit contents listed in Table 11 15 Record the 11 13 Illustrated Parts List Table 11 5 S6LN S6RN 25 and 25P Magnetos e 9z 9e t e e t2e 2 e e e e e Oo e e e 38 ZE CE AE X 1E JE r Index Description Part No S 1 Pin Cotter 10 90751 18 1 1 1 1 1 1 1 1 1 2 Nut Drive Shaft 10 51643 1 1 1 1 1 1 1 1 1 3 Washer Lock 10 3793 1 1 1 1 1 1 1 1 1 4 Washer Plain 10 52307 1 1 1 1 1 1 1 1 1 8 Coupling Impulse 30 Lag 10 400316 1 1 1 1 1 1 30 Lag 10 400307 1 1 1 9 Body Impulse Coupling 10 70371 1 1 1 1 1 1 10 76232 1 1 1 10 Spring Main 10 51324 1 1 1 1 1 1 1 1 1 11 Cam Assy Imp Cplg 10 400166 4 1 1 1 10 4001
34. 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 the 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 manufacturer holding an FAA Production Certificate issued under FAR 21 Subpart G e By acertificate of airworthiness for export issued by a for
35. be reused after maintenance inspections per Section 6 2 1 and Section 6 2 3 but must be replaced at overhaul Main and Retard Contact Assemblies 39 Felt Washer 82 and Carbon Brush 73 4 2 1 Initial Inspection Disassembly 1 Remove the cover retention screws and lock washers 12 from cover 15 Carefully pull cover 15 away from the housing 48 Remove and discard gasket 14 if installed Pry or unscrew lead terminals of capacitor lead 42 and retard lead 17 Gf installed from terminals of contact assembly ies 39 2 Remove the plug 44 44a from the distributor housing 48 Remove the plug 46 46a from magneto housing 50 Remove five screws 47 Using care that coil primary lead is released from distributor housing as parts are separated pull the distributor housing straight away from the magneto housing leaving the rotating magnet in the magneto housing Remove and discard the gasket 49 if used CAUTION Do not allow the two housings to turn in relation to each other as damage to coil or carbon brush may result S 20 S 200 Series High Tension Magneto Service Support Manual 4 1 31 August 2011 Disassembl 3 Using No 2 retaining ring pliers remove the retaining ring 74 securing the gear 72 to the block 79 discard the ring 74 Remove washer 75 and slide the gear 72 from the block 79 Remove washers 76 77 Using a a scribe or other small pointed tool remove the felt washer 82 and
36. capacitor lead to the main contacts Attach any retard or tachometer leads to the retard or tachometer contacts Install the contact cover 15 and gasket 14 if used and secure with screws 12 and washers 13 Torque the screws 12 to 20 to 25 in Ibs NOTE Screen vents located in the cover 15 are unnecessary These screen vents may be sealed with silicone adhesive or epoxy For pressurized magnetos only all vent holes in cover 15 must be sealed on inside surface of cover 3 Connect adapters assembled from Switch Terminal Kit and Retard Terminal Kit as necessary to the magneto and E 50 Timing Light or equivalent Confirm operation of the contacts by turning rotor 54 and observing the timing light response 4 Use a Slaughter Model 1305 AC Hipot Tester set to 500 V to test tachometer circuit for dielectric breakdown to ground Dielectric breakdown is not permitted adjust or replace affected parts if the dielectric breakdown test indicates leakage and repeat dielectric breakdown test on the new leads S 20 S 200 Series High Tension Magneto Service Support Manual 9 19 31 August 2011 Assembl 9 2 11 Plug Installation 9 2 11 1 Non Pressurized Magneto Plug Installation 1 Install a ventilator plug Figure 1 46 in the lower window of the housing 48 2 Install a solid plug 44 in the top timing hole of the housing 3 Torque the plugs 44 amp 46 to 10 15 in Ibs 9 2 11 2 Pressurized Magneto Plug Installatio
37. electrodes and housing by connecting to housing and each electrode Reject the distributor block 79 if it exhibits carbon tracking Figure 7 6 Check Distributor Block for Carbon Tracking 6 Inspect contact springs 80 on the tower side of the distributor block 79 If the contact spring appear fuzzy or white or exhibits signs of burning rust or corrosion remove with needle nose pliers and discard Check springs for proper height by measuring down from the top of tower If the measurement exceeds 0 422 inch Figure 7 7 the spring may be deformed or improperly installed Using a scribe or similar pointed instrument wiggle the top of spring in a circular motion to ensure only the bottom turn of the spring is captive in the block insert groove Recheck spring height if measurement still exceeds 0 422 inch remove and replace spring 7 6 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul Figure 7 7 Contact Spring Height 7 Using a small scraper or knife clean the distributor block 79 electrodes to remove any carbonized deposits Do not attempt to grind or machine the electrodes 8 If distributor block is phenolic or buna type see NOTE following step 10 and is not marked with a raised boss or a drill point indentation to the left and adjacent to No 1 high tension tower see Figure 7 8 remove old lubricant as follows a Place the distributor block high tension towers up o
38. gear 72 shaft NOTE The carbon brush spring in the distributor gear may be a loose fit Do not tip the distributor housing at an angle such that brush can fall out Turn the Distributor Gear 72 at least one complete revolution by hand to ensure freedom of movement The distributor gear electrode must not contact the distributor block electrodes Spray the gear teeth with MS 122AD dry teflon lubricant 9 2 4 Rotor Installation 9 6 1 Lightly coat the housing pole shoes and rotor pole pieces with MIL PRF 32033 rust preventive Spread three drops of clean 30 wt SAE J 1899 aviation engine oil on the surface of the sleeve bearing 69 Carefully position the rotor 54 in the distributor housing 48 Mesh the teeth of the distributor gear 72 and pinion gear 67 such that chamfered tooth of the pinion gear 67 aligns with the timing mark painted Figure 9 6 on the distributor gear in Section 7 2 2 step 5 Thread the coil lead through the passage in the distributor housing to the breaker compartment Position the gasket 49 if used between the housings 48 and 50 Push the housings straight together allowing the rotor shaft to extend through the magneto housing Ensure the bearing parts mate properly Do not allow the housings to twist or turn as this may break the carbon brush or dislodge the coil lead Verify the carbon brush rests on the coil high voltage terminal Secure the housings with new screws with lock
39. housing 50 so the coil primary lead fits in the provided slot in the housing 2 Replace coil core clamps 57 that do not match the illustration in Figure 7 11 3 Secure one side of the coil in the magneto housing with a screw w lock washer 56 and coil core clamp 57 Sandwich the ground lead terminal between a screw w lock washer 56 and coil core clamp 57 and fasten the ground lead terminal to the magneto housing with the screw w lock washer 4 Tighten screws 56 to 20 to 30 in Ibs of torque Press the coil primary lead into the slot in the housing 9 2 3 Distributor Block and Gear Assembly 1 If tower springs Figure 1 80 require replacement use the 11 8627 Spring Seating Kit Insert the Spring Insertion Guide in the distributor block 79 tower outlet hole as shown in Figure 9 6 Place contact spring 80 large end down in the top of the guide Position the Plunger Assembly with the Handle attached over the small end of the spring pushing the spring in to the tower while turning the handle counter clockwise to seat the spring in the recess of the distributor block tower 79 The spring is properly installed when the bottom turn of the spring is caught in the distributor block bushing and the top turn of the spring is approximately centered in tower outlet Check spring height according to Section 7 2 4 step 6 HANDLE PLUNGER ASS MBLY SPRING INSERTION GUIDE DISTRIBUTOR 7 Ts BLOCK Jh START F
40. knob until the pressure applied to the housing flange prevents the rotor 54 from turning freely With magnet held in the neutral position install the 11 8150 1 Timing Kit timing plate and pointer assemblies Figure 9 21 in the magneto contact compartment Align the pointer assembly with the 0 mark on the timing plate 3 Loosen the 11 8465 Holding Tool adjusting knob and turn the rotating magnet in normal direction of rotation until the pointer indexes with respective 10 mark Using the E 50 Timing Light or equivalent check that main contact points just open at 10 4 E gap position 4 Turn the rotating magnet until the contact assembly cam follower is on the high point of the cam lobe Tighten the 11 8465 Holding Tool adjusting knob and measure the contact point gap for 0 018 0 006 inch clearance If dimension does not fall within limits readjust contact points to 0 018 0 006 in and verify the points open within 10 4 E gap tolerance If points do not open within tolerance replace contact assembly 5 On dual contact assembly magnetos the retard contact assembly is adjusted to open a predetermined number of degrees after the main contact assembly opens The degree of retard for any particular magneto is stamped in the 6 8 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance bottom of the contact compartment Figure 2 3 Add degrees retard to the num
41. noted open switch Check capacitor according to instructions in connection Section 7 2 5 Carbon tracked distributor block Replace distributor block 79 3 6 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl Section 4 Disassembly 4 1 General NOTE Index numbers in parentheses refer to the exploded view of the magneto in Figure 1 and the Illustrated Parts List in Section 11 unless otherwise specified Special Tools Required A complete listing of special tools required for S 20 S 200 Magneto Maintenance Inspection Testing and Overhaul is compiled in Chapter 10 e CG240 Puller e 11 6924 1 Pressing Tool e 11 10192 Remover Tool e CG40 8 Collet e CG40 4 Expanding Rod e No 2 Retaining Ring Pliers Complete disassembly of the magneto is not necessary in all instances Disassemble magneto only to the extent required for maintenance procedures involved 4 2 Detailed Disassembly Procedures NOTE The following parts must be replaced 100 with new parts upon removal from the magneto regardless of whether disassembly is for the purpose of inspection parts replacement or overhaul Lock Washers 3 13 34 Screws 12 41 47 56 61 amp 78 Retaining Ring 74 Oil Deflector 55 Oil Seal 59 Bearings 64 70 Felt Strip 81 Identification Data Plate 52 and Pin 1 If installed the Spring 10 and Gaskets 14 49 must also be replaced The following parts may
42. standard shop practices and safety precautions should be observed at all times to avoid damage to equipment and or injury to personnel All maintenance instructions in this manual have been shop verified Shop verified procedures are those by which the manufacturer has accomplished all Disassembly Assembly Testing and Troubleshooting by performing the functions described in this manual on equipment identical in configuration to that described Dimensions are provided in U S Standard Units For reference abbreviations are listed in Table 1 1 Numbers in parentheses following part nomenclature refer to the illustrated parts in Figure 1 of the Illustrated Parts List unless otherwise specified For specific information regarding Continental Motors Ignition Harnesses Ignition Switches and Starting Vibrators used in conjunction with S 20 and S 200 Series Magnetos consult the applicable service manual and all applicable service bulletins Service Bulletins issued subsequent to the date of this manual supersede and 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 Table 1 1 Abbreviations US Standard Unit Abbreviation Degrees Fahrenheit F Inch in Inch Pound in Ibs Pound Mass Ib Standard Cubic Feet Per Hour SCFH Pounds per Square Inch Gauge psig S 20 S 200 Series High Tension
43. strip 81 with Distributor Block Lubricant 11 Install a new dry felt strip 81 in groove on electrode side of distributor block When strip is properly installed Figure 7 5 approximately 0 125 inch of the bushing shall be exposed above the felt strip 12 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 the flat surfaces take on a frosted appearance and seat the felt washer in the recess on the tower side of the distributor block 7 2 5 Capacitor Inspection 1 Visually inspect the capacitor 42 mounting brackets for cracks or looseness Check capacitor lead for damaged insulation or loose terminal connections If damage is evident or the terminals are loose discard capacitor 42 2 Using an LC 103 capacitor tester measure capacitance and leakage according to Table 7 1 specifications Using a multimeter measure DC resistance in series Replace capacitor if it does not meet Table 7 1 specifications Table 7 1 Capacitor Test Values 10 400572 or Capacitor Part No 10 400615 10 51676 Capacitance at room temperature microfarads uF 0 375 x 1096 0 375 x 10 DC series resistance ohms 1 0 max N A Leakage current 400 VDC 0 4 uA max 0 4 yA max S 20 S 200 Series High Tension Magneto Service Support Manual 7 9 31 August 2011 General Overhaul 7 2 6 Coil and Clam
44. washers 47 Apply torque of 25 to 35 in lbs to the new screws 47 Verify the rotating magnet turns freely and has correct bearing play according to Section 9 2 1 step 7 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl LEFT HAND BOOSTER COT PAINTED RED CHAMFERED TOOTH it 2 Figure 9 7 Distributor and Drive Gear Meshing 9 2 5 Contact Assembly Installation 1 Before installing new contact assemblies 39 check the cam follower felt for adequate lubrication by squeezing the felt tightly between the 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 10 86527 Breaker Felt Lubricant to felt pad Allow approximately 30 minutes for the oil to penetrate the felt and the thinner in the compound to evaporate Avoid getting oil on the contacts Blot excess oil with a clean cloth CAUTION Do not use contact assemblies P N 10 357173 marked with Batch Code 0690 and P N 10 357174 marked with Batch Codes 4289 through 1790 Batch Code format WWYY Batch Code is ink stamped on the mounting surface of part NOTE Presence of oil on contact points attracts and holds contaminants adversely affecting 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 surf
45. 0 5 Bushing 10 163049 7 Plate Drive 10 163003 10 163214 12 Screw w lock washer 10 157160 4 4 15 Cover Contact NLA 2 1 NLA 2 EE 17 Lead Assembly Tach 10 400141 m 18 Sleeving 654742 2 50 19 Grommet Tach 10 400103 mE 21 Nut Cap 10 163177 22 Disk Neoprene 10 163384 23 Lead Assembly Retard 10 157241 1 24 Paper Retard 10 163194 1 25 Screw Fillister Head 10 35937 12 4 4 37 Washer Plain 10 14268 2 37a NAS620 8L 38 Bushing Tach 10 361639 39 Contact Assembly 10 382585 1 10 382584 1 Tachometer 10 400507 40 Plate Insulating Tach 10 361624 41 Screw w lock washer 10 35935 5 2 10 35936 7 4 42 Capacitor 10 400572 1 43 Tubing 10 357494 mE 44 Plug Solid 10 157135 1 46 Plug Ventilator 10 157134 1 47 Screw w lock washer 10 157158 5 48 Housing Distributor 10 400551 1 i 10 400551 2 1 10 400551 5 10 400551 7 10 400551 8 S 20 S 200 Series High Tension Magneto Service Support Manual 11 17 31 August 2011 Illustrated Parts List Table 11 6 S4LN S4RN 200 201 204 and 205 Magnetos C o X 9 x co io amp Ww wo uw Ww wo wo uw Ww ce band b b b I ele al alalal a s amp s E E E se Index Description Part No ojo 2 2 2 2 2 23 2 49 Gasket 10 357533 50 Housing Magneto 10 400549 4 1 10 4005
46. 0 400549 1 1 1 1 10 400552 2 1 11 10 400549 4 1 nth i EMEN 10 400552 4 1 1 10 400630 4 1 10 400630 6 1 52 Plate Data 10 400012 imNEENEN BEENEN ENBENEB EBENEN 53 Key Woodruff 10907885 3 3 8 3 3 3 3 2 3 83 3 2 2 8 38 23 2 54 edm Rotating 4o 59945 1 1 1 1 10 52946 1 1 1 10 52947 Il 1 111 1 1 1 10 52948 1 1 10 357479 1 55 Slinger Oil 10 51678 imEENEN 1 ENENEN EBENEN 1 EEEREN i 56 Screw wlockwasher 10 35937 8 2 2 2 2 2 2 2 2 22 2 2 2 2 2 32 2 2 57 Clamp Coil Core 10 50765 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 11 24 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 8 SALSC S4RSC 21 21T 200 201 204 204T and 205 Magnetos Illustrated Parts List si Sil 0 s to eo R TIA e x cce X 5 i e os J SS tS a 3 3 8 2 5 S S 3 S 5 5 5 5 Mol uo to ov CO to 0 e Index Description Part No e189 829 28 gggg g gggegeggegoge 58 Coil 10 357165 1 1 METETE 1 pop 1 PETTEE 1 PATTES 1 E 59 Seal Oil 10 400554 1 nt 1 FETTET 1 tt 1 nae E 60 Pin Stop 10 56513 2 aes 2 ENSE 60 Pin Stop 0 0005 AO 10 400602 2 2 2 2 2 2 2 61 Screw w lock washer 10 391213 1 ree 1 FETTET BENENEN 1 TETTED BE 62 Washer Pla
47. 0 Series High Tension Magneto Service Support Manual 9 15 31 August 2011 Assembl 9 2 9 Magneto Internal Timing 9 16 NOTE The neutral position is located by feel of rotor As rotor is turned a few degrees backward from where distributor tooth is centered in the inspection hole the magnet will have a natural tendency to pull in and locate in the neutral position 1 Loosen the drive shaft nut and position the 11 8465 Rotor Holding Tool under the washer or bushing on the drive end of the rotor shaft Tighten the castellated nut to secure the Rotor Holding Tool on the shaft Leave the adjusting screw loose to allow the rotating magnet freedom to rotate until further notice Turn the rotating magnet in the direction of normal rotation until the painted chamfer tooth on the distributor gear is centered in the inspection window then turn the shaft in the opposite direction of normal rotation until the rotor until the rotor locates the No neutral position CAUTION When timing the magneto do not use any gear holding timing device as hidden gear tooth damage may result Tighten the adjusting screw Figure 9 20 of the Rotor Holding Tool to lock the rotor in position Figure 9 20 11 8465 Rotor Holding Tool in Position 4 Align the pins of the 11 8693 Timing Plate Assembly Part of 11 8150 1 Timing Kit with the screw holes in the flange of the contact assembly compartment Figure 9 21 and snap the 11
48. 01 204 204T and 205 Magnetos si Sil 9 co R TT sse ux t x 5 Y zzz SSS S S SPS SS 3S 5 57 5 8 s 8 8 S S 3 S S Qu ooo 2 MD o o vo wc we Index Description Part No e 8 88 8 g glg gge 28 Nut ECCLE 1 BR 3 i 1 EMEN 3 Ni 302 36 Packing 10 349263 1 BEI EEENEN EBEEENB 1 ee 1 E 37 Washer Plain 10 14268 imEENEN PME 2 EBENSENB 1 EBENEN E 37a Washer Plain NAS620 8L 1 1 38 Bushing Tachometer 10 361639 2 2 39 Contact Assembly 10 382585 111 mi 1 1 1 10 382584 11 1 14314111 1 1 1 Tachometer 10 400507 1 1 Tachometer 10 349970 1 40 Plate Insulating 10 361624 1 1 41a Screw wlock washer 10 35935 6 222 22 2 2 2 2 2 2 2 2 2 2 2 2 2 41 Screw wllock washer 10 35936 7 2 2 2 2 2 2 4 4 4 4 4 2 2 2 2 41 4 2 42 Capacitor 10 400615 1 Ree 1 FETTET ae 1 ENNENNN 1 E 43 Tubing 10 400191 1 44 Plug Solid 10 157135 1 EREDETET 1 FETTET FETRET ENNBNENN E 46 Plug Ventilator 10 157134 1 mHEENEE ENENEN EBNENEN 1 ae 47 Screw wilock washer 10 157158 5 ENENES 5 ENENSES 5 ENSENSES 5 ESESE 5 BS 48 Housing Distributor 10 400545 3 1 1 10 400551 1 1 10 400551 2 1 1 10 400551 5 1 10 400551 7 1 1 1 1 1 1 10 400551 8 11 1 1 1 1 1 50 Housing Magneto 1
