AEROSTAR AIRCRAFT

600/601/601P/602P/700P
MAINTENANCE MANUAL

CHAPTER

IGNITION

6G3
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CHAPTER 74 - IGNITION

T A B L E O F CONTENTS/EFFECTIVITY

CHAPTER
SECTION GRID
SUBJECT SUBJECT NO. EFFECTIVITY

74-00-00 GENERAL 6G5

74-01-00 Description 6G5
74-02-00 Troublestiooting 6G5

74-10-00 ELECTRICAL POWER SUPPLY 6G7

74-11-00 Magneto 6G7
74-11-01 Inspection of Magneto 6G7
74-11-02 Removal of Magneto 6G11
74-11-03 Timing Procedure (Internal Timing) 6G12
74-11-04 Installation and Timing Procedure (Timing
Magneto to Engine) 6G13
74-12-00 Starting Vibrator 6G16
74-12-01 Troublestiooting 6G16
74-12-02 Vibrator, Removal 6G20
74-12-03 Vibrator, Installation 6G20
74-12-04 Vibrator, Testing 6G20

74-20-00 DISTRIBUTION 6G21

74-21-00 Harness 6G21
74-21-01 Inspection of Harness 6G21
74-21-02 Cleaning of Harness 6G22
74-21-03 Replacements 6G22
74-21-04 Removal of Harness 6G22
74-21-05 Maintenance of Harness 6G24
74-21-06 Installation of Harness 6G24
74-22-00 Spark Plugs 6H2
74-22-01 Spark Plugs, Removal 6H2
74-22-02 Inspection and Cleaning of Spari< Plug 6H3
74-22-03 Spark Plugs, Installation 6H3
74-22-04 Spark Plug Identification 6H3

74-30-00 SWITCHING 6H4

74-31-00 Description 6H4
74-32-00 Removal/Installation of Ignition Switcfi 6H4

74 - ContTEffec.
Page -1

6G4 Issued: June 1,1995

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

GENERAL.

The ignition consists of dual magnetos, high tension hamess, spark plugs and a magneto switch.
Additionally a vibrator is used to provide an intensified spark for easier starting at low cranking rpm.

DESCRIPTION.

Each engine is provided with a combination magneto/starter switch. Moving the switch to the spring
loaded "START' position grounds the right magneto, activates the starting vibrator, retards the left magneto,
and engages the starting motor. When the engine starts, release of the switch allows it to spring back to the
"BOTH" (magnetos) position, disengages the starting motor and removes the vibrator from the starting
circuit. The right magneto is simultaneously ungrounded and both magnetos will be in full advance.
The induction type starting vibrators provide an interrupted D.C. current to the left magneto high tension
coil through the ignition switch and the "Retard" set of points. When the engine is cranked to the retard timing
position, the vibrator output is applied to the high tension coil to produce the spark to start the engine.

TROUBLESHOOTING.

Refer to Troubleshooting Chart 7401 for the most commonly encountered troubles and their remedy.

THIS SPACE INTENTIONALLY LEFT BLANK

74-02-00
Page 74-01
gQg Issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CHART 7401. TROUBLESHOOTING (MAGNETO)

Trouble Cause Remedy

Failure of engine to Defective spark plugs. Clean and adjust or replace

start. spark plugs.

Defective ignition wire. Check with electric tester

and replace defective wires.

Defective battery. Replace with charged battery.

Improper operation of Check points. Check internal

magneto breaker. timing of magnetos.

Failure of engine to Faulty ignition system. Check entire ignition system.

idle properly.

Low power and uneven Defective spark plugs. Clean and gap or replace
running. spark plugs.

Magneto breaker points Clean points. Check internal

not working properly. timing of magnetos.
.V:

Defective ignition wire. Check wire with electric

tester. Replace defective
wire.

Defective spark plug Replace connectors on spark

terminals connectors. plug wire.

Failure of engine to Faulty ignition. Tighten all connections.

develop full power. Check system with tester.
Check ignition timing.

74-02-00
Page 74-02
issued: June 1,1995
6G6
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

ELECTRICAL POWER SUPPLY.

MAGNETO. (See Chart 7402.)

- CAUTION-

Ascertain that the primary circuit of both magnetos is grounded

t>efore working on the engine.

INSPECTION O F MAGNETO.

-NOTE-

Comply with the latest revision of Bendix Service Bulletin No. 608 at
first opportunity, but no later than next magneto overhaul. Install
self-locking cam retaining screw (10-391213) and torque 21-25 inch
pounds. If self locking screw is removed at any time, always replace
with new self locking screw and torque to the specified value.

