MM 4002 PARTS CATALOG. for the AM SERIES EISEMANN MAGNETOS MODELS AM-1, AM-2H, AM-2N, AM-4, AM-6 A PRODUCT OF

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3 MM 4002 HA NDBOOK OF NSTRUCTONS WTH PARTS CATALOG for the AM SERES of ESEMANN MAGNETOS MODELS AM-1, AM-2H, AM-2N, AM-4, AM-6 A PRODUCT OF JACK & HENTZ PRECSON NDUSTRES, NC. CLEVELAND 1, OHO APRL, 1947

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5 ( i TABLE OF CONTENTS Section.... Page NTRODUCTON l. DESCRPTON General Description Detailed Description 2 ll. NSTALLATON Flange Mounted Magnetos Base Mounted Magnetos 6 V. OPERATON Principles of Operation Operation nstructions. 9 ' V. SERVCE NSPECTON AND LUBRCATON l. Service nspection Lubrication Service Troubles and Remedies 11 V. MAJOR OVERHAUL Overhaul Tools Required Disassembly, nspection, and Cleaning General Disassembly of Distributor Plate Removal and Disassembly of the mpulse Starter 6-6. Removal and Disassembly of End Plate Disassembly of Magneto Rotor Shaft Assembly Disassembly of Magneto Housing Assembly Cleaning Reassembly of Component Parts Running Test V. PARTS CATALOG NTRODUCTON 22 V. GROUP ASSEMBLY PARTS CATALOG 23

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7 Section, 11 ( ' i SECTON NTRODUCTON 1-:L Xi?,is l{andbook with Parts Catalog contains descriptive data and instructions for nstallation, Operation, nspection, Maintenance, Over. haul and Test of the Eisemann AM-Series magnetos manufactured by Jack and Heintz Precision ndustries, nc., Cleveland 1, Ohio The Parts Catalog included in this Handbook contains exploded views of a typical Model AM-4 Magneto and a parts list for identification of all procurable items in each model of the entire AM-Series All work performed on these magnetos should be carried out by qualified mechanics and in properly equipped repair shops; preferably an authorized Eisemann Service Station. ATTEMPTED REPARS OR ADJUSTMENTS BY UNTRANED PER SONNEL MAY ENDANGER HUMAN LFE AND MAY ALSO RESULT N COSTLY REPLACEMENTS. \. SECTON 11 DESCRPTON ) GENERA L DESCRPTON. a. The magnetos covered by this Handbook are of the rotating magnet, high tension type,. designed to provide efficient ignition over a wide range of applications. Figure 2 1 shows a representative type of each model in the AM-Series of Eisemann Magnetos. This series consists of Models AM-!, AM-2H, AM-2N, AM-4, and AM-6. A grounding switch is shown at tached to the ground terminal of each model in the series except the Model AM-2H. This does not indicate that a switch may not be used with the Model AM-2H, but rather to show the appearance of a magneto without such a switch. t is more convenient in many installations to employ a suitable remote control magneto switch, such as, the Eisemann Grounding Switch. f it is desired to use either type of switch, reference to the Parts Catalog Section of this Handbook will enable the selection of the proper switch with regard to the correct application. MODEL AM-1:-Supplied with a single-lobe cam and single-pawl impulse starter, designed to be driven at crankshaft speed on 2-cycle engines; and crankshaft, or camshaft speed, on 4-cycle engines. f driven at crankshaft speed on 4-cycle engines the unused sparks will occur in the exhaust stroke. MODEL AM-2H:-Supplied with a single-lobe cam and single-pawl impulse starter to be driven at crankshaft sreed on 4-cycle, 2-cylinder engines firing at 360 intervals. MODEL AM-2N:-Supplied with 2-lobe cam and 2-pawl impulse starter, gearless spark distribution, driven at crankshaft speed on 2-cycle, 2-cylinder engines firing at intervals; driven at camshaft speed on 4-cycle, 2-cylinder engines firing at 360 intervals; driven at crankshaft sreed on 4- cycle, 2-cylinder engines firing at with unused sparks occurring in the exhaust stroke. MODEL AM-4:-Supplied with a 2-lobe cam and 2-pawl impulse starter, being available in either carbon brush or jump-spark distribution, and driven at engine speed on 4-cycle, 4-cylinder engines. MODEL AM-6:-Supplied with a 2-lobe cam and 2-pawl impulse starter, jump-spark distribution, and driven at one and one half times crankshaft speed on 4-cycle, 6-cylinder engines. b. The different models of the AM-Series magnetos may be obtained with various types of mounting arrangements and equipped with impulse starters if required. mpulse starters are used to insure the best characteristics for starting under all conditions, by providing automatic spark retardation and a spark of high intensity at the instant when needed. The impulse starter should 9e selected with reference to the direction of rotation and proper lag angle as specified by the engine manufacturer. Magnetos of the AM Series are selected with regard to the type of engine

8 Section 11 Paragraphs 2-1, -2 r ( l (... mounting; namely, base mounting, or flange mounting as illustrated in figure 2-2. Two types of base mounting magnetos are obtainable: ( 1) 3 Smm. base and (2) 45mm. base. Flange mounting magnetos are designated as follows: (1) Vertical Flange (S.A.E. tractor standard); (2) Small Vertical Flange (Wisconsin AA and AB engines and other special applications); (3) Horizontal Flange (S.A.E. aircraft standard two bolt mounting). Flange mounting magnetos are offered with three different lengths of rotor shafu: (1) standard length for use where magneto drive gear is carried on a shaft in the engine; (2) an extended shaft for use where magneto drive gear is carried by the magneto shaft (a hardened steel gear bushing and thrust washer are included with magnetos having extended rotor shafts); and (3) S.A.E. aircraft shaft fo r use where the engine does not require an impulse starter. c. All AM-Series magnetos mount the magnet rotor on 15mm. ball bearings. For magnetos requiring geared distribution, the distributor rotor shaft is mounted in a permanently lubricated Oilite type bushing DETALED DESCRPTON. a. Figure 2-3 is a cutaway view showing the internal construction of the Model AM 4 Magneto. Reference numbers are provided for the principal parts illustrated. b. The housing ( 1) is a high quality aluminum alloy die casting with laminated electric steel pole shoes. The housing supports and locates the coil (11), the end plate (27), the outer race of the front ball bearing (3) for the magnet rotor (2), the housing ventilator, and che impulse scarcer catch pin (when required), as well as the oil seal (4) (on flange mounted magnetos), or the dust seal (on base mounted magnetos) for the rotor shaft. c. The coil ( 11) is constructed of a specially treated Figure 2-2. Mounting Arrangements. primary and secondary winding of very high efficiency, mounted on a laminated electric steel coil core (10). The ends of the coil core are precision ground to match the conical taper bored in the pole shoes in the housing. This conical taper provides a locating seat for the coil in the housing and minimizes the magnetic resistance between coil core and pole shoes. The coil is further secured in the housing by means of two spring clamps over the ends of the coil core which are fastened to the housing by four screws and lock washers. One end of the primary and one end of the secondary winding are connected to the condenser (2 1). The other end of the primary winding is grounded by a lead fastened under one of the coil fastening spring clamps. The high tension end of the secondary is connected to the high tension terminal ( 13) on the coil. On some applications, a different coil is required, in which case the ground lead is attached to the coil core. d. The end plate (27) is an aluminum alloy die casting and is secured to the housing by three fillister head screws and lockwashers. The end plate locates and supports the rotor bearing on the breaker end of the magnet rotor shaft (2), the Oilite bronze distributor rotor bearing (16), the distributor rotor and gear assembly (17, 18), the breaker assembly (25), and the condenser (2 1). e. The distributor rotor ( 18) is made of a special plastic material of high dielectric strength into which the distributor electrode (19), and the rotor shaft are integrally moulded. On some models, the distributor electrode is removable, being held in place with a spring clip. The distributor rotor is driven by a linen bakelite gear (17), riveted to the back face of the distributor rotor. jthis assembly is located and secured in the distributor bearing by two thrust washers, shims as applicable, and a snap ring. AM-2N models are designed for gearless spark distribution and have the distributor on the magnet rotor shaft. ; L { 1 i ' i '\. 2

