- -

UNISDN

L-I037
420016200 SERIES
Magneto Maintenance and
Overhaul Manual
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.

- --

CURRENT PAGE REVISIONS

SECTION REV. REV. SECTION REV. REV. SECTION REV. REV.
PAGE NO. DATE PAGE NO. DATE PAGE NO. DATE
1-1 E 05-01-89 7-1 F 03-01-93 11-1 F 03-01-93
1-2 E 05-01-89 7-2 F 03-01-93 11-2 E 05-01-89
2-1 E 05-01-89 7-3 F 03-01-93 11-3 E 05-01-89
2-2 E 05-01-89 8-1 F 03-01-93 11-4 E 05-01-89
3-1 F 03-01-93 8-2 E 05-01-89 11-5 E 05-01-89
4-1 F 03-01-93 8-3 F 03-01-93 11-6 E 05-01-89
4-2 F 03-01-93 8-4 F 03-01-93 11-7 E 05-01-89
4-3 E 05-01-89 8-5 F 03-01-93 T-1 F 03-01-93
4 -4 F 03-01-93 8-6 E 05-01-89 T-2 E 05-01-89
4-5 F 03-01-93 8-7 F 03-01-93 T-3A G 09-15-94
4-6 E 05-01-89 8-8 F 03-01-93 T-3B G 09-15-94
4-7 E 05-01-89 9-1 F 03-01-93 T-4 F 03-01-93
5-1 E 05-01-89 10-1 E 05-01-89 T- 5 G 09-15-94
6-1 F 03-01-93

ISSUED REVISED Slick Aircraft Products REVISION

MO DAY YR MO M Y YEAR Unison Industries
10 01 85 09 15 94 530 Blackhawk Park Avenue COVER
Rockford, Illinois, U.S.A. 61104
e 1993 Unlson lndustr~es
 Table of Contents
0.0 INTRODUCTION ...................................................................................................................... 1 -. .
0.1 COPYRIGHT STATEMENT ............................................................................................... 1.
0.2 HOW TO USE THIS MANUAL........................................................................................... 1-I
0.3 RELEVANT PUBLICATIONS ............................................................................................. 1-1
0.4 SYSTEM OVERVIEW ....................................................................................................... 1-2
TECHNICAL REFERENCE .................................................................................................... 2-1
GENERAL ......................................................................................................................... 2-1
THEORY OF OPERATION ................................................................................................ 2-1
Lag Angle - Impulse Coupled Magnetos ............................................................................... 2-1
Lag Angle - Retard Breaker Magnetos.................................................................................. 2-1
Rotation ......................................................................................................................... 2-1
MAGNETO PART NUMBERING ....................................................................................... 2-1
MAGNETO SERIAL NUMBERS ........................................................................................ 2-1

2.0 TOOLS REQUIRED ................................................................................................................. 3-1

MAINTENANCE ................................................................................................................ 4-1

MAINTENANCE SCHEDULE ............................................................................................ 4-1
100-Hour Inspection ......................................................................................................... 4.1
500-Hour Inspection - Direct Drive Magnetos .........................................................................4-1
500-Hour Inspection - Impulse Coupled Magnetos .................................. . . ............................ 4-1
500-Hour Inspection - Retard Breakernachometer Drive Magnetos ..................................................... 4-1
Additional 500-Hour Inspection Procedures for Pressurized Magnetos ......................................... 4-1
1000-Hour Inspection - All Magnetos ................................................................................... 4-1
100-HOU R INSPECTION .................................................................................................. 4-1
Adjust Timing to Engine ..................................................................................................... 4-1
Inspect Harness ............................................................................................................... 4-
Inspect Vent Holes (Non-PressurizedMagnetos) ..................................................................... 4-2
. .-

Inspect P-Lead Attachment ................................................................................................ 4-2

Inspect Switch Wire (Retard Breaker Magnetos Only) ........................................................................... 4-2
Inspect Turbo Filter (Pressurized Magnetos Only) .................................................................... 4-2
Inspect Inlet Nozzle (Pressurized Magnetos Only) ................................................................... 4-2
Inspect Orifice Vent (Pressurized Magnetos Only) ................................................................... 4-2
500-HOUR INSPECTION .................................................................................................. 4-3
Disassembly and Cleaning ................................................................................................ -4-3
Inspect Ball Bearing Assembly ............................................................................................ 4-3
Inspect Rotor ................................................................................................................. -4-3
Inspect Impulse Coupling (Impulse Coupled Magnetos Only) ..................................................... 4-3
Inspect Coil .................................................................................................................... 4.4
Inspect Contact Points .................................................................................................... 4-5
Inspect Condenser ........................................................................................................... 4-5
Inspect Distributor Block Assembly ....................................................................................... 4-5
Inspect Carbon Brush ....................................................................................................... 4-6
Inspect for Structural Damage ............................................................................................. 4.7
ADDITIONAL 500-HOUR INSPECTION PROCEDURES FOR
PRESSURIZED MAGNETOS ............................................................................................ 4-7'
inlet Nozzle ..................................................................................................................... 4-7
Orifice Vent .................................................................................................................... 4-7
Turbo Filter ..................................................................................................................... 4-7
Gaskets ......................................................................................................................... 4-7
0-Ring .......................................................................................................................... 4-7
1000-HOUR INSPECTION ................................................................................................ 4-7

4.0 OVERHAUL ....................................................................................................................... 5'.

'.
.

ISSUED REVISED Slick Aircraft P r o d u c t s PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue i F
10 01 85 3 1 93 Rockford. Illinois. U.S.A. 61 104
a ioo3 llnison Industries
 OVERHAUL PROCEDURE . ALL MODEL MAGNETOS .................................................. 5-1
Remove Magneto from Engine ............................................................................................ 5-1
Disassemble Magneto ....................................................................................................... 5.1
Discard Parts to be Replaced.............................................................................................. 5-1
Magneto Reassembly ....................................................................................................... 5.1
ADDITIONAL PROCEDURES - PRESSURIZED MAGNETOS ......................................... 5.1
Discard Parts to be Replaced.............................................................................................. 5-1
Inlet Nozzle ................................................................................................................... -5-1
Orifice Vent ................................................................................................................... -5-1
Inspect Interior of Magneto ................................................................................................ 5.1
Harness Cap 0-Ring ....................................................................................................... -5-1
REMOVING MAGNETO FROM ENGINE .......................................................................... 6-1
MAGNETO DISASSEMBLY ..:......................................................................................... -7-1
General Order of Disassembly ........................................................................................... -7-1
REMOVE IMPULSE COUPLING ....................................................................................... 7-1
REMOVE WOODRUFF KEY ............................................................................................. 7-1
REMOVE DISTRIBUTOR HOUSING ASSEMBLY ............................................................. 7-1
REMOVE DISTRIBUTOR BLOCK ASSEMBLY ................................................................. 7-2
REMOVE CONDENSER ................................................................................................... 7-2
Remove Retard Breaker Switch Wire (Retard Breaker Magnetos Only ........................................ 7-2
REMOVE ROTOR REAR .................................................................................................. 7-2
REMOVE CONTACT BREAKER ASSEMBLY ................................................................... 7-2
Impulse Coupled and Direct Drive Magnetos .......................................................................... 7-2
Retard Breaker Magnetos .................................................................................................. 7-2
Tachometer Drive Magnetos ............................................................................................... 7-2
REMOVE ROTOR ASSEMBLY ......................................................................................... 7-3
REMOVE BEARINGS FROM SHAFT ................................................................................ 7-3
REMOVE COIL ................................................................................................................. 7-3
6.1 1 REMOVE AIR VENTS ....................................................................................................... 7-3
6.12 REMOVE OIL SEAL .......................................................................................................... 7-3
7.0 MAGNETO ASSEMBLY .................................................................................................. -8-1
7.0.1 General Order of Assembly ................................................................................................ 8-1
7.1 ASSEMBLE BEARINGS ONTO SHAFT ............................................................................ 8-1
7.2 INSTALL ROTOR SHAFT ASSEMBLY .............................................................................. 8-1
7.3 INSTALL OIL SEAL .......................................................................................................... -8-2
7.4 INSTALL WOODRUFF KEY .............................................................................................. 8-2
7.5 ASSEMBLE IMPULSE COUPLING ................................................................................... 8-2
7.6 INSTALL IMPULSE COUPLING ........................................................................................ 8-2
7.7 INSTALL COIL .................................................................................................................. 8-2
7.8 INSTALL CONTACT P801NTS............................................................................................ 8-2
7.8.1 Primary Contact Points; - All Magnetos ................................................................................. 8-2
7.8.2 Retard Breaker Contaca Points - Retard Magnetos Only ........................................................... 8-3
7.8.3 Tachometer Drive Points -Tachometer Drive Magnetos Only .................................................... 8-3
7.9 INSTALL ROTOR CAM ..................................................................................................... 8-3
7.1O TIME THE MAGNETO ........................................................................................................ 8-3
7.10.1 Set Primary Points - All Magnetos ....................................................................................... 8-3
7.10.2 Set Secondary Points -.Retard Breaker Magnetos Only ............................................................ 8-4
7.10.3 Set Tachometer Drive Points - Tachometer Drive Magnetos Only ............................................... 8-5
7.10.4 Install Retard Contact breaker Lead -Retard Breaker Magnetos Only ......................................... 8-5
7.1 1 INSTALL ROTOR GEAR ................................................................................................... 8-5
7.12 INSTALL CONDENSER .................................................................................................... 8-5
'
-/
7.13 DISTRIBUTOR GEAR ASSEMBLY .........:......................................................................... 8-6

