CATALOG and SERVICE MANUAL L-1020-C

CATALOGand

SERVICE MANUALL-1020-C

CHAMPION AEROSPACE PROPRIETARY INFORMATION

THIS DOCUMENT IS PROPRIETARY PROPERTY OF CHAMPION AEROSPACE LLC. IT IS NOT TO BE COPIED OR REPRODUCEDIN ANY MANNER, NOR SUBMITTED TO OTHER PARTIES FOR EXAMINATION WITHOUT PRIOR WRITTEN APPROVAL.

CHAMPION AEROSPACE LLC LIBERTY, SOUTH CAROLINA, U.S.A. 29657March 2009

CHAMPION AEROSPACE LLC LIBERTY, SOUTH CAROLINA, U.S.A. 29657CHAMPION AEROSPACE LLC PROPRIETARY INFORMATION - Subject to the restrictions on the Title page March 2009

“600” SERIES AIRCRAFT MAGNETOS

FEATURES OF THE “600” SERIES AIRCRAFT MAGNETOS

The Model “600” Series Aircraft Magnetos are completely unique in design. Outstandingfeatures of these Magnetos are listed below.

I. SIMPLICITY, AND EASE IN SERVICING:A. Timing marks legible and accessible.B. All parts easily replaced or adjusted with regular shop tools.

II. SUPPRESSION (RADIO INTERFERENCE ELIMINATION):The Coaxial capacitor serves as a filter for suppression, and as the condenser for the magneto. Noadditional filters are required.

III. VENTING THE MAGNETO:The Magneto receives necessary circulation of air through vent holes. These must be kept clean forfree flow of air.

IV. CONTACT POINTS:The contact points are made of tungsten. A repair kit includes the contact point assembly with a newcam and cam grease.

V. TIMING GEARS:Distributor gear and drive gear are made of nylon, with raised timing identification marks molded inplace. Drive gear has molded nipple on hub to be aligned with appropriate right hand (RH) or left hand(LH) arrow on Distributor Gear.

(NOTE: An indelible red line is marked on peak of one distributor gear tooth, and black line ongear tooth peak 180° opposite, for timing magneto to engine.)

VI. CONDENSER:The condenser is a coaxial capacitor–the terminals at both ends of the condenser are common. Theground is the body or housing.

VII. DISTRIBUTOR BLOCK & HOUSING:The distributor housing contains the condenser, which is connected to the circuit with a slip terminal.The terminal in the distributor block for each spark plug wire is flat and must make positive contact withthe spring on the end of the spark plug wire.

VIII. IMPULSE COUPLING:600 Series Magnetos include impulse couplings to improve engine starting.

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CHAMPION AEROSPACE LLC LIBERTY, SOUTH CAROLINA, U.S.A. 29657CHAMPION AEROSPACE LLC PROPRIETARY INFORMATION - Subject to the restrictions on the Title pageMarch 2009

MODEL 662

6-CYLINDER

1. Rotation Clockwise (R.H.)2. Magneto Suppressed for Radio Interference3. Impulse Lag Angle set at 35°4. Impulse is spring loaded so Magneto may be mounted in any position5. No shielding required on ground wire

For Engine Approval and Application, Refer to Form L-1058

S L I C K A I R C R A F T M A G N E T O S

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MODEL 664

6-CYLINDER

1. Rotation Counter-Clockwise (L.H.)2. Magneto Suppressed for Radio Interference3. Impulse Lag Angle set at 35°4. No shielding required on Ground Wire



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MODEL 668

6-CYLINDER

1. Rotation Clockwise (R.H.)2. Magneto Suppressed for Radio Interference3. Impulse Lag Angle set at 35°4. No shielding required on Ground Wire



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600 SERIES AIRCRAFT MAGNETOSSERVICE INFORMATION AND ILLUSTRATIONS

TIMING MAGNETO TO ENGINE

1. TIMING MARKS ON DISTRIBUTOR CAP AND DISTRIBUTOR GEAR MUST BE LINED UP ASILLUSTRATED IN PICTURES.

2. INSERT TIMING PIN.

3. INSTALL MAGNETO ON ENGINE, SET IN FIRING POSITION.

4. INSERT SPARK PLUG AND GROUND WIRE.

5. REMOVE TIMING PIN FROM MAGNETO.

Figure 1 – Timing Magneto To Engine

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CHECKING MAGNETOS ON ENGINE

WHEN RED MARKS VISIBLE THROUGH VENT HOLE ARE IN LINE ON SIDE OF MAGNETO WITH SLICKELECTRO TRADE MARK, BLACK MARKS ARE IN LINE AND VISIBLE THROUGH VENT HOLE ONOPPOSITE SIDE.

