PROTOTYPE: IGNITION SYSTEM OF AN AIRCRAFT

RECIPROCATING ENGINE MAINTENANCE MANUAL AND

SAFETY MANUAL
Purpose: This safety manual is an easy-to-use guide for important information and
provides safety requirements to maintain the safety operation of the prototype:
ignition system.
THIS MANUAL INCLUDES THE MAINTENANCE INFORMATION TO BE MAINTAINED
AND ALSO INCLUDES THE SAFETY MANUAL OF THE PROTOTYPE OF THE IGNITION
SYSTEM.

INTRODUCTION

The maintenance manual provides the instructors with the information necessary to
maintain the ignition system prototype effectively. The maintenance manual provides the
description of every component of the prototype, the proper maintenance of each part, the
procedure on troubleshooting the components, and the proper procedure on how to store the
prototype.

This manual contributes in making the prototype function efficiently and effectively as
an instructional material.
 PROTOTYPE: IGNITION SYSTEM OF AN AIRCRAFT
RECIPROCATING ENGINE

1. Flywheel 2. Cylinder no.3

3. Cylinder no.1 4. Cylinder no.4
5. Cylinder no.2

6. Wires from left magneto going to left upper spark plugs 7. Left Magneto
8. Gears 9. Right Magneto
10. Wires from right magneto going to right upper spark plugs
11. Wires from right magneto going to left lower spark plugs
12. Wires from left magneto going to right lower spark plugs
 13. Speed Setting 14. Battery
15. Switch Panel 16. Main Knob

17. Crankcase 18. Push Rod

19. Upper Spark Plug 20. Lower Spark Plug
21. Starter 22. Stand
 DESCRIPTION

● DC Motor (Main)
A type of 12V motor that converts DC current electrical energy into mechanical
energy. It operates the flywheel and the accessory gears.

● DC Motor (Starter)
A type of 12V motor that converts DC current electrical energy into mechanical
energy. This motor actuates the starter pinion to initiate the rotation of the flywheel.
This prototype uses the starter pinion of the Honda Beat motorcycle.

● Main Knob
The main knob controls the DC motor (main), DC motor (starter), and LED lights of
the prototype.
1. Start - To switch on the DC (starter) that actuates the DC motor (main).
2. Both - To switch on the left (red) and right (green) LED lights of the cylinders.
3. Left - To switch on the left (red) LED lights of the cylinder.
4. Right - To switch on the right (green) LED lights.
5. Off - To switch off the power that operates the prototype.
● DC Motor Speed Controller
The DC motor controller manipulates the position, speed, or torque of a DC-powered
motor and easily reverses, so the DC motor drive current runs in the opposite
direction. Enjoy higher starting torque, quick starting and stopping, reversing, variable
speeds with voltage input and more.

● Battery
The prototype uses a 12 volts 5L battery. The battery is the source of electric power
that operates the prototype.
● LED Lights
The LED lights represent the spark plugs. The prototype uses green and red 12v
LED lights.

● Fuse
The prototype uses a 10 ampere blade type motorcycle fuse. The fuse blows when
the current draw on a circuit exceeds the amperage rating of the fuse. In order to
protect the wiring in that circuit from melting, the fuse will blow so no permanent
damage is done to the wires or accessories of the prototype.

● Electrical Wires
The electrical wires provide connections to the electrical components of the
prototype.
● Gears
The gear is a set of toothed wheels that work together to provide linkages from the
shaft of the DC motor (main) to the timing of the LED lights.

MAGNETO / SPARK PLUG TIMING

1U - Cylinder no. 1 (Upper Spark Plug) 3U - Cylinder no. 3 (Upper Spark Plug)
1L - Cylinder no. 1 (Lower Spark Plug) 3L - Cylinder no. 3 (Lower Spark Plug)
2U - Cylinder no. 2 (Upper Spark Plug) 4U - Cylinder no. 4 (Upper Spark Plug)
2L - Cylinder no. 2 (Lower Spark Plug) 4L - Cylinder no. 4 (Lower Spark Plug)
MG - Main Gear GLM - Gear (Left Magneto)
GL - Gear (Left) GRM - Gear (Right Magneto)
GR - Gear (Right)

Illustration 1.