9 Section 11 Para9raph 2-2 (,., l. Housing 2. Magnet Ro10r Shaft 3. Ball Bearing 4. Oil Seal 5. Oil Stinger 6. Woodruff Key 7. Flange Assembly 8. mpulse Spring 9. mpulse Drive Cup 10. Coil Core 11. Coil 12. Gasket 13. High Tension Terminal 14. Coil Concaccor 15. High Tension Pickup 16. Oilite Rowr Bearing 17. Discribuwr Gear 18. Distributor Rotor 19. Discribuwr Electrode 20. Carbon Brush & Spring 2 l. Condenser 22. Pinion Gear 23. Ground Terminal Assembly 24. Cam Follower 2 5. Breaker Assembly 26. Contact Points 2 7. End Place Assembly 28. Distributor Place Figure 2-3. Cutaway View of the AM-4 Magneto. 3

10 Section 11 Paragraph 2-2 Figure 2-4. Transverse Section of Magneto. f. The breaker (2 S.) is of the pivotal type which permits adjustment without changing the relationship between the contact surfaces of the points (26). The cam-follower (24) is accurately machined to conform to the breaker cam contour. The flexible bronze conductor strap insures proper electrical conductivity. g. The condenser (2 1) is a hermetically-sealed, metal-cased rolled-section type, thoroughly impregnated with a high heat and vibration resisting compound. A spacing bushing, a slotted nut and lock washer are used to position and secure the primary and secondary leads from the coil and the breaker lead, to the condenser terminal post. The ground connection is made through the integral mounting bracket which is secured to the condenser mounting bosses on the end plate (27) by two screws and lock washers. h. The magnet rotor (2) is constructed of a high output alnicq magnet, laminated electric-steel pole pieces and the rotor shaft integrally cast in aluminum alloy as indicated in figure 2-4 which shows a transverse section of the magneto. This complete unit is machined and ground o very close tolerances to assure accurate timing and a minimum air gap between the rotor pole pieces and the pole shoes in the housing. The magnet rotor is carried in the rotor tunnel on two separable-type ball bearings located in the housing (1) and the end plate (27) respectively. Accurate bearing adjustment is accomplished by means of shims located behind the inner races of the ball bearings. The drive end of the rotor shaft passes through the oil seal ( 4) and carries the oil slinger (5) (flange mounted magnetos) or through a suitable dust seal (on base mounted models). The impulse starter, drive gear bushing and drive gear may be mounted on the extension of the rotor shaft. Positive driving and accurate location of these units is assured by the woodruff key (6) and the taper on the shaft. The cam and the pinion gear (22) where required are positioned and secured on the breaker end of the rotor shaft by a shoulder, a woodruff key, a nut, and lockwasher. On applications where a hardened steel cam is required instead of an oil-impregnated cam, an oil wick is also mounted on the end plate..----note , Base-mounted AM-Series magnetos are equipped with a felt type dust seal at the drive end. The flange mounted models are equipped with an oil seal and oil slinger at the drive end. i. The distributor plate (28) is a high quality, plastic unit possessing high dielectric and thermal properties, as well as being resistant to abrasion. t contains an integral high tension pickup (15 ), distributor electrodes, and the contact spring and ground terminal assembly (23). The coil contactor (14) consists of a compression spring and a sleeve eyelet placed over the high tension pickup to insure positive contact with the high tension terminal (13) of the coil. A carbon brush and spring (20) connect the high tension pickup with the rotating distributor electrode (19). The spark plug cables are inserted in the distributor plate by firmly pressing the cables into the proper cable holder being sure that the cable clip bottoms in the cable holder. A gasket (12) is used between the housing (1) and the distributor plate (28) to insure the exclusion of all foreign substances. (, \ ( ( \.. \ l. 4

11 Section ll Paragraph 3 1 ( \ SECTON ll NSTALLATON \ \ 3-1. FLANGE.MOUNTED MAGNETOS. (See.figure 3-1) a. On flange mounted magnetos, when the magneto drive gear is to be mounted on the magneto rotor shaft, care should be exercised to insure the proper order of assembling these members, by noting the following sequence: (1) nstall impulse coupling retaining washer. (2) nstall gear bushing. (3) nstall drive gear. ( 4) nstall gear thrust washer. (;) nstall drive shaft nut. (n some instances the gear thrust washer and drive shaft out are combined in a single unit). Securely tighten the drive shaft nut and lock with a suitable cotter pin. Be sure that the drive gear does not bind and is free to move upon its bushing. To tighten the drive shaft nut, the magneto drive gear may be held in a soft-jawed vise. b. When installing the magneto on the engine, make sure that the piston in number-one cylinder is in the correct timing position as specified by the engine manufacturer. c. Remove the distributor plate from the magneto and turn the magneto rotor shaft until the distributor electrode is in the correct position for firing number one cylinder. (f the magneto is equipped with an impulse starter, the rotor shaft should be turned in a direction opposite that of normal rotation in order to avoid engagement of the impulse starter). d. When a magneto is equipped with a driving gear, the timing mark on this gear should be aligned with the corresponding timing mark on the engine gear. f the mark on the magneto drive gear does not line up, the magneto drive gear should be removed from the drive shaft and rotated 18 0 degrees and then reassembled. e. Tighten the magneto mounting screws sufficiently to hold the magneto in place but not tight enough to prohibit the movement of the magneto around its drive shaft. Connect one cable of a suitable timing indicator to the ground terminal and the other cable to the magneto frame. Rotate the magneto on the flange pilot until the timing indicator shows that the contact points are just separating. Keep the magneto in this position and securely tighten the mounting screws. f. Replace the magneto distributor plate, being careful that the center carbon brush makes pro per contact with the center of the distributor rotor and the high-tension pickup eyelet makes proper contact with the high-tension terminal on the coil. g. nstall high tension cables from the magneto to the spark plugs, being careful that the cables from the magneto connect with the proper spark plug in accordance with the firing order of the engine R. Figure 3-l. Dimensional Drawing for Typical Flange Mounted Magneto. 5

12 Section ll Paragraphs 3-1, CAUTON ----, The firing order of the magneto is a direct sequence starting from number one which is indicated on the distributor plate, i.e. The cable from number one terminal on the magneto distributor plate should go to the number one cylinder on the engine; the second terminal on the distributor plate in the proper magneto firing sequence, as determined by the direction of rotation of the magneto, should be connected to the second cylinder in the firing order of the engine (not necessarily number two cylinder); number three terminal of the distributor plate should be connected to the third cylinder as specified by the engine firing order, etc. h. Where grounding switches are mounted other than on the magneto, be sure that proper connections are made between the ground terminal of the magneto and switch BASE MOUNTED MAGNETOS. (See figure 3-2) a. When installing base-mounted magnetos, be sure that the piston in number one cylinder is in the correct timing position as specified by the engine manufacturer and that the magneto distributor rotor is in the correct position for firing number one cylinder, as outlined above for the installation of flange mounted magnetos. b. Base mounted magnetos are usually driven by means of an assembly consisting of three parts, namely: (1) "Adjustable Drive Member" fastened to engine shaft (2) ntermediate member designated "Floating Disc" (3) mpulse Starter or Flange attached to magneto. Various combinations of the above drive members together with the different positions of mounting holes in the base of the magneto permit a wide range of applications. c. Mount the magneto adjustable drive member on the engine shaft, being sure that the woodruff key is properly seated. Place the floating disc over the drive lugs of the impulse starter while maintaining the correct number one firing position of the magneto drive shaft. Place the magneto with the floating disc installed, on the engine magneto mounting pad. f the driving lugs of the adjustable drive member do not line up with the slots in the floating disc, DO NOT ROT ATE THE MAGNETO ROTOR SHAFT, as this will move the magneto out of its correct position for firing number one cylinder. Line up the drive lugs of the adjustable drive member with the slots in the floating disc by unlocking the drive member and rotating the drive lugs in the direction required, until the proper alignment with the slots in the floating disc is obtained. Slide the magneto forward toward the adjustable drive member until complete engagement of drive lugs is obtained in the slots of the floating disc. nsert the magneto fastening screws through r \ ( ( t\1 ji;,.; ot Q) r i 11 :! on l1t:1 -.sool l L $ : <7>0...:() rf7 - A--,, ' l ' Figure 3-2. Dimensional Drawing for Base Mounted Magneto (Model AM-2N). 6