TURN ENGINE BACKWARDS TO BRING MARKS ON GEAR IN VIEW.

Figure 2 – Checking Magnetos on Engine

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Figure 3 – Removing Condenser from Magneto

REMOVING CONDENSER FROM MAGNETO

NOTE — THE CONDENSER CAN BE CHECKED IN THE DISTRIBUTOR HOUSING — DO NOT REMOVEFROM HOUSING UNLESS DEFECTIVE.

1. REMOVE DISTRIBUTOR CAP BOLTS, SEPARATE CAP FROM MAGNETO SLIGHTLY.

2. REMOVE SLIP TERMINAL FROM BREAKER POINT.

3. APPLY SPANNER WRENCH TO CONDENSER END ON OUTSIDE OF DISTRIBUTOR CAP.

(LEAD WIRE WILL BE TWISTED OFF FROM THE CONDENSER IF CONDENSER IS REMOVEDBEFORE SLIP TERMINAL IS REMOVED FROM BREAKER POINT.)

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WEAR LIMIT ON DISTRIBUTOR SHAFT CARBON BRUSH:

1. CARBON BRUSH SHOULD EXTEND 1/16” FROM END OF DISTRIBUTOR SHAFT WHEN NEW.BRUSH MUST BE REPLACED WHEN WORN DOWN 1/32”.

2. ROUNDED END OF CARBON MUST BE VISIBLE — FLAT END WILL BE IN DISTRIBUTOR SHAFT.

Figure 4 – Wear limit on Distributor Shaft Carbon Brush

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Figure 5 – Removing The Coil

REMOVING THE COIL:

ILLUSTRATES PRYING OUT THE 2 ALUMINUM WEDGES FOR THE EASY REMOVAL OF COIL.

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Figure 6 – Removing Drive Gear and Cam

REMOVING DRIVE GEAR AND CAM:

1. REMOVE SNAP RING.

2. PRY THE DRIVE GEAR AND CAM, TOGETHER, FROM ROTOR SHAFT, AS ILLUSTRATED.

3. REMOVE CAM (WHICH ALSO SERVES AS KEY FOR DRIVE GEAR) FROM THE DRIVE GEAR.

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LOCATING SECONDARY LEAD SPRING AND ASSEMBLINGROTOR DRIVE GEAR

A. DISTRIBUTOR BEARING PLATE SHOULD NOT BE INSTALLED UNTIL THE LEAD SPRING ONCOIL HAS BEEN BENT OUT APPROXIMATELY 20 DEGREES FROM VERTICAL POSITION. THISIS TO PROVIDE SPRING PRESSURE AGAINST THE THRUST BEARING IN THE DISTRIBUTORBLOCK.

B. THE NYLON ROTOR DRIVE GEAR MUST BE INSTALLED AS ILLUSTRATED IN FIGURE 7 (LINEUP TIMING MARK ON THE NYLON GEAR WITH TIMING MARK ON SHAFT.)

Figure 7 – Preparing Magneto for Assembly to Distributor Housing

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EXPLODED VIEW OF BALL BEARING ASSEMBLY:

OLD BEARING CONFIGURATION

ASSEMBLE THE BALL BEARING IN THE ORDER ILLUSTRATED. PLACE THE EXPANDING WASHERCONCAVE SIDE TOWARD BEARING. PRESS THE WASHER TO EXPAND IT INTO THE ALUMINUMHOUSING TO LOCK THE BEARING IN PLACE. (THIS BEARING ASSEMBLY IS USED IN THEMAGNETO FRAME AND THE BEARING PLATE.) BEARINGS SHOULD BE CLEANED AND REGREASEDPRIOR TO ASSEMBLY. REGREASE USING RYCON NO. II GREASE (SLICK P/N M-3127).FOR INSTALLATION OF NEW STYLE BEARING (M-1293) REFER TO SERVICE BULLETIN 2-83.

Figure 8 – Exploded View of Ball Bearing Assembly

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CONTACT POINT ADJUSTMENT:

A. WHEN THE TIMING PIN IS IN PLACE, THE ROTOR IS IN THE POSITION FOR CAM TO STARTOPENING THE CONTACT POINTS. ADJUST CONTACT POINTS TO THIS POSITION BY PRYINGWITH A SCREWDRIVER IN NOTCHES PROVIDED.