49. 0549 1 1 1 1 1 1 1 10 400549 2 1 1 1 10 400549 4 1 1 1 52 Plate Data 10 400012 1 1 1 1 1 1 1 1 1 1 1 1 53 Key Woodruff 10 90788 5 3 ACTED NNMBNMBM5 BNMENME 54 Magnet Rotating Rotor 10 52945 1 1 10 52946 1 1 1 10 52947 1 1 1 1 1 1 1 55 Slinger Cil 10 51678 1 1 1 1 1 1 1 1 1 1 1 1 56 Screw w lock washer 10 35937 8 2 2 2 2 2 IE 2 2 2 2 2 57 Clamp Coil Core 10 50765 2 2 2 2 2 2 NO 2 2 2E 2 58 Coil 10 357165 208 1 1 1 1 1 1 1 1 1 10 357165 1 1 1 1 59 Seal Oil 10 400554 1 1 1 1 1 1 1 1 1 1 1 1 60 Pin Stop 10 56513 2 2 2 2 2 2 2 2 2 Pin Stop 0 0005 AO 10 400602 2 2 2 2 2 2 2 2 2 61 Screw w lock washer 10 391213 1 1 1 1 1 1 1 1 1 1 1 1 62 Washer Plain 10 51354 1 1 1 1 1 1 1 1 1 1 1 1 63 Cam 10 50772 1 1 1 1 1 1 1 1 1 1 10 50772 5 1 1 1 S 20 S 200 Series High Tension Magneto Service Support Manual 11 9 31 August 2011 Illustrated Parts List Table 11 3 S4LN S4RN 20 and 21 Magnetos ES N co a N ce bad w co N rr co i call cb GE c ad ES sb mb EQ E UM to e ce ce ce e ce ce ce e ce ce ce co co co co co co co co co co co co Sa eel ses Eres conie e es sail saill sair ee 1 w wu uw WO w LC i LC iu wu iu Index Description Part No l ee as Ss 2 S Ss 64 Bearing Ball 2 202 1 65 Washer Shim 0 002 in thick 2 199 1 AR 0 004 in
50. 1 64 cage assembly c Position the fabricated bars between the magnet assembly casting and the pinion gear 67 d Position the bars and magnet assembly in one of the slots in the web or base of an arbor press The slot must be large enough to allow the casting magnet to pass through but small enough to hold the fabricated bars CAUTION To prevent damage to the end of rotor 54 place a piece of copper or brass approximately 4 inch thick between the end of the shaft and the arbor press ram when removing the gear 67 and bearing 64 race e Using an arbor press remove the gear 67 and bearing 64 race f Remove the shim washers 65 and plain washer 66 from the shaft Keep the washers together and identify as the cam end for use in reassembly 4 2 6 Housing Disassembly 1 Support the magneto housing mounting flange down on the base plate of an arbor press using a block of wood to protect the impulse coupling stop pins 60 Insert the 11 6924 1 Pressing Tool through the bearing outer race until it seats against the oil seal Figure 4 4 59 as shown Press the oil seal out of the housing and discard PRESS Figure 4 4 Oil Seal Removal S 20 S 200 Series High Tension Magneto Service Support Manual 4 5 31 August 2011 Disassembl 2 Place magneto housing 50 mounting flange up on arbor press base plate Insert the 11 6924 1 Pressing Tool through the bearing outer race Figure 4 5 70 until it botto
51. 1 1 77 Washer Nylon 10 391309 1 1 1 1 1 1 1 1 1 1 1 1 1 1 za Screw w Plain amp Lock 0 102083 3 GUNS 3 MH 3 MIAN ES washer 79 Block Distributor 10 357426 1 mean 1 mma nn BENMEBABBNM 1 M 80 Spring Tower 10 50737 6 6 6 6 6 6 6 6 6 6 6 61 6 6 81 Strip Felt 10 163374 1 1 1 1 1 1 1 1 1 1 1 1 1 1 82 Washer Felt 10 50752 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 28 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 10 S6LSC S6RSC 200 200P 201 204 204P 204T and 205 Magnetos JEEEEEEEEEEEEEEEE Index Description Part No l l 22 g g gis 1 Pin Cotter 10 90751 18 1 RRs 1 ne ane ae 1 2 Nut Drive Shaft 10 163151 11 1 1 1 10 51643 IN 1 1 1 1 10 163178 1 1 111 1 1 3 Washer Lock 10 3793 IN 1 1 111 4 Washer Plain 10 4093 11 1 1 1 1 1 1 11 10 116860 1 1 5 Bushing 10 163048 1 14 1 HM d 1 10 357193 1 1 7 Plate Drive 10 163003 IN 1 171 10 163216 1 1 12 Screw w lock washer 10 157160 4 14 144 4 4 4 4 4 4 4 4 4 4 4 4 4 14 Gasket 10 357532 1 1 15 Cover Contact 10 400160 1 1 i 1 a mm 10 400160 2 1 10 400160 3 1111 1 1 10 400160 4 1 10 400160 7 1 16 Washer Lock MS35338 48 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 14 1 17 Lead Assembly Tach 10 400141 2 18 Sleeving 6547
52. 10 600644 1 S4LSC 204 Table 11 7 10 600644 3 S4RSC 204 Table 11 7 10 600644 4 S4LSC 204 Table 11 7 10 600644 5 S4RSC 204 Table 11 7 10 600644 201 S4LSC 204T Table 11 7 10 600644 202 S4LSC 204T Table 11 7 10 600646 1 S6LSC 204 Table 11 9 10 600646 2 S6LSC 204 Table 11 9 10 600646 3 S6LSC 204 Table 11 9 10 600646 4 S6RSC 204 Table 11 9 10 600646 101 S6LSC 204P Table 11 9 10 600646 201 S6LSC 204T Table 11 9 10 600654 1 S4RSC 205 Table 11 7 10 600656 1 S6RSC 205 Table 11 9 10 600656 3 S6LSC 205 Table 11 9 1 Indicated magnetos are eligible for update to short cover configuration Kit part applicability and contents are contained in REFERENCE Assembly instructions are covered in Section 9 2 NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List 11 2 Superseded Discontinued and Interchangeable Magnetos Table 11 2 Superseded Discontinued and Interchangeable Magnetos For Maintenance or Overhaul Follow Parts List For Replacement Use
53. 14 1 S4LSC 21 10 51360 46 10 51360 46 10 51360 46 S4RN 21 10 500514 4 S4RSC 21 10 51360 47 10 51360 47 10 51360 47 S4LN 21 10 500514 201 S4LSC 21T 10 51360 48 Discontinued 10 51360 53 Discontinued 10 51360 54 10 51360 54 10 51360 54 S4LN 21 10 500514 2 S4LSC 21 10 51360 55 10 51360 58 10 51360 58 S4LN 21 10 500514 2 S4LSC 21 10 51360 58 10 51360 58 10 51360 58 S4LN 21 10 500514 2 S4LSC 21 10 51365 1 10 51365 39 10 51365 39 S6LN 21 10 500516 4 S6LSC 21 10 51365 2 10 51365 40 10 51365 54 S6RN 21 10 500516 7 S6RSC 21 10 51365 5 Discontinued 10 51365 7 10 51365 48 10 51365 48 S6RN 21 10 500516 9 S6RSC 21 10 51365 9 10 51365 9 10 51365 9 S6LN 21 10 500516 10 S6LSC 21 10 51365 13 10 51365 40 10 51365 54 S6RN 21 10 500516 7 S6RSC 21 10 51365 14 10 51365 48 10 51365 48 S6RN 21 10 500516 9 S6RSC 21 10 51365 15 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 51365 16 Discontinued 10 51365 17 10 51365 43 10 51365 43 S6LN 21 10 500516 3 S6LSC 21 10 51365 20 10 51365 32 10 51365 32 S6LN 21 10 500516 3 S6LSC 21 11 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 2 Superseded Discontinued and Interchangeable Magnetos For Maintenance or For Replacement Use Overhaul Follow Parts List Old Part No For Part No T
54. 200 Series High Tension Magneto Service Support Manual 8 1 31 August 2011 Repair 4 After the terminal has cooled inspect the installed contact The terminal angle should be 90 2 off the horizontal axis of the coil core and the distance from the coil core to the outside of the 10 76257 contact must not exceed 1 246 inches as illustrated in Figure 8 1 5 Inspect the coil according to instructions in Section 7 2 6 8 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl Section 9 Assembly 9 1 General Refer to Table 10 1 for a list of materials and tools required during assembly Refer to Figure 1 in Section 11 for magneto 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 10096 with new parts upon removal from the magneto regardless of whether disassembly is for the purpose of inspection parts replacement or overhaul Lock Washers 3 13 34 Screws 12 41 47 56 61 amp 78 Retaining Ring 74 Oil Deflector 55 Oil Seal 59 Bearings 64 70 Felt Strip 81 Identification Data Plate 52 and Pin 1 If installed the Spring 10 and Gaskets 14 49 must also be replaced The fol
55. 2861 1 1 47 Screw w lock washer 10 157158 5 ESNEENESN 5 FRETTEN 5 OR ue 48 Housing Distributor 10 400551 4 1 10 400551 6 1 10 400551 7 1 111 Im 1 14 1 11 1 10 400551 8 1 1 1 1 49 Gasket Housing 10 357533 1 1 50 Housing Magneto 10 400552 4 151 111 10 400549 4 DNE Boo Bs ll EB ha 52 Plate Data 10 400012 1 BH 1 i 1 i 31 MIENNE 53 Key Woodruff 10 90788 5 2 ESENEN 2 Rees 3 Bees 2 EITRI 2 ag Magnet Rotating osse B 1 1 1 Rotor 10 52947 1 1 15111 1 11 10 52948 11 111 55 Deflector Oil 10 51678 ma a 17 NNENNNN 56 Screw wilock washer 10 35937 8 2 EBENEN 2 ENENEN 2 ENSENEIM 2 ENEIEI 2 57 Clamp Coil Core 10 50765 2 KARATA 2 ENENEN ENSPENENS ACIE 2 58 Coil 10 357165 1 1 DERTTE 1 TATTERED 1 ERER i 1 59 Seal Oil 10 400554 1 CERTEGE 1 ae BEBNEEN BEBNEN 1 61 Screw w lock washer 10 391213 1 mass MEBEENM NEEBENENM BMEBEEN 62 Washer Plain 10 51354 1 BEBEMENM 1 BIR NMEMBENE BEBEEN 63 Cam 10 50772 4 1 1 1 1 1 10 50772 5 13 1 1 Im 1 NBN I 1 64 Bearing Ball 2 202 1 Se 1 i NENENMENM NEEMENEMEN 1 65 Washer Shim 0 002 in thick 2 199 1 AR IAR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 199 2 AR IAR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 199 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 199 4 AR IAR AR AR AR AR AR AR AR AR AR AR AR
56. 42 2 50 1 19 Grommet Tach 10 400103 1 23a Lead Assembly 4o so0050 MEME on 3 Retard 25 Screw wilock washer 10 35937 12 5 5 5 5 5 5 5 5 4 4 4 44 4 4 4 4 26 Washer Insulating 10 16092 1 BI aa 1 i 27 Bushing Insulating 10 125996 1 eee 1 EMEND 1 28 Nut MS35650 302 3 8 8 8 3 8 38 38 3 1 1 1 1 1 1 1 1 34 Gasket 10 357520 1 1 36 Packing 10 349263 1 th BEBEBE BEBNEBNE BEBNEN 37 Washer Plain 10 14268 2 EBENEN EPNPEENB NENENNEN BENE 1 NAS620 8L 1 38 Bushing Tach 10 361639 2 39 Contact Assembly 10 382585 1 ee 1 ee 1 Fphi 1 1 1 10 382584 1 III 1 ee 1 1 Tachometer 10 400507 1 40 Plate Insulating Tach 10 361624 1 41 Screw wilock washer 10 35935 6 2 ENBEPRENM 2 CACI 2 RIAR 2 EDU 2 41a Screw w lock washer 10 35936 7 41444444 414 4 4 A4 Zl 2 2 42 Capacitor 10 400615 1 Ree 1 eee 1 eee 1 CARRET S 20 S 200 Series High Tension Magneto Service Support Manual 11 29 31 August 2011 Illustrated Parts List Table 11 10 S6LSC S6RSC 200 200P 201 204 204P 204T and 205 Magnetos JEEEEEEEEEEEEEEEE Index Description Part No eo o2ojs 2525 g 44 Plug Solid 10 157135 1 re NENNEN NENNEN EINEN 1 44a Bushing Air Inlet 10 382815 1 1 46 Plug Ventilator 10 157134 1 BIR BEMNENMN ii 1 1 1 46a Orifice Calibrated 10 38
57. 5 10 52305 Table 11 3 10 51360 47 S4LN 21 25 10 157209 Table 11 3 10 51360 54 SM4NO1 J 15 10523056 Tabeit 3 10 51360 58 S4LN 21 15 10 157209 Table 11 3 10 51365 9 S6LN 21 45 10 52305 Table 11 4 10 51365 32 S6LN 21 45 10 52305 Table 11 4 10 51365 32 S6LN 21 45 10 52305 Table 11 4 10 51365 33 S6LN 20 10 52305 Table 11 4 10 51365 34 S6RN 21 35 10 52305 Table 11 4 10 51365 35 S6RN 21 45 10 52305 Table 11 4 10 51365 39 S6LN 21 45 10 52305 Table 11 4 10 51365 40 S6RN 21 35 10 52305 Table 11 4 10 51365 43 S6LN 21 45 10 52305 Table 11 4 10 51365 44 S6LN 20 10 52305 Table 11 4 10 51365 45 S6LN 21 35 10 52305 Table 11 4 10 51365 46 S6LN 20 10 52305 Table 11 4 10 51365 47 S6LN 21 45 10 52305 Table 11 4 10 51365 48 S6RN 21 35 10 52305 Table 11 4 10 51365 54 S6RN 21 35 10 52305 Table 11 4 10 51365 57 S6LN 21 45 10 157209 Table 11 4 10 52350 20 S6LN 23 45 NLA Table 11 4 10 79020 6 S6LN 25 30 10 52305 Table 11 5 10 79020 10 S6RN 25 30 10 52305 Table 11 5 10 79020 11 S6LN 25 30 10 157209 Table 11 5 10 79020 16 S6LN 25 30 10 52305 Table 11 5 10 79020 17 S6LN 25 30 10 157209 Table 11 5 10 79020 18 S6LN 25 30 10 157209 Table 11 5 10 79020 19 S6RN 25 30 10 157209 Table 11 5 10 79020 118 S6LN 25P 30 10 382814 Table 11 5 S 20 S 200 Series High Tension Magneto Service Support Manual 11 1 31 August 2011 Illustrated Parts List Table 11 1 Equipment Covered
58. 52 4 I 52 Plate Data 10 400012 1 53 Key Woodruff 10 90788 5 2 54 Magnet Rotating Rotor 10 52945 1 10 357479 10 52947 10 52948 55 Slinger Oil 10 51678 1 56 Screw w lock washer 10 35937 8 2 b7 Clamp Coil Core 10 50765 2 58 Coil 10 357165 1 1 59 Seal Oil 10 400554 1 61 Screw w lock washer 10 391213 1 62 Washer Plain 10 51354 1 63 Cam 10 50772 4 10 50772 5 1 64 Bearing Ball 2 202 1 65 Washer Shim 0 002 in thick 2 199 1 AR 0 004 in thick 2 199 2 AR 0 005 in thick 2 199 3 AR 0 008 in thick 2 199 4 AR 0 010 in thick 2 199 5 AR 0 012 in thick 2 199 6 AR 66 Washer Plain 10 3503 1 67 Gear Pinion 10 157123Y 1 69 Bearing Sleeve 10 25788 1 70 Bearing Ball 10 81806 1 71 Washer Shim 2 161 1 AR 0 002 in thick 2 161 1 AR 0 004 in thick 2 161 2 AR 0 005 in thick 2 161 3 AR 0 008 in thick 2 161 4 AR 0 010 in thick 2 161 5 AR 0 012 in thick 2 161 6 AR 0 0015 in thick 2 161 7 AR 72 Kit Distributor Gear 10 357584 1 73 Brush Carbon 10 160844 1 74 Ring Retaining MS16624 2037 1 11 18 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Ae Illustrated Parts List aj SES RE MEE E d i Ww iu Ww wo i iu i 2 8 2 z2 3 l 3 3 8 oo o co co co o z Index Description Part No eo e e e e e e 23 75 Washer 0 750 OD 10 349511 76 Washer 0 562 OD 10 606505 77 Washer Nylon 10 391309 78 Screw w plain amp
59. 67 6 1 1 1 1 1 1 12 Screw w lock washer Short 10 35936 7 4 4 4 Screw w lock washer Long 10 157160 4 4 4 4 4 4 14 Gasket Contact Cover 1033575532 L1 15 Cover Contact 10 52939Y 1 1 1 NLA 2 1 1 1 1 NLA 1 1 17 Lead Assembly Tach 10 400141 2 2 18 Sleeving 654742 2 50 1 1 19 Grommet Tach 10 400103 1 1 21 INutCap 1019177 EEUU DUM 22 Disk Neoprene 10 163384 1 1 1 1 25 Screw Fillister Head 10 35937 12 4 4 4 4 4 4 4 4 4 33 Screw HexHead 10682056 1 1 1 34 Gasket 10 357520 1 1 35 Spring Switch Terminal 10 102090 1 1 1 37 Washer Plain 10 14268 1 1 2 1 2 1 1 1 1 37a Washer Plain NAS620 8L 1 1 38 Bushing Tach 10 361639 2 2 39 Contact Assembly 10 382585 1 1 1 1 10 357174 1 1 1 10 382584 1 1 Tachometer 10 400507 1 1 40 Plate Insulating Tach 10 361624 1 1 41 Screw wilock washer 10 35935 5 2 2 2 2 2 2 10 35936 7 3 3 4 3 4 2 2 2 2 42 Capacitor 10 51676 1 1 1 10 400572 1 1 1 1 1 11 14 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 5 S6LN S6RN 25 and 25P Magnetos Illustrated Parts List eo e S Index Description Part No 3 44 Plug Solid 10 157135 1 46 Plug Ventilator 10 157134 1 46a Orifice Air Bleed 10 382861 47 Screw w lock washer 10 157158 48 Housing Distributor
60. 7 S6RN 204 10 400415 10 600646 4 S6RSC 204 10 163050 9 S6LN 204 10 400415 10 600646 1 S6LSC 204 10 163050 12 S6LN 204 10 400412 10 600646 201 S6LSC 204T 10 163055 1 S4LN 205 10 400415 10 600654 1 S4LSC 205 10 163060 1 S6RN 205 10 400415 10 600656 1 S6RSC 205 10 163060 2 S6LN 205 10 400415 10 600656 3 S6LSC 205 11 34 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 15 Kit Contents Illustrated Parts List Kit Part Number eS 2 2 amp Figure 1 Index No Part Number Nomenclature e 2 15 10 400160 3 over 1 15 10 400160 1 Cover 1 15 10 400160 4 Cover 1 15 10 400160 7 Cover 1 42 10 400615 Capacitor 1 1 1 1 41 10 35935 6 Screw 2 2 2 2 36 10 349263 Packing 1 1 1 1 12 10 157160 Screw 4 44 4 52 10 400012 Plate 1 1 1 1 25 10 35937 12 Screw 1 23 10 400050 Lead 1 26 10 16092 Washer 1 27 10 125996 Bushing 1 28 MS35650 302 Nut 1 ES EN 34 10 357532 Gasket 1 19 10 400103 Grommet 1 17 10 400141 Lead 2 18 654742 2 50 Tubing 1 16 MS35338 43 Lock Washer 1 1 1 2 S 20 S 200 Series High Tension Magneto Service Support Manual 11 35 31 August 2011 Illustrated Parts List 11 6 Numerical Parts List
61. 8 B E E EE E EE 2 E E E EE us te io ig ig ig ig t DH DH ig 2 to Index Description Part No eis c c 9o s5 25 29o 2 22 22 2 1 Pin Cotter 10 90751 18 1 EBNEBEEN 1 II 1 PETERET 1 W 10 90751 19 1 2 Nut Drive Shaft 10 51643 IEEE EE IM 1 1 10 51652Y 1 i i 10 163178 1 3 Washer Lock 10 3793 TETTE 1 BEI 1 at Ei 4 Washer Plain 10 51370 1 1 10 116860 1 1 1 10 52307 1 1 NEM 1 ee Ni 10 51613 1 5 Bushing 10 51651 1 10 163048 1 10 357193 1 1 1 8 Coupling Impulse 30 Lag 10 400316 1 E i 35 Lag 10 400303 1 45 Lag 10 400314 1 1 45 Lag 10 400315 1 1 35 Lag 10 400305 1 45 Lag 10 400306 1 30 Lag 10 400307 1 1 1 35 Lag 10 400304 1 9 Body Impulse Coupling 10 51333 1 1 10 51395 1 10 52903 1 1 10 70371 IN 1 E 10 76232 1 1 1 1 10 Spring Main 10 51324 1 BI 1 TREEGE 1 TERDEE 1 B 1 Can 104016066 0 T 3 BID DW Eo y 10 400167 6 1 E 10 400167 10 1 1 1 1 10 400166 9 1 10 400166 4 1 1 1 12 Screw w lock washer 10 157160 4 NENMENMUM 4 NISUS MY A LE 14 Gasket 10 357532 1 1 1 15 Cover Contact 10 400160 4 I 1 10 400160 3 1 EBENEN ENENEN 5 T 10 400160 7 1 16 Washer Lock MS35338 43 1 EBENEN eRe ha aen B 17 Lead Assembly Tach 10 400141 2 11 26 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 9 S6LSC S6RSC 21 25 25P and 25T Magnetos Illustrated Parts List
62. 948 1 1 o ee dh 55 Slinger Oil 10 51678 1 Bee BEE BE 56 Screw w lock washer 10 35937 8 2 MARERE 2 ENMENMENM EMENEPNM E 57 Clamp Coil Core 10 50765 2 EBENEN 2 NSSNES EHIENES 2 NE 58 Coil 10 357165 1 1 Bee 1 n n eE i nnl 59 Seal Oil 10 400554 1 eE Be eA 60 Pin Stop 10 56513 2 ENENENS 2 ESESE 10 79011 2 EBENEN NE S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 11 27 Illustrated Parts List Table 11 9 S6LSC S6RSC 21 25 25P and 25T Magnetos le ql ele rl e 2 se 2 2 8 3 e 9 2 2 7 i5 i S 8B 5 8 8 ds 8 8 sa u2 u2 ua 10 10 10 19 2 10 P up Index Description Part No eo c cc cs sic2c 2s 2 2g 227 22 e2 Pin Stop 0 0005 AO 10 400602 2 EE NEN 2 aa 10 400603 2 oc FR 61 Screw w lock washer 10 391213 1 1 1 1 1 1 1 1 1 1 1 1 1 1 62 Washer Plain 10 51354 1 aa m ee d 63 Cam 10 50772 4 1 1 1 1 1 1 1 1 10 50772 5 1 1 1 1 1 1 64 Bearing Ball 2 202 1 1 1 1 1 1 1 1 1 1 1 1 1 1 65 Washer Shim 0 002 in thick 2 199 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 199 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 199 3 AR AR AR AR AR AR AR AR AR AR AR
63. AR AR AR AR AR AR 0 010 in thick 2 161 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 161 6 AR AR IAR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 0015 in thick 2 161 7 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 72 Kit Distributor Gear 10 357586 1 eee 1 FATTET BENENEN 1 eee E 73 Brush Carbon 10 160844 1 ree ENENNEN BENNENEN PETTEE 1 E f MS16624 74 Ring Retaining 2037 1 EMEN 1 NUMEN 1 NUMEN 1 EUM 1 i 75 Washer 0 750 OD 10 349511 IMI BEENEBNEN NNEENENO PECTED T 76 Washer 0 562 OD 10 606505 1 See 1 BEEMBENMEAA BNEENEEN 1 PETRER E 77 Washer Nylon 10 391309 imEENEEN FATTET EBENEN ENENEN he Screw w plain amp lock 78 Washer P 10 102083 3 ENENENM 2 EEE REE B RR BIR 9S EDEN 3 lE 79 Block Distributor 10 357424 1 eee ENENEN BENENEN PETTEE i 80 Spring Tower 10 50737 4144 444 4 4 4 4 4 4 4 4 4 44 4 81 Strip Felt 10 163374 1 tn Thm hh ttn i 82 Washer Felt 10 50752 1 ree NENENEN 1 FATTET TETTED E S 20 S 200 Series High Tension Magneto Service Support Manual 11 25 31 August 2011 Illustrated Parts List Table 11 9 S6LSC S6RSC 21 25 25P and 25T Magnetos o 2 4 2 ei 5 e l lel 2 2 8 8 2 2 2 2 2 3 S
64. AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 65 0 012 in thick 2 199 6 AR IAR AR AR AR AR IAR IAR IAR AR IAR AR IAR IAR AR IAR 66 Washer Plain 10 3503 1 i mu a 67 Gear Pinion 10 157120Y 1 rh Tinh HUENMUENUES UIN 69 Bearing Sleeve 10 25788 1 PP Pe Te JUI 70 Bearing Ball 10 81806 1 Ph Pin HENMUENSUES MIU 71 Washer Shim 0 002 in thick 2 161 1 AR AR AR AR AR AR IAR IAR IAR AR IAR AR IAR IAR JAR IAR 0 004 in thick 2 161 2 AR AR AR AR AR AR IAR IAR IAR AR AR AR IAR IAR AR IAR 0 005 in thick 2 161 3 AR IAR AR AR AR AR IAR IAR IAR AR AR AR AR IAR AR IAR 0 008 in thick 2 161 4 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 0 010 in thick 2 161 5 AR AR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 0 012 in thick 2 161 6 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 0 0015 in thick 2 161 7 AR IAR AR AR AR AR IAR IAR IAR AR AR IAR AR IAR AR IAR 72 Kit Distributor Gear 10 357586 1 Ph Titi iT Tai 73 Brush Carbon 10 160844 1 PP mu au a 74 Ring Retaining MS16624 2037 1 1 1 1 1 1 4 1d 101101 1 1 1 1 4d 4 75 Washer 0 750 OD 10 349511 1 PP Te UEM ms 76 Washer 0 562 OD 10 606505 1 rh PHENMHENUES III UNI 77 Washer Nylon 10 391309 1 Th 6 77 HEURE Ha Screw w plain amp lock 78 anes p 10 102083 3 Cece OS O O o SEM NS 79 Block Distributor 10 357426 1 Ph HH DENN mm 80 Spring Tower 10 50737 6 6 6 6 6 6 6 6 6 6 6 6 6 6 16 6 81 Strip Felt 10 163374 1