13 Sections ll, V l the mounting pad holes into the base of the magneto, and securely tighten. d. For correct timing, the breaker points should be just starting to open. The final timing adjustment of the magneto to the engine can be obtained by rotating the adjustable drive member in the desired direction of rotation to obtain the proper timing as mentioned in the preceding paragraph. Before locking the drive member to the engine shaft, be sure that a slight amount of clearance exists between the drive member, floating disc, and the face of the impulse starter. This should be approximately Ys4 inch and can be obtained by sliding the drive member on the engine shaft in the desired direction. Under no circumstance should the floating disc be without clear- ance, as it will tend to bind and cause improper impulse operation. Also if the clearance is too great, proper engagement of the driving lugs into the floating disc will not be obtained and undue wear will occur. After final adjustments have been made, securely lock the adjustable drive member on the engine shaft. e. n order to install the high tension cables from the magneto to the spark plugs, follow the instructions as outlined above for the flange mounted magnetos. f. Where grounding switches are mounted other than on the magneto, be sure that the proper connections are made between the ground terminal of the magneto and switch. SECTON V OPERATON l 4-1. PRNCPLES OF OPERATON. a. The AM-Series magnetos are designed for a wide range of application. Standard applications of this series include magnetos for use on tractor, marine, industrial, and special engines, with horsepower ratings ranging from fractional to several hundred horse power. Special modifications of the AM-Series are also available for use on light aircraft engines where radio shielding is not required. b. Basically, the magneto is a combination of an alternating current generator, a step-up transformer, circuit breaker and distributor to provide the high voltage ignition spark for each cylinder. (See figure 4-1.) The magneto rotor carries a two pole permanent magnet (8) with laminated pole pieces. This magnet assembly rotates in the tunnel of the main housing which includes laminated pole shoes. These pole shoes are bridged at their upper ends by the laminated coil core (13) to complete the magnetic circuit. The direction of magnetic flux through the coil core is reversed twice for each revolution of the magnet rotor. When the primary circuit ( 12) is completed by closing the breaker contacts (19), a current is generated in this winding by the reversals of flux in the coil core as the magnet rotor revolves. The current thus generated represents energy which is stored in the magnetic circuit due to changing the magnitude and direction of the flux. nterruption of the low voltage primary circuit by opening the breaker contacts releases this scored energy and allows the flux eo collapse rapidly. The rapid collapse of the primary flux induces a high voltage surge in the secondary winding (11), thus providing the ignition spark..c. The breaker assembly (16) is mechanically actu ated by a cam (17) mounted on the magnet rotor shaft. The breaker cam is designed to open and close the breaker contacts in proper relation to the position of the magnet rotor, thereby producing the maximum obtainable value of high voltage surge. A condenser ( 15) is connected in parallel with the breaker contacts in order to suppress arcing at the contact points when the primary circuit is interrupted. d. n the jump-spark method of distribution, a gaptype rotating switch is used and no actual contact is made. The distributor rotor is timed eo the magnet rotor by means of gearing (6 and 7) so that the rotat ing electrode (4) is aligned with each consecutive distributor plate electrode (5) at the instant the secondary voltage attains the maximum value. n this manner, the high voltage surges will jump across the small air-gap and pass through the terminal and associated cable (1) to serve the proper cylinder at the correct time. The model AM- does not require a distributor and the AM-2N uses the carbon brush type of distribution, whereas the jumpspark distribution is becoming standard construction on the remaining models of this series, namely Model AM-2H, AM-4, and AM-6. However, there are thousands of magnetos in the field giving completely satisfactory performance with carbon brush distribution and it is required on some special applications. 7

14 Section V Paragraph 4-1 TO SPARK PLUGS 2 3!.Y!!/ 4! \\ ----Vi _j 1. High Tension Cable 2. Cable nsert 3. Carbon Brush and Spring 4. Distributor Rotor Electrode 5. Distributor Plate Electrode 6. Distributor Gear 7. Pinion Gear 14. Breaker Condenser Lead 8. Magnet Rotor 15. Condenser 9. Coil Contactor 16. Breaker Assembly 10. High Tension Terminal 17. Breaker Cam 11. Coil-Secondary Winding 18. Ground Terminal 12. Coil-Primary Winding 19. Contact Points 13. Coil-Core Figure 4- J. Schematic Diagram of Electric and Magnetic Circuits. e. Switches commonly used for battery ignition are not suitable for magneto ignition systems. The switch used in battery ignition OPENS the circuit in the "OFF" position, whereas in the magneto ignition system the switch must CLOSE the circuit in the "OFF" position, in order to ground, or short-circuit the magneto primary. The various types of switches and the magneto models on which each is used is illustrated in figure 4-2. SWTCH USED ON NUMBER MOOEL ~ 1tiJ - H AM- H AM-4, -6 H AM- H AM-2N - H AM-4 H H \i "f ~ ~ Ju H H H Figure 4-2. Short Circuiting Switches.

15 ..., Section V Paragraphs 4-1, -2 cial installations (vertical mounting for example), spring loaded pawls are required.,, "'..., ,,.. '... ' )'.,.. #" DRECTON OF ROTATON - "'":{:. ' 'd? "' cz.,., :;:2... >o f. n many installations, it is desirable to include an impulse starter on the magneto. The impulse starter is an automatic device, which operates only during engine starting, and serves a twofold purpose. t auto matically retards the timing of the ignition spark to prevent engine "kicking", and it intensifies the spark to insure easy starting. The impulse starter is essentially two halves of a coupling unit; one half (the drive cup) engages with a corresponding drive member on the engine, while the other half (the flange) is keyed directly to the magneto rotor shaft. The two parts of the coupling are connected together by a strong spring. Pawls, mounted on the flange, are pivoted so that they engage a catch pin secured in the housing, at starting speeds. During starting, this catch pin temporarily locks the rotor during each revolution. At the same time, the drive cup continues to turn with the engine and wind up the connecting spring. The pawls are then released by cams on the drive cup which in turn permit the spring to unwind and drive the magneto rotor at a relatively high speed to produce a high intensity spark for starting the engine. When the engine is running, centrifugal force acts on the pawls to prevent their engagement with the catch pin. Thus the impulse starter ceases to operate, automatically advancing the spark to its correct running position, and becomes a direct driving coupling. On some installations, it is necessary to consider the angle of the driving lugs. While the number of parts in the impulse starter are relatively few, the variations required for specific installations are quite numerous. Combinations of different drive cups with a variety of flanges provide the required "lug" and "lag" angle for specific applications. (Seejig11re 4 3). n some spe- <;) '<;,. o '- "' o,:,.'p- v <?o"'', "' </-.;; -p. <:> \.\)G J).'G\.. HORZONTAL AXS OF MAGNETO ' " " s.,.-4"-4-"o 0 " 1'' -lta l4g 4NGlt: "'os,.,. ' o-t Figure 4-3. Typical Lag and Lug Angle Relation OPERATNG NSTRUCTONS. The operation of the AM-Series magnetos is entirely automatic. An ignition switch may be used to stop the engine by short circuiting the breaker points. ', 9