Illustration 1 shows how the spark plug on cylinder number 1 works. The main gear
(MG) rotates clockwise, it is connected on the main DC motor using the connecting
rod. Then, the gears (GL), (GR) beside the MG rotate counter-clockwise. That is why
the gears of the left magneto (GLM) and right magneto (GRM) rotate clockwise.Both
the LED lights on cylinder number 1 lights up when the timing attached on the gears
of the magneto (Red Point) get contact on the timing attached on the acrylic glass
(for GRM: upper portion of the gear - lights the upper LED light of cylinder no.1, for
GLM: lower portion of the gear - lights the lower LED light of cylinder no.1).
 Illustration 2.

Illustration 2 shows how the spark plug on cylinder number 3 works. Both the LED
lights on cylinder number 3 lights up when the timing attached on the gears of the
magneto (Red Point) get contact on the timing attached on the acrylic glass (for
GRM: right portion of the gear - lights the upper LED light of cylinder no.3, for GLM:
left portion of the gear - lights the lower LED light of cylinder no.3).

Illustration 3.

Illustration 3 shows how the spark plug on cylinder number 2 works. Both the LED
lights on cylinder number 2 lights up when the timing attached on the gears of the
magneto (Red Point) get contact on the timing attached on the acrylic glass (for
GRM: lower portion of the gear - lights the lower LED light of cylinder no.2, for GLM:
upper portion of the gear - lights the upper LED light of cylinder no.2).
 Illustration 4.

Illustration 4 shows how the spark plug on cylinder number 2 works. Both the LED
lights on cylinder number 2 lights up when the timing attached on the gears of the
magneto (Red Point) get contact on the timing attached on the acrylic glass (for
GRM: left portion of the gear - lights the lower LED light of cylinder no.4, for GLM:
right portion of the gear - lights the upper LED light of cylinder no.4).

I. Maintenance Procedures:

Battery
a. Check the voltage of the battery of the prototype by using a multimeter tester if it still
meets the required voltage.
b. Ensure that the wires are all connected
c. Inspect battery terminals and quickly disconnect plugs and pins for evidence of
corrosion, pitting, arcing, and burns. Clean as required.

Electric Wires
a. Check the wires of the prototype if it is potentially defective.
b. Change the wires immediately.
c. Check the wires if it is connected properly to the components
d. Check the wires if it's working properly.
e. Tie the wires so that it is not messed up and to prevent entanglement.

LED Lights
a. Check the lights of the prototype by operating the prototype, if it sees a defective
light.
b. Change the Led Light immediately.
c. The voltage of the LED lights must be compatible with the 12V battery.
d. Check the Led Lights to see if it is working.
Main Knob
a. Check the main knob of the prototype by turning it on and off, if it sees a potential
defect.
b. The main knob indicates what LED lights will turn on and if it is not working carefully
inspect the connection of the wire on the terminals of the main knob.
c. Change the main knob immediately if not working.

Fuse
a. Check the fuse if it is in good condition.

Acrylic Glass
a. Visually check the acrylic glass for cracks or potential defects. Replace the acrylic
glass if required.
b. Check the acrylic glass to see if it's properly screwed.

Gears
a. Check the visual alignment and attachment of the gears.
b. Inspect if there are any damages or cracks in the gears.

DC Motor Speed Controller

a. Check the speed setting of the prototype.
b. Test the DC Motor Speed controller by rotating the knob if it controls the speed of the
DC Motor (Main).
c. If the “red light” on the speed controller is on, it means that the speed controller is
working properly.

DC Motor (Starter)
a. Visually check the distance of the starter to the flywheel of the prototype.
b. Test the DC Motor (Starter) by starting the prototype if it still actuates the flywheel of
the prototype.