1. After the first 25 hour and 50 hour periods, and periodically thereafter, the contact assemblies should be
checked. Examine the points for excessive wear or burning. Points which have deep pits or excessively
bumed areas should be discarded. Examine the cam follower felt for proper lubrication. If necessary,
points can be cleaned by using any hard finished paper. Clean breaker compartment with dry cloth.
2. If engine operating troubles develop which appear to be caused by the ignition system, it is advisable to
check the spark plugs and wiring first before working on the magnetos.
3. Should the trouble appear definitely associated with the magneto, the most effective measure is to install
a replacement magneto which is known to be in satisfactory condition and send the suspected unit to the
overhaul shop for test and repair.
4. Should this not be possible, a visual inspection may disclose the source of trouble. Remove the harness
outlet plate from the magneto. Inspect for the presence of moisture and foreign matter on the rubber
grommet and high tension outlet side of the distributor block. Check height of block contact springs
(0.422 inch maximum from top of the block tower to the spring). Also check for broken leads or damaged
insulation. If either is present, remove magneto and replace with one known to be in satisfactory condi-
tion.
5. Remove the breaker cover and hamess securing screws and nuts, and separate cover from magneto
housing. Check contact assemblies to see that cam follower is securely riveted to its spring. Examine the
contact points for excessive wear or burning. Figure 74-1 shows how the average contact point will look
when surfaces are separated for inspection. Desired contact surfaces have a dull gray, sand-blasted
(almost rough) or frosted appearance, over the area where electrical contact is made. This means that
the points are worn in and mated to each other, thereby providing the best possible electrical contact and
highest efficiency of performance.

74-11-01
Page 74-03

6G7 issued: Jiine 1,1995

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CHART 7402. G E N E R A L SPECIFICATIONS, MAGNETO

SUBJECT DATA

Lubrication

Cam Follower Felt 10-86527 Breaker.Felt Lubricant

Housing Pole Shoes, Magnet Rust Preventative or S A E 30 Oil
Pole Pieces (Non-Detergent)
Gears Bendix Magneto Grease, 10-27165
Felt Washer Bendix Distributor Block Lubricant
10-391200
Distributor Block Bushing Bendix Distributor Block Lubricant
10-391200
Large Distributor Gear Shaft Bendix Distributor Block Lubricant
10-391200
Impulse Coupling Spring Light Oil
Stop Pins Bendix Magneto Grease, 10-27165
Rotating Magnet Shaft GO-JO NO-LOK 72 Compound
Cushion Drive Grommet Engine Oil

Tolerances

Capacitor 0.30 to 0.45 mfd

Contact Clearance
Main 0.003-0.016 IN
Retard 0.006-0.016 IN
"E" Gap 15° ± 2 ° Main Contact
Coil Primary 1.0-1.5 ohms
Secondary 17,000-23,000 ohms

Torques

Contact Support Screws 20 to 25 In.-Lbs.

Distributor Block Studs Start 4 to 8 In.-Lbs.
Final 18 to 22 In.-Lbs.
Cam Screw 16 to 20 In.-Lbs.
or
Self Locking Cam Screw* 21 to 25 In.-Lbs.
Drive Shaft Nut 20 to 25 Ft.-Lbs.
Capacitor Screws 8 to 12 In.-Lbs.
Flange Screws 65 to 85 In.-Lbs.
Retard Lead Screw 24 to 26 In.-Lbs.
Cover Securing Screw 30 to 35 In.-Lbs.

*Must be replaced with new screw at each removal.

-

74-11-01
Page 74-04
Issued: June 1,1995
6G8
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CHART 7402. GENERAL SPECIFICATIONS, MAGNETO (cont)

SUBJECT DATA

Ventilator Plug 10 to 15 In.-Lbs.

Timing Window Plug 10 to 15 In.-Lbs.

Miscellaneous

Internal Timing Marks See Instructions

Magneto Drive Speeds 6 cyl -1 Engine Speed '

Testing

Spark Gap Setting 7 mm

Vendors (Harness Lube and Sprays)

Silicone Spray S-512,

IMS Company,
10373 Stafford Road
Chagrin Fall, OH 44023

Flurocarbon Spray MS-SI 22 or 122N/C02

Miller-Stephenson Chemical Co., Inc.
George Washington Hwy.
Danburry, Conn. 06810

74-11-01
Page 74-05
gQg Issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

6. Minor irregularities or roughness of point surfaces are not hannful. (Refer to Figure 74-1, center.) Neither
are small pits or mounds, if not too pronounced. If there is a possibility of pit becoming deep enough to
penetrate pad. Figure 74-1, right, reject contact assembly.

-NOTE-

NO attempt stiould be made to stone or dress contact points. Should,

contact assembly have bad points or show excessive wear, the
complete contact assembly should be replaced.