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YA MO DAY YEAR Unison Industries
10 85 530 Blackhawk Park Avenue II F
01 03 01 93
Rockford, Illinois, U.S.A. 61 104
8 1993 Unison Industries
 INSTALL DISTRIBUTOR BLOCK ...................................................................................... 8-6
CONNECT CONDENSER WIRE .......................................................................................8-6
Connect Retard Contact Wire ................................................................................................................ 8-7
Connect Tachometer Contact Wire ........................................................................................................ 8-7
ALIGN ROTOR GEAR ....................................................................................................... 8-7
ALIGN DISTRIBUTOR GEAR ............................................................................................ 8-7
ATTACH THE DISTRIBUTOR HOUSING ..........................................................................8-7
SECURE DISTRIBUTOR HOUSING ................................................................................. 8-8

POST-ASSEMBLY TESTING ...........................................................................................9-1

PRE-TEST PREPARATION ..............................................................................................9-1
IMPULSE COUPLING ....................................................................................................... 9-1
COMING-IN SPEED ..........................................................................................................9-1
HIGH-SPEED TEST ..........................................................................................................9-1
LONG-TERM TEST ...........................................................................................................9-1
TEMPERATURE TEST .....................................................................................................9-1
REPEAT IMPULSE COUPLING TEST .............................................................................. 9-1
PRESSURE TESTING - PRESSURIZED MAGNETOS ONLY .......................................... 9-1

MAINTENANCE CHECKLIST .........................................................................................10-1

TROUBLESHOOTING .................................................................................................... 11-1

TROUBLESHOOTING GUIDE ..............................................................................I 1-1 - 11-7

TABLES ................................................................................................................ - 1.
T-5

ISSUED REVISED Slick Aircraft Products PAGE NO . REVISION

MO DAY YR MO DAY YEAR Unison Industries ...
530 Blackhawk Park Avenue 111 F
10 01 85 3 1 93
Rockford. Illinois. U.S.A. 61 104
0 1993 Unison Industries
 SERVICE BULLETINS, SERVICE LETTERS
AND SUPERSEDED LITERATURE
Service Bulletins incorporated into this manual:

Service Date of Last Date lncorporated

Bulletin Revision lnto This Manual
SB2-80C 12-17-80 3-01-93
12-29-90 4-10-88
04-26-81 4-10-88
02-01-81 4-10-88
12-01-82 4-10-88
09-01-83 4-10-88
10-01-86 4-10-88
10-18-83 4-10-88
10-01-84 4-10-88
08-15-85 4-1 0-88
05-10-88 4-10-88
04-10-88 5-01-89
03-10-88 5-01-89
09-01 -88 5-01-89
Service Letters incorporated into this manual:

Service Dale of Last Date Incorporated

Letters Revision Into This Manual
SL1-84A 02-27-87 4- 10-88
SL2-84A 12-02-85 4-1 0-88
SL5-85 06-13-85 4-10-88

This Manual supersedes the following Service Literature.

All previous revisions of Slick 420016200 Series Mainte-

nance and Overhaul Manual, Form L-1037, Revision E-2 or
earlier.

-,
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
MO DAY YR MO DAY YEAR Unison Industries
10 01 85 03 01 93 530 Blackhawk Park Avenue iv F
Rockford, Illinois, U.S.A. 61 104
0 1993 Unison lndustries
THIS PAGE LEFT BLANK INTENTIONALLY
 0.0 INTRODUCTION Detailed instructions for removing the magnetos
from the engine, magneto disassembly and mag-
0.1 COPYRIGHT STATEMENT neto reassembly are contained in Sections Five, Six
All rights resewed. This manual is produced exclu- and Seven, respectively.
sively for use with Slick Aircraft Products Magnetos Maintenance and Overhaul schedules and pro-
andlor lgnition Harnesses. It may not, in whole or in cedures are detailed in Sections Three and Four,
part, be copiea, photocopied, reproduced, trans- respectively. The instructions in Sections Three and
lated or reduced to any electronic medium or Four refer to procedures outlined i n the Magneto
machine readable form without prior consent, in Disassembly (Section Six) and Magneto Assembly
writing, from Slick Aircraft Products. (Section Seven) portions of this manual. It is recom-
mended that this entire manual be thoroughly read
before beginning any inspection or maintenance
APPLICATIONS OF THE INFORMATION CON- procedure.
TAINED IN THlS MANUAL MAY RESULT IN After any inspection or maintenance is done on
LOSSES OR DAMAGES TO THE USER. Slick Magnetos, the testing procedures in Section
The accuracy and applicability of this manual Eight should be performed completely.
has not been verified for any assembly, com- The Maintenance Checklist located in Section Nine
i ponent or part not manufactured by Slick Aircraft provides a summarized schedule for 100 and
Products. Any use of this manual for other than 500-hour inspections. This checklist should be
its intended purpose or for performing any instal- copied and attached to the engine log book at the
lation, maintenance, replacement, adjustment, 100 and 500-hour inspections.
inspection or overhaul of any assembly, com- Section 10, Troubleshooting, is provided as a
ponent or part not manufactured by Slick Aircraft reference guide for diagnosing ignition problems.
Products is not approved, endorsed or
sanctioned by Slick Aircraft Products. 0.3 RELEVANT PUBLICATIONS
No liability will be assumed by Slick Aircraft Slick Form L-1177 lgnition Lead Maintenance
Products for actual, consequential or other types and Overhaul Manual
of damages directly or indirectly resulting from Slick Form L-1178 lgnition Lead Assembly and
the unauthorized use of this manual for other Installation Manual
than its stated purposes. Slick Form L-1035 Harness Application Data
When performing installation, maintenance, Slick Form L-1199 Magneto Application Data
replacement, adjustment, inspection or overhaul
of any Slick assembly, component or part, it is 0.4 SYSTEM OVERVIEW
imperative that the latest revision of the
appropriate Slick manual or product support Slick Aircraft Products has been an innovative
document be referenced. Contact Slick to be leader in the design and manufacture of aircraft
ignition systems for over 25 years. Slick manu-
sure you have the latest manual or support
factures, not merely assembles, a superior
document revision before performing any work.
FAAIPMA Approved product consistently specified
All reasonable attempts were made to make this by quality conscious OEMs.
manual as complete and accurate as possible.
If you have any questions, comments, correc- VERTICALLY INTEGRATED MANUFACTURING
tions or require clarification of any information Slick Aircraft Products manufactures nearly every
contained herein, please call or write Slick Air- component in its magnetos and harnesses. This
I craft Products Customer Service Department at in-house manufacturing process allows Slick to
(815) 965-7704 or 530 Blackhawk Park Avenue, control quality to precise tolerances from raw
Rockford, IL 61104. material to finished product, setting industry
standards.
0.2 HOW TO USE THlS MANUAL DESIGN FEATURES
The procedures outlined in this manual are gener- -Smaller and Lighter
alized for all models of 4200 and 6200 Series Slick Slick's unique design allows for a dimensionally
Magnetos. Specific part numbers are detailed in the smaller magneto, resulting in easier installation
Tables located after the main text. and lighter weight-as much as one pound
The information in this manual is divided into 10 lighter than competitive units.
sections. Section One provides basic technical -Radio Noise Suppression
reference on the design and operation of Slick Slick Magnetos feature superior noise sup-
Magnetos. Section Two illustrates tools needed to pression, eliminating the need for magneto

-.
ISSUED
correctly perform inspection and maintenance.

REVISED Slick Aircraft Products

Unison Industries, Inc.
530 Blackhawk Park Avenue
filters.

1 PA;E:OT~~
REVISION 1
Rockford, Illinois, U.S.A. 61104
@ 1989 Unison Industries, lnc.
 -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.
RELlABlLlTY
Slick setects 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.
FACTORY REBUILT: "LIKE-NEW" TOLERANCES
Slick Factory Rebuilt Magnetosare remanufactured
to comply with FAR Part 43.2 (b), requiring
tolerances equivalent to new magnetos. Critical
components are upgraded to the latest revision
levels. Parts installed in Factory Rebuilt Magnetos
are also controlled by manufacturing lots traceable
through magneto serial numbers.
A COMPLETE OFFERING
Slick FAAIPMA Approved Magnetos have appli-
cations on nearly all piston engines. Slick Ignition
Components are available in the following con-
figurations:
-Complete Upgrade Kits: Cost saving kits includ-
ing 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
Slick lgnition Systems are available through an
international network of aircraft distributors that
offer outstanding product support, delivery and
service. See Slick Distributor List Form L-1051
for details.
COMPLETE AOG INVENTORY
Slick supports its distribution network with com-
plete AOG factory inventory available for next-day
delivery.

