Slick magneto overhaul service manual L-1363D 4300 6300

L-1363D 4300/6300 Series Magneto Maintenance and Overhaul Manual Technical Aspects FAA Approved SCOPE This Maintenance and Overhaul Manual provides Detailed maintenance, assembly, disassembly and Troubleshooting instructions and technical Information about the design and operation of Slick Magnetos. Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. Cover REVISION Basic

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Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 LOG OF REVISIONS To: Holders of L-1363C, dated February 28, 2006. Subject: Revision D, dated October 31, 2008. 1. All pages of this manual are new. 2. Revised pages that have important changes are shown below. Page Number Change Page 0-2 Changed e-mail address in paragraph 0-4. Page 3-1 Updated paragraph 3.1.1.B.9. Added Rotor and Distributor Block inspections to paragraphs 3.1.2, 3.1.3, 3.1.4, and 3.1.6. Page 3-2 In paragraph 3.2.2, changed L-1177 to L-1499. Updated paragraph 3.2.8. Page 3-3 Added NOTE following Figure 3.2.9. Added NOTE to paragraph 3.3.1. Added second sub-paragraph to paragraph 3.3.3.C. Added new Figure 3.3.3A. Page 3-5 Added new paragraph 3.3.5.C. Page 3-7 In paragraph 3.3.7.C.2, added tolerance to 135 VDC. Added new paragraph 3.3.8.B.3. Renumbered remaining paragraphs. Updated Figure 3.3.8. Added new paragraph 3.3.8.C.4. Page 3-8 Added new paragraph 3.3.8.D.1. Renumbered remaining paragraphs. Added new paragraph 3.3.8.E, Lubrication. Page 4-1 Updated paragraph 4.0. Page 6-4 Added new paragraph 6.10.A. Renumbered remaining sub-paragraphs. Page 7-2 Added Loctite part number to paragraph 7.2.F. Corrected torque value in paragraph 7.6.C to 120- 180 in-lbs. Updated paragraph 7.7.C. Page 7-3 Updated Figure 7.7. Page 7-8 Updated paragraph 7.21.A. Page 8-1 Corrected paragraphs 8.2.B and 8.3.B. Page 9-1 Added rotor inspection to Inspections - All Magnetos. Added Section number to Lubrication. Page 10-1 Corrected torque value in Troubleshooting Guide. In the Remedy column for Corrosion on harness lead contacts, changed L-1177 to L-1499. Added broken rotor shaft to Hard Starting Possible Cause. Page 10-2 thru 10-6 Added broken rotor shaft to Possible Causes. Page T-2, T-3 Added Harness Cap Screw NOTE. Page T-6, T-7, T-8 Changed item 23 to read 'Harness Cap'. Added Harness Cap Screw NOTE. Page T-10 In Service Torque Specifications, corrected M-3019 Impulse Coupling Nut torque value to 120-180 in-lbs. Changed oil callout for distributor block and gear assembly oilite bearings. Added Consumables. i/(ii Blank)