7. Check the condition of the cam follower felt. Squeeze felt tightly between thumb and forefinger. If fingers
are not moistened with oil, re-oil using 2 or 3 drops of Scintilla 10-391200 lubricant. Allow approximately
30 minutes for the felt to absorb the oil. Blot off the excess with a clean cloth. Too much oil rriay foul con-
tact points and cause excessive burning. .
8. Check the capacitor mounting bracket for cracks or looseness. Using the Scintilla 11-1767-1,-2, or -3
Condenser Tester or equivalent, check capacitor for capacitance, series resistance and leakage.
Capacitance shall be least 0.30 microfarads.
9. Check magneto to engine timing as follows:
A. Connect Scintilla 11 -851 Timing Light or equivalent across the contact assembly.
B. Slowly bring the engine up to number one cylinder advance firing position. At this instant the timing
light should go out. If it does, the magneto is property timed to the engine. If the timing light does not
go out, removal of the magneto for internal timing check and inspection is recommended.

-NOTE-

The magneto service Instructions in this manual are to cover minor

repairs and timing. For further repairs and adjustments of the
magneto, it is recommended that the manufacturer's recommended
service instructions be followed.

10. For Aerostars with STC SA980-NW Machen, Inc. conversion refer to the latest revisions of Lycoming S/B
459 and Bendix S/B 618.

74-11-01
Page 74-06
Issued: June 1,1995
6G10
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

REMOVAL OF MAGNETO.

Before removing the magneto, mal<e sure magneto switches are off.
1. Remove harness assembiy terminal plate from the magneto.

- WARNING-

The magneto is not internally grounded; when the ground lead is

disconnected, the magneto is hot. Removing the harness assembly
terminal plate first and installing them last minimizes the danger of
starting the engine accidentally when the ground lead is removed
from the magneto.

2. Disconnect the pressurization hose from the magneto (700P).

3. Disconnect the ground and the retard leads and the magneto.
4. Remove the nuts and washers and draw the magneto from the engine.

223

MINOR IRRBGDLARITIES WELL DEFINED MOUND

NOFMftL POINT I S SMOOTH
SMOOTH ROLLING H I L L S EXTENDING NOTICEABLY ..
AND F L A T . SURFACE HAS
AND DALES WITHODT ANY ABOVE SURROUNDING •
DOLL GRAY "SANDBLASTED'
DEEP P I T S OR HIGH PEAKS SURFACE. REJECT POINTS.
APPEARANCE.
THIS I S A NORMAL CON-
DITION OF POINT WEAR.

Figure 74-1. Contact Points

74-11-02
Page 74-07

6G11 issued: June 1,1995

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

TIMING PROCEDURE (Internal Timing).

1. Remove the cover at the contact(s), distributor blocl<, etc.

2. To internally time the contact assembly of the magnetos, proceed as follows:
A. Loosen the nut securing the drive plate to the magneto shaft sufficiently in order to install the Scintilla
11-8465 Rotor Holding Tool under the nut and flat washer as shown in Figure 74-2. Tighten the nut
securely.
B Remove the timing inspection plug from the top of the magneto. Turn rotating magnet to proper neu-
tral position. This position is determined by locating keyways on drive end of magnet shaft at 12
o'clock with respect to nameplate on housing. Tighten adjusting knob of 11-8465 Rotor Holding Tool
until pressure is applied on housing flange preventing magnet from turning.
C. Loosen and rotate cam until cam follower of contact assembly rests on highest point of cam lobe.
Adjust contact assembly to obtain the clearance of 0.016 of an inch. Tighten contact assembly secur-
ing screws to 20-25 inch-pounds.
D. Install the 11-8693 Timing Plate Assembly and the 11-8149 Pointer Assembly of the 11-8150 Scintilla
Timing Kit to breaker compartment of magneto. (Refer to Figure 74-3.) Align pointer assembly with
the 0 mark on timing plate. Loosen adjusting knob of 11-8465 Rotor Holding Tool and tum rotating
magnet in normal direction of rotation until pointer indexes with the respective E gap mark (15° ± 2°).
Tighten adjusting knob of 11-8465 Tool and remove the 11-8149 Pointer Assembly from magneto.
Using a timing light, adjust contact points to just open. This adjustment shall be made by rotating
cam, in opposite direction of rotation until contacts just open. While holding cam in this exact position^
push cam on magnet shaft as far as possible with the fingers. Extreme care must be exercised in this
operation. If cam adjustment is changed in the slightest degree, the timing of the magneto will be
thrown off. Do not drive cam on shaft with a mallet or other instrument. Tighten the securing screw
thereby drawing the cam down, evenly and tightly. Torque screw to 16- 20 inch-pounds or 21-25
inch-pounds if self-locking cam screw is installed. Loosen the 11-8465 Rotor Holding Tool adjusting
knob and retum rotating magnet to neutral position. Reinstall the 11-8149 Pointer Assembly over 0
mark on timing plate. Rotate magnet shaft in normal direction of rotation and check for opening of
main contact points at E gap setting (15° ± 2°).
3. If the distributor block was not removed from the housing, the internal timing may be checked by turning
the magneto in the normal rotation to number one firing position (keyway up and points just opening). At
this position, the reference line on the distributor block should line up between the L and LB marks on the
gear.
4. If the distributor block was removed from the housing, the distributor gear alignment and intemal check
may be accomplished as follows:
A. Turn rotating magnet in direction of rotation until it is located in firing position (keyway up and points
just opening). Tighten adjusting knob of 11 -8465 Rotor Holding Tool. Apply a light coating of Bendix
Grease P/N 10-27165 to teeth of distributor gear, if needed. The large distributor gear incorporates
four timing mari<s, L and LB for left-hand rotation and R and RB for right-hand rotation.
B. With distributor gear assembly to block, tum gear until raised rib on block lines up between the L and
LB marks. Assemble block and gear into housing, meshing the distributor gears together. The rib
should favor the L mark if possible. (Refer to Figure 74-4.)