16 Section V Paragraphs 5-1, -2 SECTON V SERVCE NSPECTON AND LUBRCATON ( \ r----warnng ---. Under no condition should any work be performed on the engine while the high tension cables are connected to the spark plugs from the magnetos, without first checking the following: (1) The ignition switch must be in the "OFF" position. (2) The ignition switch must be properly grounded to the engine. (3) The ground connection between the ignition switch and the magnetos must be properly made SERVCE NSPECTON. a. Remove the ignition cables from the holders in the distributor plate noting the firing order of the engine and cylinder number of the cables. Note any chafed or cracked cables, condition of cable clips and brass inserts where it is necessary to replace cable clips, the detailed operations are indicated in figure 5-l. b. Remove the four screws which hold the distributor plate to the magneto housing and carefully remove this assembly from the magneto. (1) JUMP-SPARK TYPE. Clean by wiping inner surface of distributor plate with a clean lint-free cloth; remove any corrosion on the electrodes of the distributor plate and distributor rotor; inspect the carbon brush and spring for freedom of movement in the socket and to see that the outer end of the brush extends sufficiently beyond the socket to make proper contact with the di_stributor rotor. The high tension spring assembly on the distributor plate should be free on the high-tension pick-up post. (2) CARBON BRUSH TYPE. Clean by using a lint-free cloth to remove any engine oil or other foreign material that may be deposited on the inner surface of the distributor plate, or on the face of the distributor rotor. After cleaning, thoroughly dry all parts before reassembling. Never use an emery cloth, sandpaper or other abrasive material in cleaning the distributor plate, distributor rotor or breaker cam..----note ----., Do not wash the distributor rotor bearing or oil impregnated breaker cam in any solvent because these are oil-impregnated permanently lubricated parts. c. A visual inspection should be made to insure that the contact points are free from dirt, oil, or other foreign substances. d. At regular inspection periods, check the adjustment of the breaker contact points. The breaker is so arranged that the contact point opening should be within ( inches). n making this check, the cam follower must be on the high portion of the breaker cam. e. f the contact opening is not between these limits, loosen (but do not remove) breaker plate fastening screw, and move the entire breaker assembly in either direction-toward the.cam to increase gap, or away from cam to decrease gap. Recheck gap after tightening breaker fastening screw. Do not disturb hexagonal nut holding breaker tension springs. ( \...---Note ----., f it is found necessary to re-adjust the contact points, the magneto timing to the engine should be rechecked as outlined in Section ll. Figure 5- J. Attaching Terminal Clips LUBRCATON. a. The ball bearings of the magneto are packed with high melting point grease (Texas Company's Regal Starfak No. 2), and should require no further lubrication, except when the magneto is disassembled for overhaul. 10

17 :' '. b. The bronze distributor bearing and sinteredsteel breaker cam are both oil-impregnated and therefore are permanently lubricated and require no further attention. On those magnetos e quipped with a hardened ground steel cam, a single drop of medium grade high quality engine oil should be applied to the breaker cam wick as required..----cauton Do not add any lubricant to any oil-impregnated part. Do not wash these parts in any grease solvent SERVCE TROUBLES AND REMEDES. a. Before a magneto is assumed to be defective and the cause of possible ignition trouble, the spark plugs, high tension cables, switches, and connections should be carefully checked and tested. Section V Paragraphs 5-2, -3 b. n most instances, tampering with magnetos by inexperienced personnel does more harm than good. Therefore, if a magneto performs in a questionable manner, it is advisably to refer the magneto to an experienced magneto repairman-preferably to an Eisemann Service Station. c. Common troubles, their corresponding causes and remedies are listed below. f these remedies fail to overcome the difficulty, the magneto should be removed from the engine and inspected according to the instructions given in Section V of this Handbook. ---Note ---, Be sure that the trouble is due to the magneto before removing the magneto from the engine. TROUBLE PROBABLE CAUSE REMEDY ENGNE FALS TO START ENGNE S ROUGH OPERATES ERRATCALLY Short circuit in ground lead or switch. Moisture on magneto distributor plate. mproper timing of magneto to engine or internal timing of magneto. Dirty contact points Loose connections in magneto primary circuit. Remove ground lead from the magneto and test ground lead and switch. Thoroughly dry all internal parts. Refer to engine manufacturer's timing specifications and installation section of this handbook. Clean contact points. Check leads to condenser post for loose wires in terminals and tighten round nut. ' mproper timing of magneto to engine or internal timing of n:agneto Moisture in magneto Dirty contact points Refer to engine manufacturer's timing specifications and installation section of"this handbook. Dry all dielectric parts of magneto. Clean con tact points. 11

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19 ..., J..- Section V Paragraphs " ( SECTON V MAJOR OVERHAUL 6-1. OVERHAUL TOOLS REQURED. (See figure 6-1) a. n addition to ordinary wrenches, screw drivers, pliers, measuring tools, and an arbor press, the following special tools are required_. -. NDEX PART No. NOMENCLATURE APPLCATON 1. H Spring Winding Tool 2. H Spring Remover Tool For assembling Starter For disassembling mpulse starter 3. H Bushing For removing inner ball races 4. H Thimble Sleeve 5. H Drift 6. H Complete Puller 7. H Support Bushing 8. H Catch Pin nstalling 9. H Tubular Drift 10. H Support Block 11. H Wrench 12. H Drift 13. H Puller 14. H Reversible Arbor 15. H Bearing Puller Set 16. H Base Plate 17. H Puller For protection of oil seal For removing and replacing For removing outer ball races Used with Part No. H For installing mpulse starter For assembling inner ball races Used in conjunction with Part No. H To hold mpulse starter For assembling outer ball races to housing and end plate Fo removing catch pin For removing and replacing oil seal in housing For removing all bearings (nner Race) To fit or remove distributor bearings For removing mpulse starter ' 6-2. DSASSEMBLY, NSPECTON AND CLEANNG GENERAL. a. The following instructions are given for the dis_. assembly of the complete unit after it has been removed from the engine. b. During disassembly, the condition of each part should be carefully noted and such parts as may require replacement, should be obmined before starting re-assembly. More detailed inspection will be noted as required., Note ---. Bearings should be replaced as a unit (outer race, cage assembly and inner race). c. For reference purposes, the principal sub-assemblies of a typical AM-4 Magneto are shown in Figure DSASSEMBLY OF DSTRBUTOR PLATE. a. Remove the four screws (1 and 2), lockwashers (3), and plain washers (4), noting that two screws are longer than the others. (See figure 6-2). b. Slide the distributor plate off the magneto, noting the dowel pins in the housing were used to align it with the magneto. Remove and inspect the gasket. Replace it if necessary. c. Remove the four screws (10), lockwashers (9), filter hoods (8), filter screens (7), and filter gaskets ( 6). (See figure 6-3). Clean all parts and replace any that may be needed. d. Examine the center distributor carbon (2) for freedom of movement in the insert and for sufficient length to insure contact with the center of the distributor electrode. Replace if necessary. 13

20 0.#;... ');;; -.;:... 11"' voo 0,..Pi"' :--:... '!!' '0 Q \ ' - - ".t.. ' l'-,i f\ ' '?... --;-.. e o(@ ( \ ( { '! ( Figure 6-2. Principal Sub-Assemblies. \, ( i i i ' \ Figure 6-3. Distributor Plate Assembly. 14