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 Table of Contents 0.0 INTRODUCTION ........................................................................................................................................... 0-1 0.1 COPYRIGHT STATEMENT .......................................................................................................................... 0-1 0.2 HOW TO USE THIS MANUAL ...................................................................................................................... 0-1 0.3 RELEVANT PUBLICATIONS ........................................................................................................................ 0-2 0.4 SYSTEM OVERVIEW ................................................................................................................................... 0-2 1.0 TECHNICAL REFERENCE ............................................................................................................................. 1-1 1.1 GENERAL .................................................................................................................................................... 1-1 1.2 THEORY OF OPERATION ........................................................................................................................... 1-1 1.2.1 Lag Angle - Impulse Coupled Magnetos ............................................................................................ 1-1 1.2.2 Lag Angle - Retard Breaker Magnetos ................................................................................................ 1-1 1.2.3 Rotation ................................................................................................................................................ 1-1 1.3 MAGNETO PART NUMBERING ................................................................................................................... 1-1 1.4 MAGNETO SERIAL NUMBERS ................................................................................................................... 1-2 2.0 TOOLS REQUIRED ....................................................................................................................................... 2-1 3.0 MAINTENANCE ............................................................................................................................................ 3-1 3.1 MAINTENANCE SCHEDULE ...................................................................................................................... 3-1 3.1.1 100-Hour Inspection ............................................................................................................................ 3-1 3.1.2 500-Hour Inspection - Direct Drive Magnetos .................................................................................... 3-1 3.1.3 500-Hour Inspection - Impulse Coupled Magnetos ........................................................................... 3-1 3.1.4 500-Hour Inspection - Retard Breaker Magnetos .............................................................................. 3-1 3.1.5 Additional 500-Hour Inspection Procedures for Pressurized Magnetos ........................................... 3-1 3.1.6 500-Hour Inspection - Tachometer Drive Magnetos .......................................................................... 3-1 3.1.7 Operational Check - All Magnetos ....................................................................................................... 3-1 3.2 100-HOUR INSPECTION ............................................................................................................................ 3-1 3.2.1 Adjust Timing to Engine ...................................................................................................................... 3-1 3.2.2 Inspect Wiring Connections and Condition ........................................................................................ 3-2 3.2.3 Inspect Vent Holes (Non-Pressurized Magnetos) .............................................................................. 3-2 3.2.4 Inspect P-Lead Attachment .................................................................................................................. 3-2 3.2.5 Inspect Switch Wire (Retard Breaker Magnetos Only) ....................................................................... 3-2 3.2.6 Inspect Tachometer Drive Contact Wire (Tach Drive Magnetos Only) ............................................... 3-2 3.2.7 Inspect Turbo Filter (Pressurized Magnetos Only) ............................................................................. 3-2 3.2.8 Inspect Inlet Nozzle (Pressurized Magnetos Only) ............................................................................. 3-2 3.2.9 Inspect Orifice Vent (Pressurized Magnetos Only) ............................................................................. 3-3 3.3 500-HOUR INSPECTION ............................................................................................................................ 3-3 3.3.1 Disassembly and Cleaning ................................................................................................................ 3-3 3.3.2 Inspect Ball Bearing Assembly ........................................................................................................... 3-3 3.3.3 Inspect Rotor ........................................................................................................................................ 3-3 3.3.4 Inspect Impulse Coupling (Impulse Coupled Magnetos Only) ......................................................... 3-3 3.3.5 Inspect Coil .......................................................................................................................................... 3-5 3.3.6 Inspect Contact Points ......................................................................................................................... 3-6 3.3.7 Inspect Condenser .............................................................................................................................. 3-6 3.3.8 Inspect Distributor Block Assembly .................................................................................................... 3-7 3.3.9 Inspect Carbon Brush ......................................................................................................................... 3-8 3.3.10 Inspect for Structural Damage ............................................................................................................. 3-8 3.4 ADDITIONAL 500-HOUR PROCEDURES FOR PRESSURIZED MAGNETOS ......................................... 3-8 3.4.1 Inlet Nozzle ........................................................................................................................................... 3-8 3.4.2 Orifice Vent ........................................................................................................................................... 3-9 3.4.3 Turbo Filter ........................................................................................................................................... 3-9 3.4.4 Gaskets ................................................................................................................................................ 3-9 3.4.5 O-Ring .................................................................................................................................................. 3-9 iii