B. CHECK DISTRIBUTOR LEAD SPRING TO MAKE SURE IT IS LOCATED IN THE CENTER OF THEDISTRIBUTOR SHAFT HOLE IN THE DISTRIBUTOR BEARING PLATE.

C. APPLY A DROP OF SAE 20 LUBRICATING OIL TO OILITE BEARINGS EACH TIME THE MAGNETOIS INSPECTED.

Figure 9 – Contact Point Adjustment

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Figure 10 – Adjusting Impulse Coupling Stop Pin Plate

ADJUSTING IMPULSE COUPLING STOP PIN PLATE:

ILLUSTRATION SHOWS NORMAL, PROPER SETTING MARK FOR THE MODEL 667 MAGNETO. THESTOP PIN PLATE IS ADJUSTABLE FOR LAG ANGLE IN 5 DEGREE INCREMENTS FROM THIS“NORMAL” SETTING. TO DETERMINE POSITION OF STOP PLATE FOR MAGNETOS OTHER THANMODEL 667, REFER TO SPECIFICATIONS UNDER MAGNETO MODEL NUMBER FOR CORRECT LAGANGLE AND ROTATION. IMPULSE COUPLING CAN BE REMOVED BY A PULLER (A 5/8” - 11 CAPSCREW, WITH A 13/32” FLAT BOTTOM HOLE 5/8” DEEP IN THREADED END OF CAP SCREW — PARTNO. 0-21-CMT) OR IMPULSE PULLER NO. T-106 ON MAGNETOS WITH SLOT IN IMPULSE HUB.

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Figure 11 – Breaker Point Opening, and Cam Lubrication

TIMING DISTRIBUTOR GEAR, CAM LUBRICATION, AND GEAR BACKLASH:

A. CLOCKWISE ROTATION OF MAGNETO, WHEN VIEWED FROM IMPULSE COUPLING END OFMAGNETO, INDICATES A RIGHT HAND (RH) MAGNETO. LINE UP RED MARK ON DRIVE GEARWITH RH ARROW ON DISTRIBUTOR GEAR FOR A RIGHT HAND MAGNETO.

B. USE M-1827 CAM GREASE PROVIDED IN M-998 CONTACT POINT KIT. APPLY GREASE TO EACHLOBE OF CAM SPARINGLY.IF YOUR MAGNETO HAS THE M-1190 CAM OILER, REMOVE THE M-1190 CAM OILER ANDTHROW IT AWAY.

C. NYLON GEARS —THERE IS A VERY NOTICEABLE AMOUNT OF BACKLASH IN THE NYLON GEARS WHICH IS VERYNECESSARY, AS WHEN THE MAGNETO GETS TO IT’S RUNNING TEMPERATURE, THE NYLONEXPANDS ENOUGH SO THAT THE GEARS ARE IN THE PROPER MESH. SEE FIGURE 11.

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REMOVING IMPULSE COUPLINGS

ASSEMBLING IMPULSE HUB AND SPRING IN SHELL

AFTER IMPULSE HUB AND SPRING ARE ASSEMBLED IN SHELL IT SHOULD BE REMEMBERED THATNO TENSION HAS YET BEEN PLACED ON THE SPRING. TO PLACE PROPER TENSION ON SPRING,CAREFULLY PULL THE HUB ASSEMBLY PARTLY OUT OF THE SHELL FAR ENOUGH TO CLEAR THEPROJECTIONS ON THE SHELL. HOLD THE SHELL STATIONARY AND ROTATE THE HUB TO WINDTHE SPRING UNTIL THE PROJECTIONS ON THE OUTER SECTION OF THE PAWL PLATE PASS THEPROJECTIONS ON THE SHELL (APPROXIMATELY ONE-HALF REVOLUTION, 180°).

Figure 12 – Pulling Coupling Hub from RotorShaft (12-CMTA Puller)

Figure 13 – Pulling Coupling Hub from RotorShaft (021-CMT Puller)

Figure 14 – Pulling Coupling Hub from RotorShaft (T-106 Puller)

FIG. 14 AFTER REMOVING NUT FROM SHAFT, THESHELL AND SPRING CAN BE REMOVED BYHAND AS A UNIT.

TO REMOVE THE HUB ASSEMBLY WITHGROOVE IN THE HUB, SLIDE T-106 PULLEROVER THE FLAT PORTION OF THE HUB ANDTURN THE PULLER SO IT FITS IN THE GROOVE.