21 Section V Paragraphs 6-4, -6 l : e. nspect the spring sleeve and eyelet assembly (3) for freedom of movement on the high tension pickup post and that a good contact can be made with the high tension terminal of the coil. f. Check the binding post of the switch ( 15) for tightness and condition of contact spring. On some distributor plates, the binding post or ground terminal is moulded in place, while on others it is removable. g. Clean and inspect the distributor plate electrodes. Remove any corrosion and- carbon dust by the method outlined in Section V of this Handbook. h. Examine the distributor plate ( 1) for cracks or other damage and replace if necessary REMOVAL AND DSASSEMBL V OF THE MPULSE STARTER. a. Remove the cotter pin (14), and the drive nut (13). (See figure 6-7). Remove the impulse starter from the drive end of the magneto by using puller (Tool No. H19-946). While perforrr.ing this operation, exercise caution to avoid allowing the starter spring to jump free. b. nsert the spring remover tool H into the taper of the flange in the impulse starter. c. Firmly holding the cup, slightly turn the tool so that the spring is given a little additional wind-up. d. Slowly pull the cup and flange assembly apart until the cup is free to turn with respect to the flange. e. Permit the spring to slowly unwind. f. Examine the drive cup (3), the spiral spring (2), and the flange and pawl assembly (1). (See pgure 6-4). Replace any or all of the parts if necessary. Figure 6-4. mpulse Starter Assembly REMOVAL AND DSASSEMBLY OF END PLATE. a. Remove the nut (2), lockwasher (3), and pinion gear (4) from the breaker end of the magneto rotor shaft. (See figure 6-7). b. Remove the slotted round nut (21) from the condenser terminal post ( 15) and remove the high tension coil lead from the condenser. (See figure 6-.5). c. Reove the three fillister-head screws (7) and lock washers ( 6). (See figure 6-2). d. Slide the end plate from the magneto rotor shaft and housing, while noting the dowel pin used to align the end plate to the housing. e. Lift the breaker lead ( 19) off the condenser terminal post and also the condenser spacing bushing (18). (See figure 6-.5) ' Figure 6-5. End Plate Assembly. 15

22 Section V Paragraphs 6-6, -7 Figure 6-6. Checking Breaker Spring Tension. f. Remove the two screws (16) and lockwashers ( 1 7). Lift the condenser off the end plate ( 1) and test it on any appropriate condenser tester, such as an Alien E 191, or a Weidenoff condenser tester. The capacity of the condenser should be between microfarads; a series resistance of not over 0.4 ohm; a leakage resistance of not less than 5 0,000 ohms. g. Remove the breaker adjusting screw (38), lockwasher (3 7), and plain washer (36). Remove lock spring (35) and plain washer (34). Lift the breaker off the brass pivot post of the end plate. h. nspect the breaker for the following: ( 1) Excessive burning, pitting, etc. of contact points. f the contact points are unsatisfactory, it is recommended that the complete breaker assembly (22) be replaced. The dressing of contact points is not generally advisable. However in an emergency, contact resurfacing may be accomplished by the use of a very fine, flexible, carborundum stone known as "Flexstone". The stone should be thin enough to dress the contact points in their assembled condition on the breaker. Dressing with a file has generally proven unsatisfactory. (2) Spring tension-the tension of the breaker spring should be between 10 and 18 ounces when measured as indicated in Figure 6-6. i. Remove the soap ring (14) from the groove in the distributor gear and rotor shaft ( 4) by means of a suitable snap ring tool. (See figure 6-5). j. Remove th s_hill! washer (13) and withdraw the shafi: from the oilite bearing (3). k. Remove the shim washers (11 and 12) from the inner end of the shaft. 1. nspect the distributor rotor assembly (4) for wear on the electrode and for tightness to the distributor gear. Check the distributor gear. f necessary, replace the entire assembly. m. f the distributor rotor bearing (3) requires replacement, it can be removed by placing the end plate, outer race side up, on base plate fixture (Part No. H19-938). Line up the bearing with the hole in the base plate, and place drift (Tool No. Hl9-937) in the bearing hole and press out bearing. n. f the outer ball bearing race (2) is scored or otherwise damaged, it should be removed from the end plate by using bearing puller (Tool No. H19-923). o. nspect the end plate for damae, condition of dowel pins (if installed) and replace 1f necessary DSASSEMBL V OF MAGNETO ROTOR SHAFT ASSEMBLY (See figure 6-7) a. Remove the breaker. cam ( 5), and the Woodruff key ( 6) from the breaker end of the magneto rotor shaft ( 1). b. Slowly press drive-end of shaft out of the housing until the oil slinger ( 11) is free. Remove the slinger. o@ '""'- :... ol t)c» c;o Figure 6-7. Rotor Shaft Assembly. 16

23 Section V Paragraphs 6-7, -11 u 14-1 (6')_-- f?j e;,ci'. t?(;) f:? c '0 ----@ Figure 6-8. Housing Assembly. ( ' c. Remove the roror from the housing and take off the two ball bearing cage assemblies (7). d. Remove the two inner ball races (8) by means of bearing puller (Tool No. H19-995), if their condition necessitates replacement. e. f the inner ball races are to be removed, remove the shims (9 and 10) from both ends of the rotor shaft; noting the quantity and relative position DSASSEMBLY OF MAGNETO HOUS NG ASSEMBLY. (See.figure 6-B) a. Remove the four screws (6), lockwashers (7), and the two coil clamps ( 15). b. Remove the coil (14) from the housing (1) by tapping the open end of the housing against a wooden block, being careful not to damage the coil or the dowel pin of the housing. The winding should be tested on Eisemann Winding Tester (Tool No. H ), as sho wn in Figure 6-9. Complete operating instructions as well as coil data are furnished on cards located in the case on the back panel of the winding tester. c. f the outer ball race (tem 5 of figure 6-8) needs to be replaced, it may be removed from the magneto housing by using bearing puller (Tool No. H ). d. To remove the oil seal (10), when necessary, use reversible arbor (Tool No. Hl9-936). e. f necessary, the catch pin (8) may be removed for replacement by using catch pin puller (Tool No. H ). Note from which of the two holes in the flange the pin was removed. f. Remove the ventilator screw (13), cover (12), and screen (11) CLEAN NG. Clean all parts thoroughly in a suitable solvent with the exception of the condenser, coil, oil-impregnated oilite bearing, and cam. Filter screens should be dismantled and cleaned. Dry all parts thoroughly. Examine magnet rotor and housing tunnel in which the rotor revolves, making sure both are free from metal particles, burrs, chips or foreign matter REASSEMBL Y OF COMPONENT PARTS REASSEMBLY OF MAGNETO HOUSNG. a. Replace the ventilator screen, cover, and fastening screw. b. Replace the outer ball race by using support block (Tool No. H19-933), and drift (Tool No. Hl9-932) as sown in figure When replacing outer ball races in old style housings, insure the proper fit by using suitable insulating strips and washers around and behind the bearing race (Refer to parts catalog section for part numbers). c. nstall the coil, with core end radius, fitting into corresponding radius in housing laminations. nstall the two coil clamps with the ground lead terminal under the clamp. Fasten the two clamps with the four screws and lockwashers. - "';:... :. -, w. -.\ - - it _/ -, ;-. ; 11 l'il -a Figure 6-9. Eisemann Winding Tester. 17

