CONTINENTAL AIRCRAFT ENGINE service bulletin

Transcription

1 CONTINENTAL AIRCRAFT ENGINE service bulletin M81-13R1 Supersedes M81-13 Technical Portions are FAA-DER Approved 18 July, 1981 TO: SUBJECT: MODELS AFFECTED: All Manufacturers, Distributors, Dealers, Engine Overhaul Facilities, Owners and Operators of Teledyne Continental Motors Aircraft Engines. SLICK SERVICE BULLETIN 1-81 (Revised) A65, A75, C75, C85, C90, O200, IO360, TSIO360, O470, IO470, IO520 and TSIO520 which may have the Slick Model Magneto as listed on page 1 of Slick Service Bulletin 1-81 (revised) installed. Gentlemen: The attached Slick Service Bulletin No (revised) must be complied with as applicable. Please see the revised Slick Bulletin 1-81, revision dated which follows. The revisions to the bulletin are in the serial numbers affected, the affected dates of field installed coils, inspection procedures and the labor allowance. TELEDYNE INDUSTRIES, INC Member of GAMA General Aviation Manufacturer s Association TELEDYNE CONTINENTAL MOTORS Aircraft Products Division PO Box 90 Mobile Alabama 36601

2 Aircraft Ignition Parts BLACKHAWK PARK AVENUE, ROCKFORD, ILLINOIS PHONE April 6, 1981 June 29, 1981 (Rev'd.) SERVICE BULLETIN 1-81 (Revised) BACKGROUND Possible Magneto Malfunction Due to Cracking of the Coil Potting Compound There have been magneto malfunctions reported recently that have resulted from a crack in the orange potting compound of the magneto coil. The crack is observable as emanating from the high voltage output post of the coil, on the ends near the corners of the bridge, or across the rear of the coil. EQUIPMENT AFFECTED Only the following magneto model numbers are affected: 4201, 4201R 4252, 4252R 4216, 4216R 4230, 4230R 4281, 4281R 6210, 6210R R 4250, 4250R R The serial number range of these magnetos includes Serial Number Month of Manufacture October, November, December, January, February, March, April, May, June, July, August, September, October, November, December, January, February, March, April, 1980 It also includes all coils that have been field-installed (in magneto models listed above) as replacements between October 1, 1978, and today's date. Coil manufacturing dates are stamped on each coil and agree with magneto manufacturing date. Only coils manufactured between October 1, 1978, and April 30, 1980, are affected.

3 Service Bulletin 1-81 (Revised June 29, 1981) Page 2 COMPLIANCE For engine model numbers affected, please refer to Teledyne-Continental Service Bulletin #M81-13 (Rev. 1) and Avco Lycoming Service Bulletin #457A. The coil must be visually inspected within the next 25 hours of service, or no later than August 31, No material and/or labor claims will be honored if submitted later than September 30, 1981, for domestic claims, or November 30, 1981, for international claims. Coils should be re-inspected for cracks as a routine matter at each 500-hour service interval. Our service manual currently recommends that our magneto be opened at 500-hour intervals as normal procedure. To check the coil for cracks, remove the magneto from the engine, and remove the coil from the magneto. This must be done in accordance with our Detailed Instructions in this Service Bulletin. The labor allowance will be: Coil Inspection, Replacement if necessary, and Reassembly hrs./magneto - at current posted shop rate - Claims are to be handled by any Slick distributor listed in the back of this Bulletin. All claims for labor for coil inspection must be accompanied by our Pro Rata Form #1030, filled out completely with magneto model number, serial number, total hours, date stamped on coil, and the shop labor rate. All claims for parts and labor (for coil inspection and replacement with a new coil) are to be submitted with the old coil and Form #1030, filled out as noted above. All 4200 series magnetos use Slick Coil part number M All 6200 series magnetos use Slick Coil part number M CERTIFICATION OF COMPLIANCE All magnetos inspected and/or serviced as per this Service Bulletin must have the letter "C" stamped into the metal name plate following the last digit of the magneto serial number. DETAILED INSTRUCTIONS 4200/6200 SERIES AIRCRAFT MAGNETOS MAINTENANCE AND OVERHAUL INSTRUCTIONS 1. Before beginning disassembly, proceed as if you were timing the magneto to the engine and follow the engine manufacturer's procedure. It will be necessary to remove the top #l spark plug and rotate the propeller until compression is noted in #l cylinder with your thumb. Continue rotating the propeller until the impulse coupling trips. Now reverse the propeller and stop at the engine specification timing mark noted on the name plate of the engine. 2. Remove the harness cap from the magneto by removing the 3 screws that secure it. When removing the cap, place a visible mark on the harness cap and an adjacent mark on the distributor housing. This will insure that the cap is properly oriented upon re-assembly. 3. To remove the magneto from the engine, proceed as follows:

4 Service Bulletin 1-81 (Revised June 29, 1981) Page 3 (a) Remove the wire that connects the ignition switch to the condenser on the magneto (P-lead). (b) Remove the 2 nuts, washers and clamps that secure the magneto to the engine. (c) The magneto can now be removed from the engine for inspection. NOTE: USE OF THE SLICK T-100 ASSEMBLY AND TIMING KIT IS STRONGLY RECOMMENDED FOR DISASSEMBLY AND ASSEMBLY OF THE MAGNETO. THE 1037-A SERVICE MANUAL 4200/6200 Series Aircraft Magnetos Maintenance and Overhaul Instructions IS AVAILABLE FROM YOUR LOCAL SLICK DISTRIBUTOR. THESE INSTRUCTIONS SHOULD BE USED IN CONJUNCTION WITH THE FOLLOWING INFORMATION. 4. Remove the 4 screws that secure the distributor housing to the frame. Break the housing loose from the frame, but do not remove completely. The condenser wire that is mounted in the distributor housing must be disconnected from the contact breaker assembly mounted in the frame before the housing is completely removed. Remove the housing. The orange coil should be visible. 5. To remove the coil from the magneto, proceed as follows: The T-122 Wedge Extractor that comes with the T-100 tool kit should be used to pry the coil wedges (M-3040) loose. The coil can then usually be removed from the magneto by holding the coil by the protruding tower and shaking the coil from side to side until it comes loose. 6. Inspect the coil for visible cracks. The crack is observable as emanating from the high voltage output post of the coil, on the ends near the corners of the bridge, or across the rear of the coil. (See Fig. I attached for typical cracks.) If any cracks are evident, regardless of size or location, the coil should be re-placed. IF THE COIL HAS NO VISIBLE CRACKS BUT HAS BEEN IN SERVICE LESS THAN 250 HOURS, IT SHOULD BE REPLACED, REGARDLESS OF WHETHER CRACKS ARE OBSERVED. If the coil has been in service for more than 250 hours and has no visible cracks, replacement is not necessary. NOTE: While the magneto is disassembled, the opportunity exists to perform routine maintenance on the other components: (1) Check the stop pin that protrudes from the bottom of the magneto, for wear. If any deformation is noted, the frame and the impulse coupling should be replaced. If the stop pin is loose, the entire frame should be replaced. (2) Check the contact breaker assembly for point wear. If there is pitting or wear on the contact points, both the breaker assembly (M-3081) and the condenser (M-2766) should be replaced. (3) Disassemble the distributor block assembly from the distributor housing by removing the two screws that hold the assembly to the housing. Examine the high voltage contact terminals in the distributor block, the carbon brush on the shaft of the gear,

5 Service Bulletin 1-81 Page 4 and the centerwiper electrode that is connected to the nylon gear for pitting or material breakdown of any kind. If wear is observed, the entire assembly (M-3122, 6-Cyl.; M- 3121, 4-Cyl.) should be replaced. (4) Inspect internal and external threads of all threaded hardware. Damaged or worn parts should be replaced. (5) Inspect the magneto frame as well as the distributor housing for cracks or other damage. Inspect the mounting flange of the frame for possible cracks, and move from side to side to check for looseness if the magneto is still on the engine. Any cracks or damage should result in replacement. RE-ASSEMBLY PROCEDURES 1. If the coil has been removed, it should be replaced as follows: Seat the new coil in the frame, making sure that the coil bridge is touching the mounting pads by pressing firmly against the coil housing. Drive the 2 wedges tight using a hammer and a flat punch. Attach the white or black ground wire of the coil to the frame using the screw and lockwasher provided. Tighten to 20 inch-lbs. 2. Check the bent metal portion of the high tension lead of the coil, making sure it protrudes 1/16" beyond the face of the frame. This provides spring pressure against carbon brush electrodes on the distributor gear and the thrust bearing in the distributor block. IMPORTANT: IF THIS HIGH VOLTAGE LEAD IS NOT FIRMLY PRESSING AGAINST THE CARBON ELECTRODE, THE ELECTRODE WILL WEAR RAPIDLY. THIS COULD LEAD TO MALFUNCTION OF THE COIL AND/OR MAGNETO. 3. If the breaker assembly has been removed, proceed as follows: (a) Assemble the contact point kit on the bearing plate, using screws from the kit. Insert the black plastic cam in the cam slot with a screw- driver blade, and tap with a light hammer. Drive the cam all the way to the bottom of the cam slot. (b) Assemble the rotor gear onto the rotor shaft, making sure the key slot of the gear fits into the cam slot of the rotor. Tap with a light hammer until the gear bottoms on the shaft. 4. The next operation is to time the magneto internally and assemble the distributor housing onto the frame. (a) To time the magneto internally, place the magneto on the T-100 assembly and timing tool base, making sure the coupling lugs are in the slots of the index plate. Swing the frame counterclockwise against the pin, which will line up the rotor and cam for E gap position. (b) Attach either the red or the green wire of the timing light to the bronze point terminal, and the black wire to the frame of the magneto. With a screwdriver, adjust the points so the timing light indicates that the points are just opening. Secure the points by tightening the screws. This will provide a point gap of ". Attach the coil wire to the