65. ARD TERMINAL IN COVER MAIN CONTACT ASSEMBLY CAPACITOR B Clockwise Rotation Magneto Figure 9 10 Lead Routing in Contact Compartment Short Cover TACHOMETER MAIN CONTACT CONTACT ASSEMBLY ASSEMBLY TO GROMMET THROUGH COVER CAPACITOR Counterclockwise Magneto with Tachometer Contacts Figure 9 11 Lead Routing with Tachometer Contacts S 20 S 200 Series High Tension Magneto Service Support Manual 9 9 31 August 2011 Assembl 9 2 7 Oil Seal and Oil Slinger Installation 1 Apply a thin film of clean 30 wt SAE J 1899 aviation engine oil to the lip of a new oil seal 59 Carefully slide the new oil seal on to the rotor shaft avoiding contact with threads or keyway and position the seal squarely at the edge of the recess in housing Place the magneto in an arbor press with the contact compartment rim supported by a block of wood and press the new oil seal in to the flange with the 11 6924 1 Pressing Tool CAUTION After installing oil seal and deflector check cam securing screw 61 torque for 21 to 25 in lbs to ensure the cam washer 62 did not deform during pressing operation Replace the washer 62 and screw 61 if washer deformed 11 6924 1 Figure 9 12 Oil Seal Installation 2 Rest the cam securing screw on a wooden block and press a new oil deflector 55 on to the rotor 54 until it seats agains
66. C 21 25 Table 11 8 10 500514 5 S4RSC 21 25 Table 11 8 10 500514 8 S4LSC 21 25 Table 11 8 10 500514 201 S4LSC 21T 25 Table 11 8 10 500516 2 S6LSC 21 45 Table 11 8 10 500516 3 S6LSC 21 45 Table 11 8 10 500516 4 S6LSC 21 45 Table 11 8 10 500516 5 S6RSC 21 35 Table 11 8 10 500516 6 S6RSC 21 45 Table 11 8 10 500516 7 S6RSC 21 45 Table 11 8 10 500516 9 S6RSC 21 35 Table 11 8 10 500516 10 S6LSC 21 45 Table 11 8 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 1 Equipment Covered Degrees Applicable Magneto Part Number Model Number Lag Retard Use Terminal Kit Part No Parts List 10 500556 1 S6RSC 25 30 Table 11 8 10 500556 3 S6LSC 25 30 Table 11 8 10 500556 101 S6RSC 25P 30 Table 11 8 10 500556 103 S6LSC 25P 30 Table 11 8 10 500556 203 S6LSC 25T 30 Table 11 8 10 500556 901 SRSC 25P 30 Table 11 8 10 600604 1 S4RSC 201 20 Table 11 7 10 600606 1 S6RSC 201 30 Table 11 9 10 600606 3 S6LSC 201 30 Table 11 9 10 600614 1 S4LSC 200 25 Table 11 7 10 600614 2 S4LSC 200 15 Table 11 7 10 600614 3 S4LSC 200 25 Table 11 7 10 600616 3 S6LSC 200 37 5 Table 11 9 10 600616 4 S6RSC 200 30 Table 11 9 10 600616 5 S6LSC 200 30 Table 11 9 10 600616 6 S6LSC 200 30 Table 11 9 10 600616 7 S6RSC 200 25 Table 11 9 10 600616 9 S6LSC 200 30 Table 11 9 10 600616 101 S6LSC 200P 30 Table 11 9
67. Cam Breaker 63 10 157160 Screw w lock washer 12 10 51324 Spring Impulse Coupling 10 10 157241 Lead Assembly Retard 23 10 51333 Body Impulse Coupling 9 10 160844 Brush Carbon 73 10 51354 Washer Plain 62 10 160850 Plate Drive 6 10 51370 Washer Plain 4 10 160893 Cam Assembly 11 10 51391 Plug Ventilator 46 10 163008 Plate Drive 7 10 51395 Body Impulse Coupling 9 10 163048 Bushing 5 10 51613 Washer Keyed 4 10 163049 Bushing 5 10 51643 Nut Drive Shaft 2 10 163151 Nut DriveShaft 2 10 51651 Bushing 5 10 163177 Nut Cap 21 10 51652Y Nut Drive Shaft 2 10 163194 Paper Retard 24 10 51676 Capacitor 42 10 163214 Plate Drive 7 10 51678 Slinger Oil 55 10 163216 Plate Drive 7 10 52307 Washer Plain 4 10 163374 Strip Felt 81 10 52320 Gasket Magneto Housing 49 10 163384 Disk Neoprene 22 10 52321Y Gasket Contact Cover 14 10 180128 1 Sleeving 20 FT 18 10 52326 Housing Distributor 48 10 349263 Packing 36 10 52327 Housing Magneto 4g 10 349970 Contact Assembly Tachometer 39 10 52903 Body Impulse Coupling 9 10 357165 1 Coil 58 1052931 Housing Distributor 48 10 357165 20S Coil 58 11 36 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 16
68. Drive Plate and Front End Hardware Disassembly esse 4 2 4 2 4 Impulse Coupling Disassembly eeseeeeeeeeeeeeeeeee eee 4 2 4 2 5 Rotating Magnet Rotor Disassembly eee 4 4 4 2 6 Housing Disassembly eese eterne nennen nennen 4 5 5 Cleaning Debs General sistas TES 5 1 5 2 Detailed Magneto Cleaning Procedures sees 5 1 6 Periodic Maintenance s ls Genetalz ect IERI tus aimes pr MM ca HS a CUT 6 1 6 2 Detailed Maintenance Procedures eeeeeeeee eee 6 2 6 2 1 Contact Assemblies 2e imet terree dee ore ER redde te coa ere e eR 6 2 6 2 2 Impulse Couplings essei teet rette tp rrr eerie inp ests 6 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 6 2 3 500 Hour Inspection ee te ettet tet rtt hee rette ette cette 6 7 7 General Overhaul FEES SIC p varaase epeauvaa tins tae AR ATAA A a 7 1 7 2 Detailed Overhaul Procedures 2p vsaisssesovssieriades pjeontssausad eengersintecateaspaastte 7 2 7 2 1 Magneto Disassembly 5 uet OO HERE GER OA Ea 7 2 7 2 2 Distributor Gear Inspection sseseseeeeeeeee ener eerte nennen 7 2 7 2 3 Cam Washer and Pinion Gear Inspection eese 7 5 7 2 4 Distributor Block Inspection sees enne 7 5 7 2 5 Capacitor Inspection seniper 7 9 7 2 6 Coil and Clamp Inspecti
69. INISH Figure 9 6 Contact Spring Installation S 20 S 200 Series High Tension Magneto Service Support Manual 9 5 31 August 2011 Assembl Position the distributor block Figure 1 79 in the distributor housing 48 and secure with three new screw lock washer and washer 78 assemblies Ensure the distributor block is fully seated in the housing then tighten the screws evenly first to 4 8 in lbs torque followed by a final torque of 16 20 in Ibs Form the felt strip 81 in a ring and install it dry in the deep groove next to the distributor block bushing so that it does not interfere with the washers 76 77 Saturate a new or clean serviceable felt washer 82 with P N 10 391200 distributor block lubricant Blot excess oil from washer 26 until the flat surfaces take on a frosted appearance Seat washers in the recesses on the tower side of the distributor block 79 Place a nylon washer 77 and 0 562 in OD steel skid washer 76 on the gear 72 shaft and slide the large distributor gear shaft 72 in to the distributor block 79 Secure the gear on the shaft with a 0 750 inch OD washer 75 and retaining ring 74 Verify the retaining ring snaps firmly into mating groove Do not stretch the ring out of shape during installation if the ring is loose fitting on the shaft replace it Do not attempt to reshape a loose retaining ring Install the carbon brush 73 in the hole in the distributor
70. 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 Ibs torque under any circumstances OPTIONAL fa CUT HERE i Figure 9 18 Repeated for Reference CAUTION If the impulse coupling cam cracks Figure 9 19 during this procedure an audible cracking noise is evident and nut torque reduces immediately If the cam cracks replace it with a new cam Figure 9 19 Repeated for Reference 9 2 14 Post Overhaul Test Perform the applicable Post Overhaul Testing according to instructions in Section 3 2 S 20 S 200 Series High Tension Magneto Service Support Manual 9 21 31 August 2011 Assembl 1 SESE 9 3 Mlagneto Installation on Engine 9 22 NOTE Comply with all engine manufacturer s installation instructions and parts lists regarding drive adapters spacers gaskets mounting hardware torque values and related specifications WARNING When the P lead terminal is removed from the magneto the spring inside the magneto may 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 Remove the plug Figure 1 44 to gain visual access to the distributor gear 72 Turn rotating magnet until the red tooth on the gear is approx
71. KWISE AS VIEWED FROM DRIVE END NOTE SIX CYLINDER GEAR HAS NO ARROW COUNTERCLOCKWISE ROTATION VIEWED FROM DRIVE END Figure 9 1 Correct Assembly of Gear and Cam 9 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl b Six cylinder magnetos incorporate a pinion gear 67 which has a chamfer on only one end of the tooth There are no arrows on this gear The chamfered end of the tooth may be installed in either direction 2 Place a plain washer 66 on the shaft next to the pinion gear followed by shim washers 65 totaling approximately 0 036 in thickness Using the small end of the 11 6924 1 Pressing Tool and an arbor press Figure 9 2 press the inner race of new bearing 64 on the rotor shaft lettered side toward the pressing tool vuu Figure 9 2 Cam End Bearing Inner Race Installation 3 Position shim washers totaling 0 012 in thickness on the drive end of the rotor shaft Using the large end of the 11 6924 1 Pressing Tool and an arbor press Figure 9 3 press the inner race of the new bearing 70 on the shaft lettered side toward the pressing tool 4 Place the bearing cage assemblies 64 70 on their respective inner bearing races on rotor shaft 5 27777 IA Figure 9 3 Drive End Bearing Inner Race Installation 5 Using large end of the 11 6924 1 Pressing Tool and an arbor press Figure 9 4 seat the outer races of the bearing
72. 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 Bearing Grease Gears Cam Cam Follower Felt Distributor Block Bushing Felt Washer Housing Pole Shoes Rotor Pole Pieces Impulse Coupling Spring Magneto Shaft Taper Oil Seal Sleeve Bearing Distributor Block Buna Rubber Testing Coming in speed Spark gap setting Tolerances Cam Washer Thickness Capacitor Coil Contact Point Clearance Main Retard and Uninsulated Contacts Tachometer Insulated Contacts E Gap Pressurized Magneto Leakage Torques Cover Screws Cam Screw Capacitor Screw Coil Core Clamp Screws Coil Primary Lead Screw Contact Assembly Screws Main Retard amp Uninsulated Tachometer Tachometer Insulated Drive Shaft Nut Distributor Block Screws Switch Terminal Bushing Housing Screws Plastic Timing Window Plug Vent Plug Metal Orifice Harness Outlet Plate Screws Switch and Retard Stud Nuts Retard Lead Nuts Miscellaneous Magneto Drive Speed Magneto Grease Part No 10 400550 1 Breaker Felt Lubricant Part No 10 86527 Distributor Block Lubricant Part No 10 391200 Silicone Free Rust Preventive Light Oil Part No 646943 SAE 30 Oil Distributor Block Coating Part No 10 391400 150 RPM 0 157 in 4mm 0 095x0 010 0 375 ufarads 10 1 0 ohm feed through max
73. Magneto Service Support Manual 6 7 31 August 2011 Periodic Maintenance a The contact assembly area shall be free of moisture dirt oil or grease residue Clean as necessary b Inspect the assembly according to instructions in Section 6 2 1 step 1 through step 6 CAUTION If the self locking cam securing screw 61 is removed or loosened at any time always replace with a new self locking screw and torque 21 25 in lbs c Ensure cam securing screw 61 is tightened to a torque value of 21 25 in Ib d Check magneto internal timing 1 Loosen the nut securing drive member of magnet shaft sufficiently in order to install the 11 8465 Rotor Holding Tool under nut and flat washer as shown in Figure 9 20 Tighten the nut securely WARNING Rotor is to be locked on drive shaft end only Do not use gear lock devices Use of such devices may result in gear tooth damage and subsequent magneto failure NOTE Tighten the 11 8465 Rotor Holding Tool adjusting knob only enough to hold magnet shaft firmly in desired position Over tightening the adjusting knob may damage the drive end bearing 2 Remove the timing inspection plug 44 from the top of the magneto Turn the rotating magnet in normal direction of rotation until the applicable timing mark on the distributor gear is aligned with the center of the timing window Turn the magnet backward until the magnet finds its neutral position Tighten the 11 8465 Holding Tool adjusting
74. NLA 10 400551 7 10 400551 8 49 Gasket Housing 10 357533 50 Housing Magneto 10 400552 1 10 400552 2 52 Plate Data 10 400012 53 Key Woodruff 10 90788 5 54 Magnet Rotating Rotor 10 52948 55 Slinger Oil 10 51678 56 Screw w lock washer 10 35937 8 57 Clamp Coil Core 10 50765 58 Coil 10 357165 20S 10 357165 1 59 Seal Oil 10 400554 60 Pin Stop 10 79011 Pin Stop 40 0005 AO 10 400603 61 Screw w lock washer 10 391213 62 Washer Plain 10 51354 63 Cam 10 50772 1 10 50772 4 10 50772 5 64 Bearing Ball 2 202 65 Washer Shim 0 002 in thick 2 199 1 0 004 in thick 2 199 2 0 005 in thick 2 199 3 0 008 in thick 2 199 4 0 010 in thick 2 199 5 0 012 in thick 2 199 6 66 Washer Plain 10 3503 67 Gear Pinion 10 157120Y 69 Bearing Sleeve 10 25788 70 Bearing Ball 10 81806 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 10 79020 10 10 79020 11 10 79020 16 10 79020 18 10 79020 19 10 79020 118 110 79020 119 11 15 Illustrated Parts List Table 11 5 S6LN S6RN 25 and 25P Magnetos e e e E il Sei S B BBBRB B BB eB Index Description Part No 2 71 Washer Shim W 0 002 in thick 2 161 1 AR AR 0 004 in thick 2 161 2 AR AR 0 005 in thick 2 161 3 AR AR 0 008 in thick 2 161 4 AR AR 0 010 in thick 2 161 5 AR AR 0 012 in thick 2 161 6 AR AR 0 0015
75. Numerical Parts List Table 11 16 Numerical Parts List Part No Description Index Part No Description Index 10 357173 Contact Assembly 39 10 400306 Impulse Coupling 8 10 357174 Contact Assembly 39 10 400307 Impulse Coupling 8 10 357193 Bushing 5 10 400313 Impulse Coupling 8 10 357424 Distributor Block 4 Cylinder 79 10 400314 Impulse Coupling 8 10 357426 Distributor Block 6 Cylinder 79 10 400315 Impulse Coupling 8 10 357479 Magnet Rotating Rotor 54 10 400316 Impulse Coupling 8 10 357494 Tubing 43 10 400315 Impulse Coupling 8 10 357532 Gasket Contact Cover 14 10 400316 Impulse Coupling 8 10 357533 Gasket Housing 49 10 400320 Impulse Coupling 8 10 357584 Kit Distributor Gear 4 Cylinder 72 10 400321 Impulse Coupling 8 10 357586 Kit Distributor Gear 6 Cylinder 72 10 400507 Contact Assembly Tachometer 39 10 361624 Plate Insulating 40 10 400547 3 Cover Contact 15 10 361637 Cover Contact 15 10 400547 5 Cover Contact 15 10 361639 Bushing 38 10 400549 1 Housing Magneto 50 10 382584 Contact Assembly 39 10 400549 2 Housing Magneto 50 10 382585 Contact Assembly 39 10 400549 4 Housing Magneto 50 10 382815 Bushing 44 10 400551 1 Housing Distributor 48 10 382861 Orifice 46 10 400551 2 Housing Distributor 48 10 391213 Screw w lock washer 61 10 400551 4 Housing Distributor 48 10 391309 Washer Nylon 77 10 400551 5 Housing Distributor 48 10 400012 Plate Data 52 10 400551 6 Housing Distributor 48 Lead Assembly Retard 23A 10 400551 7 Hous
76. R AR AR AR AR AR 66 Washer Plain 10 3503 1 BEMBNEMBM BNMEMEMEMENM O BEEMENMENM Bi 67 Gear Pinion 10 157123Y 1 I RR OEM eee li 69 Bearing Sleeve 10 25788 1 ma 1 mas a i 1 70 Bearing Ball 10 81806 1 BEBNEN EE i EE y E 1 ii 71 Washer Shim 0 002 in thick 2 161 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 161 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 161 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 161 4 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 010 in thick 2 161 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 161 6 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 0015 in thick 2 161 7 AR AR AR AR AR AR AR AR AR AR AR AR AR AR 72 Kit Distributor Gear 10 357586 1 BI BB BMEMNMEMENM EBENEN Ni 73 Brush Carbon 10 160844 i BEBNENENM LEAT UL EU E 74 Ring Retaining MS16624 2037 1a 1 eee 1 eee 1 75 Washer 0 750 OD 10 349511 1 tte cae bhain Ei S 20 S 200 Series High Tension Magneto Service Support Manual 11 21 31 August 2011 Illustrated Parts List Table 11 7 S6LN S6RN 200 201 204 and 205 Magnetos x 9 Y x Tex x4 2 2 2 2 2 8 amp 8I sis 8 885 8 8 83 83 3 8 SS SS a se Index Description Part No l g gl gl g glg l g
77. S 20 S 200 Series High Tension Magneto CONTINENTAL IGNITION SYSTEMS SERVICE SUPPORT MANUAL Technical Portions Approved by the FAA Publication X42002 3 2011 CONTINENTAL MOTORS INC AUG 2011 Supersedure Notice This manual is a revision of the service instructions contained in X42002 2 published in September 2010 Upon FAA Approval and release of this document previous versions of X42002 are superseded and should not be used for S 20 S 200 Series magneto maintenance inspection or overhaul Effective Changes for this Manual Oss ies 31 August 2011 List of Effective Pages Document Title S 20 S 200 Series High Tension Magneto Service Support Manual Publication Number X42002 3 Initial Publication Date 31 August 2011 Page Change Page Change Page Change Page Change GOVOM sns eot 0 usc d II 0 DV 0 1 1 thru 922 tea 0 2 1 thru 2 6 0 3 1 thru 8 65 0 4 1 thru 4 6 0 5 1 thru 5 2 0 6 1 thru 6 10 0 7 1 thru 7 20 0 8 1 thru 8 2 0 9 1 thru 9 24 0 10 1 thru 10 2 0 11 1 thru 11 40 0 Published and printed in the U S A by Continental Motors Inc Available exclusively from the publisher P O Box 90 Mobile AL 36601 Copyright 2011 Continental Motors Inc All r
78. S 200 Series Only 4 Four Cylinders T Tachometer Breaker Points 6 Six Cylinders P Pressurized 8 Eight Cylinders Rotation Designator Viewed Looking in to Drive End N Scintilla Design L Left counterclockwise SC Short Cover R Right clockwise 2 2 2 2 Figure 2 2 Magneto Part Number Elements Detailed Description The magneto is a completely self contained unit The rotating magnet turns on two ball bearings one located at the contact assembly end and the other at the drive end A two lobe cam is secured to the contact assembly end of the rotating magnet shaft In a six cylinder magneto the rotating magnet turn 1 1 2 times engine speed Thus six sparks are produced through 720 degrees of engine rotation In a four cylinder magneto the rotating magnet turns at engine speed Therefore four sparks are produced through 720 degrees of engine rotation Some S 20 Series 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 S 200 Dual Contact Assembly Magnetos Figure 2 3 incorporate a retard contact assembly This contact assembly is actuated by the same cam as the main contact assembly It is positioned so its points open a
79. SC 200 10 163010 11 10 163010 11 10 163010 11 S6LN 200 10 600616 6 S6LSC 200 10 163010 15 10 163010 15 10 163010 15 S6RN 200 10 600616 7 S6RSC 200 10 163010 17 Discontinued 10 163015 1 Discontinued 10 163015 2 Discontinued 10 163015 3 10 163015 3 10 163015 3 S4RN 201 10 600604 1 S4RSC 201 10 163015 4 Discontinued 10 163020 1 Discontinued 10 163020 3 S6RN 201 10 600606 1 S6RSC 201 11 6 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 2 Superseded Discontinued and Interchangeable Magnetos For Maintenance or Overhaul Follow Parts List For Replacement Use Old Part No For Part No Type No Part No Type No 10 163020 2 Discontinued 10 163020 3 10 163020 3 10 163020 3 S6RN 201 10 600606 1 S6RSC 201 10 163020 4 10 163020 4 10 163020 4 S6LN 201 10 600606 3 S6LSC 201 10 163020 103 Discontinued 10 163030 1 Discontinued 10 163030 4 Discontinued a 10 163045 1 10 163045 1 10 163045 1 S4LN 204 10 600644 4 S4LSC 204 10 163045 2 Discontinued 10 163045 3 10 163045 3 10 163045 3 S4LN 204 10 600644 1 S4LSC 204 10 163045 4 Discontinued 10 163045 6 10 163045 6 10 163045 6 S4LN 204 10 600644 201 S4LSC 204T 10 163045 7 Discontinued 10 163045 8 10 163045 3 10 163045 3 S4LN 204 10 600644 1 S4LSC 204 10 163050 1 10 163050 1 10 163050 1 S6LN 204 10 600646 2 S6LSC
80. SC 200 Series Magneto Product Line 10 3 94 SIL648 Optional Conversion to Shower of Sparks Ignition 10 18 94 SB650 Stop Pin Procedures 3 17 95 SB653 Hot Magneto Test 5 23 95 SB654A Improved Capacitor P N 10 400604 for Certain Short Cover S 20 and S 200 Series Magnetos 11 15 96 SIL656 Relay Vibrator Supersedure 5 17 96 SIL657A Supersedure of P N 10 163136 and 10 361638 Covers and of 10 361637 Cover Kit 10 09 97 SB658 Distributor Gear Maintenance 8 16 96 SB663A Two Wire Magneto Tachometer Breaker Contact Assembly P N 10 400507 1 24 07 SB664 Magneto Capacitor P N 10 400558 Replacement 9 6 02 SB665A Magneto Capacitor P N 10 400615 Inspection and Replacement 8 20 04 CSB 668 Inspection of Ignition Harness Attachment Plate 5 18 10 S 20 S 200 Series High Tension Magneto Service Support Manual i 31 August 2011 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 s