FIG. 13 AFTER REMOVING NUT FROM SHAFT WITHLONG IMPULSE COUPLING HUBS, THE COM-PLETE IMPULSE CAN BE REMOVED BY USINGTOOL NO. 021-CMT OR A 5/8” - 11 CAP SCREWWITH A 13/32” FLAT BOTTOM HOLE 5/8” DEEPIN THREADED END OF CAP SCREW AS SHOWNIN FIG. 13.

FIG. 12 AFTER REMOVING NUT FROM SHAFT, THESHELL AND SPRING CAN BE REMOVED BYHAND AS A UNIT.

TO REMOVE THE HUB ASSEMBLY WITHSHORT IMPULSE COUPLING HUBS, USE SLICKPULLER #12-CMTA OR SIMILAR PULLER ASSHOWN IN FIG. 12.

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“600” SERIES AIRCRAFT MAGNETOS — PARTS DIAGRAM17


“600” SERIES AIRCRAFT MAGNETOS — PARTS LIST18


MAINTENANCE PROCEDURES100 HOUR INSPECTION

AFTER 100 HOURS OF OPERATION AND EVERY 100HOURS THEREAFTER, OR AT ANNUAL INSPEC-TION, WHICHEVER COMES FIRST, THE MAGNETO-TO-ENGINE TIMING SHOULD BE CHECKED. THISIS ACCOMPLISHED IN THE FOLLOWING MANNER:

WARNING: BE SURE IGNITION SWITCH IS IN“OFF” POSITION AND THE CON-DENSER LEAD IS GROUNDED.

1) TURN THE ENGINE CRANKSHAFT IN THE NOR-MAL DIRECTION OF ROTATION UNTIL THE NO. 1CYLINDER IS IN THE FULL-ADVANCE FIRING PO-SITION, FOLLOWING THE ENGINEMANUFACTURER’S PROCEDURE FOR TIMING OFMAGNETOS.

2) LOOSEN THE MAGNETO MOUNTING BOLTS,AND CONNECT A STANDARD TIMING LIGHT BE-TWEEN ENGINE GROUND AND THE MAGNETO CON-DENSER TERMINAL.

NOTE: IGNITION SWITCH MUST BE “ON”.

3) ROTATE THE COMPLETE MAGNETO OPPOSITENORMAL ROTATION OF THE MAGNETO ON THEENGINE MOUNTING UNTIL THE TIMING LIGHT IN-DICATES THE CONTACT BREAKER POINTS AREJUST OPENING. SECURE THE MAGNETO IN THISPOSITION.

WARNING: TURN IGNITION SWITCH “OFF”.

500 HOUR INSPECTIONAT 500 HOUR INTERVALS, THE CONTACT POINTASSEMBLIES SHOULD BE CHECKED FOR BURN-ING OR WEAR. IF THE POINTS ARE NOT DISCOL-ORED AND HAVE A WHITE FROSTY SURFACEAROUND THE EDGES, THE POINTS ARE FUNCTION-ING PROPERLY. APPLY M-1827 CAM GREASESPARINGLY TO EACH LOBE OF THE CAM BEFORERE-ASSEMBLY AND ADJUST POINT GAP (SEEPAGE 13).

IF THE POINTS ARE BLUE (INDICATING EXCESSIVEARCING) OR PITTED, THEY SHOULD BE DIS-CARDED. REPLACE BOTH CONDENSER (PART NO.M-3064) AND DAMAGED POINTS. USE PART NO.M-998 (SEE PAGE 13) FOR REPLACING POINTS.ADJUST POINT GAP (SEE PAGE 13).

AT 500 HOURS INSPECTION, IT IS NECESSARY TOCHECK AND REPLACE THE CARBON BRUSH IN THEDISTRIBUTOR GEAR IF WORN, CRACKED ORCHIPPED. THE DISTRIBUTOR BLOCK SHOULDALSO BE CHECKED FOR CRACKS AND/OR SIGNSOF CARBON TRACKING AND REPLACED IF NEC-ESSARY.

INSPECT AND PUT A DROP OF SAE #20 NON-DE-TERGENT MACHINE OIL IN EACH OILITE BEARING

IN THE DISTRIBUTOR BLOCK AND BEARING BARBEFORE RE-ASSEMBLY.