24 Section V Paragraphs 6-12, -13 Hl9 933 SUPPORT BLOCK the recess cut in the base plate (Tool No. H ), and with bearing hole toward the solid end of base plate, use drift (Tool No. H ) to press bearing into the end plate (See figure 6-12). Stake the oilite bearing to the end plate on the outer ball bearing race side. c. Replace the shim washers on the inner end of the distributor rotor shaft and insert the distributor rotor in the oilite bearing...<!.. Replace the shim washers, and the snap ring on the other end. e. Lightly lubricate the pivot pin and mount the breaker assembly on the end plate. Replace the breaker fastening screw, lockwasher, and fiat washer. f. Assemble the condenser to the end plate with the screws and lockwashers. Figure Replacing Outer Race in Housing REASS EMBL Y OF END PLATE ASS EMBLY. a. Replace the outer ball race in the end plate by using support block (Tool No. H19 933) and drift (Tool No. Hl9-932) as shown in figure When replacing outer ball races in old style end plate, insure the proper fit by using suitable insulating strips and washers around and behind the bearing race. b. Replace the distributor rotor bearing by placing the end plate with ball bearing side down and set in REASS EMBLY OF MAGN ETO ROTOR ASS EMBLY. a. Replace the bearing end shims on the shaft. b. Replace the two inner ball races by using tubular drift (Tool No. H19 935) and support bushing (Tool No. Hl9 934)..--- Note ---, f new bearings are required, it will be necessary to recheck the rotor end play by the following procedure: (1) (2) (3) ( 4) Assemble the ungreased ball cages on the inner races. Place the rotor in the housing and assemble the end plate to the housing. Check rotor for freedom of rotation with imperceptible end play. f necessary, reshim and recheck until the proper bearing adjustment is obtained. H DRFT - H 7 \ 11 Hl9-933 SUPPORT BLOCK Figure 6-1 J. Replacing Outer Ball Race in End Plate. 18 Figure 6- J 2. Replacing Distributor Rotor Bearing.

25 ---, \ _.- l._ c. Replace the oil seal in the housing by using reversible arbor (Tool No. Hl9-936) as shown in figure d. Replace the catch pin in the housing hole from which it was removed by using catch pin installing tool No. Hl e. Repack ball bearing cages with Texas Co. Regal Starfak No. 2 grease or approved equivalent and replace on inner races. f. Place sleeve Tool No. Hl on the shaft taper to protect the oil seal while replacing the rotor in the magneto housing. g. Fasten end plate to the housing with the three screws and lockwashers. h. Press oil slinger on drive end of rotor shaft by using drift (Too No. H19-935) and support bushing (Tool No. H19-934). Leave a space of.010 inch between oil slinger and housing using Tool No. H i. Replace the Woodruff key on the drive end of the rotor shaft. j. nstall the driving members (impulse starter, etc.) using the reverse order of disassembly. k. Replace the cotter pin. 1. Replace the Woodruff Key and breaker cam on the rotor shaft with the slots or directional arrow facing outward or inward as required for the proper magneto rotation. Note that most cams are reversible and can be used for either clockwise or anti-clockwise rotation. For anti-clockwise magneto rotation, the slots must face in toward the bearing race. m. Replace the pinion gear so that the timing mark on the gear, lines up with the desired timing mark (i.e. clockwise or anti-clockwise) on the distributor gear. Secure the pinion gear with lockwasher and hexagon nut. n. Set the breaker contact points as described in paragraph 5-l. The correct internal timing of the magneto is such that the breaker points open when the edge gap "E" between the edge of the steel laminations in the rotor and the edge of the steel laminations in the housing is between mm ( ) inches. (See figure 6-14.).---- Note -- - On applications not using impulse starters where the H cam is supplied, the edge gap limits are mm ( inches). The H cam may be identified by the number "7" stamped on one end of the cam. t is recommended that a timing light be used to accurately check the point where the breaker contacts begin to open. f a timing light is not available, it may be necessary to use feeler strips, but these should not exceed.0015 inch in thickness and should be free from oil or dirt of any kind. The use of feeler strips for this purpose is not recommended for several reasons. They do not give an accurate check, and, unless kept absolutely clean, may leave a trace of oil or dirt which has a tendency to foul the ontact surfaces fl Section V Paragraph 6-13 Figure Replacing Oil Seal in Housing..--- CAUTON ---, f the internal timing is not within the prescribed limits, the complete breaker assembly should be replaced. Always keep the breaker free from oil, dirt, or other foreign substances. o. Place condenser spacing bushing, coil and breaker lead terminals, and lockwasher on the condenser post. Lock securely with condenser nut. Figure Checking Edge Gap. EDGE GAP "E " 19

26 Section V Paragraph 6-14 c Figure Spring Winding Tool (H27-824) REASSEMBL Y OF MPULSE STARTER. a. Raise plunger "A" of the spring winding tool (Part No ) and fasten in raised position with screws "B". (See figure 6-15). b. Slide the flange assembly on the shaft taper with the pin "C" entering the spring-anchoring hole in the flange. When sliding the flange on the taper, the pawls should be fitted under the two ears provided for this purpose on the shaft. -c. Release screw "B" and slide plunger "A" as far as it will travel. Retighten screw "B". d. Place the anchoring hook on the inner end of the impulse starter spring into the anchoring hole in the flange. Care should be taken to insure that the spring can be wound in the proper direction, since the same spring is used for either clockwise or anticlockwise rotation. For clockwise impulse starters, the spring should be wound by turning the tool handle in a clockwise direction. e. Lightly lubricate the spring with Regal Starfak No. 2 grease. f. Rotate the shaft until the anchoring hook on the outer end of the spring can be held in position by the slot in plunger "A". With both the inner and outer ends properly engaged, wind the spring by turning the handle approximately one and one half revolutions from the free position. g. Position the drive cup so that the anchoring hole of the cup slides over the anchoring hook on the outer Figure Eisemann Three Point Test Rack. 20

27 Section V Paragraphs 6-14, -16? i end of the spring and the cup interlocks with the flange assembly. h. Loosen screw "B", raise the plunger "A" and retighten the screw. i. Slide the impulse starter off the tool by appl y ing pressure on the pawls of the flange, and push the drive cup into full engagement with the flange. j. When properly assembled, the two ends of the spring will be on opposite sidesj of the cup. \ REASSEMBLY OF DSTRBUTOR PLATE. a. Replace the filter gaskets, screens, and filter hoods with the four screws and lockwashers. b. Replace the gasket between the distributor plate and magneto housing; slide the distributor plate into position, noting the dowel pins used for alignment. c. Fasten the distributor plate to the magneto housing by means of the four screws, lockwashers, and plain washers RUNNNG TEST. a. Mount the magneto on any approved test stand with a variable speed range and approved three-point test gap rack,. such as Eisemann H (See figut e 6-16). b. The magneto should conform to the following specifications: (1) With the distributor plate removed from the magneto, connect the high tension terminal on the coil with a suitable test lead to one of the test gaps, and set to a standard 5mm. opening as shown in figure Run the magneto through a speed range to a maximum speed of 2,000 r.p.m. The breaker assembly should operate without excessive arcing between the contact points. Excessive arcing may be an indication of a faulty condenser or loose connections.,.--- Note ----, Oil, dirt, or other foreign matter will also cause arcing between the points and care should be exercised to assure that the contact points are clean. (2) Replace the distributor plate, connect the high tension cables from the distributor plate to the test rack and set the three point test gaps to a 5mm. NOTE ALL DMENSONS N MLLMETERS. 0 0 Figure 6- J 7. Spark Gap Setting. opening. Run the magneto through the following speed range as indicated: MAGNETO MODEL AM-1, AM-2H AM-2N, AM-4 AM-6 SPEED RANGE R.P.M During this test, there should be regular sparking of the test gaps. Decrease the speed for a low speed check. Regular sparking on all models should occur at 150 r.p.m. or less. (3) On magnetos equipped with an impulse starter, a test should be made to assure the proper operating characteristics of the impulse starter. Up to r.p.m., the pawls on the flange of the ipulse starter should engage the catch pin on the housing and the impulse starter should operate. Above this speed, the pawls on the flange should cease to engage the catch pin and the starter should then act as a direct drive coupling. - 21