81. aces with a piece of clean hard cardboard such as a business card Ensure no paper particles are left between the contact surfaces 2 Install the contact assemblies 39 in the contact compartment Main and retard contact assemblies both require a screw with lock washer 36 at the pivot end and a screw with lock washer 36 and plain washer 37 at the slotted end If a tachometer contact assembly is used install the contact assembly insulating plate 40 and insulating bushings 38 with screws and lock washers 36 and plain washer 37 Do not tighten contact securing screws fully until final adjustment of contact clearance and E gap is complete S 20 S 200 Series High Tension Magneto Service Support Manual 9 7 31 August 2011 Assembl 9 2 6 Capacitor Installation 1 Secure capacitor P N 10 51676 42 in the contact compartment using screw with washer 41 and 20 to 25 in Ibs of torque Secure capacitor P N 10 400572 or 10 400615 to the contact cover 15 with new screws with lock washers 41 tighten the screws to 8 to 12 in Ibs of torque For capacitor mounted in the housing 48 connect the coil primary lead and capacitor lead to the contact assembly with a screw 33 torque the screw to 7 to 9 in Ibs of torque Magnetos with a ground terminal on flat type contact cover use a separate ground terminal spring 35 This spring must be assembled at the same time the leads are connected and must fit directly ag
82. afety issue Category 3 Service Bulletin SB Information which the product manufacturer believes may improve the inherent safety of an aircraft or S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 aircraft component this category includes the most recent updates to Instructions for Continued Airworthiness 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 1 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 Airworth
83. ainst breaker assembly bracket to ensure correct position Verify the coil primary lead does not rest against the edges of housing 48 Figure 9 8 For capacitors mounted in the cover 15 connect the coil primary to the main contact as shown in Figure 9 9 or Figure 9 10 Set the capacitor 42 and cover 15 assembly aside until after magneto internal timing is complete If used install a bushing 45 in the threaded hole in the housing 48 tighten the bushing 45 to 120 156 in lbs of torque COIL LEAD GROUND SPRING Figure 9 8 Lead Routing with Ground Terminal in Flat Cover NOTE colored wires in the following examples are for clarification only colors do not represent magneto wire colors RETARD TERMINAL if used 2 R a MAIN H D QUEUE m if used q AR b 2j D if used RETARD S RETARD CONTACT CAPACITOR CONTACT ASSEMBLY ASSEMBLY A CCW Magneto B CW Magneto 9 8 Figure 9 9 Lead Routing in Contact Compartment Long Cover S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl MAIN CONTACT RETARD CONTACT ASSEMBLY ASSEMBLY if used Q TO RETARD io TERMINAL IN COVER CAPACITOR A Counterclockwise Rotation Magneto RETARD CONTACT ASSEMBLY if used TO RET
84. al inspection may disclose the source of trouble Inspect as follows a Remove harness securing screws and separate the cover from magneto Inspect for presence of moisture and foreign matter on rubber grommets and high tension outlet side of the distributor block Also check for broken or burned outlet towers If either is present remove magneto and replace as necessary b Check the springs in the block towers for proper height The end of the spring shall not be more than 0 422 inch from top of tower Replace burned or otherwise short springs must be replaced according to instructions in Section 9 2 3 Check for broken leads or damaged lead insulation If either is present replace magneto c Inspect contact assemblies as specified 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 the test stand using a standard harness assembly Set spark gaps at 4 mm 0 157 in as shown in Figure 3 1 CAUTION Do not operate magneto on 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 59 installed for longer than five minutes as hidden damage may result 45 MATERIAL TUNGSTEN BRASS OR STAINLESS STEEL A 0 008 in R max 3 Places 4mm 0 157 in 0 007 in N IONIZING TEASER ELECTRODE 1
85. alf moon indentation or white dykem lacquer paint in the position illustrated in Figure 7 11 and may have a black oxide or silver colored finish Discard clamps which fail to meet current specifications or clamps exhibiting wear physical damage or deformities 7 10 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul HALF MOON UNE ATION R WHITE DYKEM PAINT Figure 7 11 Current Design Core Clamp 7 2 7 Impulse Coupling and Related Component Inspection 1 Visually inspect the bushing 5 2 Inspect for wear or deformation Look particularly at the surface where the lock washer or nut seat contacts the bushing If the bushing wear or deformation is present replace bushing 5 3 Replace sintered iron bushing with a machined steel bushing 5 Machined steel bushings have an undercut 0 062 wide by 0 005 in deep immediately behind the bushing shoulder Figure 7 12 Refer to the Illustrated Parts List in Chapter 11 for correct part numbers Upon compliance with this step Magneto Part Number 10 51360 30 converts to Part Number 10 51360 37 Over stamp the magneto identification plate 52 with the new magneto part number Identify all other part number magnetos complying with this step by stamping a 0 125 inch high letter B in the lower left hand corner of the data plate Discard sintered iron bushings OLD NEW SINTERED IRON MACHINED STEEL Figure 7 12 Drive Bushings
86. ance 6 2 2 Impulse Couplings For all S 21 S 23 and S 25 series magnetos inspect snap ring impulse couplings Figure 1 8 at the first 500 hours in service and every 500 hours thereafter or inspect riveted impulse couplings 8 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 1 Check flyweight and axle for wear WARNING A polished area on the heel of the flyweight Figure 6 4 is an indication of severe wear and cause for immediate rejection of the cam assembly 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 STOP TOE i APPROX A 1 8 IN HEEL TRIGGER RAMP ROTATING MAGNET SHAFT Figure 6 3 Flyweight Terminology 6 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance Figure 6 4 Heel Inspection WARNING Lock the rotor on drive shaft end only Do not use gear locking devices Clamping the gear may result in gear tooth damage and subsequent magneto failure a Rotate the impulse coupling so the flyweight axles are next to the stop pins Position flyweight as shown in Figure 6 3 Lock rotor in place using an 11 8465 rotor holding tool NOTE Dimensions in Figure 6 5 are approximat
87. ares qoi e tei atte Mix E eaaa 11 6 D 3000 Series Magneto Exploded View 11 17 D 3000 Series Magneto Harness Assembly Exploded View 11 18 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 XV Intentionally Left Blank xvi S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 e SS Introduction and Specifications Section 1 Introduction and Specifications 1 1 General This manual provides complete maintenance instructions with illustrated parts list for S 20 and S 200 Series Magnetos manufactured by Continental Motors S 20 and S 200 Series Magnetos convert mechanical energy into a sequenced series of high voltage pulses for reciprocating engine ignition This manual is subdivided with sub heads as listed in the Table of Contents Revision service will be provided as required This manual may be inserted as Chapter 74 10 of applicable GAMA format publications These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency to be met in connections with installation operation or maintenance Should further information be desired or particular problems arise which are not covered sufficiently for purchaser s purpose contact Continental Motors Aircraft Products using the contact information provided under the heading Contact Information on page viii of this manual Good
88. 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 documents 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 s
89. ber of degrees past neutral where the main contacts just open Unlock the holding tool and turn the rotating magnet in the normal direction of rotation until pointer of timing kit indexes this total Lock the holding tool in this position Using a timing light adjust retard contact assembly to just open Tolerance of retard is 2 0 Unlock the holding tool Turn the rotating magnet until the cam follower is on the high point of the cam lobe Measure retard contact clearance 0 018 0 006 in If dimension is not within limits readjust retard contact assembly and verify the points will open within retard degree tolerance Replace the contact assembly if retard degree tolerance and contact clearance cannot be met 6 If used adjust tachometer contacts to maximum opening of 0 019 0 003 in when on the highest point of the cam lobe 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 7 Inspect the magneto cover 15 for damage Check capacitor 42 for case or flange looseness and for evidence of lead chafing Using clean dry compressed air clean as necessary and replace faulty or unserviceable components See appropriate procedures in Section 9 2 if capacitor replacement is necessary 8 Form the capacitor and coil leads and install the magneto cover 15 with a new gasket 14 if required on the distributor housing
90. bore deeper than 0 120 inch below the face of the housing measure the bore with a 0 2840 inch gauge pin If the 0 2840 pin will not insert in the bore deeper than 0 120 inch below the face of the housing replace the stop pin with a 0 0005 Authorized Oversize stop pin according to instructions in step c If the 0 2840 gauge pin enters the bore deeper than 0 120 inch the bore exceeds allowable limits replace the housing 0 25 20 NUT BAR STOCK DRILLED TO FIT OVER STOP PIN MAGNETO FLANGE WASHERS NOTE TIGHTEN NUT TO END OF THREADS REMOVE NUT ADD WASHERS AND REPEAT UNTIL THE PIN PULLS FREE OF THE FLANGE Figure 7 19 Impulse Coupling Stop Pin Removal c Place the housing 50 on a wood block and press new stop pin 60 into position using an arbor press The dimension from the top surface of the pin to the face of the mounting flange shall be 0 688 0 016 0 000 inch for all types except housing 50 P N 10 81942 used with S6RN and S6LN 25 magnetos in which case the dimension shall be 0 500 0 016 0 000 inch 7 Inspect retard lead assembly 23 or tachometer leads 17 for damage Inspect the terminals for proper attachment to leads Examine leads for damaged insulation Check the grommet 19 in the cover for damage Ensure the retard lead 23 is insulated from ground with p lead installed Replace damaged leads or grommet S 20 S 200 Series High Tension Magneto Service Support Manual 7 17 31 August 2011 Gene
91. d the coil Each time vibrator points V1 open the 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 therefore produced at the spark plug due to the S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation opening and closing of vibrator points V1 while the main and retard contact assemblies are open When the engine fires and begins to pick up speed the switch is released which deenergizes relay K1 in the starter solenoid This opens the vibrator circuit and retard contact circuit rendering them inoperative The single contact assembly right magneto is no longer grounded therefore both magnetos are simultaneously firing in full advance NOTE Reference only for actual schematic see Airframe Maintenance Manual LEFT MAGNETO DISTRIBUTOR L Q MAN CONTACT ASSEMBLY RETARD CONTACT R RETARD ASSEMBLY Q Q Oo SPARK PLUG START SWITCH STARTING VIBRATOR 24V ONLY e RIGHT MAGNETO DISTRIBUTOR SPARK PLUGS e MAN CONTACT ASSEMBLY H H K STARTER SOLENOID Figure 2 4 Sample Magneto Circuit with Starting Vibrator Schematic S 20 S 200 Series High Tension Magneto Service Support Manual 2 5 31 August 2011 Description and Operation 2 b Serial Numbers Manufacturing numbers commonly refe
92. e rN A 0 125 Max 136 Je 3 0 3 0 A S 25 MODELS B S 21 AND 23 MODELS Figure 6 5 Wire Hook Configuration b For Model S 25 magnetos push on the flyweight trigger ramp See Figure 6 6A using bent wire as shown in Figure 6 5A Proceed to step d c For Model S 21 and S 23 magnetos form wire into hook as shown in Figure 6 5B 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 6B S 20 S 200 Series High Tension Magneto Service Support Manual 6 5 31 August 2011 Periodic Maintenance d Insert a feeler gauge between the stop pin and flyweight to determine clearance X of Figure 6 6 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 a 0 014 feeler gauge blade to the X value measured in step d Figure 6 7 Attempt to pass the X value plus 0 014 feeler gauges between the flyweight and stop pin If feeler gauges pass remove and discard worn cam assembly cy USy anr BR Emm WIRE gag BODY TRIP DOG MODELS EAR B S 21 amp S 23 MODELS Figure 6 6 Flyweight to Axle Wear Check X PLUS 0 014 NOT STOP PIN PERMISSIBLE Figure 6 7 X Value Measurement 2 If the impulse coupling is found to be unacceptable as a result of any of the precedi
93. e 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 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 viii S 20 S 200 Series High Tension Magneto Service Support Manual 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 overhauled unit The performance rules for replacement of parts and materials used in the maintenance and alteration of U S certified aircraft
94. e the cam in the opposite direction winding the spring slightly until the trip dogs on the edge of the cam 11 clear the projections on body 9 Push the cam assembly down into the body while removing the screwdriver from the assembly 7 Insert a spare rotor with woodruff key installed in the tapered portion into the cam assembly Figure 9 16 Turn the magnet slightly in the direction of coupling rotation to wind spring Carefully lift the cam only enough to clear the trip dogs on the body Wind the spring one half turn and re engage the cam assembly into body Figure 9 16 Winding Coupling Spring Procedure continues on next page S 20 S 200 Series High Tension Magneto Service Support Manual 9 13 31 August 2011 Assembl WARNING Use of unapproved hardware and or failure to utilize approved lubricants during magneto assembly will produce inaccurate torque values and increased stress on the impulse coupling during assembly 8 Install a new woodruff key 53 in the tapered portion of the shaft Apply a light coating of Part No 646943 anti seize lubricant to the tapered section of the rotating magnet shaft Figure 9 17 to inhibit cam assembly seizure to the shaft and avoid damage during disassembly Install the impulse coupling assembly 8 and washer 4 with flat side of washer toward the impulse coupling If applicable install the drive member woodruff key 53 and bushing 5 Install a new lock washer 3 if us
95. ed and thread the nut 2 on to the shaft 9 Using a calibrated torque wrench tighten the nut 2 to the minimum torque of 180 in Ibs LUBRICATE Figure 9 17 Apply Anti Seize Lubricant to Magneto Shaft 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 10 Install and secure a new cotter pin 7 through the holes in the castellated nut and the magneto shaft 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 9 14 S 20 8 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl castellated nut Do not exceed 300 in Ibs torque under any circumstances After installation the cotter pin may bent to conform to the shaft or trimmed as shown in Figure 9 18 OPTIONAL CUT HERE Ea Figure 9 18 Proper Cotter Pin Installation CAUTION The impulse coupling may crack Figure 9 19 during this procedure if an audible cracking noise accompanied by immediate reduction in nut torque remove and replace the cracked impulse coupling assembly Figure 9 19 Impulse Coupling Cracks 11 Inspect the impulse coupling according to instructions in Section 6 2 2 S 20 S 20
96. eign government under the provisions of FAR 21 Subpart N S 20 S 200 Series High Tension Magneto Service Support Manual ix 31 August 2011 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 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 materials Particular caution should be exercised when the identity of materials parts and appliances cannot be established or when their origin is in doubt
97. emoval from storage for evidence of corrosion If no exposure is indicated continue with normal acceptance inspection and installation S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 e a IWF n esting amp Troubleshootin Section 3 Testing amp Troubleshooting 3 1 General NOTE Index numbers in parentheses refer to the exploded view of the magneto in Figure 1 and the Illustrated Parts List in Section 11 unless otherwise specified Special Tools Required A complete listing of special tools required for S 20 S 200 Magneto Maintenance Inspection and Overhaul is compiled in Chapter 10 e Magneto Test Stand Part No 11 10500 1 If an engine malfunction appears to be attributed to the ignition system check the spark plugs and wiring first before removing 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 inspections to avoid uncommanded engine starts during maintenance Do not stand or place equipment within the arc of the propeller 2 Perform a Magneto Drop Check test according to instructions in the applicable Airplane Flight Manual AFM Pilot s Operating Handbook POH to verify proper ignition system operation RPM drop is expected when one magneto channel in a dual ignition system is turned off Absence of an RPM drop may indica
98. ervice 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 Lo Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Lu Affected Sections Title Bulletin Number Release Date s Affected Sections Title Bulletin Number Release Date pow Affected Sections Title Bulletin Number Release Date E Affected Sections Title Bulletin Number Release Date E Affected Sections Title Bulletin Number Release Date amp Affected Sections Title Bulletin Number Release Date t Affected Sections Title Bulletin Number Release Date a Affected Sections Title Bulletin Number Release Date Iu Affected Sections Title Bulletin Number Release Date a Affected Sections Title ii S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Scope and Purpose of this Manual This manual provides installation operation maintenance and overhaul instructions applicable to S 20 and S 200 series magnetos manufactured b
99. es 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 a Install a 10 70506 10S Protective Cap over each end of the bronze bushing in the distributor block Figure 7 9 Brushcoat all surfaces of the distributor block insulating material with 10 391400 Distributor Block Coating Do not apply the Distributor Block Coating to any exposed surface of the bronze bushing Allow the Distributor Block Coating to dry for a minimum of 30 minutes before assembling the distributor block 79 with the housing 48 or gear assembly 72 PROTECTIVE CAPS INSTALLED Figure 7 9 Protective Caps Installed b Remove the 10 70506 10S protective caps from the distributor block Insert a C cork stopper in one end of the bushing and fill the bushing with 10 391200 Distributor Block Lubricant Using care not to spill oil on coated surfaces place the distributor block in an oven and bake the distributor block at 190 210 F 88 99 C for two to three hours S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul d Remove the distributor block and oil from the oven and allow them to cool to room temperature together the bushing absorbs residual oil as it cools e Carefully remove the cork stopper and allow excess oil to drain from bushing CAUTION Do not lubricate the felt