INSPECT THE HIGH TENSION LEAD FROM THECOIL TO MAKE SURE IT MAKES CONTACT WITHTHE CARBON BRUSH ON THE DISTRIBUTOR GEARSHAFT. CLEAN RESIDUE FROM HIGH TENSIONLEAD BEFORE RE-ASSEMBLY, TAKING CARE NOTTO SCRATCH SURFACE OF THE LEAD.

AT 500 HOUR INSPECTION, VISUALLY INSPECTTHE IMPULSE COUPLING SHELL AND HUB FORCRACKS, LOOSE RIVETS OR ROUNDED PAWLSTHAT MAY SLIP WHEN LATCHING UP ON THE STOPPIN. IF ANY OF THESE CONDITIONS IS EVIDENT,THE COUPLING SHOULD BE REPLACED. ALSO ITIS NECESSARY TO INSPECT THE IMPULSE PAWLBY MEASURING THE CLEARANCE BETWEEN THEBOSS ON THE UNDERSIDE OF EACH (2) IMPULSEPAWL AND THE PAWL PLATE USING A FEELERGAGE. POSITION THE LATCHING END OF THEIMPULSE PAWL OVER THE PAWL PLATE ASSHOWN IN FIGURE ONE.

MAXIMUM CLEARANCE FOR PAWLS WITH ONE (1)BOSS IS .150 INCH. MAXIMUM CLEARANCE FORPAWLS WITH TWO BOSSES IS .150 INCH FOR LEFTHAND ROTATION COUPLINGS AND .140 INCH FORRIGHT HAND ROTATION IMPULSE COUPLINGS. IFTHE FEELER GAGE CAN PASS BETWEEN THE FULLWIDTH OF THE BOSS AND THE PAWL PLATE RE-PLACE THE IMPULSE COUPLING. SEE FIGURETWO. FOR COUPLING ROTATION SEE MAGNETODATA PLATE.

THESE MAGNETOS SHOULD BE COMPLETELYOVERHAULED AS REQUIRED BY THE INSPECTIONSOUTLINED ABOVE. THEY MUST BE OVERHAULEDAT EVERY ENGINE OVERHAUL. IN MANY IN-STANCES, THE MECHANIC MAY FIND IT EASIERTO REPLACE A MAGNETO WITH A FACTORY AS-SEMBLED NEW OR EXCHANGE UNIT THAN TO PER-FORM THE OVERHAUL IN THE FIELD.

FIGURE TWO

FIGURE ONE

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TESTINGMOUNT THE MAGNETO ON A SUITABLE TEST STANDHAVING THREE-POINT GAPS, SET AT 5MM (.197 IN.).OPERATE THE MAGNETO AT 1000, 1500, 2000 AND2800 RPM TO OBSERVE ELECTRICAL AND MECHANI-CAL PERFORMANCE.

REDUCE THE DRIVE SPEED TO DETERMINE THE LOW-EST RPM THE ROTOR CAN BE TURNED AND STILL

CONTINUALLY FIRE THE TEST GAPS WITHOUT MISS-ING. THE TEST GAPS MUST FIRE CONSISTENTLY. IN-CREASE SPEED TO 2800 RPM, AT WHICH SPEED NOMISFIRING IS PERMISSABLE.

SERVICE LIMITSTORQUE:M-924 BREAKER BAR SUPPORT SCREW 18-22 IN.-LBS.M-1077 AIR VENT BODY 80-90 IN.-LBS.M-1723 ENGINE MOUNTING CLAMP 190-220 IN.-LBS.M-2567 HOUSING SCREW 18-20 IN.-LBS.M-1381 IMPULSE COUPLING NUT 120-180 IN.-LBS.M-2551 CONTACT POINT SCREW 18-22 IN.-LBS.M-2553 DISTRIBUTOR BLOCK SCREW 18-22 IN.-LBS.M-3064 CONDENSER 150-160 IN.-LBS.M-2555 & M-2552 BEARING CAP SCREW 20-24 IN.-LBS.

LUBRICATION:BALL BEARING GREASEROTOR CAM GREASEOILITE BEARINGS

TOLERANCES:PRIMARY COILSECONDARY COIL

CONDENSER

M-3127-1 AND M-3127-2M-1827

SAE 20 NON-DETERGENT

.50-1.5 OHMSCOILS DATED PRIOR TO AUGUST 1, 1991

7,500-10,300 OHMSCOILS DATED AUGUST 1, 1991 AND LATER

13,000-20,500 OHMS.20 MFD ± 10%

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CATALOG and SERVICE MANUAL L-1020-C

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