II. Operation Procedures:

a. When starting the prototype: ignition system, turn the main knob to “start” indicator
then immediately turn it back to “both”.
b. Turn the main knob into the preferred indicator (R, L) depending on the magneto the
instructor wants to operate.
c. Check if the LED lights are operating properly when the switch is on "both", "left", and
"right" indicators.
d. Set the DC motor speed controller on the speed setting to the preferred speed the
instructor needs.
e. When the Prototype is operating, maintain the proper distance in any objects that
move such as flywheel and the gears.
f. In switching off the prototype, turn the main knob into the “off” indicator.
III. Storage Maintenance:

a. Check the floor if it's levelled to ensure that the prototype will not collapse.
b. Ensure that there are no harmful materials near the prototype to avoid damages.
c. Carefully observe if there are no prone accidents that can occur on the surrounding
d. Avoid placing the prototype in places that people often walk on.
e. If possible, provide a logbook to know who will use the prototype and the time it is
used and the time it is put back in the storage room.

IV. Troubleshooting / Damages:

Component Problem Source of Problem Solution

No Power Battery terminal Check all

connections or connections,
discharged. especially the
battery terminal and
tighten or charge the
battery.

The battery Check the cables

Battery terminals may be and reinstall the
incorrectly installed. battery with proper
designation of
terminals.

The terminals have The battery may be Clean the battery

corrosion old or stock for a and check if it is still
long time. in a good condition.
Replace a new
battery if required

Insulation damage Wires can be Replace a new set

Electric wires damaged from heat, of electric wires with
corrosion, and a proper colour of
bending. wires.

No lights / failure to LED lights may be

function old and stock for a
long time.
Check the
connection of the
LED light. Replace a
LED Lights new LED light if
required with a
Overheating of LED LED lights may be proper designated
lights exposed at a high colour of light.
temperature or
directly from the
sun.
 The main knob is The knob thread Remove the knob,
hard to rotate may be loose or check the knob
Main Knob damaged. thread if it has
damages or loose. If
required, replace a
new knob.

The fuse is blown Too much power Replace a new 10

Fuse from the circuit. ampere blade type
motorcycle fuse.

The acrylic glass Scratched or Clean the acrylic

has scratches and damaged done by glass using alcohol
dents any pointed objects. and a smooth towel.

The acrylic glass is Replace a new

broken acrylic glass by
Acrylic Glass simply removing the
screws attached on
the corners of the
glass and replacing
it with a new and
shaped acrylic
glass.

Damaged gear teeth Excessive friction of Replace a new gear.

gears due to The gear can be
rotation. made using the
website
“geargenerator.com”
with the following
Gears measurements: a)
tooth spacing -
13mm, b) contact
angle- 35 degrees,
c) shaft hole
diameter - 13mm, d)
number of teeth -
16.

The knob is hard to The knob may be Check the knob lock
rotate loose or it has a by simply pulling it
damaged lock. (do not rotate). If the
knob lock is
damaged, replace it
with a new knob by
simply attaching the
DC Motor Speed knob appropriate to
Controller the lock of the knob.

The “red light” on The wire or cable Check the back of

the speed controller may be disattached the speed controller.
do not function or removed. Check the wire
 connections if it is
still attached to the
module, then
reattach the wire.

Replace the DC
Motor Speed
Controller if needed.

Do not actuate The wires may be Check the

during start removed or connections of the
disattached. starter.
If found damaged,
reattach the wire of
the starter.

Do not initiate the The starter may be Check the distance

flywheel when moved from a of the starter to the
DC Motor (Starter) starting distance. flywheel. Test the
starter if it initiates
the flywheel.
If not, simply loosen
the thread of the
clamp attached on
the starter.
Adjust the distance
of the starter to its
proper distance to
where it will initiate
the flywheel when
starting.
Then, tighten the
clamp of the starter
to fix it.
MANUAL INFORMATION AND IMPORTANT POINTS

Do not spin the flywheel while holding its fan belt to avoid misalignment and damage.
If necessary to spin while the prototype is off, hold the knob in front of the flywheel.

In starting the prototype, rotate the main knob gently to the “start” indicator until the
starter actuates. Then, rotate the main knob to the “both” indicator to continuously
run the prototype.

Do not stock the prototype direct from the sun, otherwise the LED lights may be
damaged.

For maximum prototype life, always refer to manual before operating or performing
actions.