74-11-03
Page 74-08
issued: June 1,1995
6G12
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

C. Secure distributor blocl< to tiousing witti studs and wastiers. Tigtiten studs finger tigfit. Loosen tfie 11-
8465 Rotor Holding Tool and turn rotating magnet in reverse direction of rotation until timing ligfit indi-
cates contact assembly had just opened and check to make certain timing marks align within toler-
ance indicated above. Tighten block securing studs, first to 4-8 inch-pounds torque and final torque to
20 inch^ pounds.
5. Adjusting retard contact assembly. V ^

-NOTE-

On dual contact assembly magnetos, the retard contact assembly Is

adjusted to open a predetermined number of degrees after the main
contact assembly opens. The degree of retard for any particular
magneto is stamped in the bottom of the breaker compartment.

A. At EXACT position of rotating magnet that main contact assembly opens, lock the 11-8465 Holding
Tool. Install the Timing Kit (Figure 74-3) and move the pointer back to zero.
B. Unlock holding tool and advance rotating magnet until pointer of timing kit indexes with required
degree of retard. Lock the holding tool in this position.
C. Using timing light, adjust retard contact assembly to just open. Tolerance of retard is +2, -0.
D. Unlock holding tool. Tum rotating magnet until cam follower is on high point of cam lobe. Measure
point clearance; should be .016 ± .006 inch. If not within tolerance, reset point clearance.
E. Recheck to be sure points open within retard degree tolerance. Replace contact assembly if toler-
ance cannot be obtained.
F. Remove pointer assembly and timing plate assembly from magneto.
G. Tighten block securing studs, first 4-8 inch-pounds, and then final torque to 20 inch-pounds.
H. Insert the tip of your small finger through timing hole in housing and against large distributor gear
teeth. Rock distributor gear back and forth slightly. There must be perceptable backlash between
teeth of large and small gears. This check should be made at three different points, 120° apart on
gear. If backlash is not evident, replace large distributor gear.
I. Install the breaker cover and complete reassembly of the magneto. Refer to the manufacturer's publi-
cations for complete disassembly and reassembly procedures.
6. Install and time triagneto, removed from engine, in accordance with Installation and Timing Procedure
(Timing Magneto to Engine).
7. Secure external switch leads to the breaker cover terminals. Connect harness assembly to the magneto.

INSTALLATION AND TIMING PROCEDURE (Timing Magneto to Engine).

Although only the left magneto is equipped with a retard breaker, the timing procedure in the following para-
graphs is the same for both magnetos.
1. Remove the upper and lower engine cowling and left tialf of nose cowl.
2. Remove the spark plug from No. 1 cylinder and place a thumb over the spark plug hole. Rotate the
crankshaft in direction of normal rotation until the compression stroke is reached; this is indicated by a
positive pressure inside the cylinder tending to push the thumb off the spark plug hole. Continue rotating
the crankshaft in direction of nornial rotation until the advance timing mark (20) on the face of the starter
ring gear is in exact alignment with the small hole located at the two o'clock position on the front face of
the starter housing. (Refer to Figure 74-5, Detail A.)

74-11-04
Page 74-09
gQ'^ 2 Issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

B689

Figure 74-2. Rotor i-ioiding Tooi Instaiied

B689

Figure 74-3. Timing Kit instaiied

74-11-04
Page 74-10
Issued: June 1,1995
6G14
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

Figure 74-5. Engine Timing IViari(s

.74-11-04
Page 74-11
6G15 issued: June 1,1995
9
AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

-NOTE-

The advance timing marif on the top face of the starter ring gear is
marlied at both 20 and 25 BTC. Use only the 20 BTC mark when
timing the magneto to the engine.