L
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
YO DAY YR MO DAY YEAR Unison Industries, Inc. --
530 Blackhawk Park Avenue 1-2 E
10 01 85 05 01 89
Rockford, Illinois, U.S.A. 61104 -
@ 1989 Unison Industries. I ~ c
 1.0 TECHNICAL REFERENCE a balanced LRC circuit which should not be altered
from its original condition. Slick Aircraft Products
1.1 GENERAL goes to great lengths to ensure that product and
Slick 4200 and 6200 Series Aircraft Magnetos are design improvements are retrofittable to prior
manufactured by Slick Aircraft Products, a division magneto models.
of Unison Industries, for use on 4- and &cylinder
1.2.1 LAG ANGLE-IMPULSE COUPLED MAGNETOS
aircraft engines. Slick Magnetos are specified as
OEM equipment by aircraft engine manufacturers The impulse coupling is a mechanical device to
and carry all FAA/PMA approvals from the Federal assist in enginestarting. At low cranking speed, the
Aviation Administration. magneto impulse coupling retards the magneto
ignition timing until the engine crankshaft is at its
Each magneto is identifiedwith a data plate affixed proper position for starting. The lag angle, noted on
to the side of the magneto frame. The data plate the magneto dataplate, is the impulse coupling's
contains serial number and model number informa- retard angle measured in degrees. After engine
tion, lag angle of the impulse coupling, shaft rota- start, the impulse coupling disengages and returns
tion direction (L indicates counterclockwise shaft
the magneto to normal engine timing.
rotation; R indicates clockwise shaft rotation).
Customer part numbers are also provided on the 1.2.2 LAG ANGLE-RETARD BREAKER MAGNETOS
data plate.
The retard breaker assembly is an electrical device
All current production Slick Magnetos are provided powered by the aircraft battery, used to aid in start-
as new units, identified by a red data plate. Slick ing the engine. At low cranking speed, the retard
Factory Rebuilt Magnetos (manufactured prior to breaker retards the magneto ignition timing until the
January 1,1988) are identified by a blue data plate. engine crankshaft is at its proper position for start-
ing. The lag angle, noted on the magneto dataplate,
1.2 THEORY OF OPERATION is the retard breaker's retard angle measured in
The magneto is a completely self-containedignition degrees. When the engine starter disengages, the
generating device. Typically, two magnetos are in- retard breaker assembly is also d~sengaged and the
stalled on each aircraft engine for redundancy. magneto returns to normal engine timing.
When the aircraft engine crankshaft rotates, gears
located in the engine accessory case turn the 1.2.3 ROTATION
magneto rotor shaft containing permanent mag- Rotation specifies the direction that the magneto
nets. With the rotating shaft, a magnetic field is rotor shaft turns when viewed from the mounting
producedthat is transformed into high tension cur- end of the magneto. Left-Hand Rotation is
rent through primary and secondary coil windings. counterlockwise when viewed from the magneto
The high tension current is distributed to the mounting end; Right-Hand Rotation is clockwise
appropriate cylinder through a distributor block when viewed from the magneto mounting end.
assembly and ignition cables. Important Check the dataplate on the magneto
A two-lobe cam and two-pole rotating magnet being replaced for the shaft rotation. Replace with
assembly are used to generate magnetic flux and a magneto with the same rotation.
trigger the high tension spark energy. Four-cylinder
magnetos are driven at engine speed and produce 1.3 MAGNETOPARTNUMBERING
four sparks through 720 degrees of crankshaft ro- Current production magnetos have four digits in the
tation. Six-cylinder magnetos are driven at one and part number and an optional suffix. The first two
one half times engine speed and produce six digits indicate the Series:
sparks through 720 degrees of engine crankshaft
42xx - 4200 Series for four-cylinder engines
rotation.
62xx - 6200 Series for six-cylinder engines
Slick Magnetos are constant timing ignition devices
The last two numbers indicate the model number.
once the engine has started. The magneto is
An "R" suffix indicates Factory Rebuilt.
typically timed to fire at an advancetiming position
for maximum power of the aircraft engine. Example: 4251 - 4200 Series four-cylinder,
model number 51
A typical Slick Magneto will produce in excess of
6262R - 6200 Series six-cylinder,
25,000V at normal speed and although simple in
model number 62,
outward appearance and construction, the mag-
Factory Rebuilt
neto is a complicated electromechanical device.
The size and shape of the rotating magnet head 1.4 MAGNETO SERIAL NUMBERS
assembly, magnet material selection, pole lamina-
tion design, ignition coil design and capacitor Sllck Magnetos have either a seven-digit or an
design are ail equally important in determining the eight-digit serial number. Serial numbers indicate
efficiency of the device. Electrically, the magneto is date of manufacture as follows:

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries, Inc.
01 85 01 89 530 Blackhawk Park Avenue 2-1 E
10 05
Rockford, Illinois, U.S.A. 61104
1989 Unison Industries. Inc
 A. Seven-Digit Serial Numbers
All Slick Magnetos with seven-digit serial
numbers were manufactured prior to January 1,
1988. The first digit indicates the year, the
following 2 digits indicate the month and the
remaining digits are sequenced in order of

'
manufacture per model number for that month.
EXAMPLE: 5 02 0 4 0 6

I
1986
I
Sequence Number
February

6.Eight-Digit Serial Numbers

Slick Magnetos manufactured on or after
January 1, 1988 have an &digit serial number.
The first two digits indicate the year of manlu-
facture, the following 2 digits indicate the month
and the remaining digits are the sequence
number.
EXAMPLE: 88 01 0 0 2 5

l i
1988
I
Sequence Numbler
January

PARTS MAY ADVERSELY AFFECTTHE

PERFORMANCE AND RELIABILITY OF
THE MAGNETO.

ISSUED (1 REVISED Slickc Aircraft Products PAGE NO. (1 REVISION

MO I DAY 1 YR I/ MO1 DAY I YEAR Unison Industries, Inc.
530 IBlackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
a 1989 Unison Industries, Inc.
 2.0 TOOLS REQUIRED
T-100 Assembly and Timing Kit includes:
PIN Description Q~Y
TI 01 Bearing Assembling Plug ...................... 1

PULLER
~106

T151. T153 CAM AND ROTOR SET

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

- + MO DAY YR MO DAY YEAR Unison Industries
10 01 85 03 01 93 530 Blackhawk Park Avenue 3-1 F
- Rockford, Illinois, U.S.A. 61104
0 1993 Unison Industries
THIS PAGE LEFT BLANK INTENTIONALLY
 L-1037
3.0 MAINTENANCE 3.1.6 1000-HOUR INSPECTION-ALL MAGNETOS
In addition to the 500-Hour Inspection listed above,
.-,,
3.1 MAINTENANCE SCHEDULE replace ball bearing assembly following instruc-
tions in Section 7.0, Magneto Assembly.
3.1 .I 100-HOUR INSPECTION 3.2 100-HOUR INSPECTION
A. Adjust timing to engine
B. Inspections The following maintenance procedures should be
1. Wiring connections and conditions followed every 100 hours of service or at annual
2. Vent holes (non-pressurized magnetos) inspection, whichever comes first. Perform main-
3. P-lead attachment tenance on each magneto.
4. Retard breaker switch wire (retard breaker 3.2.1 ADJUST TIMING TO ENGINE
magnetos)
5. Turbo filter used with pressurized CAUTION: BE SURE IGNITION SWITCH
magnetos IS IN "OFF" POSITION AND THE CON-
6. lnlet noule (pressurized magnetos)
DENSER LEAD IS GROUNDED.
7. Orifice vent (pressurized magnetos)
8. Pressure test magnetos
A. Turn the engine crankshaft in the normal
3.1.2 500-HOUR INSPECTION - direction of rotation until the No. 1 cylinder is in
DIRECT DRIVE MAGNETOS the full-advance firing position, following
A. Cleaning engine manufacturer's procedure for timing
B. Ball bearing assembly of magnetos. Scribe a reference mark on the
C. Coil magneto mounting flange and engine acces-
D. Contact points sory case.
E. Condenser B. Loosen the magneto mounting bolts and
F. Carbon brush connect astandard timing light between engine
G. Lubrication ground and condenser stud, according to the
timing light manufacturer's instructions.
3.1.3 500-HOUR INSPECTION -
C. Turn ignition switch to "ON" position.
IMPULSE COUPLED MAGNETOS
A. Cleaning
WARNING: WITH THE IGNITION
B. Ball bearing assembly
SWITCH IN THE "ON" POSITION,
C. lmpulse coupling
THE MAGNETOS WILL FIRE THE
D. Coil
SPARK PLUGS IFTHE PROPELLER
E. Contact points
IS ROTATED, POSSIBLY CAUSING
F. Condenser
FATAL INJURY. DO NOT ROTATETHE
G. Carbon Brush
PROPELLER WITH THE IGNITION
H. Lubrication
SWITCH IN THE "ON" POSITION.
3.1.4 500-HOUR INSPECTION
RETARD BREAKER TACHOMETER DRIVE D. Rotate the magneto in the direction of normal
rotation (see magnetodata plate) until the timing
MAGNETOS light indicatesthe breaker points are open. (Most
A. Cleaning timing lights indicate open points with a light
B. Ball bearing assembly "on" condition or an audible signal.)
C. lmpulse coupling E. Slowly rotate the magneto in the opposite
D. Coil direction of normal rotation until the light goes
E. Primary contact points "out" or the audible signal stops.
F. Secondary contact points F. Measure the distance from the original installed
G. Condenser mark on the accessory case and the corre-
H. Carbon Bmsh sponding magneto reference mark. If this
I. Lubrication dimension is greater than 1/8", the magneto
3.1.5 ADDITIONAL 500-HOUR INSPECTION must be removed and the contact breaker points
PROCEDURES FOR PRESSURIZED inspectedladjusted per Section 3.3.6 of this
MAGNETOS Manual. A 118" change corresponds to an
A. Inlet nozzle, orifice vent and turbo filter approximate 5O change in internal magneto
6. Inspect inside of magneto for turbocharger timing.
contaminants G. Tighten the magneto mountingclamps to secure
C. Frame gasket and screw gasket the magneto to the engine.
D. Harness cap 0-Ring 1. Alternately tighten the magneto mounting
E. Pressure testing clamp nuts to 8 ft-lbs of torque.
C