6 Service Bulletin 1-81 (Revised) Page 5 vertical bronze male terminal of the point assembly. Apply cam grease M-1827 sparingly to each lobe of the cam. (c) Assemble the condenser into the distributor housing, being careful to rotate the condenser wire the same rotation as the condenser is tightened in the housing. Torque to 110 inch-lbs. Assemble the distributor gear in the distributor block, with the L & R facing you. Assemble the bearing bar to the distributor block so that the open side of the dust collector is toward the air vent and hood. Assemble the distributor block in the distributor housing, with the cut-away toward the condenser. Use screws and lockwashers. Torque to inch-lbs. (d) Connect the condenser wire to the slip terminal on the point assembly. BE SURE THAT THE CONDENSER WIRE IS NOT ALLOWED TO RUB AGAINST THE ROTOR GEAR. THIS CAN BE ACCOMPLISHED BY GIVING THE WIRE A TWIST IN THE APPROPRIATE DIRECTION TO HOLD THE WIRE AWAY FROM THE GEAR. Align the L or R (depending on magneto rotation) on the rotor gear so it points toward the high tension lead of the coil. (e) Align the L or Ron the distributor gear with the L or Ron the distributor block, and insert the timing pin (T-118) through the block into the gear. (a) (f) CAUTION: MAKE SURE THAT THE FLAT HIGH TENSION LEAD OF THE COIL PROTRUDES 1/16" ABOVE THE FACE OF THE MAGNETO HOUSING BEFORE RE- ASSEMBLY. (f) Fit the distributor, housing to the frame, making sure the bosses of the distributor housing are seated in the slots of the frame. Start by fitting the top boss (next to the vent) and assemble the distributor housing into place. (g) Secure the distributor housing to the frame with screws and lockwashers. Torque to inchlbs. 5. Take the following precaution in re-mounting the magneto onto the engine: CAUTION: TIGHTEN BOTH FLANGE-CLAMP NUTS BY HAND TO FINGER TIGHTNESS. TIGHTEN EACH NUT TO 8 FT.-LBS., AND THEN TIGHTEN THEM ALTERNATELY IN SEVERAL STEPS TO 17 FT.-LBS. EXCEEDING 17 FT.-LBS. MAY CAUSE THE MOUNTING FLANGE TO CRACK. 6. After the magneto is installed on the engine, remove the timing pin. 7. The timing of the magneto to the engine should be done per the engine manufacturer's specifications.

7 Service Bulletin 1-81 Page 6 Fig.1 Typical Coil Cracks

8 SLICK ELECTRO, INC. Domestic Aircraft Distributors (Listed Alphabetically by State) Name Location Phone Hughes Aviation Services Cutter Aviation Van Dusen Aircraft. Supplies Cooper Airmotive, Inc. E1 Cajon Aircraft Supply Hagelin Aircraft Supply Omaha Airplane Supply Sacramento Sky Ranch Superior Air Parts, Inc. Aviation Sales, Inc. Combs-Gates Denver, Inc. Atlantic Aviation Aviation Supply Corp. Aviation Supply Corp. Aviation Supply Corp. Aviation Supply Corp. Universal Export Aviation Supply (before May 1) Aviation Supply (before May 1) Aviation Supply (after May 1) Cooper Aviation Supply Edgecomb/G & N, Inc. Schneck Aviation, Inc. Combs-Gates Indianapolis, Inc. G & N Aircraft, Inc. Airparts Company, Inc. Aviation Distributors, Inc. Anchorage, Alaska Phoenix, AZ Long Beach, CA San Jose, CA San Leandro, CA Van Nuys, CA EI Cajon, CA Long Beach, CA Long Beach, CA Sacramento, CA Signal Hill, CA So. San Francisco, CA Van Nuys, CA Denver, CO Wilmington, DE Ft. Lauderdale, FL Tampa, FL Orlando, FL Opa Locka, FL Ft. Lauderdale, FL Miami, FL Miami Springs, FL Atlanta GA Atlanta, GA College Park, GA College Park, GA Atlanta, GA Honolulu, Hawaii Wheeling, IL Elk Grove Village, IL Elgin, IL Rockford, IL Elk Grove Village, IL Indianapolis, IN Griffith, IN Wichita, KS Olathe, KS Overland Park, KS Wichita, KS Lafayette, LA East Boston, MA (907) (907) (602) (602) (602) (602) (213) (408) (415) (213) (714) (213) (213) (916) (213) (415) (213) (303) (303) (302) (305) (813) (305) (305) (305) (305) (305) (404) (404) (404) (404) (404) (808) (312) (312) (312) (815) (312) (317) (219) (316) (913) (913) (316) (318) (617)