100. eto is individually selected either the magneto selected is timed far in advance of the other magneto or the magneto control circuit is primary circuit and airframe ground Either condition must be remedied before further flight and before moving the propeller by hand 3 Stop the engine using normal procedures as detailed in the Pilots Operating Handbook 3 4 Troubleshooting CAUTION If the self locking cam securing screw Figure 1 61 is removed or loosened at any time always replace with a new self locking screw and torque 21 25 in lbs 3 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 EE Sw 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 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 vibrator 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 buzz
101. f 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 Upon completion of inspection make an appropriate logbook entry signifying inspection compliance referencing the serial numbers of the inspected magnetos Magnetos are subject to the same environmental conditions and wear as the engine and must be overhauled when the engine is overhauled Engine overspeed sudden stoppage or other unusual circumstances may require engine overhaul prior to engine manufacturer s recommendations In such circumstances the magneto regardless of in service time must be overhauled with particular attention focused on rotating parts bearings and electrical components In addition magnetos must be overhauled or replaced five years after the date of manufacture or last overhaul or four years after the date placed in service which ever occurs first without regard to accumulated operating hours since new or last overhaul S 20 S 200 Series High Tension Magneto Service Support Manual 2 3 31 August 2011 Description and Operation 2 4 2 4 1 2 4 2 2 4 S 20 and S 200 Magneto Operation General Theory The rotating magnet is of a two pole design As the magnet is turned the polarity continually changes thereby producing flux reversals in the magneto coil core The number of flux re
102. felt strip 81 from the block 79 Remove the carbon brush 73 from the distributor gear 72 4 Remove the screws 78 and distributor block 79 from the housing 48 4 2 2 General Overhaul Disassembly Remove the contact assemblies 39 from magneto by taking out screws 41 33 and washers 37 34 discard the contact assemblies NOTE Tachometer contact assembly identified by smaller 0 125 in diameter silver contact points may be reused 2 Remove the screws 41 and capacitor 42 from the cover 15 or distributor housing 48 If a retard lead 17 is installed and replacement is necessary carefully remove it from cover 15 Remove the screws with lock washers 56 and coil core clamps 57 discard the lock washers Lift the coil 58 from the housing CAUTION If self locking cam securing screw 61 is removed or loosened at any time always replace with a new self locking screw and torque 21 25 in lbs 3 Using a pair of padded jaw pliers grip the drive member on drive end of the rotating magnet 54 While holding the rotating magnet loosen the cam securing screw 61 and remove the screw 61 washer 62 and cam 63 4 2 3 Drive Plate and Front End Hardware Disassembly 1 Remove the cotter pin 1 from the rotating magnet shaft 2 While holding the drive member with a pair of padded jaw pliers remove the nut 2 Lift off the lock washer 3 bushing 5 and washer 4 if used If a drive plate 6 o
103. for Small Gear and Bushing Removal 4 7 Check Contact Point Security esee 6 2 Normal Contact Point 6o ern ecauhe eot eot ept ud Pone cedes dtd 6 2 Flyweight Terminology 2 e eoi ine nene eto tee no eee nuni ode 6 4 Flyweight Heel Inspection odo e octo ed oett qees 6 5 Enspecttone selon eer ioter a pipe tester a ee idea ee ERR EHIO 6 6 Wire Hook Configuration eee 6 6 Flyweight to Axle Wear Check oie eere neret esee 6 7 X Value Measurement 5 rario eoe teca uae 6 7 Distributor Gear Identification Marks sss 7 2 Check Electrode SeCurity Looditex ed ER IGUR ore adea tese ns 7 3 Stress Line in Distributor Block sees 7 4 Check Distributor Block for Carbon Tracking 7 5 Contact Spring Height 414 5 oett nnti 7 5 Lubrication Identification Mark eese 7 6 Capacitor Date Code sesasscscsecissacadeassevcitesenssctesnncastiscaseasaseoacveass 7 7 SOLE Ply were ht C Beck 3 2525 dedo ue at DES E sre auus 7 8 Inspect Flyweight WashllESc oec i o oh Ee faa qi adore ps 7 9 Worn Drive Eug iisiietent oeste eo opptiteend cd etes dan ius 7 10 Coupling Body Wear Points esee 7 10 Coil Lead Repair 1 5 tme hnne Ride ene EUN ELS REV EUR RU sea 8 1 Helical or Repait o esGstesste dh desee a Si oti piden ve ONERE EUR 8 2 Position Springs in Magneto Housing eee 9 2 Position P
104. ge will require flyweight replacement 3 Install the nut 2 on the end of the rotating magnet Figure 1 54 shaft to protect the cotter pin holes Engage the puller over the shaft and align the jaws of the puller under the cam assembly as shown in Figure 4 2 Figure 4 2 Impulse Coupling Cam Removal 4 Tighten the puller handle to remove the coupling from the shaft If the cam assembly 11 does not release with maximum hand torque applied to the puller handle apply S 20 S 200 Series High Tension Magneto Service Support Manual 4 3 31 August 2011 Disassembl penetrating thread release compound between the cam assembly Figure 1 11 and the shaft While the puller is still fully tightened hold the tip of hot heavy duty soldering iron in contact with the cam assembly hub Figure 4 3 Solder wetting of the tip 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 Release Coupling CAUTION Do not strike the puller with a hammer If the puller is struck with a hammer magneto ball bearings must be replaced Do not tighten the puller handle further after the impulse coupling cam releases from shaft This could damage a flyweight if the flyweight is caught under the woodruff key 5 Remove the puller Holding the toe See Figure 6 3 for flyweight terminology of the flyweight inward lift the cam from the shaf
105. gure 7 1 incorporate a captive washer If the distributor gear does not match the current production design discard the superseded gear and replace with the current production design ORIGINAL ASSEMBLY AU y CMM Distributor Gear Copper Electrode Captive Washer Distributor Block Figure 7 1 Old Gear Assembly NEW ASSEMBLY ULL TER A Distributor Gear IRI Copper Electrode Nylon Insulating Washer Plain Washer Distributor Block LANG CMM NN Figure 7 2 Production Gear Assembly 7 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 2 If the distributor gear 72 matches the current production design inspect the gear a Inspect the gear for discoloration If the surface of the gear is chalky or crazed discard and replace the gear If the color of the gear has turned brown or the gear teeth are turning brown the gear has been exposed to extreme heat discard and replace the gear b Inspect the gear for missing or damaged missing or damaged teeth If portions of the gear teeth are broken or missing discard and replace the gear c Ifthe axle or electrode exhibit wear or damage or there is evidence of looseness between the axle and gear or the strap and gear discard and replace the gear assembly If the electrode surface is slightly carbonized smooth off with a nylon scouring pad 3 Wipe the gear 72 free of all oil film and other contam
106. he cover 15 from the housing 48 according to instructions in Section 4 2 1 2 Examine the magneto coil capacitor and contact point leads for condition and security Inspect insulation for chafing or discoloration Discoloration could indicate thermal breakdown If insulation is nicked chafed or cut replace the affected component 3 Turn the magneto drive shaft until the cam follower of the main contacts rests on the high lobe of the cam holding the points in their open position Using a fiber or plastic rod with a screwdriver shaped end prod the contact points as illustrated in Figure 6 1 If looseness is noted replace the contact assembly Repeat the procedure for retard and tachometer point contacts if installed Figure 6 1 Check Contact Point Security NOTE Do not attempt to burnish stone or dress contact points Do not clean contact points with emery cloth If the contact assembly points appear to be unserviceable replace the entire contact assembly 4 Examine contact points for wear or burning Discard and replace contact assemblies Figure 1 39 with points that are deeply pitted or burned Figure 6 2 shows how a typical contact point will look when the surfaces are separated for inspection Desired contact surfaces have a dull gray sandblasted almost rough or frosted appearance over the area where electrical contact is made indicating the points are wearing evenly and mating properly Replace burned pitted pea
107. ights 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 S 20 S 200 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 S 20 and S 200 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 viii 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 Publication X41005 for a complete listing of active magneto Service Bulletins Service Bulletins affecting S 20 and S 200 Series Magnetos and or applicable
108. ill damage these items 3 Clean the capacitor 42 retard lead 17 cam 63 coil 58 and contact compartment by wiping with a clean dry cloth 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 4 Clean the distributor block 79 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 bronze bushing 5 Install 10 70506 10S protective caps to cover both ends of the distributor block bronze bushing This masking will prevent contamination of the bearing during the second stage of the cleaning operation 6 Treat distributor blocks according to Section 7 2 4 7 Hold the distributor block with the outlet towers in a vertical plane Using a 1 2 inch bristle brush dipped in isopropyl alcohol clean in and around the distributor block S 20 S 200 Series High Tensi
109. imately centered in the timing window of the magneto housing 48 to position the rotating magnet at the approximate No 1 cylinder firing position Turn the rotor slightly in the reverse direction of normal rotation and allow rotor to rest in magnetic neutral position The red tooth will appear off center in window Using an E 50 Timing Light and adapters made from applicable See Table 11 1 terminal kits install and adjust magneto to engine timing 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 the distributor gear resulting in magneto failure and subsequent engine failure personal injury or death Assemble Terminal Kits for each magneto as shown in Figure 9 22 or Figure 9 23 as required Install the switch and applicable retard and or tachometer wiring by securing terminal nut s to the magneto terminals Tighten terminals finger tight 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 Apply MS 122AD dry teflon spray to the harness grommets and install the har
110. imum 0 4 y Ampere leakage maximum at 400 VDC Primary 0 2 to 0 6 ohms Secondary 12000 to 16000 ohms 0 018 0 006 in 0 019 0 003 in 10 4 2 4 to 11 8 SCFH at 2 9 to 3 1 psig 20 to 25 in lbs 21 to 25 in lbs 8 to 12 in lbs in cover 20 to 25 in Ibs in housing 20 to 30 in lbs 7 to 9 in lbs 20 to 25 in lbs 8 to 10 in Ibs 180 to 300 in Ibs Initial 4 to 10 in Ibs Final 16 to 20 in lbs 120 to 156 in lbs 25 to 35 in lbs 10 to 15 in Ibs 60 to 80 in Ibs 12 to 15 in Ibs 15 to 17 in lbs 24 to 26 in lbs S6 Magnetos 1 5 times crankshaft speed 4 Magnetos equal to crankshaft speed 1 CAUTION Self locking cam screw is single use If loosened or removed for any reason replace with a new self locking screw 1 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation Section 2 Description and Operation 2 1 General S 20 and S 200 Series Magnetos are designed to provide ignition for four and six cylinder aircraft engines These magnetos generate and distribute high voltage for aircraft engine ignition To obtain the retard spark necessary for starting S 20 Series Magnetos employ an impulse coupling and S 200 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 S 200 Ignition System incorporating a starting vibrator
111. in thick 2 161 7 AR AR 72 Kit Distributor Gear 10 357586 1 1 73 Brush Carbon 10 160844 1 1 74 Ring Retaining MS16624 2037 1 1 75 Washer 0 750 OD 10 349511 1 1 76 Washer 0 562 OD 10 606505 1 1 77 Washer Nylon 10 391309 1 1 78 Screw w plain amp lock washer 10 102083 3 3 79 Block Distributor 10 357426 1 1 80 Spring Tower 10 50737 6 Es 6 81 Strip Felt 10 163374 1 1 82 Washer Felt 10 50752 1 1 po NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly Magneto may be converted to a short cover model using the conversion chart in Table 11 14 and associated kit contents listed in Table 11 15 Record the conversion in the engine log book 11 16 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 6 S4LN S4RN 200 201 204 and 205 Magnetos v x i x 2 97 x e 82 2 2 2 i 8 2 8 8 8 8 8 88 Index Description Part No S 3 S 3 S 3 S 3 1 Pin Cotter 10 90751 18 1 2 Nut Drive Shaft 10 163151 1 10 51643 3 Washer Lock 10 3793 4 Washer Plain 10 4093 1 10 40064
112. in 10 51354 1 itn 1 FATTET EBENEN nn T 63 Cam 10 50772 4 1 1 1 1 1 1 1 10 50772 5 1 1 111 1 BEEN 1 111 64 Bearing Ball 2 202 1 Bee 1 PECTED Ba ha i aa ain 65 Washer Shim 0 002 in thick 2 199 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 199 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 199 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 199 4 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 010 in thick 2 199 5 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 012 in thick 2 199 6 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 66 Washer Plain 10 3503 1 eee ENENEN BENENEN TETTED 31 E 67 Gear Pinion 10 157128Y 1 11 1 1 11 1 1 1 1 1 1 1 1 1 1 11 1 69 Bearing Sleeve 10 25788 imNENEEN ENENEN nth BEIRN E 70 Bearing Ball 10 81806 1 NENNEN ENENEN BENENNEN eee E 71 Washer Shim 0 002 in thick 2 161 1 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 004 in thick 2 161 2 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 005 in thick 2 161 3 AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 0 008 in thick 2 161 4 AR AR IAR AR AR AR AR AR AR AR AR AR
113. inants 4 Check the gear 72 electrode for wear with vernier calipers or a micrometer at the points indicated in Figure 7 3 The electrode must measure 0 933 0 000 0 023 in If the electrode is worn beyond specifications discard and replace the gear 72 Procedure continues following Figure 7 3 Figure 7 3 Check Distributor Gear Electrode Wear S 20 S 200 Series High Tension Magneto Service Support Manual 7 3 31 August 2011 General Overhaul 5 Using Red Dykem or red lacquer paint timing marks on the gears a For SALN magnetos paint tooth and indent marks indicated by Figure 7 4A CCW arrows For SARN magnetos paint tooth and indent marks indicated by Figure 7 4A CW arrows b For S6LN 200 and 201 magnetos paint tooth and indent mark indicated by the outer CCW BOOSTER Figure 7 4B arrows For S6RN 200 and 201 magnetos use the outer CW BOOSTER Figure 7 4B arrows These magnetos are used in conjunction with a starting vibrator or booster and retard contacts c For all other S6LN magnetos paint tooth and indent mark indicated by the inner NORMAL CCW Figure 7 4B arrows For all other SORN magnetos use the inner NORMAL CW Figure 7 4B arrows B Six Cylinder Figure 7 4 Distributor Gear Timing Marks 7 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 7 2 3 Cam Washer and Pinion Gear Inspection NOTE Do not reuse ny
114. iness 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 Internet 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 viii Printed Continental Motors publications may be ordered through a Continental Motors authorized distributors or via our web site See Contact Information on page viii 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 C
115. ing Distributor 48 10 400050 m Tachometer 10 400551 8 Housing Distributor 48 10 400103 Grommet Tachometer 19 10 400552 1 Housing Magneto 50 10 400141 Lead Assembly Tachometer 17 10 400552 2 Housing Magneto 50 10 400160 1 Cover Contact 15 10 400552 4 Housing Magneto 50 10 400160 2 Cover Contact 15 10 400552 5 Housing Magneto 50 10 400160 3 Cover Contact 15 10 400554 Seal Oil 59 10 400160 4 Cover Contact 15 10 400572 Capacitor 42 10 400160 7 Cover Contact 15 10 400615 Capacitor 42 10 400166 2 Cam Assembly 11 10 400630 4 Housing Magneto 50 10 400166 6 Cam Assembly 11 10 400630 6 Housing Magneto 50 10 400166 9 Cam Assembly 11 10 400640 Washer Plain 4 10 400167 1 Cam Assembly 11 10 606505 Washer Plain 0 562 in O D 76 10 400167 4 Cam Assembly 11 10 682025 Screw Fillister Head 33 10 400167 8 Cam Assembly 11 654742 2 50 Sleeving 18 10 400167 10 Cam Assembly 11 MS16624 2037 Ring Retaining 74 10 400191 Tubing 43 MS393338 43 Washer Lock 16 10 400301 Impulse Coupling 8 MS35650 302 Nut 28 10 400302 Impulse Coupling 8 NAS620 8L Washer Plain 37 10 400303 Impulse Coupling 8 10 400304 Impulse Coupling 8 10 400305 Impulse Coupling 8 S 20 S 200 Series High Tension Magneto Service Support Manual 11 37 31 August 2011 Illustrated Parts List Intentionally Left Blank 11 38 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List HARNESS OUTLET Lec PA Me Rl
116. ing 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 good electrical continuity through switch and through magneto points Retard contact assembly in retard dual contact magneto not operating electrically Engine may kick back during cranking due to advanced ignition timing 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 No output from vibrator magneto combination Turn engine in direction of normal rotation until retard points just open on No 1 cylinder position Remove input connection from starter to prevent engine turning and while holding the No 1 plug lead 3 16 inch from ground energize the vibrator by turning switch to START Plug lead should throw a 3 16 inch spark If spark is weak or missing install new vibrator If the malfunction persists remove the 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 Man
117. ion or galling is found at the mating surfaces 5 Inspect the cover 15 for cracks stripped threads or other damage Replace cracked or damaged covers or covers with stripped threads 6 Inspect the impulse coupling stop pin 60 If the stop pin is loose bent or damaged or shows signs of wear remove and replace the stop pin a Remove pin 60 using a steel bar 1 4 20 nut and plain washers Figure 7 19 The bar should measure a nominal x 3 x inch with a hole drilled in the center large enough to fit over the stop pin Note the hole from which the pin was removed b Measure the size of the stop pin bore 1 Attempt to insert a 0 2800 inch gauge pin in the housing 50 stop pin boss If the gauge pin will not enter the boss the housing was not designed to accept a stop pin obtain a housing 50 designed for a stop pin See Chapter 11 and repeat the measurement 2 If the 0 2800 inch gauge pin enters the stop pin boss bore measure the bore with a 0 2820 inch gauge pin a 0 2820 inch gauge pin should not enter the bore deeper than 0 120 inch below the face of the housing 3 If the 0 2800 inch gage pin and 0 2820 gauge pin measurements pass replace the stop pin with a standard size stop pin according to instructions in step c otherwise proceed to the next measurement 7 16 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 4 If the 0 2820 inch gauge pin enters the