If the crankshaft is accidentally turned in the direction opposite

normal rotation, repeat the above procedure as accumulated
backlash will make the final timing incorrect.

3. At this point, the engine is ready for assembly of the magnetos. Remove the inspection plugs from both
magnetos and turn the drive shafts in direction of normal rotation (counterclockwise facing the coupling),
until the first painted chamfered tooth on the distributor gear is aligned in the center of the inspection win-
dow. (Refer to Figure 74-4.) Being sure that the gear does not move from this position, install gaskets
and magnetos on the engine. Secure with clamps, tighten only finger tight.
4. Using a battery powered timing light, attach the positive lead to a suitable terminal connected to the
ground terminal of the magneto and the negative lead to any unpainted portion of the engine. Rotate the
magneto in its mounting flange to a point where the light comes on, then slowly turn it in the opposite
direction until the light goes out. Bring the magneto back slowly until the light just comes on. Repeat this
with the second magneto.

-NOTE-

AC timing lights operate in the reverse manner as described above;

the light goes out when the breaker points open.

5. After both magnetos have been timed, check, as described below, to ascertain that both magnetos are
set to fire together.
6. Back off the crankshaft a few degrees; the timing lights should go out. Bring the crankshaft slowly back in
direction of normal rotation until the timing mark and the hole in the starter housing are in alignment. At
this point, both lights should go on simultaneously. Tighten nuts to specified torque.
7. After magnetos have been properly timed, replace breaker cover and secure.
8. Install the ground lead and the retard spark lead on the left magneto.
9. Connect pressurization hose to magneto (700P).
10. Place the harness terminal plate on the magneto and tighten nut around the plate altemately to seat
cover squarely on magneto. Torque nuts to 18 to 22 inch-pounds.

STARTING VIBRATOR.

The starting vibrators are located on the Master Electrical Panel at fuselage station 176.88 bulkhead, aft
end of cabin.

TROUBLESHOOTING.

Refer to Troubleshooting Chart 7403

74-12-01
Page 74-12

Issued: J u n e l , 1995 6G16

 AEROSTAR AIRCRAFT
600/601/6(31 P/602P/700P
MAINTENANCE MANUAL

CHART 7403. TROUBLESHOOTING (VIBRATOR)

Trouble Cause Remedy

Hard starting. Low voltage at vibrator Measure voltage between

input. vibrator terminal marked "IN"
and the ground terminal while
operating starter. Must be at
least 13 volts on 24 volt
systems.

Inoperative or defective If voltage is adequate, listen

vibrator. for buzzing of vibrator during
starting. If no buzzing is
heard, either the vibrator is
defective or the circuit to the
retard (dual contact assembly)
magneto is open. Check both
"Switch" and "Retard" circuits.
Also check for good electrical
ground.

Retard contact assembly Retard points may not be

in retard (dual contact) closing due to wrong adjust-
magneto not operating ment, or may not be electrical-
electrically. Engine ly connected in the circuit due
may kick back during to a poor connection. Inspect
cranking due to advance retard points to see if they
timing of ignition. close. Check for proper con-
tact at the "Switch" and "Re-
tard" terminals of retard (dual
contact assembly) magneto and
at the vibrator. Check wiring.

,-

74-12-01
Page 74-13
Issued: J u n e l , 1995
6G17
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CHART 7403, TROUBLESHOOTING (VIBRATOR) (cont)

Trouble Cause Remedy

Hard starting, (cont) Vibrator-magneto combina- Tum engine in proper direction

tion not "putting out" of rotation until retard points
electrically. just open on No. 1 cylinder
position. Remove input connec-
tion from starter to prevent
engine turning and, while hold-
ing No. 1 plug lead 3/16 inch
from ground, energize vibrator
by fuming switch to start. Plug
lead should throw a 3/16 inch
spark. If spark is weak or miss-
ing try new vibrator. If this does
not correct trouble remove mag-
neto and check for improper
intemal timing or improperly
meshed distributor gears.

Magneto improperly Check magneto to engine timing

timed to engine. in accordance with the sec-
tion titled Timing Pro-
cedure (Internal Timing).

Advance contact assembly Check magneto timing per

out of adjustment (inter- section titled Timing Pro-
nal timing off.) cedure (Internal Timing).

Retard points opening Check timing of retard points

too late. according to the section
titled Timing Procedure
(Intemal Timing)7

Engine rougtiness. Try new spark plugs.

Check plug leads for continuity

and breakdown.

Check magneto contact assem-

blies for burning or dirt. (Main
and Retard.)

Magneto check out of Check magneto-to-engine

limits. timing.

Inspect contact assemblies for

proper opening.

Check plugs and leads.