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 Table of Contents (Continued) 4.0 OVERHAUL .................................................................................................................................................. 4-1 4.1 OVERHAUL PROCEDURE - ALL MODEL MAGNETOS ............................................................................. 4-1 4.1.1 Remove Magneto from Engine ............................................................................................................ 4-1 4.1.2 Disassemble Magneto ........................................................................................................................ 4-1 4.1.3 Discard Parts to be Replaced ............................................................................................................. 4-1 4.1.4 Magneto Reassembly ......................................................................................................................... 4-2 4.2 ADDITIONAL PROCEDURES - PRESSURIZED MAGNETOS ................................................................... 4-2 4.2.1 Discard Parts to be Replaced ............................................................................................................. 4-2 4.2.2 Inlet Nozzle ........................................................................................................................................... 4-2 4.2.3 Orifice Vent ........................................................................................................................................... 4-2 4.2.4 Inspect Interior of Magneto .................................................................................................................. 4-2 4.2.5 Harness Cap O-Ring ........................................................................................................................... 4-2 4.2.6 Pressure Test Magneto ....................................................................................................................... 4-2 5.0 REMOVING MAGNETO FROM ENGINE ........................................................................................................ 5-1 6.0 MAGNETO DISASSEMBLY .......................................................................................................................... 6-1 6.0.1 General Order of Disassembly ........................................................................................................... 6-1 6.1 REMOVE IMPULSE COUPLING ................................................................................................................. 6-1 6.2 REMOVE WOODRUFF KEY ........................................................................................................................ 6-2 6.3 REMOVE DISTRIBUTOR HOUSING ASSEMBLY ........................................................................................ 6-2 6.4 REMOVE DISTRIBUTOR BLOCK ASSEMBLY ............................................................................................ 6-2 6.5 REMOVE CONDENSER .............................................................................................................................. 6-2 6.6 REMOVE ROTOR GEAR ............................................................................................................................. 6-3 6.7 REMOVE CONTACT BREAKER ASSEMBLY ............................................................................................... 6-3 6.7.1 Impulse Coupled and Direct Drive Magnetos .................................................................................... 6-3 6.7.2 Retard Breaker Magneto ...................................................................................................................... 6-3 6.7.3 Tachometer Drive Magnetos ................................................................................................................ 6-3 6.8 REMOVE ROTOR ASSEMBLY ..................................................................................................................... 6-3 6.9 REMOVE BEARINGS FROM SHAFT ........................................................................................................... 6-4 6.10 REMOVE COIL ............................................................................................................................................. 6-4 6.11 REMOVE AIR VENTS ................................................................................................................................... 6-4 6.12 REMOVE OIL SEAL ..................................................................................................................................... 6-4 7.0 MAGNETO ASSEMBLY ................................................................................................................................ 7-1 7.0.1 General Order of Assembly ................................................................................................................. 7-1 7.1 ASSEMBLE BEARINGS ONTO SHAFT ....................................................................................................... 7-1 7.2 INSTALL ROTOR SHAFT ASSEMBLY ......................................................................................................... 7-1 7.3 INSTALL OIL SEAL ...................................................................................................................................... 7-2 7.4 INSTALL WOODRUFF KEY ......................................................................................................................... 7-2 7.5 ASSEMBLE IMPULSE COUPLING ............................................................................................................. 7-2 7.6 INSTALL IMPULSE COUPLING .................................................................................................................. 7-2 7.7 INSTALL COIL .............................................................................................................................................. 7-2 7.8 INSTALL CONTACT POINTS ....................................................................................................................... 7-3 7.8.1 Primary Contact Points - All Magnetos ................................................................................................ 7-3 7.8.2 Retard Breaker Contact Points - Retard Magnetos Only ................................................................... 7-3 7.8.3 Tachometer Drive Points - Tachometer Drive Magnetos Only ........................................................... 7-3 7.9 INSTALL ROTOR CAM ................................................................................................................................ 7-3 7.10 TIME THE MAGNETO .................................................................................................................................. 7-3 7.10.1 Set Primary Points - All Magnetos ....................................................................................................... 7-3 7.10.2 Set Secondary Points - Retard Breaker Magnetos Only .................................................................... 7-4 7.10.3 Set Tachometer Drive Points - Tach Drive Magnetos Only ................................................................. 7-5 iv

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 Table of Contents (Continued) 7.11 INSTALL CONDENSER .............................................................................................................................. 7-6 7.12 DISTRIBUTOR GEAR ASSEMBLY ............................................................................................................... 7-6 7.13 ASSEMBLE DISTRIBUTOR BLOCK ........................................................................................................... 7-6 7.14 ALIGN ROTOR GEAR .................................................................................................................................... -6 7.15 ALIGN DISTRIBUTOR GEAR ...................................................................................................................... 7-7 7.16 CONNECT CONDENSER WIRE ................................................................................................................ 7-7 7.17 CONNECT RETARD CONTACT WIRE ....................................................................................................... 7-7 7.18 CONNECT TACHOMETER CONTACT WIRE ............................................................................................. 7-8 7.19 ATTACH DISTRIBUTOR HOUSING - NON-PRESSURIZED MAGNETOS ................................................. 7-8 7.20 ATTACH DISTRIBUTOR HOUSING - PRESSURIZED MAGNETOS .......................................................... 7-8 7.21 SECURE DISTRIBUTOR HOUSING .......................................................................................................... 7-8 8.0 POST-ASSEMBLY TESTING ........................................................................................................................ 8-1 8.1 PRE-TEST PREPARATION ......................................................................................................................... 8-1 8.2 IMPULSE COUPLING .................................................................................................................................. 8-1 8.3 COMING-IN SPEED ..................................................................................................................................... 8-1 8.4 HIGH-SPEED TEST ..................................................................................................................................... 8-1 8.5 LONG-TERM TEST ...................................................................................................................................... 8-1 8.6 TEMPERATURE TEST ................................................................................................................................. 8-1 8.7 PRESSURE TESTING - PRESSURIZED MAGNETOS ONLY .................................................................... 8-1 8.8 PREFLIGHT OPERATIONAL CHECK ......................................................................................................... 8-2 9.0 POSTFLIGHT OPERATIONAL CHECK ......................................................................................................... 9-1 9.1 MAINTENANCE CHECKLIST ...................................................................................................................... 9-1 10.0 TROUBLESHOOTING ................................................................................................................................. 10-1 10.1 TROUBLESHOOTING GUIDE ....................................................................................................... 10-1 - 10-7 11.0 TABLES ......................................................................................................................................................... T-1 TABLE ONE .................................................................................................................................................. T-1 TABLE TWO ......................................................................................................................................... T-2 - T-3 TABLE THREE .............................................................................................................................................. T-4 TABLE FOUR ................................................................................................................................................ T-5 TABLE FIVE .......................................................................................................................................... T-6 - T-8 TABLE SIX ..................................................................................................................................................... T-9 TABLE SEVEN ............................................................................................................................................ T-10 v/(vi Blank)