118. ked or otherwise damaged contact assemblies 6 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance SERVICEABLE CONTACT POINTS ARE SMOOTH AND FLAT WITH A DULL GRAY SANDBLASTED APPEARANCE Figure 6 2 Normal Contact Point 5 Check the condition of cam follower felt Squeeze the felt tightly between the thumb and forefinger If no oil residue is left on the fingers lubricate the felt with 2 3 drops of 10 86527 Lubricant Allow approximately 30 minutes for the felt to absorb the oil Blot excess oil from the felt with a clean cloth Too much oil may foul contact points and cause excessive burning 6 Clean dirty breaker points according to instructions in step 1 of Section 5 2 7 Check magneto to engine timing as follows a If necessary ensure magneto impulse coupling flyweights are not engaged on the stop pins Connect the E 50 Timing Light or equivalent across the main contact assembly b Slowly bring engine up to number one cylinder advance firing position according to the engine manufacturer s instructions At this instant timing light should go out indicating the magneto is properly timed to the engine If the timing light remains illuminated remove magneto from engine and perform internal timing check and inspection according to instructions in Section 6 2 3 step 7 S 20 S 200 Series High Tension Magneto Service Support Manual 6 3 31 August 2011 Periodic Mainten
119. l 76 Washer 0 562 OD 10 606505 1 I i 77 Washer Nylon 10 391309 1 1 78 Screw w Plain amp Lock 10 102083 3 washer 79 Block Distributor 10 357426 1 Hi 80 Spring Tower 10 50737 6 IE 6 81 Strip Felt 10 163374 1 82 Washer Felt 10 50752 1 I B 1 10 163050 7 10 163050 9 10 163050 12 10 163060 2 2 e J 10 163060 1 1 NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly 2 Magneto may be converted to a short cover model using the conversion chart in Table 11 14 and associated kit contents listed in Table 11 15 Record the conversion in the engine log book 11 22 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Illustrated Parts List Table 11 8 SALSC S4RSC 21 21T 200 201 204 204T and 205 Magnetos si Sil 0 s to eo R TIA e x cce X 5 i zziz zz FS SS S S S S S13 SS S53 2 3 3 8 2 5 S S 3 si 5 5 5 5 vol uo to ov o CO oo 7o we Index Description Part No eec 898 88 gg gegeggegegeegele 1 Pin Cotter 10 90751 18 1 1
120. late with Recess Facing Up sees 9 3 Kit Parts Installed in D 2000 Magneto sese 9 4 Spur Gear Alignment on Shaft sse 9 6 Contact Spring Installation eee 9 9 Distributor Block Timing eere 9 11 Dial Indicator Mounted on Housing esee 9 11 Shims Positioned Around the Rotating Magnet 9 13 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 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 eese eee etienne nnne ennes 9 15 11 8465 Rotor Holding Tool in Position 9 16 Timing Marks on Rotating Magnet eere 9 17 Rotor Timing Marks Aligned with Pointer 9 17 Painted Tooth Centered in Window esse 9 17 Check Impulse Coupling for Magnetism
121. ll Strom 11 8465 Rotor Holding Tool Hold rotor to check magneto internal timing Kell Strom 11 8627 Spring Seating Kit Seat tower springs 80 in distributor block 79 Kell Strom 11 10192 Removal Tool Remove bearing inner race 70 from rotor 54 Kell Strom 11 10500 Magneto Test Stand or equivalent For off engine magneto testing Kell Strom 11 10600 Magnet Charger Magnetize rotor 54 Kell Strom 11 10090 Air Flow Tester Test magneto pressurization system Kell Strom 1305 AC Hipot Tester Tachometer lead dielectric breakdown test Slaughter Fluke 8840A Digital Multimeter or equivalent Test coil Commercial off the shelf CG240 Puller Remove drive plate or cam Snap On Remov ring outer r 4 from housing 48 CG40 8 Collet with C Exoanding eed VOTRE eles Snap On CG40 4 Expanding Rod Com er upr race 64 from housing 48 Used Snap On E 5 High Voltage Cable Tester Test high tension lead insulation strength and continuity Se Corp E 50 Timing Light or equivalent Check magneto to engine timing EET Corp LC 103 Capacitor Tester Test capacitor Sencore No 2 Retaining ring pliers Remove and install retaining ring Waldes Truarc Consumable Supplies 10 400550 1 Magneto Grease Pack berarings Continental 10 391200 Distributor Block Lubricant Distributor block bushings Continental 10 391400 Distributor Block Coating Apply to Black distributor blocks to inhibit moisture Continental sheeting on dielectric MS 122AD Teflon Dry Lubricant Lubricate distributor gea
122. llustrated Parts List 28 83 3 2 23 S SF F S FSi Ss 5 a wo wo Q Q 1 15 15 S 9 cO 6 8 cO 8 8 8 8 8 cO S cO cO c So iD iD bl ID ID ID IO ID IO ID I D S SS Index Description Part No e sis sisi sisi g g g g ee 1 Pin Cotter 10 90751 18 1 1 1 1 10 90751 19 1 2 Nut Drive Shaft 10 163151 10 51643 1 1 10 51652Y 1 10 163178 1 1 3 Washer Lock 10 3793 1 1 4 Washer Plain 10 4093 10 51370 10 116860 1 1 10 52307 1 1 10 51613 1 5 Bushing 10 51651 1 NLA 10 163048 1 1 10 357193 8 Coupling Impulse 35 Lag 10 400303 1 45 Lag 10 400314 45 Lag 10 400306 45 Lag 10 400315 1 1 4 35 Lag 10 400305 35 Lag 10 400320 35 Lag 10 400304 1 9 Body Impulse Coupling 10 51333 1 10 51395 1 10 52903 10 70371 1 1 Ji 10 76232 10 Spring Main 10 51324 EM DEM 11 Cam Assy Imp Cplg 10 400166 6 1 10 400167 8 10 400167 10 1 1 Ji 10 400166 9 12 Screw w lock washer 10 35936 7 4 4 4 4 10 157160 4 14 Gasket 10 52321Y 1 15 Cover Contact NLA 2 1 NLA 1 1 NLA 1 NLA 1 S 20 S 200 Series High Tension Magneto Service Support Manual 11 11 31 August 2011 Illustrated Parts List Table 11 4 S6LN S6RN 20 21 and 23 Magnetos
123. lock washer 10 102083 79 Block Distributor 10 357424 80 Spring Tower 10 50737 81 Strip Felt 10 163374 82 Washer Felt 10 50752 NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly Magneto may be converted to a short cover model using the conversion chart in Table 11 14 and associated kit contents listed in Table 11 15 Record the conversion in the engine log book po S 20 S 200 Series High Tension Magneto Service Support Manual 11 19 31 August 2011 Illustrated Parts List Table 11 7 S6LN S6RN 200 201 204 and 205 Magnetos zla E 5 lel xxi uie Sl sla 2 2 2 2 2 amp 8 amp i5 i5 51010 0 co 2822952332 3 2 2 89 2 Index Description Part No S 3 3 S 3 S 3 S S 3 S 3 S S 1 Pin Cotter 10 90751 18 1 tnt i nnn 1 Rae 1 2 Nut Drive Shaft 10 163151 1 1 1 1 1 10 51643 1 1 1 1 1 1 10 163178 1 i 4 3 Washer Lock 10 3793 441 1 4 4 Washer Plain 10 4093 1 1 1 BEBNEB 1 1 1 10 116860 1 1 5 Bushing 10 163048 1 1 1 1 10 357193 1 1 7 Plate Drive 10 163003 1 1 1 1 10 163216 1 1 12 Screw w lock
124. lon pinion gears 67 replace the nylon pinion gear with sintered iron pinion gear 1 Visually inspect the cam 63 if the cam exhibits scratches or wear replace it with a new assembly Measure the cam washer 62 thickness replace if not 0 095 0 010 inch thick 2 Wipe the cam with a clean lint free cloth 3 Submerge the cam completely in a vat of 10 391200 Distributor Block Lubricant heated to 200 F for 30 minutes 4 While the cam is still submerged in the oil bath allow the cam and oil to cool to room temperature together 5 After cooling remove the cam from the oil bath wipe with a lint free cloth and place the cam in service or store the cam in a sealed plastic bag until needed 6 Do not reuse nylon pinion gears Replace nylon pinion gear found in the assembly with a current production sintered iron pinion gear 67 7 2 4 Distributor Block Inspection NOTE Current design distributor blocks 79 are made of brown polyester material and have part number and batch code molded into the surface on the tower side Older blocks made of phenolic black material or buna rubber very dark brown with letters cc molded in the tower side of the block material may remain in service in unpressurized applications if they incorporate annular felt groove Figure 7 5 and pass tests outlined below For pressurized magnetos use only brown polyester distributor blocks 1 16 INCH OF BUSHING ANNULAR FELT GROOVE ABOVE FELT STRIP
125. lowing parts may be reused after maintenance inspections per Section 6 2 1 and Section 6 2 3 but must be replaced at overhaul Main and Retard Contact Assemblies 39 Felt Washer 82 and Carbon Brush 73 S 20 S 200 Series High Tension Magneto Service Support Manual 9 1 31 August 2011 Assembl 9 2 Detailed Assembly Procedures 9 2 1 Bearing Pinion Gear and Cam Assembly CAUTION If bearings are not a press fit in the housings 48 50 or on the rotating magnet rotor 54 shaft do not attempt to repair worn bearing seats by knurling staking punch marking or any other means If bearing seats are loose replace the housing 48 50 or rotor 54 NOTE Serviceable rotating magnets must be recharged before installation in magneto 1 Support the rotating magnet shaft 54 on a block of wood tap the pinion gear Woodruff key 53 into the keyway and install the gear 67 on the shaft a Four cylinder magnetos incorporate a pinion gear 67 with an arrow on each side If the magneto is designed for clockwise rotation install the gear on the shaft so the arrow points in a clockwise direction when viewed from the drive end Figure 9 1 If magneto is designed for counterclockwise rotation arrow must point in a counterclockwise direction when viewed from the drive end ARROWS ON CAM AND GEAR POINT CLOCKWISE AS VIEWED FROM DRIVE END CLOCKWISE ROTATION VIEWED FROM DRIVE END ARROWS ON CAM AND GEAR POINT COUNTERCLOC
126. lowly Brush shall move freely within the hole in the axle Generously apply MS 122AD teflon dry lubricant spray to the distributor gear teeth Ensure washers 76 77 are in place on the gear axle and in good condition Ensure the nylon washer 77 is positioned against distributor gear 4 Inspect the housings 48 50 for damage Clean housings 48 50 with a clean dry lint free cloth 5 Inspect the coil 58 a Using a dry lint free cloth clean contaminants from accessible surfaces of coil b Ensure the coil outlet tab is parallel with the housing to cover mating surface C Bend the tab with a finger as necessary to align the tab If the carbon brush 73 has caused wear in the coil outlet tab indicated by a visible depression in the tab disassemble the coil 58 from housing 55 according to instructions in Section 4 2 2 and repair the coil 58 according to instructions in Section 8 2 1 Install the coil 58 in the housing 50 according to instructions in Section 9 2 1 6 Install the distributor block 79 and distributor gear 72 assembly in the magneto housing 48 according to instructions in Section 9 2 4 Assemble housing halves 48 50 together according to instructions in Section 9 2 3 If used install a gasket 49 between the housing halves Pay particular attention to proper distributor gear positioning 7 Inspect contact assemblies 39 and related components S 20 S 200 Series High Tension
127. mm 0 039 in NO ELECTRICAL CONNECTION DO NOT GROUND TO MAGNETO Figure 3 1 Spark Gap Setting 3 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Testing amp Troubleshootin Determine the lowest speed at which the rotating magnet can be turned and still spark all gaps without missing coming in speed Magnetos must spark consistently at 150 RPM If coming in speed is greater than 150 RPM the trouble may be due to dirty contact points a weak coil a weak magnet defective 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 the test Observe electrical and mechanical performance at 150 and 1000 RPM Perform high speed test run at 3000 RPM minimum Do not exceed 5100 RPM Magneto shall fire all gaps consistently and operate smoothly throughout its operating range Test magnetos equipped with impulse couplings Couplings must engage fully at speeds up to 150 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 After testing check rotating magnet for 0 0005 to 0 0015 in end play and no perceptible radial play If end play is out of limits adjust shims and or replace parts as necessary and re test For pressurized mag
128. ms as shown Remove and discard the outer race PRESS Figure 4 5 Bearing Outer Race Removal 3 Record the magneto type part number and serial number Remove and discard the nameplate Figure 1 52 Clean pad area to remove adhesive and dirt 4 Using CG40 8 Collet CG40 4 Expanding Rod and arbor press remove the bearing 64 outer race from the distributor housing 48 4 6 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Cleanin Section 5 Cleaning 5 1 General NOTE Index numbers in parentheses refer to the exploded view of the magneto in Figure 1 and the Illustrated Parts List in Section 11 unless otherwise specified Using a clean dry lint free cloth wipe accessible areas of the housing 48 50 and other external surfaces free of grease oil film or other contaminants 5 2 Detailed Magneto Cleaning Procedures 1 Clean contact points 39 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 2 All other parts of magneto except the capacitor 42 retard lead 17 distributor block 79 cam 63 and coil 36 may be washed in a standard cleaning solvent and dried with compressed air Blow out holes in ventilator plug 46 with compressed air CAUTION Do not immerse the cam 62 or distributor block 79 in solvent solvents w
129. n 1 Install an air inlet bushing Figure 1 44a in the top timing hole of the housing 2 Install a calibrated orifice 46a in the bottom hole of the housing 3 Tighten the plugs to 60 80 in Ibs 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 50 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 52 with the housing 50 and apply firm pressure across entire surface of the label 9 20 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 9 2 13 Final Assembly 1 If necessary remove the front end hardware to install the engine drive gear Assemble the bushing 5 washers 3 amp 4 drive member 6 amp 7 and nut 2 on the shaft 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 2 Install a new lock washer 3 if used and thread the nut 2 on to the shaft tighten the nut 1 to 180 in Ibs with a calibrated torque wrench 3 Install and secure a new cotter pin 1 as shown in Figure 9 18
130. n a piece of absorbent material such as cardboard in a 250 F oven for four hours This should cause impregnating oil to appear on the bushing surface and on the absorbent material b Remove the distributor block from the oven and using a clean dry cloth immediately wipe all oil possible from the inside diameter of the bushing It may be necessary to wipe the bushing several times as it cools as well as to repeat this procedure until the old oil is thoroughly purged 9 Identify distributor block by stop drilling a 0 125 inch diameter indentation to a depth of 0 016 inch in the location shown in Figure 7 8 NO 1 NA Lol C D IDENTIFICATION MARK Figure 7 8 Lubrication Identification Mark S 20 S 200 Series High Tension Magneto Service Support Manual 7 7 31 August 2011 General Overhaul 7 8 10 Impregnate bronze bushing and coat the distributor block NOTE Only black phenolic or buna rubber type distributor blocks 79 must be coated at each 500 hour inspection and at each overhaul period DO NOT COAT POLYESTER brown distributor blocks Bronze bushings in all types of distributor blocks 79 are impregnated with oil during assembly at the factory when new and must be oil impregnated at each 500 hour inspection and at each overhaul period The bronze bushing in the distributor block 79 is impregnated with oil to provide proper distributor shaft lubrication The phenolic or buna rubber dielectric surfac
131. nd 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 Flight Check is required after engin tallation inspection repairs or adjustments Follow these same However the Wl k 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 n B r AUTION High ver ground operation resulting in cylinder and a ge a X ji ial operating limits can be l Start the engine according to on in Section 7 3 2 Engine Start l 2 Conduct a normal take off ac g to 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 a n Oil pressure Oil temperature moo Cylinder Head Temperature g Turbine Inlet Temperature Exhaust Gas Temp 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
132. ness outlet plate with a gasket P N 10 357520 for pressurized magnetos on the magneto and tighten the harness outlet plate evenly to the magneto Torque the outlet plate screws evenly to 12 15 in lbs Install the switch and retard if used wiring by securing the terminal nut s to the magneto Torque the nuts on the switch and retard terminal to 15 17 in Ibs Tighten other P lead terminals finger tight S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl STRIP INSULATION 0 125 0 031 STRIP SHIELDING 0 672 0 031 IF SHIELDED CABLE IS USED SOLDER SECURE SHIELDING HERE WIRE I NS d BRILON MAIN 0 453 t 0 010 RETARD TACH 0 609 0 010 COUPLING NUT Figure 9 22 Terminal Assembly Kit 10 157208 10 157209 10 382813 10 382814 7 For pressurized magnetos remove and discard the plug 44 supplied for shipping purposes Install an air inlet fitting into magneto housing 48 timing window according to the engine manufacturer s instructions Ensure the air inlet fitting does not interfere with internal magneto parts 8 Attach the tachometer fittings to the magneto according to the manufacturer s instructions If the hole adjacent to the rotating magnet 54 in magneto housing 50 will be used for a tachometer pick up in an unpressurized magneto install a ventilator plug 46 in the distributor housing 48 timing window and discard the solid plug
133. netos only test flow rate as follows a Install a sealed harness cover and gasket onto magneto Apply 25 35 in Ib torque to four attaching screws b Install all applicable ground and retard terminals with sealing insulators c For magneto P N 10 500556 901 only install a B amp D Tachometer Sensor P N 0406 002 or P N 0406 003 Use pointed tool such as a scribe or a scratch awl to remove the screen and cotton filter from sensor d Connect the magneto to the Pressurized Magneto Tester as shown in Figure 3 2 Using dry filtered air at 2 9 to 3 1 psig flow rate must be within the range 2 4 to 11 8 standard cubic feet per hour SCFH If flow rate is below 2 4 SCFH inspect the orifice for blockage If flow rate exceeds 11 8 SCFH determine and correct the source s of the leakage Repeat test following any corrective action AIR SUPPLY FILTER REGULATOR MAGNETO Figure 3 2 Pressurized Magneto Tester S 20 S 200 Series High Tension Magneto Service Support Manual 3 3 31 August 2011 Testing amp Troubleshootin 3 3 Hot Magneto Test 1 In addition to performing the magneto related operational checks specified by the 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 as detailed in the Pilot s Operating Handbook Normally found under Preflight Engine Run Up Procedures 2 If no RPM drop is noted when a magn