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

-
,,
, MO DAY YR MO DAY YEAR Unison Industries
01 1 530 Blackhawk Park Avenue 4-1 F
10 85 3 93
Rockford, Illinois, U.S.A. 61 104
@ 1993 Unison Industries
L-1037
2. Continue to tighten both nuts alternately in 3.2.6 INSPECT TURBO FILTER
several steps to 17 ft-lbs of torque. (PRESSURIZED MAGNETOS ONLY)
-
CAUTION: IN NO CASE SHOULD lnspect for yellow or red color, condensation or free
17 FT-LBS BE EXCEEDED. IF THE standing water or foreign matter in the filter
MOUNTING NUTSARE TORQUED element. (See Figure 3.2.6). If the filter is contami-
IN EXCESS OF 17 FT-LBS, DAM- nated, reference the engine andlor airframe manu-
AGE TO THE MAGNETO MOUNT facturer's literature for pressurization system
ING FLANGE MAY RESULT, corrective action. Replace turbo filter. If filter shows
RENDERING THE UNIT KON- contamination, the magneto must be removed and
AIRWORTHY. inspected for contaminant damage. Follow pro-
cedures in Section 3.3 of this manual.
H. Turn ignition switch to "OFF" position.

3.2.2 INSPECT HARNESS

Refer to Harness Maintenance Manual L-1177 for
complete wiring inspection instructions.
Figure 3.2.6
3.2.3 INSPECT VENT HOLES (NON-PRESSURIZED
3.2.7 INSPECT INLET NOZZLE
MAGNETOS) (PRESSURIZED MAGNETOS ONLY)
Vent holes must be clean and clear of any obstr:uc- lnspect and clean inlet nozzle to insure it is clean
tion. Correct as necessary. and free of obstruction. (See Figure 3.2.7). Yellow or
3.2.4 INSPECT P-LEAD ATTACHMENT white particles or any oily film in the inlet nozzle
indicates moisture contaminationand possible lack
The P-lead connects the magneto primary circuitto of pressurization. Reference the engine andlor
the airframe ignition switch. If the P-lead is discon- airframe manufacturer's literaturefor pressurization
nected, the magneto will be "ON" and will fire'the system corrective action.
spark plug if the propeller is rotated. Possible fatal
injury can result. Confirm that the P-lead is securely
attached to the condenser stud.
Torque P-lead nut to 13-15 in-lbs.

3.2.5
CAUTION: IF 13-15 IN-LBS TORQUE
LlMlT IS EXCEEDED, CONDENSER
PERFORMANCE MAY BECOME INTER-
MITTENT OR TOTALLY INOPERATIVE.
REPLACE CONDENSER IF TORQUE
LIMIT IS EXCEEDED, FOLLOWING
INSTRUCTIONS IN SECTIONS 6.5 AND
7.12 OF THIS MANUAL.
Follow airframe manufacturer's recommendatiions
to ensure the ignition switch and P-lead are
operating properly.
INSPECT SWITCH WIRE (RETARD BREAKER
MAGNETOS ONLY)
I 3.2.8 INSPECT ORIFICE VENT
Figure 3.2.7

(PRESSURIZED MAGNETOS ONLY)

Inspect and clean orifice vent to insure it is clean
and free of obstruction. Maximum orifice diameter

The retard breaker lead connectsthe retard contact

points to the ignition vibrator. If this lead is dis-
connected the starting circuit will become in-
operative.
Torque retard breaker switch stud to 13-15 in-lbs.

CAUTION: IF 13-15 IN-LBS TORQUE

LIMIT IS EXCEEDED, STARTING CIR-
CUIT MAY BECOME INOPERATIVE.
Follow the airframe manufacturer's recommenda-
7
tions to ensure that the ingition switch and retard ..-
breaker lead are operating properly. Fiaure 3.2.8

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR uo DAY YEAR Unison Industries
530 13lackhawk Park Avenue 4-2 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61104
0 1993 Unison Industries
 3.3 500-HOUR INSPECTION C. lnspect Magneto Rotor Shaft
Follow instructions in Section 5.0, Removing lnspect magneto rotor shaft at impulse coupling
Magneto from Engine. All procedures needed to location. If the heel of the pawl has struck the
perform the 500-hour inspections are detailed in shaft and caused the shaft to dimple in excess
Section 6.0, Magneto Disassembly and Section 7.0, of .006 inch per side, the rotor shaft must be
Magneto Assembly. replaced. (See Figure 3.3.3).

3.3.1 DISASSEMBLY AND CLEANING ROTOR

Proceed with magneto disassembly, following in-

structions in Section 6.0, Magneto Disassembly.
3.3.2 INSPECT BALL BEARING ASSEMBLY
A. Determine if bearing is old style obsolete open
bearing or approved double-shielded bearing
assembly:
1. Locate the part number stamp on the bear-
ing cap. The correct bearing configuration
will have the letter 3" or later (i.e., '3': "K",
"C',et.al) stamped on it in either of the loca-
tions shown in Figure 3.3.2. MAGNETO
FRAME

Figure 3.3.3

33.4 INSPECT IMPULSE COUPLING

A. Clean Impulse Coupling
1. All portionsof the impulse coupling must be
cleaned, exposing bare metal, to ensure a
reliable inspection.
2. Use a suitable grease dissolving solvent to
remove all oil or sludge buildupson impulse
coupling.
B. lnspect Coupling
Figure 3.3.2
IMPULSE SHELL IMPULSE
B. Old style open bearings must be replaced with \ /PAWL
the new double-shielded configuration using
Slick Bearing Replacement Kit and following
instructions in Section 7.0, Magneto Assembly.

NOTE: IF BEARINGSARE REMOVED RIVET

FROM SHAFT; BEARINGS MUST BE

DISCARDED AND REPLACED. IMPULSE HUB \ /
.
- IMPULSE HUB
C. lnspect ball bearing assembly by rotating rotor ASSEMBLY
shaft. Check for free movement. If rotor shaft
binds, sticks or feels loose in bearing cap, Figure 3.3.4
replace ball bearing assembly following
instructionsin Section 7.0, Magneto Assembly.
3.3.3 INSPECT ROTOR NOTE: IN MANY CASES, STRINGERS,
lnspect rotor for damaged or worn keyway. Check INCLUSIONS AND HEAT CHECKS MAY
rotor bearing surfaces for wear. APPEAR AS SURFACE DISCONTI-
A. lnspect Oil Seal NUITIES ON IMPULSE COUPLING
lnspect oil seal location on shaft. COMPONENTS. THESE CONDITIONS
B. Assemble Bearings and Rotor ARE NORMAL AND GENERALLY DO
Assemble bearings and rotor following in- NOT, BY THEMSELVES, REQUIRE
structions in Sections 7.1 and 7.2, Magneto IMPULSE COUPLING REPLACEMENT.
Assembly.