74-12-01
Page 74-14
issued: June 1,1995
6G18
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

B691

I G N m C N AND
STARTER SWITCH
STARTING!
VIBRATOR

NOTE
THIS DRAWnSG FOR REFERENCE ONLY.

Figure 74-6. Starting Circuit

74r12-01
— Page 74-15
gQ-| g issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

REMOVAL OF VIBRATOR.

1. Master Battery switch OFF/Auxiliary power unit disconnected.

2. At aft end of cabin, remove "Royalite" panel for access to Master Electrical Panel.
3. Locate starting vibrator(s) at center left portion of panel, looking aft.
4. Remove electrical leads (2) from vibrator. Tag leads for identification.
5. Remove screws securing unit and remove vibrator.

INSTALLATION OF VIBRATOR.

1. Locate vibrator placement at Master Electrical Panel.

2. Install vibrator. Secure with screws to panel.
3. Identify and connect electrical leads to the IN and BO terminals.
4. Replace "Royalite" panel.

TESTING VIBRATOR. (Referto Figure 74-6.)

1. Disconnect all spark plug leads at spark plugs.

- WARNING -

Be sure all magneto spark plug leads are removed and grounded to
the engine case, thus preventing the hazardous condition of plug
firing during test.

2. Rotate engine crankshaft until No. 1 cylinder is in its retard firing position. Using a timing light (Bendix 11-
9110-1 or equivalent), ensure retard and main contact assemblies (points) are open.
3. Electrically disconnect starting solenoid or remove battery cable from starter so engine will NOT crank
during this test.

- WARNING -

It is necessary that the starter be electrically removed from the

circuit before the vibrator is put into operation to eliminate the
possibility of starter t)eing energized during test.

4. Place ignition/starter switch in "START" position.

5. Using care not to touch "hot" portion of spark plug lead, hold lead (No. 1 plug) about 3/16 inch from
engine ground. A series of sparks or high voltage arcs should be seen jumping gap to ground.
6. If spari< fails to jump gap or is weak, check voltage to vibrator; should be 24 volts D.C.
7. If voltage is correct, check contact points at magneto. Both sets of points should be open (Step 2).
8. Any vibrator failing the proceeding requirement should be rejected.

-NOTE-

Vibrators can be swapped to help isolate the problem.

74-12 04
Page 74-16
Issued: June 1,1995
6G20
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

DISTRIBUTION. (Refer to Figure 74-7.)

Each magneto distributes the spark to one set of the dual spark plugs at each cylinder. A high tension
ignition hamess routes the magneto output to the spark plugs.
The ignition harness is composed of a six-wire assembly from each magneto. It is held securely in place by
clamps and clips.

HARNESS.

INSPECTION O F HARNESS.

1. Check lead assemblies for nicks, cuts, mutilated braiding, badly worn section or any other evidence of
physical damage. Inspect spark plug sleeves for chafing or tears and damaged or stripped threads on
coupling nuts. Check compression spring to see if it is broken or distorted. Inspect grommet for tears.
Check all mounting brackets and clamps to see that they are secure and not cracked.
2. Using an ohmmeter, buzzer, or other suitable low voltage device, check each lead for continuity. If conti-
nuity does not exist, wire is broken and must be replaced.
3. For electrical test of harness assembly, use a high voltage, direct current tester such as the TAKK Model
86 or 86A or an equivalent direct current high voltage tester capable of delivering a test potential of
10,000 volts. Connect ground lead to high voltage tester to outer shielding braid of a single lead. Connect
plug terminal. Turn tester "ON" and apply 10,000 volts. The insulation resistance should be 100
megohms minimum. Proceed to check other leads of harness in same manner.
4. Minor repair of the hamess assembly, such as replacement of contact springs, spring retainer assem-
blies, insulating sleeves or of one lead assembly, can be accomplished with the harness assembly
mounted on the engine. However, should repair require replacement of more than one lead assembly or
of a cable outlet plate, the hamess should be removed from the engine and sent to an overhaul shop.

Figure 74-7. Magneto instaiiation and Harness Assembiy

74-21-01
Page 74-17
efjo-l issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

CLEANING OF HARNESS.

- WARNING -

Methylethylketone, fed/spec. TT-M-261 is flammable - keep away

from heat, sparks, and open flames. Use only with adequate
ventilation. Avoid prolonged or repeated breathing of vapors.
Avoid prolonged or repeated contact with skin. Prolonged contact
may cause drying and irritation of skin. Keep in approved safety
container.

- CAUTION-

USE ONLY MEK OR UNLEADED GASOLINEI

1. Using a clean, lint-free clotfi moistened witfi Metfiyletfiylketone (MEK) or unleaded gasoline, wipe tfie
insulating sleeve until free of contaminants.
2. Clean tfie contact spring in a similar manner.
3. Dry sleeves and springs witfi a gentle blast of compressed air, not to exceed 30 psig.
4. Inspect contact springs for signs of arcing, corrosion or lack of normal lengtti or compression pressure.
Replace any springs tfiat appear questionable.