134. ng checks described replace the worn or faulty components or the entire impulse coupling assembly 3 Examine the stop pins in the magneto flange or housing when inspecting the impulse coupling assembly A shiny spot at the flyweight contact point is acceptable a step 6 6 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Periodic Maintenance 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 6 2 3 500 Hour Inspection 1 Disassemble the magneto according to instructions in Section 4 2 1 2 Inspect and treat the distributor block 21 according to instructions in Section 7 2 4 3 Inspect the distributor gear assembly 25 and carbon brush 26 a Wipe the distributor gear and axle 25 free of all oil film and other contaminants Inspect for damage or unusual wear according to instruction in Section 7 2 2 replace as necessary Remove the carbon brush and spring 26 from the hole in the gear axle 25 Clean the hole with a pipe cleaner Check carbon brush for side loading or unusual wear Measure carbon brush from spring shoulder to working end of brush Overall length shall be 0 375 in minimum Replace worn brushes as necessary with new brush and spring assembly 26 Seat new brush and spring 26 in gear 25 axle hole and compress brush to within 1 8 in of gear then release s
135. ngs the spring must coil in a clockwise direction from the outside toward the center when viewed from the spring recess side of the impulse coupling body On counterclockwise couplings the spring must coil in a counterclockwise direction when viewed from spring recess side Insert the eye of the outer end of the spring 10 in the hole drilled in the inner rim of the impulse coupling body 9 CW CCW Figure 9 14 Spring Coupling in Body Orientation WARNING Nicks or scratches in the spring 10 will cause the spring to break 4 Using heavy gloves to protect the hands carefully wind the spring 10 into the body 9 lifting the spring coils one at a time over projections on body avoid scratching or nicking the spring After winding spring brush a light coating of 30 wt SAE J 1899 aviation engine oil over the spring coils 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 position as shown in Figure 9 15 Do not allow the screwdriver to scratch the spring Figure 9 15 Lift Inner End of Spring 9 12 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 6 Engage recess in the hub on the cam assembly 11 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 the cam hub to slip into the inner turn of the spring Rotat
136. o shielded S 22 and S 23 Series Magnetos these magnetos may be converted to or replaced by standard 10 116861 is provided Use Part No 10 51365 9 or P N 10 500516 10 Magnetos on engines not converted per Continental Service Bulletin M53 3 If magneto drive configuration is as Illustrated Parts List 11 3 Illustrated Parts Lists by Magneto Series Table 11 3 SALN S4RN 20 and 21 Magnetos aN S8 amp 5S S S 2 3 Fl 3 B iU 2 Hi el to uo 0 vo o Index Description Part No sis 2 9e 2S e 1 Pin Cotter 10 90751 18 1 1 1 1 1 1 1 1 1 10 90751 19 1 1 1 2 Nut Drive Shaft 10 163151 1 1 10 51643 1 1 1 1 1 1 1 10 51652Y 1 1 1 3 Washer Lock 10 3793 1 1 1 1 1 1 1 4 Washer Plain 10 4093 1 1 10 51370 1 1 1 1 1 1 1 4 Washer Keyed 10 51613 1 1 1 5 Bushing 10 51651 1 1 1 10 163049 1 1 1 1 1 1 1 6 Plate Drive 10 160850 1 8 Coupling Impulse 25 Lag 10 400302 1 1 25 Lag 10 400313 1 1 1 1 25 Lag 10 400301 1 15 Lag 10 400321 1 1 9 Body Impulse Coupling 10 51333 1 1 1 10 51395 1 10 52903 1 1 1 1 1 1 10 Spring Main 10 51324 1 1 1 1 1 1 1 1 1 11 Cam Assy Imp Cplg 10 400166 2 1 1 1 10 400167 4 1 1 1 1 10 400167 1 1 1 12 Screw w lock washer 10 35936 7 4 4 4 4 4 4 4 4 4 10 157160 4 4 4 15 Cover Contact NLA 2 1 1 1 NLA 2 EE EM
137. on eeeeeeeeeeeeeeene eene emen nennen nenne 7 10 7 2 7 Impulse Coupling and Related Component Inspection eee eee 7 1 7 2 8 Magneto Housing and Cover Inspection 7 15 7 2 9 Rotating Magnet Inspection eene enne 7 18 7 2 10 Sleeve Bearing Inspection sessi 7 19 7 2 11 Contact Assembly Inspection enne nennen nennen 7 19 8 Repair 8 1 Generali eeno er E Bu auvgpnnidasn chess wanna Ca had ga R A 8 1 8 2 Detailed Repair Procedures eeeeeeeeeseesrerrrrreeernsrennnernhersnresnsennesnnaa 8 1 8 2 1 Coil Pad Repas nine ek Ee eg ens 8 1 9 Assembly PEE P 9 1 0 2 Detailed Assembly Procedures iid see i eibi bnaeose e vo edP EUD E 9 2 9 2 Bearing Pinion Gear and Cam Assembly sse 9 2 9 2 2 Magneto Coil Installation seen 9 5 9 2 3 Distributor Block and Gear Assembly see 9 5 9 24 RototInstall tion eR he di esses EU SESE He UE RERO ERUNT ETE REE 9 6 9 2 5 Contact Assembly Installation sese 9 7 9 2 6 Capacitor Installation seseeeeseeeeeeee eene nennen enne 9 8 9 2 7 Oil Seal and Oil Slinger Installation ieeereeeeeeereereerereeresrenerreseeseseessseessseas 9 10 9 2 8 Impulse Coupling Assembly and Installation eee 9 11 9 2 9 Magneto Internal Timing esee 9 16 9 2 10 Cover Installations ienris eerie enorer nennen nennen
138. on Magneto Service Support Manual 5 1 31 August 2011 Cleanin outlet towers and the distributor block electrodes allowing the cleaning fluid to flush out any remaining contaminants from the inside of the block 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 8 Use dry oil free compressed air to blow the block dry and remove the protective caps from the bronze bushing 5 2 S 20 S 200 Series High 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 view of the magneto in Figure 1 and the Illustrated Parts List in Section 11 unless otherwise specified Special Tools Required e 10 400550 1 Magneto Grease e 10 86527 High Temperature Lubricant e 11 8465 Rotor Holding Tool e 11 8150 1 Timing Kit e E 50 Timing Light or equivalent 1 Use a 4 to 5 power magnifying glass for all visual inspections NOTE The following parts must be replaced 10096 with new parts upon removal from the magneto regardless of whether disassembly is for the purpose of inspection parts replacement or overhaul Lock Washers 3 13 34 Screws 12 41 47 56 61 amp 78 Retaining Ring 74 Oil Deflector 55 Oil Seal 59 Bearings 64 70 Felt Strip 81 Identification Data Plate 52
139. on with the Rotor Holding Tool adjusting knob Connect the timing light to the retard contact assembly tab and adjust the retard contact points to just open at this position Loosen Rotor Holding Tool adjusting knob and turn the rotor in the normal direction of rotation to check retard contact operation The retard contact points must open within 2 0 of the specified setting For example if the main contact opened at 12 and the retard angle specification is 30 the retard contact points must open between the 42 and 44 Continue turning rotor until the retard cam follower is on the high point of cam lobe Tighten the Rotor Holding Tool adjusting knob and measure retard contact point clearance Clearance must be 0 018 0 006 inch If retard contact clearance exceeds 0 024 inch repeat the timing procedure with E gap set at maximum If retard clearance is less than 0 012 inch repeat the timing procedure with E gap set at minimum E gap tolerance is 10 4 Tighten the contact assembly screws 41 to 20 25 in lbs of torque and verify opening clearance to ensure tightening the screws did not alter contact point clearance If a tachometer contact assembly is used turn the rotor until the tachometer contact cam follower is on the high point of the cam lobe and secure the rotor with the Rotor Holding Tool adjusting knob Adjust the tachometer contact to 0 019 0 003 inch clearance There is no angular timing requirement f
140. ontinued Airworthiness ICAs prepared by Continental Motors and approved by the Federal Aviation Administration FAA S 20 S 200 Series High Tension Magneto Service Support Manual V 31 August 2011 Continental Motors releases publication changes in the form of either change pages or complete publication revisions 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 our 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 7 2 3 Flight Check and Break In An Operational Check a
141. or the tachometer contact assembly Tighten the tachometer contact assembly screws 41 For insulated tachometer breaker point screws apply 8 10 in lbs of torque to the screws 41 for uninsulated tachometer breaker point screws apply 20 25 in lbs of torque to the screws 41 Verify opening clearance to ensure tightening the screws did not alter contact point clearance Inspect the bushing 38 for damage after final torque on the contact assembly Screws Disconnect the E 50 timing light from the magneto Remove the Timing Kit from the magneto and remove the Rotor Holding Tool from the rotor shaft S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 e B Assembl 9 2 10 Cover Installation NOTE Refer to Figure 9 8 through Figure 9 10 for wire routing in the contact compartment and under the magneto cover 1 If used form a new insulation sheet 24 into a loop and insert in the retard lead recess of the contact cover 15 Place the retard lead assembly 23 in the recess and secure by staking the ears of the spring washer so they wedge against the recess wall Check the security of the lead assembly in the cover by exerting a pulling force of 3 or 4 pounds on the lead wire do not pull on the terminal The spring washer must not shift or slip out of position For short cover style magnetos apply 24 26 in Ibs torque to the retard lead screw 25 2 If not previously assembled attach a
142. ot for installation purposes With the combination ignition and starter switch in its START position the right magneto is grounded The coil in relay K1 of the starter solenoid is energized the closed relay contact provides a path for operating voltage to the starter Battery current flows through vibrator points V1 coil L1 and L2 in 24 volt models through the BO Booster Output terminals to the switch where it is split and flows to both the 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 stops flowing through coil L1 causing the magnetic field to collapse and vibrator points V1 to again 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 of the magneto 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 magneto coil producing a magnetic field aroun
143. p Inspection 1 Ensure the coil matches current design specifications The coil must exhibit red epoxy compound external ground lead and a valid part number Figure 7 10 Coil may be cylindrical or barrel shaped discard all old coils S 20 AND S 200 SERIES S 20 SERIES Figure 7 10 Current Design Coils 2 Visually inspect the coil 58 a Inspect the core laminations 58 for wear at the point of contact with pole shoe laminations in the magneto housing If wear is present the coil will not fit tightly to laminations and must be replaced regardless of electrical characteristics b Visually inspect the coil leads If the leads exhibit damaged insulation or loose connections Discard coil with these conditions c Inspect high tension tab for wear caused by contact with the carbon brush 73 indicated by a visible depression in the tab If tab is worn repair coil according to instructions in Section 8 2 1 Coil Pad Repair d Visually inspect the coil case discard the coil if the epoxy case exhibits cracks or the beginning of cracks 3 Using a Fluke 8840A Digital Multimeter or equivalent measure primary resistance between coil leads Primary resistance shall be 0 2 to 0 6 ohms Measure secondary resistance between the ground lead and high tension tab Secondary resistance shall be between 12 16K ohms Replace coils failing to meet specifications 4 Inspect core clamps 57 closely Current production clamps feature a h
144. r 7 is employed remove using the CG240 puller 3 Remove the Woodruff key s 53 as necessary 4 2 4 Impulse Coupling Disassembly WARNING Using tools methods or procedures other than those specified herein for impulse coupling removal may damage magneto components NOTE Use of the specified anti seize compound during previous assembly will ease disassembly of the impulse coupling 1 Using heavy gloves or a clean shop towel grasp the coupling body 9 firmly to prevent the internal spring from unwinding suddenly Pull outward on the coupling body only enough to release it from cam assembly 11 Keep the coupling body close against the cam and allow the body to turn as the spring 10 unwinds After one or two turns spring coils will wedge against projections on the body restraining the spring from further unwinding 4 2 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl 2 Look into the hole in body and note location of inner eye of the spring Figure 4 1 where it engages with the mating recess in cam hub Insert a screwdriver under the spring end and pry the spring eye out of the recess Remove the body and spring together Uncoil the spring from the body and pry the spring eye from body recess to disengage the spring discard the spring Figure 1 10 Figure 4 1 Spring Engaged with Cam CAUTION Do not allow puller jaws to apply pressure to the flyweights resulting dama
145. r teeth Miller Stephenson 10 70506 108 Protective Caps 2 required Protect bushing during coating of block Continental 10 76257 Contact Contact Continental 10 86527 High Temperature Lubricant Contact assemblies cam follower felt Continental 646943 Anti seize Lubricant Prevent drive menbers from locking on rotating magnet Continental shaft taper Dykem Stain Red DNC Mark distributor gears Dykem Permabond 910 Industrial Grade Adhesive Bond Data Plate to Housing Permabond S 20 S 200 Series High Tension Magneto Service Support Manual 10 1 31 August 2011 Special Tools Equipment and Supplies 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 Corporation 42 nelson St 860 528 9821 easterntech com East hartford CT Emhart Fastening Teknologies Industrial Division 203 924 9341 emhart com products 50 Shelton Technology Center P O Box 859 Shelton CT 06484 Kell Strom Tool Company 214 Church Street Wethersfield CT 06109 860 529 6851 800 851 6851 kell strom com 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 permabond com
146. ral Overhaul 7 2 9 Rotating Magnet Inspection 1 Inspect the rotating magnet 54 for damaged threads cracks in the magnet casting scored or otherwise damaged laminations and wear or galling in the bearing race seat area cam and gear seat areas Measure each bearing seat at 90 intervals If either bearing seat exceeds limits shown in Table 7 2 replace the rotating magnet Visually inspect the drive end of the rotor shaft for grooves or scratches that might allow oil to pass under the sleeve bearing If an interference press fit condition is not obtained after installation of new bearing races and sleeve bearing replace the rotating magnet Discard the rotating magnet if any of these conditions are found CAUTION Replace any rotor matching the features depicted in Figure 7 20 with current specification rotor BRASS INSERTS ROTOR FLATS VISIBLE Figure 7 20 Conditions Requiring Rotating Magnet Replacement 7 18 S 20 8 200 Series High Tension Magneto Service Support Manual 31 August 2011 General Overhaul 7 2 10 Sleeve Bearing Inspection 1 Inspect the sleeve bearing 69 to determine if it matches the current production specifications The current production sleeve bearing is steel and has a ground finish characterized by a bright silvery surface The old design is sintered iron which has a dull gray appearance Regardless of condition replace the sintered iron sleeve bearings with the current production steel bearing 2
147. rance is under 0 012 inch adjust contact to 0 012 inch opening If contact assembly clearance is required repeat step 5 Replace the contact assembly if E gap is less than 6 or greater than 14 after setting main contact clearance Tighten the contact assembly screws 41 to 20 25 in lbs of torque and verify opening clearance to ensure tightening the screws did not alter contact point clearance 7 On retard contact assembly magnetos the retard contact assembly is adjusted to open at a predetermined number of degrees Table 11 1 after the main contact assembly The degree of retard for any particular magneto is stamped in the bottom of the contact compartment S 20 S 200 Series High Tension Magneto Service Support Manual 9 17 31 August 2011 Assembl 9 18 10 11 12 13 14 15 CAUTION The magneto distributor housing can be used only for retard angle stamped in housing as shown in Figure 2 3 Attempts to alter retard angle by adjusting the retard contact clearance will result in improper magneto operation Note the number of degrees indicated by the pointer on the scale at the exact point the main contact assembly opens and add the applicable number of degrees retard angle to determine the number of degrees the retard contact assembly should open Turn the rotor in the normal direction of rotation from the point of main contact opening the exact number of retard degrees and lock the rotor in positi
148. riggering ramp or cam stop contact areas Figure 7 17 If either ear shows a perceptible groove or a ridge can be felt when a fingernail is drawn across the surface reject the impulse coupling body 9 Z E TRIGGERING RAMP CONTACT FLYWEIGHT TAIL CONTACT CAM STOP CONTACT Figure 7 17 Impulse Coupling Body Wear Points 7 14 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 SB General Overhaul 7 2 8 Magneto Housing and Cover Inspection Examine both housings 48 and 50 for cracks stripped threads or other damage Check the bearing outer race seats in both housings for wear or peening due to operation with loose bearings Measure the bearing bore at four points with 90 of separation If bearing bores are worn peened or exceed Table 7 2 dimensions replace the housing If an interference press fit condition is not obtained after installation of new bearing races replace the housing Table 7 2 Bearing Seat Limits Bearing Seat Location Diameter Magneto Housing 50 1 3769 Maximum Distributor Housing 48 1 1014 Maximum Rotor 54 Front 0 5904 Minimum Rotor 54 Rear 0 3937 Minimum 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
149. riginal Magneto Original Magneto Cover Service Kit Converted Magneto Converted Magneto Part Number Type Part Number Part Number Type 10 51360 45 ALN 21 10 400415 10 500514 1 4LSC 21 10 51360 47 S4LN 21 10 400412 10 500514 201 S4LSC 21T 10 51360 58 S4LN 21 10 400415 10 500514 2 S4LSC 21 10 51365 57 S6LN 21 10 400415 10 500516 2 S6LSC 21 10 79020 11 S6LN 25 10 400412 10 500556 203 S6LSC 25T 10 79020 17 S6LN 25 10 400412 10 500556 203 S6LSC 25T 10 79020 18 S6LN 25 10 400415 10 500556 3 S6LSC 25 10 79020 19 S6RN 25 10 400415 10 500556 1 S6RSC 25 10 79020 118 S6LN 25P 10 400413 10 500556 103 S6LSC 25P 10 79020 119 S6RN 25P 10 400413 10 500556 101 S6RSC 25P 10 163005 2 S4LN 200 10 400417 10 600614 1 S4LSC 200 10 163005 3 S4LN 200 10 400417 10 600614 3 S4LSC 200 10 163010 1 S6RN 200 10 400417 10 600616 4 S6RSC 200 10 163010 2 S6LN 200 10 400417 10 600616 5 S6LSC 200 10 163010 10 S6LN 200 10 400417 10 600616 3 S6LSC 200 10 163010 11 S6LN 200 10 400417 10 600616 6 S6LSC 200 10 163010 15 S6RN 200 10 400417 10 600616 7 S6RSC 200 10 163015 3 S4RN 201 10 400417 10 600604 1 S4RSC 201 10 163020 3 S6RN 201 10 400417 10 600606 1 S6RSC 201 10 163020 4 S6LN 201 10 400417 10 600606 3 S6LSC 201 10 163045 1 S4LN 204 10 400415 10 600644 4 S4LSC 204 10 163045 3 S4LN 204 10 400415 10 600644 1 S4LSC 204 10 163045 6 S4LN 204 10 400412 10 600644 201 S4LSC 204T 10 163050 1 S6LN 204 10 400415 10 600646 1 S6LSC 204 10 163050 2 S6LN 204 10 400415 10 600646 3 S6LSC 204 10 163050