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 0.0 HOW TO USE THIS MANUAL All rights reserved. This manual is produced exclusively for use with Unison Industries Magnetos and/or Ignition Harnesses. It may not, in whole or in part, be copied, photocopied, reproduced, translated or reduced to any electronic medium or machine readable form without prior consent, in writing, from Unison Industries. WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF THE INFORMATION CONTAINED IN THIS MANUAL MAY RESULT IN LOSSES OR DAMAGES TO THE USER. The accuracy and applicability of this manual has not been verified for any assembly, component or part not manufactured by Unison Industries. Any use of this manual for other than its intended purpose or for performing any installation, maintenance, replacement, adjustment, inspection or overhaul of any assembly, component or part not manufactured by Unison Industries is not approved, endorsed or sanctioned by Unison Industries. No liability will be assumed by Unison Industries for actual, consequential or other types of damages directly or indirectly resulting from the unauthorized use of this manual for other than its stated purposes. When performing installation, maintenance, replacement, adjustment, inspection or overhaul of any Unison assembly, component or part, it is imperative that the latest revision of the appropriate Unison manual or product support document be referenced. Contact Unison to be sure you have the latest manual or support document revision before performing any work. All reasonable attempts were made to make this manual as complete and accurate as possible. If you have any questions, comments, corrections or require clarification of any information contained herein, please call or write Unison Industries, Technical Publications, 7575 Baymeadows Way, Jacksonville, FL 32256, Phone 904-739-4132 (Fax 904-739-4006), or e-mail techpubs@unisonindustries.com. 0.2 HOW TO USE THIS MANUAL The procedures outlined in this manual are generalized for all models of 4300/6300 Series Slick Magnetos, using only genuine Unison manufactured parts. This manual must not be used to maintain or overhaul a Slick Magneto that contains parts not manufactured by Unison Industries. Specific part numbers are detailed in the Tables located after the main text. Use only genuine Unison manufactured parts obtained from Unison Industries Approved sources. 0-1 Slick parts are produced and inspected under rigorous procedures to insure airworthiness and suitability in Slick magnetos. Parts purchased from sources other than Unison Industries, even though outwardly identical in appearance may not have had the required tests and inspections performed, may be different in fabrication techniques and materials, and may be dangerous when installed in a Slick magneto. Salvaged magneto parts, reworked parts obtained from non- nison approved sources, or parts the service history of which is unknown or cannot be authenticated, may have been subjected to unacceptable stresses or temperatures, or have other hidden damage, not discernible through routine visual or usual nondestructive testing techniques. This may render service work with this part, even though originally manufactured by Unison Industries, unsuitable or unsafe for use in a Slick magneto. Slick expressly disclaims any responsibility for malfunctions, failures, damage or injury caused by use of non-Unison approved parts. Slick magnetos are engineered so that mechanical parts wear at a balanced rate. Consistent and complimentary wear patterns establish the recommended maintenance intervals defined in Unison service literature, therefore used, service worn parts should never be used to troubleshoot or repair a magneto, nor should original parts be replaced by used service worn parts on magnetos being returned to service. Further, non-Unison manufactured parts may wear at uneven and different rates than original Unison manufactured parts, making Unison service literature an inappropriate guide to proper maintenance. Parts not manufactured by Unison Industries, even if FAA/PMA Approved may not fit or operate like original Unison manufactured parts. FAA testing of PMA parts does not require operation on an engine or flight tests and does not require the test duration to exceed the maintenance intervals called out in Unison literature. For these reasons, used service worn parts or parts not manufactured by Slick may adversely affect magneto reliability in ways not anticipated by Unison Industries and its service literature. The information in this manual is divided into 10 sections. Section One provides basic technical reference on the design and operation of Slick Magnetos. Section Two illustrates tools needed to correctly perform inspection and maintenance. Detailed instructions for removing the magnetos from the engine, magneto disassembly and magneto reassembly are contained in Sections Five, Six and Seven, respectively. Maintenance and Overhaul schedules and procedures are detailed in Sections Three and Four, respectively. The instructions in Sections Three and Four refer to procedures outlined in the Magneto Disassembly (Section Six) and Magneto Assembly (Section Seven) portions of this manual. It is recommended that this entire manual be thoroughly read before beginning any inspection or maintenance procedure. After any inspection or maintenance is done on Slick Magnetos, the testing procedures in Section Eight should be performed completely.