d
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
MO DAY YR MO DAY YEAR
Unison Industries, Inc.
10 01 85 05 01 89 530 Blackhawk Park Avenue 4-3 E
Rockford, Illinois, U.S.A. 61104
@ 1989 Unison Industnes, Inc
L-1037
. .
1. Using acceptable procedures, inspect the 2. Lubricate the hub and spring with aircraft
impulse coupling shell for cracks, rust or engine oil.
signs of corrosion. None of these conditioris 3. Follow re-assembly instructions, Section 7.5
are acceptable. Replace impulse couplir~g of this manual.
as necessary. D. Inspect Stop Pin
2. Inspect the impulse coupling hub for crack:^, 1. Inspect the stop pin for looseness, cracks or
rust or signs of corrosion. None of these corrosion. None of these conditions are
conditions are acceptable. Replace impulse acceptable. Replace magneto frame as
coupling as necessary. necessary. (See Figure 3.3.4C).
3. lnspect the hub shaft and keyway for
deformation or damage. Replace impulse
coupling as necessary.
4. Inspect impulse coupling pawls. If the latch- STOP PIN
ing end that contacts the stop pin in the
magneto frame is rounded, peened or
excessively worn, replace the impul!;e
coupling.
5. lnspect pawl retaining rivets. If the rivets are
loose or show indications of movement, MAGNETO
FLANGE
then replace the impulse coupling.
6. Measure the clearance between the boss
on the underside of each (2) impulse pawl
and the pawl plate using a feeler gage. MAGNETO-
FRAME
Positionthe latchingend of the impulse pawl
over the pawl plate as shown in Figure Figure 3.3.4C
3.3.4A.
LATCHING END OF PAWL 2. Inspect the stop pin for flat spots. Flat spots
are a normal sign of wear and do not, by
themselves, require corrective action. If the
HEEL OF PAWL flat spots are excessive and cause the
,--..
impulse coupling pawl to slip past the stop
pin, either the impulse coupling, magneto
frame or both components need replace-
ment.
PAWL PLATE E. Install Impulse Coupling
Follow instructions in Section 7.6 of this manual
to install impulse coupling in magneto.
Figure 3.3.4A
7. Maximum clearance for pawls with one (1) 3.3.5 INSPECT COIL
boss is 0.150 inch. Maximum clearance for A. Inspect coil for visible radial cracks. If any
pawls with two bosses is 0.150 inch for left- cracks are evident, replace coil. (See Figure
hand rotation couplings and 0.140 inch lior 3.3.5).
right-handrotation impulse couplings. If the 6. Inspect coil for primary and secondary circuit
feeler gauge can pass between the full resistance and continuity. Coil must be re-
width of the boss and the pawl plate, replace placed if resistance is outside of tolerances or
the impulse coupling. See Figure 3.3.49.For an open exists. Refer to Table Five for toler-
coupling rotation, see magneto data plate. ances.
BOSS
IMPULSE PAWL CRACKS

: FEELERWGE

Figure 3.3.48
C. Reassemble Impulse Coupling
1. Lubricate the pawl assembly with aiircraft
engine oil. Ensure that the pawls move
Figure 3.3.5
freely. --.~
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 4-4 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61 104
0 1993 Unison Industries
 3.3.6 INSPECT CONTACT POINTS
B. Visual Inspection for Over-Torqued Condition
A. Primary Contact Points (All Magnetos)
1. Using a magnifying lens, examine the glass
NOTE: In a retard breaker magneto, the primary
bead end seals of the capacitor for broken
contact points are secured by a BLACK
glass or for glass separation from the retain-
anodized screw.
ing steel rings. Either condition is cause for
1. lnspect primary contact points for signs of
component rejection.
pitting and discoloration. If points are not
2. lnspect the condenser for signs of cor-
discolored and have a white, frosty surface
rosion. This condition is cause for com-
around the edges, points are functioning
ponent rejection. (See Figure 3.3.7).
properly and can be reused.
2. If points are blue (indicating excessive 3. inspect the condenser P-lead stud for
arcing) or pitted, they should be discarded. twisting or "pulled" condition. Either of
Replace primary contact point assembly, these conditions is cause for component
condenser and cam. rejection. (See Figure 33.7A).
B. Retard Breaker Contact Points (Retard Breaker
Magnetos Only)
NOTE: In a retard breaker magneto, the retard
breaker contact points are secured by a SILVER
screw.
1. lnspect retard breaker contact points for
signs of pitting and discoloration. If points
are not discolored and have a white, frosty
surface around the edges, points are func-
tioning properly and can be reused.
2. If points are blue (indicating excessive Figure 3.3.7A
arcing) or pitted, they should be discarded.
C. Test Condenser
Replace retard breaker contact point
Test the electrical properties of the condenser
assembly and cam.
using appropriate calibrated test equipment.
C. Tachometer Drive Contact Points 1. Test for capacitance value with condenser
(Tachometer Drive Magnetos Only) charged to 400 volts DC.
1. lnspect tachometer drive contact points for Service limit: .35 microfarad f 10 percent.
signsof pittinganddiscoloration. Ifpointsare 2. Test for resistance. Measured between
not discolored and have a white, frosty sur- condenser lead wire and condenser shell,
face around the edges, points are function- resistanceshould be greater than 10 mega-
ing properly and can be reused. ohms.
2. If points are blue (indicating excessive arc-
ing) or pitted, they should be discarded. NOTE: NO FIELD REPAIRS OF
Replace tachometer drive contact point as- THE CONDENSER ARE AP-
sembly and cam. PROVED. UNDER NO CIR-
CUMSTANCES SHOULD THE
3.3.7 INSPECT CONDENSER CONDENSER LEAD BE RESOL-
A. Clean Condenser DERED TO THE CONDENSER
1. If the external surfacesof the condenser are STUD IF I T BECOMES DE-
dirty, clean with light soapy water. TACHED. SOLDERING THIS
2. Rinse soapy water and dirt from condenser LEAD CAN RESULT IN ELEC-
surfaces with clear water and pat dry before TRICAL BREAKDOWN INSIDE
reinstallation into the magneto housing. THE CAPACITOR AND/OR LOSS
OF HERMETIC INTEGRITY.
D. Install Condenser
Install condenser following instructions in
Section 7.12 of this manual.

3.3.8 INSPECT DISTRIBUTOR BLOCK ASSEMBLY

A. Clean block assembly
1. Disassemble and clean the distributor block
bearing bar using standard non-filming,
non-conductive cleaner. Clean distributor
gear with soapy water and rinse with clear
Figure 3.3.7 water.

ISSUED 1 REVISED Slick Aircraft Products PAGENO. )I REVISION

d MO DAY YR MO DAY Unison Industries II
530 Biackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
Q 1993 Unison Industries
 CAUTION: DO NOT PUT CLEANER 2. lnspect the electrode finger for looseness.
IN EITHER BRONZE OlLlTE The electrode should be held securely to the
BUSHING. THESE BUSHINGS shaftwhen tested with light finger pressure.
ARE IMPREGNATEDATTHE FAC- Loose condition requires block and gear
TORY AND CLEANER WILL replacement. (See Figure 3.3.8A).
DRAW THE LUBRICANT OUT OF
THE BUSHING.

2. Using a cotton swab or "Q-Tip", clean all

surfaces free of dirt, oil, carbon dust and
other contaminants.
B. lnspect Distributor Block
1. Visually inspect the block for cracksor other
physical damage. Replace block assembly
as necessary.
2. lnspect the brass electrode posts for signs
of physical wear. Replace block assembly
ELECTRODE FINGER
as necessary. During normal operation, the
post will experience an electrical-metal Figure 3.3.8A
transfer with the distributor gear electrode.
This condition is normal and not cause for 3. Clean the end of the electrode to remove
rejection. (See Figure 3.3.8). electrical deposits.
D. lnspect Bearing Bar
1. Visually inspect for cracks or other physical
L POSTS
damage. Replace assembly as necessary.
2. Make sure the bearing bar is free of all oil
and carbon dust prior to reassembly.

3.3.9 INSPECT CARBON BRUSH

A. Visually inspect the carbon brush. Overall
length of the carbon brush must be greaterthan
19164 inch and the OD of the brush diameter
must be uniform. (See Figure 3.3.9). Carbon
brushes that do not meet these limits must be

(q'XCH
replaced. Reference Section 7.13 of this
manual.
Figure 3.3.8

3. lnspect oilite bushing for gumming oil con-

dition. The bushing should be free of
contamination and the gear should turn
freely in the distributor block with no
appreciable drag. If the bushing isgummed, BAD GOOD
wipe the bushing with MEK and lubricate
with one drop of Texaco Terestic 100 Oilite Figure 3.3.9
Bushing Oil. No other oil should be placed
in this bushing. B. Visually inspecithe loading spring. Overall free
4. Make sure the distributor block surfaces are standing length should be greater than 19/32
free of all oil and carbon dust prior to inch. (See Figure 3.3.9A). Look for flat spots on
reassembly. the spring windings. Springs that appear worn
or do not meet the overall length requirements
C. lnspect Distributor Gear must be replaced. Reference Section 7.13 of
1. lnspect gear teeth for wear and general this manual.
integrity. Replace block assembly as
necessary.