9 Slick Domestic Aircraft Distributors Page 2 Name Location Phone Q'Air Parts Tasco Aviation Supply Aviation Distributors, Inc. Omni Air, Inc. Omaha Airplane Supply Co. Hughes Aviation Service Sky Ranch Airparts Eastern Aero Supply, Inc. Cutter Flying Service Mattituck Aviation Corp. General Aviation, Inc. T. W. Smith Engine Co. A.A.R. of Oklahoma, Inc. Omni Air, Inc. A.A.R. Western Skyways, Inc. Atlantic Aviation Supply Co. Ellis-Horn Company, Inc. Omni Air, Inc. Schneck Aviation, Inc. Superior Airparts Hughes Aviation Service Hughes Aviation Services Melridge Aviation Co. Romulus, MI Pontiac, MI Minneapolis, MN St. Paul, MN Edina, MN Chesterfield, MO Kansas City, MO St. Louis, MO Kansas City, MO Omaha, Nebraska Las Vegas, NV Reno, NV Millville, NJ Teterboro, NJ Albuquerque, NM Bohemia, NY Mattituck, L.I., NY Cinciannati, OH Willoughby, OH Cincinnati, OH Vandalia, OH Oklahoma City, OK Tulsa, OK Tulsa, OK Oklahoma City, OK Troutdale, OR Fiarview, OK Philadelphia, PA New Cumberland, PA Anderson, SC Memphis, TN Dallas, TX Ft. Worth, TX Houston, TX Dallas, TX San Antonio, TX Dallas, TX Addison, TX Dallas, TX Houston, TX Salt Lake City, UT Sandston, VA Seattle, WA Vancouver, WA Seattle, WA (313) (313) (313) (612) (612) (612) (314) (314) (816) (314) (816) (402) (702) (702) (609) (201) (505) (516) (516) (513) (216) (513) (513) (405) (918) (918) (405) (503) (503) (215) (717) (803) (901) (214) (817) (713) (214) (512) (214) (214) (214) (713) (801) (804) (206) (206) (206) (206)

10 SLICK ELECTRO, INC. Canadian Aircraft Distributors (Listed Alphabetically by State) Name Location Phone Leavens Brothers, Ltd. Leavens Brothers, Ltd. Leavens Brothers, Ltd. Leavens Brothers, Ltd. Calgary, Alberta Edmonton, Alberta Calgary, Alberta Edmonton, Alberta Edmonton, Alberta Vancouver, British Columbia Richmond, British Columbia Winnipeg, Manitoba Winnipeg, Manitoba Fredericton, New Brunswick Mississauga, Ontario Ottawa, Ontario Mississauga, Ontario Mississauga, Ontario Lachine, Quebec Lachine, Quebec Lachine, Quebec (403) (403) (403) (403) (403) (604) (604) (204) (204) (506) (416) (613) (416) (416) (514) (514) (514)

11 SLICK ELECTRO, INC. Foreign Aircraft Distributors Aeronautica Van Dusen, S.A. Comair Johannesburg, Cooper Airmotive Cooper Airmotive Cooper Airmotive Rex Aviation, Ltd. Dalhoff & King Aviation, Ltd. Rolls Royce Motors, Ltd. Satair, Ltd. Van Dusen SarI Co. Van Dusen Airstocks Co., S.A. Co., GmbH Austrailia, Ltd. Mexico City, Mexico South Africa Melbourne, Australia Oxford, England Germiston, South Africa Bankstown, NSW, Australia Paupakura, New Zealand Crewe, Cheshire, England Copenhagen, Denmark London, England Melbourne, Australia Aeroport de Bourget, France Oxford, England Kowloon, Hong Kong Transvaal, South Africa Helsingborg, Sweden Englsbach, West Germany New South Wales, Australia Avco Lycoming Distributors which stock Slick parts C.S.E., Ltd. Fenwick Aviation Motoren-Und Turbinum Union A.B. Nyge Aero Osterman's Aero AB Aerospares (pty.) Ltd. N.Z. Aerospace, Ind. Ltd. Airwork (N.Z.) Ltd. Oxford, England Paris, Cedex, France Munich, West Germany Nykaping, Sweden Barkarbyvagen, Sweden Transvaal, South Africa Hamilton, New Zealand Christchurch, New Zealand