Unison Industries 530 Blackhawk Park Avenue Rockford, Illinois, U.S.A. 61104 ©2008 Unison Industries, Inc. ISSUED MO DAY YR 05 01 91 REVISED MO DAY YR 10 31 08 PAGE NO. REVISION D L-1363 The Maintenance Checklist located in Section Nine provides a summarized schedule for 100 and 500-hour inspections. This checklist should be copied and attached to the engine log book at the 100 and 500-hour inspections. Section 10, Troubleshooting, is provided as a reference guide for diagnosing ignition problems. 0.3 RELEVANT PUBLICATIONS Unison Industries L-1499 Ignition Lead Assembly & Maintenance Manual. Unison Industries L-1318 Consolidated Application Data 0.4 SYSTEM OVERVIEW Unison Industries has been an innovative leader in the design and manufacture of aircraft ignition systems for over 25 years. Unison manufactures, not merely assembles, a superior FAA PMA Approved product consistently specified by quality conscious OEMs. VERTICALLY INTEGRATED MANUFACTURING. Unison Industries manufactures nearly every component in its magnetos and harnesses. This in-house manufacturing process allows Unison to control quality to precise tolerances from raw material to finished product, setting industry standards. DESIGN FEATURES - Smaller and Lighter Unison's unique design allows for a dimensionally smaller magneto, resulting in easier installation and lighter weight-as much as one pound lighter than competitive units. - Radio Noise Suppression Slick Magnetos feature superior noise suppression, eliminating the need for magneto filters. - Easy to Maintain Slick Magnetos use up to 50% fewer parts than competitive units. In addition, almost 70% of the parts in any Slick Magneto are interchangeable with the comparable parts in other current production Slick Magnetos. - High-Altitude Performance Slick Pressurized Magnetos maintain low altitude ambient pressure inside the magneto to reduce the likelihood of high altitude misfire. RELIABILITY Unison selects materials that are known for their reliability and durability with proper installation and compliance with maintenance procedures. Slick Magnetos should last the life of the engine before overhaul or replacement is required. 0-2 A COMPLETE OFFERING Unison FAA/PMA Approved Magnetos have applications on nearly all piston engines. Unison Ignition Components are available in the following configurations: - Complete Upgrade Kits: Cost saving kits including two magnetos, a complete harness and all mounting hardware. - Single magnetos and harnesses. Timing pins and mounting hardware included for easy installation. - Complete parts supply for all current production Slick and non-Slick Magnetos. WORLDWIDE NETWORK Unison Ignition Systems are available through an international network of aircraft distributors that offer outstanding product support, delivery and service. See Unison Distributor List Form L-1051 for details. COMPLETE AOG INVENTORY Unison Industries supports its distribution network with complete AOG factory inventory available for next-day delivery. FACTORY TECHNICAL ASSISTANCE Unison technical experts are available to assist you. Please contact our Piston Products Support line at 904-739-4081 or pistonhelp@unisonindustries.com.

Slick magneto overhaul service manual L-1363D 4300 6300

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