\&
19/32 INCH

Figure 3.3.9A

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries, Inc.
530 Blackhawk Park Avenue 4-6 E
10 01 85 05 01 89
Rockford, Illinois, U.S.A. 61104
@ '1989 Un~sonIndustr~es,Inc.

-- - -
 L-1037

C. Reinstall following Section 7.13B. 3.4..3 TURBO FILTER

lnspect for yellow or red color, condensation or free
3.3.10 INSPECT FOR STRUCTURAL DAMAGE standing water or foreign matter in the filter
Check magneto frame and distributor housing for element. (See Figure 3.4.3). If the filter is con-
cracks or other damage. lnspect threaded areas to taminated, reference the engine and/or airframe
ensure threads are intact and not damaged. manufacturer's literature for pressurizationsystem
Replace as necessary, following instructions in corrective action. Replace turbo filter. If filter shows
Assembly Section of this manual. Complete contamination, the magneto must be removed and
magneto reassembly, Section 7. inspected for contaminant damage. Follow pro-
cedures in Section 3.3 of this manual.
3.4 ADDITIONAL 500-HOUR INSPECTION
PROCEDURES FOR PRESSURIZED
MAGNETOS
3.4.1 INLET NOZZLE
Inspect and clean inlet nozzle to insure it is clean
and free of obstruction. (See Figure 3.4.1). Yellow or
white particles or an oily film in the inlet nozzle Figure 3.4.3
indicates moisture contamination and possible lack
of pressurization. Reference engine and/or air- 3.4.4 GASKETS
frame manufacturer's literature for pressurization lnspect frame gasket for wear and replace as
system corrective action. necessary. Gasket contains a metal mesh founda-
tion to insure proper ground between the magneto
frame and the magneto housing. Replace ONLY
with Slick Replacement Gaskets. lnspect screw
gaskets for wear and replace as necessary.
Replace ONLY with Slick Replacement Gaskets
and Slick Mounting Screws.

3.4.5 O-RING
lnspect harness cap O-ringfor wear and replace as
necessary.

NOZZLE 3.5 1000-HOUR INSPECTION

Ball bearing assembly must be replaced at 1000
hours. Follow procedures in Section %0,Magneto
Assembly.

Figure 3.4.1

3.4.2 ORIFICE VENT

lnspect and clean orifice vent to insure it is clean
and free of obstruction. Maximum orifice diameter
is .025 inch. (See Figure 3.4.2).

Figure 3.4.2

A
1
MO
ISSUED
I
DAY
I
YR
I/
II
REVISED
MO
I
DAY
I
YEAR
I Slick Aircraft Products
Unison Industries, Inc.
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
1989 Unison Industries, Inc.
' d i l
PAGE NO. REVISION
THIS PAGE: LEFT BLANK INTENTIONALLY
 4.0 OVERHAUL 4.1.4 MAGNETO REASSEMBLY
Slick 4200/6200 Series Magnetos should be com- Proceed with magneto reassembly, following
pletely overhauled when conditions indicate. instructions in Section 7.0 of this manual.
Magnetos must be overhauled at every engine 4.2 ADDITIONAL PROCEDLJRES-
overhaul. In no case should magnetos have in-
service times greater than the TBO hour limit for the
PRESSURIZED MAGNETOS
engine on which it is installed. In addition to the overhaul procedures outlined
above, the following must be performed.
Magnetos must be overhauled after a lightning
strike on the aircraft and following asudden engine 4.2.1 DISCARD PARTS TO BE REPLACED
stoppage.
Discard parts as listed in Table Four.
A complete list of parts that must be replaced at
overhaul can be found in Table Three (4200 Series) 4.2.2 INLET NOZZLE
and Table Four (6200 Series). Refer toTablesThree lnspect and clean inlet nozzle to ensure it is clean
and Four as you overhaul your Slick Magneto. and free of obstruction. Presence of dirt or other
--
contaminants indicates that the magneto pressuri-
NOTE: AN ALTERNATIVE TO OVERHAUL zation system is not functioning properly. Consult
IS COMPLETE MAGNETO REPLACE- engine manufacturer's manuals for corrective
MENT WlTH A NEW SLlCK MAGNETO. action.
NEW SLlCK MAGNETOS INCORPORATE
ALL THE LATEST DESIGN FEATURES 4.2.3 ORIFICE VENT
AND ARE A COST EFFECTIVEALTERNA- lnspect and clean orifice vent to ensure it is clean
TIVE TO OVERHAUL. and free of obstruction. Maxirnum orifice diameter
is .025 inch.
4.1 OVERHAUL PROCEDURE-
ALL MODEL MAGNETOS 4.2.4 INSPECT INTERIOR OF MAGNETO
lnspect inside of magneto for corrosion, oil and
4.1.1 REMOVE MAGNETO FROM ENGINE other turbocharger contaminants. Clean if neces-
Follow procedures in Section 5.0, Removing sary and inspect aircraft pressurization system
Magneto from Engine. according to the engine and/or airframe manu-
facturer's recommended procedures.
4.1.2 DISASSEMBLE MAGNETO
Proceed with magneto disassembly, following 4..2.5 HARNESS CAP O-RING
instructions in Sections 6.0. lnspect O-ring in harness cap for cuts or other
conditions that would inhibit a proper seal. Replace
4.1.3 DISCARD PARTS TO BE REPLACED O-ring as necessary.
ReferenceTable Three, 4200 Series Overhaul Parts
Replacement List or Table Four, 6200 Series
Overhaul Parts Replacement List. Discard all parts
removed for overhaul replacement and REPLACE
WITH NEW SLlCK PARTS.
Slick does not author~zethe use of "used" parts as
replacement parts for other magnetos. In many
cases, subcomponent parts are matched at the
factory and will function improperly if used in con-
junction with other similar parts.

NOTE: SLlCK AUTHORIZES THE USE

OF ONLY SLlCK REPLACEMENTPARTS
IN THE MAINTENANCE AND/OR OVER-
HAUL OF SLlCK AIRCRAFT PRODUCTS
EQUIPMENT. USE OF PARTS OR
FASTENERS NOT MANUFACTURED OR
APPROVED BY SLlCK VOIDS ANY AND
ALL WARRANTIES AND MAY AD-
VERSELY AFFECT THE PERFOR-
M A N C E A N D JEOPARDIZE T H E
AIRWORTHINESS OFTHE MAGNETO.

'1 ISSUED /I REVISED I Slick Aircraft Products PAGE NO. I/ REVISION

MO DAY YR MO DAY YEAR Unison Industries, Inc. II
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
0 1989 Unison Industries. Inc
THIS PAGE LEFT BLANK INTENTIONALLY
 5.0 REMOVING MAGNETO FROM ENGINE
A. To remove magneto, proceed as if you were
timing the magneto to the engine. Follow the
engine manufacturer's procedure to set the
engine to fire cylinder number one, at the timing
setting shown on the engine data plate.
B. Removethe harness cap from the magneto by
removing the 3 screws that secure it to the
magneto. When removing the cap, place a
visible mark on the harness cap and an ad-
jacent mark on the distributor housing. Use this
mark to ensure that the cap is properly oriented
upon reassembly.
C. To remove the magneto from the engine, pro-
ceed as follows:
1. Remove the P-lead wire that connects the
ignition switch to the magneto condenser.
Retard breaker magnetos only - Remove
the lead that connects the retard contact
points to the starting circuit.
Tachometer drive magnetos only - Re-
move the lead that connects the tachometer
points to the tachometer.
Pressurized magnetos only - Disconnect
pressurization tube from magneto.
2. Remove the 2 nuts, washers and clamps
that secure the magneto to the engine.
NOTE: THE MAGNETO MUST BE
REMOVED FROM THE ENGINE
FOR DISASSEMBLY AND IN-

D. To prevent any contaminant from entering the

magneto accessory hole, coverthe hole with a
suitable material while the magneto is removed
from the engine.

CAUTION: EXTRA CARE MUST BE

TAKEN TO PREVENTANY FOREIGN
OBJECT FROM PASSING INTO THE
ENGINE THROUGH THE MAGNETO
ACCESSORY HOLE O N T H E
ENGINE WHEN THE MAGNETO IS
REMOVED.

E. Remove Drive Gear

In certain applications, it will be necessary to
remove the drive gear from the magneto. If
applicable, remove drive gear and save for
reinstallation. Inspect drive gear according to
the engine manufacturer's recommended
procedures.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 6-1 F
10 01 85 03 01 93
Rockford, Illinois, u.S.11.61 104
@ 1993 Unison Indusrrier.
 6.0 MAGNETO DISASSEMBLY
Following are disassembly instructions for Slick
420016200 Series Magnetos. The directions are
generalized and refer to both 4200 and 6200 Series
Magnetos unless specifically noted. Refer to Table
Two for specific part numbers and to Table One,
Exploded Assembly Diagram.
6.0.1 GENERAL ORDER OF DISASSEMBLY
Remove: Impulse Coupling
Woodruff Key
Distributor Housing Assembly
Condenser
Rotor Gear Figure 6.1A
Contact Breaker Assembly
Rotor Assembly 6.2 REMOVE WOODRUFF KEY
Bearings from Shaft
Coil Pry woodruff key from rotor shaft using pliers. (See
Oil Seal Figure 6.2).