28 Section V SECTON V PARTS CATALOG NTRODUCTON ( 7-1. The parts catalog consists of a group assembly listing of all replacement parts used in.each model magneto. n the column under "NOMENCLATURE", the various sub-assemblies and associated parts are indented to indicate their relative relationship. Exploded view photographs are shown on the page opposite the listing, in order to associate any part with another. Reference to these illustrations is made by means of the figure number and individual index number The quantity of parts required for each model is shown in the column under "UNTS PER ASSEM BLY". The designations "1, 1AR and AR" in this column are used as follows: 1. (or more )-:-Denotes that the quantity specified is always required for any particular magneto of that model. 1AR-Denotes that one part is required but the particular part number must be selected from one of several parts depending upon the specific application. AR-Denotes that the quantity to be used is variable to meet a specific condition and in some cases may not be required Note When ordering replacement parts or complete magnetos, it is essential that reference be made to the magneto assembly number. SEE FGURE 8-2 SEE FGURE 8-3 SEE FGURE SEE FGURE SEE FGURE 8-6 SEE FGURE 8-7! ' \.,,,, 1 C, "\. l l\ lt. ' '... e.. (.. ft}t' 0 ="'....; o ve '1'6.. 'CD. \., Figure 8-1. Magneto Assembly. 22

29 Section V,- / SECTON V GROUP ASSEMBLY PARTS CATALOG \ FG. NDEX PART No. No. No. NOMENCLATURE UNTS PER ASSEMBLY STARTER MOUNTNG AM1 AM2H AM2N AM4 AM6. (, Magmito ( LW)- Fairmont Rwy. & Wise. 8-1 * Magneto (ACL W)-Wisconsin Magneto (CL W)-Le Roi Magneto (CL W)-Wisconsin Magneto (CL W)-Novo 8-1 * Magneto (CL W)-Vaughn Magneto (CLW)-ndustrial Eng Magneto (ACLW)-Climax 8-1 * Magneto (CLW)-nvincible 8-1 * Magneto (ACLW)-nvincible ' Magneto (R)-Fairmont Rwy Magneto (CLW)-Hornet 8-1 * Magneto (ACLW)-Electric Tamper Magneto (ACLW)-Le Roi 8-1 " Magneto (CLW)-Le Roi Magneto (CLW)-Le Roi Magneto (CLW)-Le Roi Magneto (ACLW)-Le Roi Magneto (CLW)-Novo 8-1 * Magneto (CLW)-Deep Sea Export Magneto (CLW)-Hornet 8-1 * Magneto (ACLW)-Todd Magneto (CLW)-Fairmont Rwy Magneto (CLW)-Kohler Magneto (CLW)-Fairmont Rwy Magneto (ACLW)-Fuller & johnson 8-1 * Magneto (ACLW)-Palmer Bros. 8-1 * Magneto (CL W)-Waukesha 8-1 * Magneto (CL W)-Le Roi Magneto (CLW)-Novo Magneto (ACL W)-Le Roi Magneto (CLW)-Le Roi, Kalamazoo Rwy Magneto (CLW)- Continental Magneto (CL W)-Aircooled Magneto (CLW)-Aircooled 8-1 * Magneto (CLW)-Waukesha Magneto (ACL W)-Le Roi Magneto (CLW)-Le Roi Magneto (CL W)-Continental, aircraft Magneto (CL W)-Continental, aircraft 8-1 * Magneto (CLW)-Fairmont Rwy Magneto (CLW)-Continental 8-1 * Magneto (ACL W)-J. Deere Screw-Fillister head, upper (10-32 x 17.( in.) Screw-Fillister head, upper (10-32 x 1 in Screw-Fillister head, lower (10-32 x 1% in Screw-Fillister head, lower (10-32 x 1% in Washer-Lock Washer-Plain Terminal Cable H Washer-Lock Screw-Fillister head (No ) SVF mm mm SVF VF mm HF HF (Sp.) mm mm 1 KOH 1 HF (Sp.) mm VF mm VF mm mm VF HF 1 HF 1 45mm VF 1 KOH mm 1 45mm mm mm mm VF VF VF HF HF HF mm mm mm 1 HF HF mm VF mm , LEGEND *Magneto supplied with floating disc ROTATON CL W-Clockwise ACL W-Anticlockwise R-Reversiblc MOUNTNG:-35mm-35mm base 45mm-45mm base HF -Horizontal flange HF (Sp.)-Horizontal flange (no ventilator) VF-Vertical flange SVF -Small vertical flange KOH-Special Kohler 23

30 - 0 en ' :::-. 0: c: 0...,. Q ;; )> "' "' 3.,. -

31 Section V,- l FG. NDEX PART No. No. No. NOMENCLATURE UNTS PER ASSEMBLY AM1 AM2H AM2N AM4 AM6 8-2 H Distributor Plate Assembh- 8-2 HH-262 Distributor Plate Assembiy (with H2-!-028 switch) 8-2 H26--!86 DistributorPlate Assembl\' 8-2 H2-!-2H Distributor Plate Assembh 8-2 H2-t-923 Distributor Plate Assembl -Jump spark distribution 8-2 HH-1 10 Distributor Plate Assembly 8-2 Plate-Dist., machined 8-2. Plate-Dist., machined (mouldpd ground terminal). 8-2 "PTateDist., machined Plate-Dist., machined (moulded ground terminal) 8-2 Plate-Dist., machined H9-922 Brush Assembh--Center H Brush Assembly-Long H Contact Assembly H Eyelet H Spring H2-!-909 Gasket-Ventilator (jump spark) H2-!-910 Screen-Ventilator (jump spark) H23-1-!2 Hood-\'e1tilator (jump spark) H Washer-Lock (jump spark) H Screw-Round head (jump spark) 8-2! H Nut 8-2! H Nut H9-407 Washer-Lock H9--!07 Washer-Lock H Washer-Plain H Spring-Short circuiting H2-t-2-!8 Screw-Ground terminal, square head H2-!-026 Switch Assembly H Switch Assembly H Switch Assembly H Switch Assembly H Washer-Cupped.spring 8-2 is H Bushing H Spring-Switch H Handle H Handle H Screw-Fit. hd. (No m. head) H Screw-Fit. hd. (No in. h'ead) m pulse Starter Assembl (Rpfer to following tabulation) H23-8!6 Spring-Spiral 8-3 AR AR ! 6 1 2AR 2AR 2:\R 2AR 2AR 2AR 2AR 2AR 2AR -!AR HR -tar -!AR -!AR HR 1 AR AR AR JAR J A R AR 1:\R AR. lar AR AR AR 1.'\R AR 1:\R AR 1:\R AR AR JAR AR AR 1AR 1AR 1:\R 1 1 () (3) RO- LAC Lt:G FLANGE DRVE TATON ANGLE ANGLE ASSEMBLY CL'P ' \.... ' H c H23-8-!1 H H c H H23-8!2 H c H23-8-!3 H H c H23-8-!3 H23-9-l5 H23-H2 A H H H c 20 H H H c H H H c 25 H H26-1-!9 H c H23-77-! H23-8!2 H c 30 H H H c H H H A H H23-81 i H A H H23-81 i H c H23-7H H H A H H H c S 20 H H H c 2S 30 H H H c S 20 H23-8-!l H:: H A 2S 30 H H J AR 1AR 1AR AR AR JAR J AR AR AR AR JAR JAR AR 1:\R JAR JAR AR JAR 1:\R 1:\R 1:\R JAR 1:\R JAR 8--t End Plate Assembh H27--l62 End Plate-Machin<!d H End Platc-Machinl d 8--l 2 H6-912 RacL -Outer (H 3-S07 n, arin-sl'c Fig' -5) 3 H Bearing-Oilite, bronzl' l \. *A denotes anticlockwise and C denotes clockwise rotation. 25