-NOTE-

Contact springs will corrode and deteriorate quickly if a trace of

moisture or solvent remains. Spark plug cavity must be completely
dried out.

REPLACEMENTS.
Refer to tfie latest revision of Bendix Ligtit aircraft Ignition Harness "Installation and Maintenance
Instructions", Publication Form L-2039 for procedures covering individual parts replacement.

REMOVAL OF HARNESS.

1. Disconnect ttie clamps ttiat secure tfie wires to tfie engine and accessories.
2. Loosen tfie coupling nuts at tfie spark plugs and remove ttie insulators from tfie spark plug barrel well.
Use caution wfien witfidrawing tlie insulator not to damage ttie insulator spring. -
3. Place a guard over tfie harness insulators.
4. Remove the harness assembly terminal plate from the magneto.
5. Remove the harness from the airplane.

74-21-04
Page 74-18

Issued: June 1,1995 6G22

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

B693

Figure 74-8. Harness lUlaintenance

74-21-04
Page 74-19
RC^O"^ issued: Junel, 1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

MAINTENANCE OF HARNESS.

1. To replace contact springs or spring retainer assemblies, proceed as follows:

A. Using a Scintilla 11-7073 Needle or a mechanical pencil with the lead retracted, hook the end of the
contact spring as shown in Figure 74-8(A).
B. Using the needle or pencil, unscrew the spring.
C. Slide insulating sleeve and spring retainer assembly off end of lead assembly.
D. Replace defective component and reassemble as follows:
(1) Fabricate a tool for installing the insulating sleeves over cable terminals. Refer to Chapter 91 for
tool fabrication.
(2) Push the tool through insulating sleeve and spring retainer assembly as shown in Figure 74-
8(B). Screw the cable terminal into the tool.
(3) Work insulating sleeve and spring retainer assembly into position over the cable and unscrew the
tool. Install contact spring on cable terminal.

-NOTE-

It may be necessary to lubricate cable and insulating sleeve by

spraying with either Silicone spray S-512 or Fluorocarbon spray
MS-122 to facilitate assembly.

INSTALLATION OF HARNESS.

Before installing harness on magneto, check mating surfaces for cleanliness. Spray entire face of grommet
with a light coat of Plastic Mold Spray, SM-O-O-TH Silicone Spray or equivalent. This will prevent hamess
grommet from sticking to magneto distributor block.
1. Place the harness terminal plate on the magneto and tighten nuts around the plate altemately to seat
cover squarely on magneto. Torque nuts to 18 to 22 inch-pounds.
2. Route ignition wires to their respective cylinders.
3. Clamp the harness assembly in position.
4. To prevent sticking of insulating sleeves to the spark plug barrel, spray the sleeve with either Silicone
Spray S-312 or Fluorocarbon Spray MS-122. (See Figure 74-9.)
5. To reduce friction of coupling nut to ferrule shoulder, lubricate the ferrule shoulder with GO-JO-NO LOK
or Molykote Type G as shown in Figure 74-9.
6. Install the harness spark plug ends in their proper plug barrels.

- CAUTION-

Avoid contamination of terminal sleeves during installation to ^

sparkplug wells.

7. Torque coupling nuts to 90-95 inch-pounds for 5/8-24 spark plug coupling thread or 110-120 inch-
pounds for 3/4-20 thread.

74-21-06
Page 74-20
Issued: June 1,1995
6G24
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

B694

LUBRICATE (A) COAT

(B)

(A) GO-JO-NO LOK OR MOLYKOTE TYPE G

(B) SILICONE SPRAY S-312 OR FLUOROCARBON SPRAY MS-SI22.

Figure 74-9. Ferruie and Sieeve Lubrication

Figure 74-10. Removing Spari< Piug Frozen to Bushing

74-21-06
Page 74-21
6H1 Issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

SPARK PLUGS.

REMOVAL OF SPARK PLUGS.

1. Loosen the coupling nut on the hamess lead and remove the terminal insulator from the spark plug barrel
well.

-NOTE-

When withdrawing the ignition cable lead connection from theiplug,

care must be taken to pull the lead straight out and in line with the
center line of the plug barrel; otherwise a side load will be applied,
which frequently results in damage to the barrel insulator and
connector. If the lead cannot lie removed easily in this manner, the
resisting contact between the neoprene collar and the barrel
insulator will be broken by a rotary twisting of the collar. Avoid
undue distortion of the collar and possible side loading of the barrel
insulator.

