Service Manual - Continental Motors
Contents
1. 9 20 Impulse Coupling Spring Orientation 9 2 art Tres End uses atat ier o a CIS EDU EDS 9 2 Apply Anti seize to Magneto Shaft 9 22 Proper Cotter Pin Installation 9 23 Typical Impulse Coupling Crack 9 23 Lead Preparation 9 25 Ledid Assemb Detail eue obe aetas 9 25 Dura Blue Lead Assembly us oio t oie ERE mte Pero ER un 9 26 Eyelet Crimping sarina 9 27 Ignition Harness Assembly Tool 9 29 Pormed Capacitor Leads ode tm ERE DV ume SE NEUE 9 30 Lubricate Insulating Sleeve 9 32 Terminal Kit Assembly diede 9 33 EIDOW Kit 9 33 Eyelet Presse TOOL xou ouod m eni emet em a dine m b rude 10 3 Harness Assembly qp ed ea UNS 10 3 INE Varr c 10 3 11 9998 Bearing Pressing Tool 10 4 11 9999 Bearing Pressing Support 10 4 Support Bar Dimensions 10 5 Small Gear Support Bar Dimensions esses 10 5 Wood Support Block Dimensions 10 6 Dial Indicator Mounting Plate 10 6 Terminal KICS pare S 11 6 D 3000 Series Magneto Exploded View2. 11 17 D 3000 Series Magneto Harness Assembly Exploded View 11 18 D 2000 D 3000 Series High Tension Magneto Service Support Manual 31 August 2011 NM d 2 Testing amp Troubleshootin Section 3 Testing amp Troubleshooting 3 1 General NOTE Index numbers in parentheses refer to the exploded views of the magneto in Figure or the harness in Figure 2 and the Illustrated Parts List in Section 11 unless otherwise specified 1 If engine malfunctions develop which appear to be caused by the ignition system check the spark plugs and wiring first before working on the magnetos WARNING Turn the Ignition Switch OFF disconnect engine electrical power and confirm continuity between the magneto capacitor and aircraft ground before commencing maintenance or inspections to avoid uncommanded engine starts during maintenance Do not stand or place equipment within the arc of the propeller 2 Perform a Magneto RPM drop off test according to the instructions in the applicable Airplane Flight Manual AFM Pilot s Operating Handbook POH to assess the ignition system operation A drop in RPM is expected when one magneto in a redundant ignition system is shut off Absence of an RPM drop may indicate The magneto timing has been advanced beyond setting specified or A Magneto primary lead is open Hot Magneto or The ignition switch 1s inoperative or The grounding circuit of the feed through capacitor 1s open or a co
3. 8 4 4 Rotor on Support Bars for Bearing Removal 4 5 Bearing Pressing Tool in Position 4 6 Rotor on Support Bars for Small Gear and Bushing Removal 4 7 Check Contact Point Security eese 6 2 Normal Contact Point 6 2 Eh0 6 4 Flyweisht Heel Inspection redeo ra Ecole 6 5 TOS PCCTION 6 6 Wire Hook Configuration essere 6 6 Flyweight to Axle Wear Check eere 6 7 X EISE 6 7 Distributor Gear Identification Marks 7 2 Check Electrode 7 3 Stress Line in Distributor Block 7 4 Check Distributor Block for Carbon Tracking 7 5 Contact Spine T 7 5 Lubrication Identification Mark 7 6 Capacitor Date CONS ascetics shige tarasntasb 7 7 PO PIVO DEC IOC 7 8 Inspect Flyweight Washers sees 7 9 wom Dinie CI HA 7 10 Coupling Body Wear Points 7 10 COT Ec e 8 1 8 2 Position Springs in Magneto Housing 9 2 Position Plate wi
4. D 2000 D 3000 Series High Tension Magneto CONTINENTAL IGNITION SYSTEMS SERVICE SUPPORT MANUAL Technical Portions Approved by the FAA Publication X42003 3 CHANGE 1 2011 2012 CONTINENTAL MOTORS INC APR 2012 CONTINENTAL Eg This manual is a revision of the service instructions contained in X42003 2 published in July 2010 Upon FAA approval and release of this document all previous versions of X42003 are superseded and should not be used for Continental Motors D 2000 D 3000 magneto service maintenance or overhaul Supersedure Notice Effective Changes for this Manual List of Effective Pages Document Title D 2000 D 3000 Series High Tension Magneto Service Support Manual Publication Number X42003 3 Initial Publication Date 31 August 2011 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 2012Continental Motors Inc All rights reserved This material may not be reprinted republished broadcast or otherwise altered without the publisher s written permission This manual is provided without express statutory or implied warranties The publisher will not be held liable for any damages caused by or alleged to be caused by use misuse abuse or misinterpretation of the contents Content is subject to change without notice Other products and companies mentioned herein may be trademarks of the respe