6.1 REMOVE IMPULSE COUPLING

A. Remove cotter pin, nut, washer, bushing and
drive gear where applicable. (Section 5.OE).
B. Grasp shell of impulse coupling assembly and
gently pull the assembly outward to clear the
latching earsof the impulse hub assembly. (See
Figure 6.1).

Figure 6.2

6.3 REMOVE DISTRIBUTOR HOUSING

ASSEMBLY
A. Remove three long screws and single short
screw from distributor housing.
B. Separate distributor housing from magneto
frame. (See Figure 6.3).

Figure 6.1

/ CAUTION: STRONG SPRING TENSION

Figure 6.3
C. Turn shell to release spring tension. C. Disconnectcondenserleadfrom contact breaker
D. Remove impulse shell and attached inipulse assembly.
spring. D. Retard breaker magnetos only - Disconnect
E. Engage Slick T-106 hub puller into grooves in retardbreaker switch leadfrorncontact breaker
the hub assembly. Tighten T-106 puller bolt and assembly.
remove impulse coupling hub assembly. (See E. Tachometer drive magnetos only - Discon-
Figure 6.1A). nect lead wire from contact points.
,-

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
10 01 85 3 1 93 530 Elackhawk Park Avenue 7-1 F
Rockford, Illinois, U.S.A. 61 104
b 1993 Unison Industries
 D. Remove cam by prying straight up with a
6.4 REMOVE DISTRIBUTOR BLOCK screwdriver blade. (See Figure 6.7.1).
ASSEMBLY REMOVE SCREW
AND WASHER
Remove two screws and remove distributor bearing
bar, distributor gear and distributor block from the
housing. (See Figure 6.4).

Figure 6.4 Figure 6.7.1

REMOVE CONDENSER 6.7.2 RETARD BREAKER MAGNETOS

When removingthe condenser from the distributor NOTE: In a retard breaker magneto, the primary
housing, carefully rotate the condenser wire contact points are secured by a BLACK anodized
counterclockwise in the same direction as the screw. The retard breaker contact points are
condenser to eliminate twisting the condenser lead. secured by a SILVER screw. (See Figure 6.7.2).
(See Figure 6.5). A. Disconnect coil lead wire from primary contact
breaker assembly.
B. Remove cam by prying straight up with a screw-
driver blade.
C. Remove screw and washer from primary con-
tact breaker assembly.
D. Remove primary contact breaker assembly.
E. Remove screw and washer from retard breaker
contact breaker assembly.
F. Remove retard breaker contact breaker
assembly and spacer.
t-
- . <

Figure 6.5

6.5.1 REMOVE RETARD BREAKER SWITCH WlRE

(RETARD BREAKER MAGNETOS ONLY)
Remove the screw that secures the retard contact
breaker switch wire to the distributor housing.

6.6 REMOVE ROTOR GEAR

Pry rotor gear out of the end of the rotor assembly
using two flat-blade screwdrivers.

6.7 REMOVE CONTACT BREAKER Figure 6.7.2

ASSEMBLY 6.7.3 TACHOMETER DRIVE MAGNETOS
6.7.1 IMPULSE COUPLED AND DIRECT DRIVE A. Disconnecttachometer leadwiresfrom tachom-
MAGNETOS eter contact point assembly.
A. Disconnect coil lead wire from contact breaker B. Remove cam by prying straight up with screw-
assembly. driver blade.
B. Remove screw and washer from breaker C. Remove screws and washers from tachometer
assembly. contact point assembly.
C. Remove contact breaker assembly from D. Remove tachometer contact point assembly
bearing cap. and spacers.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 7-2 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61 104
0 1993 Unlson lndustr~es
 L-1037

6.8 REMOVE ROTOR ASSEMBLY CAUTION: ROTOR IS MAGNETIZED. DO NOT

A. Remove two screws and two bearing plate ALLOW ROTOR TO COME INTO CONTACT
clamps. WITH METAL CHIPS OR FILINGS.
B. Press against the drive end of the rotor shaft
and withdraw the rotor and bearing cap
assembly from the drive frame. (See Figure

6.9 REMOVE BEARINGS FROM SHAFT'

k
A. Insert Slick T-121 bearing puller (both halves)
PIN M-3485BEARING CAP ASSEMBLY

Figure 6.9A

between the bearings and the rotor magnet 6.10 REMOVE COIL
head. A. Remove coil primary ground screw.
B. Place rotor and T-121 on T-152 spacer. (See B. Using coil wedge extractor T-122, remove coil
Figure 6.9). wedges and lift out coil. (See Figure 6.10).

u Figure 6.10
Figure 6.9
6.11 REMOVE AIR VENTS
CAUTION: BEARING CAP ASSEMBLY Remove air vents from magneto.
PART NUMBER M-3485 HOLDS A 6.12 REMOVE OIL SEAL
DOUBLE-SHIELDED BEARING CAP-
TIVE IN THE BEARING CAP. THIS Remove oil seal from magneto.
ASSEMBLY IS PRE-LUBRICATEDATTHE
FACTORY WlTH SPECIAL GREASE THAT
TOLERATES THE OZONE RICH EEN-
VIRONMENT WITHIN THE MAGNETO.
PART NUMBER M-3485 SHOULD
NEVER BE DISASSEMBLED.

C. Press rotor shaft and remove bearings. (See

Figure 6.9A).

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

lJnison lndustries
530 Blackhawk Park Avenue 7-3 F
Rockford, Illinois, U.S.A. 61104
0 1993 Unison Industries
 7.0 MAGNETO ASSEMBLY 7.2 INSTALL ROTOR SHAFT ASSEMBLY
A. Place magneto frame in T-100 base (flange
7.0.1 GENERAL ORDER OF ASSEMBLY down).
Assemble Bearings onto Shaft B. Position rotor shaft assembly in the magneto
lnstall Rotor Shaft Assembly frame.
lnstall Oil Seal C. lnsert rotor and frame assembly plug (T-101)
lnstall Woodruff Key into the T-100 fixture T-handle. (See Figure
Assemble Impulse Coupling 7.2).
Install Impulse Coupling
lnstall Coil
lnstall Contact Point Assembly
lnstall Rotor Cam
lnstall Rotor Gear
Timing the Magneto
lnstall Retard Breaker Lead Wire
(Retard Breaker Magnetos Only)
lnstall Condenser
lnstall Distributor Gear Assembly
lnstall Distributor Block
Connect Condenser Wire
Align Rotor Gear
Align Distributor Gear
Attach and Secure the Distributor Housing
7.1 ASSEMBLE BEARINGS ONTO SHAFT
A. lnsert the base plate (T-117) and adapter plate
bushing (T-119) into the T-100 tool kit base.
B. Place one ball bearing and bearing cap Figure 7.2
assembly onto the rotor shaft.
C. Insert the rotor shaft into the adapter plate D. Turn T-handle until the bearing cap bottoms in
bushing (threaded end down). the frame. Place capoverend of rotor shaft first.
D. Place the bearing assembly plug (T-101) E. Place T-151 cam and rotor set onto the end of
onto the exposed end of the rotor shaft. (See the rotor shaft and turn T-handle until the shaft
Figure 7.1). bottoms in magneto frame. (Figure 7.2.1)
F. lnstall bearing clamps and the hold-down
screws.
G. Torque screws to 20-24 in-lbs.

ISSUED
Figure 7.1

E. Turn T-handle screw to seat the bearings

against the bearing shoulders on the rotor
shaft.
F. Remove the rotor shaft, adapter bushing,
adapter plate and bearing assembly plug from
the T-100 tool base.

REVISED Slick Aircraft P~roducts

- Figure 7.2.1

PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 8-1 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61 104
a 1993 Unlson lndustr~es
 C. Install coupling nut and torque to 120-180 in-lbs
7.3 INSTALL OIL SEAL to seat couplingonto the rotor shaft. Ifcotter pin
A. Lubricate oil seal with engine oil. will not align with pin hole within the specified
B. Reversethe magneto on the T-100 base so the torque range, remove nut and lightly lap the
flange is facing up. bottom surface of the nut with a piece of emery
C. Insert the oil seal over the rotor shaft. cloth.
D. Press the oil seal flush into the frame using the
oil seal assembly plug 0-103) and the T-handle NOTE: ON SOME MAGNETOS, IT
screw. (See Figure 7.3). WILL BE NECESSARY TO REMOVE
THE IMPULSE COUPLING NUT AND
WASHER DURING DRIVE GEAR IN-
STALLATION. LEAVE THE NUT AND
WASHER INSTALLED AS IN STEP C,
UNTIL AFTER POST-INSPECTION
TESTING.