2. Remove the spark plug from the engine. In the course of engine operation, carbon and other combustion
products will be deposited on the end of the spark plug and will penetrate the lower threads to some
degree. As a result, greater torque is frequently required for removing a plug than for its installation.
Accordingly, the torque limitations given do not apply to plug removal and sufficient torque must be used
to unscrew the plug. The higher torque in removal is not as detrimental as in installation, since it cannot
stretch the threaded section. It does, however, impose a shearing load on this section, and may, if suffi-
ciently severe, produce a failure in this location.

-NOTE-

Torque indicating handle should not be used for spark plug removal
because of the greater torque requirement.

3. As soon as they are removed, place spark plugs in a tray that will identify their position in the engine.

-NOTE-

Spark plugs should not be used if they have been dropped.

A: Removal of seized spark plugs in the cylinder may be accomplished by application of liquid carbon diox-
ide by a Conical metal funnel adapter with a hole at the apex just large enough to accommodate the fun-
nel of the C02 bottle. (Refer to Figure 74-10.) When a seized spark plug cannot be removed by nomnal
means, the funnel adapter is placed over and around the spark plug. Place the funnel of the C02 bottle
inside the funnel adapter and release the carbon dioxide to chill and contract the spark plug. Break the
spark plug loose with a wrench. A warm cylinder head at the time the carbon dioxide is applied will aid in
the removal of an excessively seized plug.
5. Do not allow foreign objects to enter the spark plug hole.

74-22-01
Page 74-22

Issued: June 1,1995 6H2

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

INSPECTION AND CLEANING OF SPARK PLUG.

1. Visually inspect eacti spark plug for ttie following non-repairable defects:
A. Severely damaged stiell or sfiield ttireads nicked up, stripped or crosstfireaded.
B. Badly battered or rounded sfiell fiexagons.
C. Out-of-round or damaged stiielding barrel.
D. Cfiipped, cracked or broken ceramic insulator portions.
E. Badly eroded electrodes worn to approximately 50% of original size.
2. Clean tfie spark plug as required, removing carbon and foreign deposits.
3. Set tfie electrode gap at .017 to .021 incties.
4. Test tfie spark plug botti electrically and for resistance.

INSTALLATION OF SPARK PLUGS.

Before installing spark plugs, ascertain tfiat the threads within the cylinder are clean and not damaged.
1. Apply anti-seize compound sparingly on the threads and install gasket and spark plugs. Torque to 420
inch-pounds.

-NOTE-

Make certain tfie deep socket is property seated on tfie sparkplug

tiexagon as damage to ttie plug could result if the wrench is cocked to
one side when pressure is applied.

2. Carefully insert the terminal insulator in the spark plug and tighten the coupling unit.

SPARK PLUG IDENTIFICATION. (Refer to Chart 7404.)

Two types of spari< plugs are used, depending on the model. The model 600 engine uses a short reach spark
plug, while the model 601, 601P, 602P and 700P use the long reach spark plug.

CHART 7404. COLOR CODE FOR FIN A R E A BETWEEN SPARK PLUG AND ROCKER BOX

Engine grey, blue or unpainted Cylinder designed for short reach spari< plugs.

Yellow Cylinder designed for long reach spark plugs.

- CAUTION-

I It is very important to use only approved spark plugs for all models
of Avco Lycoming engines. Severe engine damage will result from
use of long reach plugs in engines designed for short reach plugs.

74-22-04
Page 74-23
Issued: June 1,1995
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

-NOTE-

See latest revision of service instruction No. 1042 for sparkplugs

approved for Avco Lycoming engines.

SWITCHING.

The ignition system is equipped with a combination ignition/start switch. It is a rotary type, 3-pole, 5-
position unit.

DESCRIPTION.

The five switch positions are as follows: (Figures 74-11 and 74-12.)
1. OFF - both magnetos are grounded.
2. R - right magneto operating, left one grounded.
3. L - left magneto operating, right one grounded.
4. BOTH - both magnetos operating.
5. START - starter motor engaged and vibrator energized to supply chopped D.C. current to left magneto
through switch and retard points. Right magneto grounded.

REMbVAUINSTALLATION O F IGNITION SWITCH.

Refer to Chapter 39 for removal/installation procedures.

THIS S P A C E INTENTIONALLY LEFT BLANK

74-32-00
Page 74-24
Issued: June 1,1995
6H4
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

Figure 74-11. Starter Switch

B695
IGNITION AND
STARTER SWITCH

LR

Figure 74-12. Schematic, ignition/Starter Switch

74-32-00
Page 74-25
issued: June 1,1995
6H5
 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

 AEROSTAR AIRCRAFT
600/601/601P/602P/700P
MAINTENANCE MANUAL

THIS PAGE INTENTIONALLY LEFT BLANK

6H8