150. rotor 54 Remove debris and burrs as necessary 8 After satisfactory preload is obtained separate the distributor and magneto housings and remove the rotating magnet Pack Magneto Grease 10 400550 1 in the bearing cages 64 and 70 9 Apply an even coating of clean 30 wt aviation engine oil to the drive end of the rotor shaft position the sleeve bearing 69 on the drive end of the rotor shaft Figure 9 5 and press the sleeve bearing into position with the 11 6924 1 Pressing Tool Figure 9 5 Sleeve Bearing Installation CAUTION If self locking cam securing screw is removed or loosened at anytime always replace with a new self locking screw and apply torque to the specified value Before installing measure thickness and replace washer 62 if it is not 0 096 0 010 inch thick 10 Place the cam 63 on shaft so the arrow on cam points in the correct direction for magneto rotation Figure 9 1 Secure the cam to the shaft with a new self locking cam screw 61 and washer 62 Torque the screw to 21 to 25 in Ibs 9 4 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 9 2 2 Magneto Coil Installation CAUTION After coil installation verify the coil clamps secure the coil tightly against the pole shoes in housing If there is any play at this point wear will occur the parts will loosen and magneto output will be degraded 1 Position the coil Figure 1 58 in the magneto
151. rred to as serial numbers are currently used to identify magnetos built by Continental Motors These manufacturing numbers employ a coding system below The build date derived from this code rather than the magnitude of the numbers determines the date of manufacture Therefore 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 Current Manufacturing Numbers may be read as follows SERIAL DO9EAO005R NO Continental Motors Inc Figure 2 5 Magneto Identification Plate Example DO9EA005R H Ignition Switches J Ignition Vibrators K Ignition Harness D April E May F June G July H August September J October K November L December month After unit 999 alpha character changes to B etc D 09 E A005 R Component ID l l l Condition D S 20 Year Month Manufactured Fifth unit produced Blank New E S 200 Manufactured A January in month Begins R Rebuilt F S 1200 09 2009 B February with A001 at the No letter G D 3000 C March start of each for new 2 6 Storage 2 6 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 r
152. s 64 70 in the magneto and distributor housings BEARING RACE NOT YET SEATED Figure 9 4 Bearing Outer Race Installation S 20 S 200 Series High Tension Magneto Service Support Manual 9 3 31 August 2011 Assembl 6 Temporarily assemble the rotor 54 with the gear bearings and shim washers in the housings 48 50 using a gasket 49 when applicable Install three screws with lock washers 47 adjacent to the rotor to secure the housing To avoid excessive bearing preload test the rotor for free rotation as the screws are tightened the rotor must turn freely If friction increases on the bearings as the screws are tightened disassemble and remove shim washers from the pinion gear end of the rotor Reassemble the magneto and tighten the screws to 30 to 35 in Ibs of torque Apply a force of 30 Ibs in each direction of rotation to determine total end play Adjust the number of shims to obtain the total end play of 0 0005 to 0 0015 in loose 7 When proper bearing preload is achieved the rotor will spin freely with 0 0005 to 0 0015 inches of end play and no perceptible radial play of the shaft If either a tight or too loose condition is found repeat the shimming procedure CAUTION If the rotor binds or rubs during rotation the rotor shaft may be bent the rotor bore may be contaminated with debris or a burr on the rotor 54 or housing 50 could be the cause Do not attempt to straighten a bent rotor shaft replace the
153. sher Seeve Assembly Adapter Lock Washer Gasket Bushing 9 Lock Washer 5 Cover Oi 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 S 20 S 200 Series High Tension Magneto Service Support Manual iii 31 August 2011 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 Publications Service Documents Six categories of Service Documents may be issued by Continental Motors ranging from mandatory Category 1 to informational Category 6 Definitions of the categories are listed
154. specific number of degrees after the main contact points open A battery operated starting vibrator used with this magneto provides retarded ignition for starting regardless 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 All S 200 Series Magnetos and some S 20 Series Magnetos utilize feed through capacitor technology for suppression of conducted radio interference S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Description and Operation 2 3 Maintenance and Overhaul Periods NOTE Refer to Figure 1 for an exploded view of the Magneto NO DEGREES RETARD STAMPED IN HOUSING Figure 2 3 Cam End of Dual Contact Assembly Magneto Any time the magneto to engine timing is found to be outside the engine manufacturer s limits inspect the contact assemblies Figure 1 39 according to the instructions in Section 6 2 1 Inspect magnetos equipped with snap ring impulse couplings Figure 1 8 at the first 500 hours in service and every 500 hours thereafter according to instructions in Section 6 2 3 Inspect magnetos equipped with riveted impulse couplings Figure 1 8 at the first 100 hours in service and every 100 hours thereafter according to instructions in Section 6 2 2 Inspect all magnetos according to instructions in Section 6 2 3 at the first 500 hours in service and every 500 hours thereafter I
155. t 6 Remove woodruff key s Figure 1 53 from the rotating magnet shaft discard the woodruff key s 4 2 5 Rotating Magnet Rotor Disassembly 1 Install the nut 2 on the end of the rotating magnet 54 shaft to support cotter pin holes With the Woodruff keys s 53 removed from drive end press the magnet 54 from the housing 50 using an arbor press The Oil Deflector 55 will come off during this operation 2 Remove and discard the bearing 70 cage assembly CAUTION To prevent damage to the end of the rotor 54 place a piece of copper or brass approximately 1 4 inch thick between the end of the shaft and the arbor press ram when removing the bearing 70 inner race and sleeve bearing 69 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Disassembl 3 Clamp the knife edge of the 11 10192 removal tool between the inner race of the front bearing 70 and the wide portion of the rotor 54 Thread the nut 2 onto the rotor 54 to support and cover the cotter pin holes Remove the bearing 70 inner race and sleeve bearing 69 by pressing on the rotor 54 with arbor press Discard the bearing 70 inner race Remove the shim washers 71 Keep washers together and identify as drive end for reassembly 4 Disassemble the pinion gear 67 and bearing 64 inner race Fabricate two support bars similar to the ones shown in Figure 10 1 b Remove and discard the bearing Figure
156. t the sleeve bearing using the 11 6924 1 Pressing Tool 9 10 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Assembl 9 2 8 Impulse Coupling Assembly and Installation 1 Check cam assembly 11 and body 9 for magnetization which would prevent flyweights from engaging Hold assembly as shown in Figure 9 13 and push upper position flyweight tail against body 9 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 13 Check Impulse Coupling for Magnetization NOTE Failure to thoroughly degauss ferrous parts following the magnetic particle inspection will result in the parts retaining the magnetic properties Moving parts that take on magnetic properties from an external source may not operate according to their design specifications Ensure engine parts such as the impulse coupling body 9 are properly degaussed before assembly 2 If the impulse coupling body is magnetized demagnetize it with a degaussing coil Procedure continues on next page S 20 S 200 Series High Tension Magneto Service Support Manual 9 11 31 August 2011 Assembl 3 Clamp one drive lug of the impulse coupling body 9 in a copper jaw vise with the spring recess side up Orient the spring 10 with the impulse coupling body 9 for correct rotation Figure 9 14 On clockwise coupli
157. te The magneto timing has been advanced beyond the specified setting or a magneto primary lead is open Hot Magneto or an 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 RPM drop during the Magneto Drop Check is must be shut down and the cause for the problem corrected before further flight The normal magneto channel drop is specified in the appropriate AFM POH and the 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 b Ifthe grounding circuit is working as prescribed the engine should quit c If the Magneto did not ground out investigate and correct the cause prior to continued engine operation and before the next flight d Return the switch key or lever to the BOTH position and shut down the engine using normal procedures S 20 S 200 Series High Tension Magneto Service Support Manual 3 1 31 August 2011 Testing amp Troubleshootin 5 If problems persist install a replacement magneto which is known to be in satisfactory condition and send the suspected unit to the overhaul shop for test and repair 6 Should this not be possible a visu
158. the inspection a 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 manufacturer 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 the housing Do not reuse a housing if it has been staked punched or knurled Procedure continues on next page S 20 S 200 Series High Tension Magneto Service Support Manual 7 15 Look for cracks or indications of cracks especially in the areas adjacent to the 31 August 2011 General Overhaul 3 Inspect coil seat areas Figure 7 18 in the magneto housing 50 for wear If a ridge can be felt when a fingernail is drawn across the coil seating surface at the top of the pole shoe laminations replace the housing Ph T w E Figure 7 18 Wear in Coil Seat Area 4 Replace the housing 48 or 50 if evidence of corros
159. the technical manual Figure C If change pages are issued for the manual the change will be vi S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 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 ss pr zDGT 1 OT e Effective Manual UT Mar 203E Changes and cci Engine lasisiston and Operst Change Dates TA LLL ToS Hey Te 1 i Ld dod og ba c c da c ps TAY they T Sh RA hra Bb B1 fw 8 12 CA En C H oaeen E j C 10 thea C 18 E Figure C List of Effective Pages 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 continentalmotors aero S 20 S 200 Series High Tension Magneto Service Support Manual vii 31 August 2011 Contact Information Notify Customer Service immediately using our toll free number if you discover incorrect information which adversely affects safety Continental Motors is available to answer technical questions and encourages suggestions regarding products parts or servic
160. thick 2 199 2 AR 0 005 in thick 2 199 3 AR 0 008 in thick 2 199 4 AR 0 010 in thick 2 199 5 AR 0 012 in thick 2 199 6 AR 66 Washer Plain 10 3503 1 67 Gear Pinion 10 157123Y 1 69 Bearing Sleeve 10 25788 1 70 Bearing Ball 10 81806 1 71 Washer Shim 0 002 n DIR 2 161 1 AR 0 004 i thick 2 161 2 AR 0 005 i Tek 2 161 3 AR 0 008 in thick 2 161 4 AR 0 010 i thick 2 161 5 AR 0 012 in thick 2 161 6 AR 0 0015 in thick 2 161 7 AR 72 Kit Distributor Gear 10 357584 1 73 Brust Carbon 10 160844 1 74 Ring Retaining MS16624 2037 1 75 Washer 0 750 OD 10 349511 1 76 Washer 0 562 OD 10 606505 1 77 Washer Nylon 10 391309 1 78 Screw w Plain amp Lock 10 102083 3 washer 79 Block Distributor 10 357424 1 80 Spring Tower 10 50737 4 81 Strip Felt 10 163374 1 82 Washer Felt 10 50752 1 NLA No Longer Available The part number of the original component or assembly is no longer available Should a part identified as NLA require replacement modify the assembly as noted herein to convert the assembly to meet the current specification of the approved replacement assembly Magneto may be converted to a short cover model using the conversion chart in Table 11 14 and associated kit contents listed in Table 11 15 Record the conversion in the engine log book m 11 10 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 4 S6LN S6RN 20 21 and 23 Magnetos I
161. to 5 power magnifying glass for all visual inspections NOTE The following parts must be replaced 100 with new parts upon removal from the magneto regardless of whether disassembly is for the purpose of inspection parts replacement or overhaul Main and Retard Contact Assemblies 39 Lock Washers 3 13 34 Screws 12 41 47 56 61 amp 78 Retaining Ring 74 Oil Deflector 55 Oil Seal 59 Bearings 64 70 Felt Strip 81 Identification Data Plate 52 Carbon Brush 73 and Pin 1 If installed the Spring 10 and Gaskets 14 49 must also be replaced 2 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 General Overhaul Section 7 General Overhaul 31 August 2011 General Overhaul 7 2 Detailed Overhaul Procedures 7 2 1 Magneto Disassembly Disassemble the magneto completely according to instructions in Section 4 Disassembly 7 2 2 Distributor Gear Inspection CAUTION Use only the latest configuration distributor gear available at the time of overhaul 1 Determine if the distributor gear matches the current production Figure 7 2 design Very old gears are dark brown laminated phenolic Old nylon gears Fi
162. ufacturer s instructions Advance contact assembly out of adjustment internal timing off Retard points opening too late Inspect contact assemblies according to instructions in Section 6 2 3 step 7 Adjust and replace parts as necessary Check timing of retard points according to instructions in Section 6 2 3 step 7 S 20 S 200 Series High Tension Magneto Service Support Manual 3 5 31 August 2011 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 or dirt according to instructions in Section 6 2 1 step 1 through step 4 Carbon tracked distributor block Replace distributor block 79 Magneto Drop off Magneto timing incorrect Check magneto to engine according to instructions Check Out of Limits in the Engine Manufacturer s instructions Contact assemblies not opening properly Inspect contact assemblies for proper opening according to instructions in Section 6 2 3 step 7 Main contact assembly out of adjustment Check magneto internal timing according to internal timing off instructions in Section 6 2 3 step 7 Faulty plugs or leads Check plugs and leads No drop off
163. ure 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 eeeseess 2 2 Sample Magneto Circuit with Starting Vibrator Schematic 2 3 Lead Termination Detail 4 esee eet 2 4 Harness Outlet Cover Configuration eese 2 5 Gold Seal Cable eiie dotted er ete nue 2 5 Magneto Data Plate 5 eeu datei rni tas 2 8 5mm Spark Gap Setting is oreaecestees miis ed ami ded tassi ati pius 3 2 Pressurized Magneto Test Stand Block Diagram 3 4 Spring Engaged with Cam sccccsscccsssssscnsssessrecesenesererersees 4 3 Coupling Cam Removal 5 ences t eet ei teen ee ines 4 4 Apply Heat to Release Coupling eee 4 4 Rotor on Support Bars for Bearing Removal 4 5 Bearing Pressing Tool in Position eee 4 6 Rotor on Support Bars
164. versals during one complete revolution of the magnet is two 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 contact assembly points open the magnetic field around the primary winding collapses causing a high tension voltage to be induced in the secondary winding of the coil This high tension voltage 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 S 200 Magneto System with Starting Vibrator A schematic diagram of a magneto circuit with a starting vibrator is shown in Figure 2 4 The starting vibrator supplies interrupted battery current to the left magneto This type of vibrator should be 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 in the START position In Figure 2 4 all switches are shown in their normal OFF position Figure 2 4 must only be used for following the electrical operation of the magneto circuit n
165. washer 10 157160 4 4 4 4 4 4 4 4 4 4 4 4 4 4 15 Cover Contact NLA 2 1 1 ee 1 E 17 Lead Assembly Tach 10 400141 2 18 Sleeving 654742 2 50 1 19 Grommet Tach 10 400103 1 21 Nut Cap 10 163177 a i 1 1 22 Disk Neoprene 10 163384 Ha 111 23 Lead Assembly Retard 10 157241 1 BIR BIMBI 24 Paper Retard 10 163194 1 mam BM 25 Screw Fillister Head 10 35937 12 4 4 4 4 4 4 4 4 4 4 4 4 4 4 37 Washer Plain 10 14268 2 ARARE 2 BR RR 1 NENNEN 1 Bi 37a Washer Plain NAS620 8L 1 38 Bushing Tach 10 361639 2 39 Contact Assembly 10 382585 1 Be i ie 1 i 1 10 382584 1 BEBMNMEN BENI 1 1 1 1 Tachometer 10 400507 1 40 Plate Insulating Tach 10 361624 1 41 Screw w lock washer 10 35935 5 2 EBENEN Ea a 2 eee 2 E 10 35936 7 4 PAN ASA 4 MEIMION EXE 42 Capacitor 10 400572 1 BEBE BEI de BENE Ei 44 Plug Solid 10 157135 1 See ee 1 ee 1 46 Plug Ventilator 10 157134 1 BEBNEN eee ae E 47 Screw w lock washer 10 157158 5 Ma aa 5 CERTES 5 omimomimom E 48 Housing Distributor 10 400551 4 1 10 400551 6 1 10 400551 7 1 1 1 111 Ups 1 10 400551 8 1 1 1 1 49 Gasket Housing 10 357533 1 11 20 S 20 S 200 Series High Tension Magneto Service Support Manual 31 August 2011 Table 11 7 S6LN S6RN 200 201 204 and 205 Magnetos Illustrated Parts List
166. y Continental Motors Instructions apply only to the 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 bii dide s l Carefully slide the sleeve igure 615 3 nd drive gear assembly 5 out of the hr 2 accessory drive adapter throtteh k CAS magneto pad opening 2 Remove the nuts 10 amp 11 lock washers 8 amp 9 and washers 6 amp J Remove the accessory drive assemblies from the rear of the chnkcase Discard tlje lock washers 8 amp 9 3 Remove and discard the gasket 1 and residue from th crankcase ad the face of the accessory adapter 4 Repeat steps 1 through 3 for the second accessory drive adaNer 5 Disassemble the accessory drive adapters according to instructigns in Chapter 7 a Part References amp by index numbers 14 15 16 AT Og 18 Illustration e Number Indexed Part names Gasket 7 Plain Wa
167. ype No Part No Type No 10 51365 25 10 51365 33 10 51365 33 6LN 20 10 600646 2 6LSC 204 10 51365 26 10 51365 34 10 51365 34 S6RN 21 10 500516 5 S6RSC 21 10 51365 27 10 51365 46 10 51365 46 S6LN 20 10 600646 1 S6LSC 204 10 51365 28 10 51365 47 10 51365 47 S6LN 21 10 500516 2 S6LSC 21 10 51365 29 10 51365 44 10 51365 442 S6LN 20 Discontinued 10 51365 30 10 51365 45 10 51364 45 S6LN 21 Discontinued 10 51365 31 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 51365 32 10 51365 32 10 51365 32 S6LN 21 10 500516 3 S6LSC 21 10 51365 33 10 51365 33 10 51365 33 S6LN 20 10 600646 2 S6LSC 204 10 51365 34 10 51365 34 10 51365 34 S6RN 21 10 500516 5 S6RSC 21 10 51365 35 10 51365 35 10 51365 35 S6RN 21 10 500516 6 S6RSC 21 10 51365 39 10 51365 39 10 51365 39 S6LN 21 10 500516 4 S6LSC 21 10 51365 40 10 51365 40 10 51365 54 S6RN 21 10 500516 7 S6RSC 21 10 51365 41 Discontinued 10 51365 42 Discontinued 10 51365 43 10 51365 43 10 51365 43 S6LN 21 10 500516 3 S6LSC 10 51365 44 10 51365 44 10 51365 44 S6LN 20 10 51365 45 10 51365 45 10 51365 45 S6LN 21 10 51365 46 10 51365 46 10 51365 46 S6LN 20 10 600646 1 S6LSC 204 10 51365 47 10 51365 47 10 51365 47 S6LN 21 10 50051602 S6LSC 21 10 51365 48 10 51365 48 10 51365 48 S6RN 21 10 500516 9 S6RSC 21 10 51365 53 Discontinued 10 51365 54 10 51365 54 10 51365 54 S6RN 21 10 500516 7 S6RSC 21 10 51365 57 10 51365 57 10 51365 57 S6LN 21 10 500516 2 S6LSC 21 10 52350 1 Discontinued 10 52350 2

Service Support Manual

Contents

Download Pdf Manuals

Related Search

Related Contents