5. ctive owners A D 2000 D 3000 Series High Tension Magneto Service Support Manual CHANGE 1 10 April 2012 ee MMC CONTINENTAL Seer TM WT N Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 Figure 7 11 Figure 8 1 Figure 8 2 Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 9 6 Figure 9 7 Figure 9 8 10 April 2012 LIST OF ILLUSTRATIONS D 3200 Magneto and Associated Components 2 Magneto Model Number Elements 2 2 Sample Magneto Circuit with Starting Vibrator Schematic 2 3 Lead Termination Detail 2 4 Harness Outlet Cover Configuration 2 5 euo red qe 2 5 Tata PEG oido 2 8 Spark Gap Sell ID 3 2 Pressurized Magneto Test Stand Block Diagram 3 4 Spring Engaged with Cam esses 4 3 Coupling Cam REMOVAL 4 4 Apply Heat to Release Coupling
6. d kits to capacitors When applicable install a retard lead made with 10 157208 kit and or tachometer lead made with 10 157209 kit Determine lowest speed at which rotating magnet can be turned and still spark all gaps without missing coming in speed Magnetos must spark consistently at 150 D 2000 D 3000 Series High Tension Magneto Service Support Manual 10 April 2012
7. mbination of these factors 3 An engine which does not exhibit a normal drop off in RPM when the Magneto is checked must be shut down and the cause for the problem corrected before further flight The normal engine drop off is specified in the appropriate AFM POH the and Engine Maintenance and or Overhaul Manual 4 As a precautionary measure test the Magneto grounding circuit prior to shutting down the engine using the following procedure a With the engine at normal idle rotate the switch key or lever momentarily to the off position one magneto is still functioning If the grounding circuit is working as prescribed the engine should quit If the magneto did not ground out determine and correct the cause prior to continued operation of the engine and before the next flight Return the switch key or lever to the BOTH position and shut down the engine using normal procedures 5 If problems persist replace the magneto with a known serviceable unit and send the suspect unit to the overhaul shop for test and repair D 2000 D 3000 Series High Tension Magneto Service Support Manual 3 1 31 August 2011 ee be E por Testing amp Troubleshootin 6 If a replacement unit is not readily available inspect the following to isolate the cause of the malfunction a Remove harness securing screws and separate the cover from the magneto Inspect for presence of moisture and foreign matter on rubber gr
8. ommets and high tension outlet side of the distributor block Check for broken or burned outlet towers If either is present remove magneto and replace as necessary b Check block tower springs for proper height End of spring shall not be more than 0 422 inch from top of tower Replace burned or otherwise short springs according to the instructions in Section 9 2 4 Check for broken leads or damaged lead insulation If either is present replace magneto c Inspect contact assemblies according to the Contact Assembly Inspection in Section 6 2 1 3 2 Post Overhaul Testing 1 Mount the magneto on a 11 10500 test stand Connect the high voltage outlet to 3 2 CHANGE 1 spark gaps on test stand using a standard harness assembly Set spark gaps at 0 157 in 4 mm as shown in Figure 3 1 CAUTION Do not operate the magneto on a test stand unless all high voltage leads are connected to spark gaps an open high voltage circuit would subject magneto parts to damage Do not operate magneto on test stand with oil seal installed for longer than five minutes as hidden damage may result MATERIAL TUNGSTEN BRASS OR STAINLESS STEEL 4mm 0 197 in 0 007 in 0 008 in R max 3 Places IONIZING TEASER ELECTRODE 1mm 0 039 in NO ELECTRICAL CONNECTION DO NOT GROUND TO MAGNETO Figure 3 1 Spark Gap Setting Install magneto grounding leads fabricated using 10 382698 ground terminal lea
9. th Recess Facing Up 9 3 Kit Parts Installed in D 2000 Magneto 9 4 Spur Gear Alignment on Shaft 9 6 Contact Spring Installation essere 9 0 Distributor Block TMINE 9 11 Dial Indicator Mounted on Housing 9 11 Shims Positioned Around the Rotating Magnet 9 13 D 2000 D 3000 Series High Tension Magneto Service Support Manual XV CHANGE 1 XVI Figure 9 9 Figure 9 10 Figure 9 11 Figure 9 12 Figure 9 13 Figure 9 14 Figure 9 15 Figure 9 16 Figure 9 17 Figure 9 18 Figure 9 19 Figure 9 20 Figure 9 21 Figure 9 22 Figure 9 23 Figure 9 24 Figure 9 25 Figure 9 26 Figure 9 27 Figure 9 28 Figure 9 29 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 10 9 Figure 11 1 Figure 1 Figure 2 Distributor Block Secured and Centered 9 13 Cam End View of Coe Da debet 9 15 11 8465 Rotor Holding Tool in Position 9 16 Timing Marks on Rotating Magnet esee 9 177 Rotor Timing Marks Aligned with Pointer 9 177 Painted Tooth Centered in Window esses 9 17 Check Impulse Coupling for Magnetism
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