32 r ' J :., c(j" c:... ::' '1 ::r Q ::::-

33 Section V ( i \ { \.. \, FG. No. 8--! 8--! 8--! 8--! 8--! 8--! 8--! g 4 8--! 8-S 8 5 NDEX No. PART No. 4 H HH H2-l H H H H26-85-l 8 HU H H2-l H H HZ H H Hl H H H H H H H H H H H H23-S6 28 H H23-S07 H H H23-S09 32 H H H H20-48S 35 H H H H H H H H H H H H H H H H H H H H H H H H H H6-91l 8 H H H H H Hl H9-179 H HH ! S H23-61J5 15 ll H2.J-JO-l. 16 Hl NOMENCLATURE Rotor-Distributor assy., moulded (Carbon brush distribution) Rotor..:... Distributor assy., moulded Rotor-Distributor assy., moulded (jump spark distribution) Rotor-Distributor assy., removahle electrode (jump skarp) Rotor-Distributor assy., removable electrode Ele trode-removable} H Or H onlv} Spnng-Clamp Rotor-Distributor assy. (A:\!-2N models only} Bushing-Distributor rotor {A:\1-2:-.1 models only) Screw-Set (AM-2N models only) Washer-Shim (.0156 in.) Washer-Shim (.0156 in.) Washer-Shim (.0082 in.) Ring-Snap Condenser Assemblv Screw-Round head Washer-Lock Spacer-Condenser screw Terminal-Lead Washer-Lock Nut-Round, slotted head Breaker Assembly Nut-No Washer-Plain Washer-Lock Washer-nsulation Spring-Breaker Lever Assembly-Breaker, tungsten point Lever Assembly-Breaker, platinum point Plate Assembly-Tungsten contact Plate Assembly-Platinum contact Washer-nsulation Washer-nsulation Lead Assembly-Breaker Screw-Special Washer-Plain.016 in.) Washer-Plain.006 in.) Spring-Lock Washer-Plain Washer-Lock Screw-Fillistcr head Rivet-Split Wick-Oil Rotor Assembly Rotor-S.A.E. aircraft shaft (Aircraft Only-Flange Mount' d) Rotor-Extended Shaft (Flange Mounted) Rotor-Standard shaft ' Rotor-Standard shaft (AM-2N model only) Rotor-Ext. shaft (For AM-2N only} Rotor-Standard shaft Rotor-Extended shaft Nut-Pinion, gear Washer-Lock Gear-Pinion Gear-Pinion Cam-1 lobe (Short) Cam-2 lobe (with impulse starter) Cam-1 lobe Cam-1 lobe (Short) Cam-! lobe (Reversible) Cam-2 lope (without impulse starter) Key-Woodruff Bearing-Ball (15mm) Ball Cafre Assembly.. Race- nncr Washer-Shim (.!mm) Washer-Shim (.3mm) w hoc--5pi l him (.0080,,.)) Washer-Special shim (.0226 in.) Washer-Special shim (.0063 in.) Washer-Special shim (.0100 in.) Washer-Special shim (.0020 in.) K<'y-Wood ruff Washer-Thrust (For < xtendcd shafts) Washer-Thrust ( rotor only) Bushing-Driving Gl ar (For extended shafts) Nut-Drive, cast(\llatcd Nut-Drive ( rotor onlv) Washl r-shim ( nut o1ily) Pin-Cotter. UNTS PER ASSEMBLY AM1 AM2H AM2N AM4 AM lar 1AR 1AR 1AR AR AR AR AR AR AR AR AR AR AR 1AR AR AR AR!AR 1AR AR AR 1AR AR AR AR AR 1AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR AR 1 1AR AR AR AR AR AR AR AR

34 Q" c:.. Cl) Q" c: Cl) Q :l 0.. '" :l (Q :; Cl) 0.. <" Cl)!" :X: 0 c: "' :; (Q )> "' "' Cl) 3 tr

35 Section V \ \. ( l L FG. NDEX PART UNTS PER ASSEMBLY No. No. No. NOMENCLATURE AM1 AM2H AM2N AM4 AM6 8-6 Housing As se m bl y 1 H2i-140 Housing-;\lachined, horizontal flange 8-6 H2i-li-! Housing-lachincd, \'ertical flange 1 H2i-i31 Housing-;\lachined, 35mm base mounting H2i-i32 Housing-;\lachined, 45mm base mounting H2i-i34 Housing-Machined, 35mm base mounting (special Kohler) H2i-733 Housing-;\[achined, small vertical Aange H2i-i35 Housing-i\ lachined, horizontal Aange (without ventilator) HH-300 PlateAdapter. For changing 35mm to 45mm base H Plate-Name, blank (data as required) H Screw-Drive H22-5i7 Pin-Dowel.) 3 3 " H6-912 Race-OutPr (H3-507 Bearing-Sec Fig. ) f Seal Assembly-Dust (base mounting only) 1 f Washer-Retaining f Washer-Felt f Retainer-Dust seal H Screw-Fillister head (No. 6-32) H Washer-Lock H Pin-Catch (with impulse starter) H Seal-Dust, felt H Seal-Oil (Spring Tye) f Gasket-Ventilator. or ha se screen H26-78S H Gasket-Ventilator. For H screen f Screen-Ventilator. for 4Smm base H Cover-Plate. for 45mm base ventilator hole H Screen-Ventilator. For housing. (Flange Mounting) H Cover-Plate H Screw-Round head H Coil-Complete AR f Coil-Complete (with H c1:n only) AR 8-6 S f Clamp-Coil H Gasket-Distributor-Plate *H3-568 Washer-! nsulating (.008 in.) AR AR AR AR AR *H Washer-nsulating (.010 in.) AR AR AR AR AR *H Washer-nsulating (.012 in.) AR AR AR AR AR *H Washer-nsulating (.01-1 in.) AR AR AR AR AR *H3-569 Strip-nsulating (.010 in.) AR AR AR AR AR *H7-775 Strip-nsulating (.016 in.) AR AR AR AR AR *H Strip-[ nsulating (.008 in.) AR AR.AR AR AR *H Strip-[ nsulating (.012 in.) AR AR AR AR AR *H Strip-nsulating (.014 in.) AR AR AR AR AR 8-7 H Magneto Hub Assembly-Drive AR f Screw-Set, cup point H Hub-Drive H Magneto Flange-Drive AR f Coupling Assembly-Complete AR f Coupli ng-adj usta ble H Hub-Drive. For %' inch shaft 1 HU-212 Hub-Drive. For :Ys inch shaft HH-215 Hub-Drive. For % inch shaft H2-l-218 Hub-Drive. For.Y2 inch shaft H Screw-Set H Disc-Rubber 8-i 10 H Disc-Floating, canvas bakdite AR H Disc-Floating, metal AR f Disc-Floating, canvas bakelite AR 1AR AR R-7 13 H Disc-Floating, canvas bakclite AR f Disc-Floating, canvas bakelite AR f Disc-Floating, canvas bakt.'lite JAR H Flange-Engine drive (used without impulse starter) AR H Coupling Assembly-Engine drive, adjustable (%' in. hub) AR AR AR H Coupling Assembly-Engine drive, adju,;table (?/g in. hub) AR AR R-7 19 H24-.J6 Washer-Lock H2.J-147 Nut-Lock H24-H Flangc-Drjvinf; H2P-738 Hub-Driving %'in. horl') AR.n H Hub-Driving (?/g in. bore) lar 8-7 H Coupling Asst mhly-f.nginc drivl', Ve rnier AR A{ AR AR H Flange-Hub 8-i 26 HH-973 Hub-Driving /l-7 27 f Screw-Vernier 8-i 28 f Washt r-plain f Nut H9-318 Pin-Cotter 1 2.\ 24 *For use wil h old style housing. 29

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