D. Check to see that the coupling is free by

snapping it through 3 or 4 times.

7.7 INSTALL COIL

A. Place the frame on the T-100 assembly and
timing tool. Insertthecoil into the frame, making
sure that it is back against the stops. Insert the
coil wedges betweenthe bridge and the frame.
Figure 7.3 B. Drive the two wedges tight, using a hammer
and flat punch. Attach the ground wire of the
7.4 INSTALL WOODRUFF KEY coil (either black or white in color depending on
Press woodruff key into the key slot of the rotor the coil type) to the frame, using screw. Torque
shaft. to 20 in-lbs.
C. Positionthe coil high tension lead flush to 1/32
7.5 ASSEMBLE IMPULSE COUPLING inch below the parting surface of the magneto
frame. (See Figure 7.7).

r
Retard Breaker Magnetos-Proceed t o '7.7
A. Assemble the inner eye of the impulse spring CAUTION: IF THE HIGH TENSION
into the grooves in the impulse hub. LEAD PROTRUDES ABOVE THE
B. Set the impulse shell on the hub. There is no MAGNETO FRAME, IT CAN MAKE
tension in the coupling in this position. DIRECT CONTACT WITH THE DIS-
C. Hold the shell in one hand and the pawls with TRIBUTOR GEAR AND CAUSE THE
the thumb and forefinger of the other hand. MAGNETO TO MALFUNCTION.
D. Pull the hub straight back slowly far enough to
clear the projections on the shell.
E. Hold the shell stationary and rotate the hub to 1132 BELOW PARTING SURFACE
OF FRAME
wind the spring until the projections on the
other section of the pawl plate pass the projec-
tions on the shell. (Approximately one-qua~ter
revolution; 90 degrees.)

/ CAUTION: DO NOT WIND COUPLING

MORE THAN 114 TURN.

F. Make sure the shell is seated squarely on the

hub and turns freely. Figure 7.7

7.6 INSTALL IMPULSE COUPLING 7.8 INSTALLCONTACTPOINTS

A. Install impulse coupling assembly onto the rotor 7.8.1 PRIMARY CONTACTPOINTS-ALL MAGNETOS
shaft. A. Attach contact point assembly on the bearing
B. Install impulse washer. cap using appropriate screw.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries, inc.
10 01 85 05 01 89 530 Blackhawk Park Avenue 8-2 E
Rockford, Illinois, U.S.A. 61 104
@ 1989 Unison Industries, Inc.
 NOTE: ON RETARD BREAKER MAG- 7.10 TIME THE MAGNETO
NETOS, THE PRIMARY POINTS ARE
SECURED WITH A BLACKANODIZED NOTE: FOR RETARD BREAKER MAGNE-
TOS, THE PRIMARY POINTS MUST BE
SET FIRST. THE RETARD (SECONDARY)
POINTS ARE SET IN REFERENCETOTHE
CAUTION: RETARD BREAKER MAG- PRIMARY POINTS AND THE PRIMARY
NETOS USE DIFFERENT LENGTH POINTS MUST BE SET CORRECTLY TO
SCREWS TO SECURE THE CONTACT ENSUREACCURACYOF RETARDCON-
BREAKER ASSEMBLIES. USE OF IN- TACT SETTINGS.
CORRECT MOUNTING SCREWS WILL
DAMAGE UPPER MAGNETO BEAR- 7.1 0.1 SET PRIMARY POINTS - ALL MAGNETOS
ING AND CAUSE POSSIBLE MAG- A. Place the magneto on the T-125 base, flange
NETO FAILURE. down.
6200 Series Magnetos - Remove T-509 tim-
7.8.2 RETARD BREAKER CONTACT POINTS - ing base adapter.
RETARD BREAKER MAGNETOS ONLY -
Retard Breaker Maanetos Install the T-123
timing plug on the rot& shaft before placing the
NOTE: INSTALL PRIMARY POINT magneto on the T-125 rotor base.
ASSEMBLY BEFORE INSTALLING
RETARD POINT ASSEMBLY. Impulse Coupled Magnetos - Do not use
T-123 timing plug.
A. Place spacer on bearing cap and attach retard Direct-Drive Magnetos - Install the T-123
contact points assembly using silver screw and timing plug on the rotor shaft before placingthe
plain washer. magneto on the T-125 base.
B. Do not tighten screws until magneto is timed. B. Looking directly down on the magneto, align
the magneto so that the coil is oriented in the
7.8.3 TACHOMETER DRIVE CONTACT POINTS - 12 o'clock position.
TACHOMETER DRIVE MAGNETOS ONLY C. Insert T-150 "EmGap Gauge (Figure 7.10.1)
between the pole laminations in the rotor shaft
NOTE: INSTALL PRIMARY POINT and the pole laminations in the frame.
ASSEMBLY BEFORE INSTALLING
TACHOMETER POINT ASSEMBLY. NOTCHED END

A. Place tachometer contac points on bearing cap

and secure using two screws and plain wash-
ers.
B. Do not tighten screws until magneto is timed.
FLAT END
7.9 INSTALL ROTOR CAM
A. Install cam using a light hammer and T-151 Figure 7.10.1
cam and rotor set.
B. Drive the cam until it bottoms in the rotor cam Insert flat end of T-150 when using old style
slot. (See Figure 7.9). rotor (no slots on the magnet head). See Figure
7.10.2. Reference the magneto data plate for
magneto rotation. Insert the "EmGap Gauge
against the right lamination for right-hand rota-
tion magnetos and against the left laminations
for left-hand rotation magneto.

Figure 7.9 Figure 7.1 0.2

-
ISSUED REVISED Slick Aircraft P~roducts PAGE NO. REVISION
MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 8-3 F
10 01 85 3 1 93 Rockford, Illinois, U.S,.A. 61 104
C

o 1993 Unison Industries

 Insert notched end of T-150 when using new 7.10.2 SET SECONDARY POINTS-RETARD BREAKER --.
style rotors (with slots on magnet head). See MAGNETOS ONLY
Figure 7.10.3. Locate the appropriate "C' or "R" --

timing slot on the rotor magnet head and insert NOTE: FOR RETARD BREAKER MAG-
the notched end of the "Engap gauge. Use the NETOS, THE PRIMARY POINTS MUST
"L"slot for left-hand rotation magnetos and the BE SET FIRST. THE RETARD (SECON-
"R" slot for right-hand rotation magnetos. DARY) POINTS ARE SET IN REFER-
ENCE TO THE PRIMARY POINTS, AND
THE PRIMARY POINTS MUST BE SET
CORRECTLY TO ENSURE ACCURACY
OF RETARD CONTACT SETTINGS.

A. Set primary points according to instructions in

Section 7.10.1 above. Do not removeT-150 "E"
gap gauge, and do not remove magneto frame
from T-125 base.

Figure 7.10.3
B. Rotate the magneto frame on the T-100 base
until the T-150 "En gap gauge rests against the
pole lamination in the magneto frame. Rotate
the magneto frame clockwise for left-hand
rotation magnetos and counterclockwise for
right-hand rotation magnetos. The magneto
,
1
1
NOTE: RETARD POINTS ARE S E T ~ N
REFERENCE TO PRIMARY POINT
SETTINGS. THE LAG ANGLE ON
THE MAGNETO DATAPLATE IS THE
RETARD BREAKER'S RETARD
ANGLE MEASURED IN DEGREES.
THE FOLLOWING PROCEDURE
WILL SETTHE RETARD POINTS THE
REQUIRED NUMBER OF DEGREES
FROM THE PRIMARY POINTS.
1
rotor shaft is now in "E" gap position. B. Holding magneto securely in base (in "E" gap
E. Using a timing light, adjust the contact points to position), tip magneto and T-125 base and
be just opening when the frame is against the loosen timing disk retaining screws. Timing
T-150 gauge. This will provide a point gap open- disk should rotate freely.
ing of .008-.012 inches. C. Ensure that the T-150 "E" gap gauge is still
F. Impulse Coupled and Direct Drive Mag- positioned against the correct lamination.
netos: Secure the points in this position by Rotate magneto frame until it contacts the pin
tightening the screws. Torque adjusting screw in the T-125 base. Rotate the magneto frame
to 18-20 in-lbs. Torque the pivot screw to 15-18 clockwise for left-hand rotation magnetos,
in-lbs. counterclockwise for right-hand rotation
Retard Breaker Magnetos: Secure primary magnetos.
points by tightening the adjustingscrew. Torque D. Hold magneto securely in base and tip mag-
to 15-18 in-lbs. Proceed to 7.10.2. net0 and T-125 base. Tighten one timing disk
G. Apply cam grease sparingly to each lobe of the retaining screw to hold the timing d~skin place.
cam. (See Figure 7.10.4). Remove magneto from T-125 base.
E. Turn T-125 base over so that tim~ngd ~ s kis fac-
ing you. Loosen timing disk retaming screw.
Scribe a mark on the timing disk corresponding
to the index mark on the T-125 base. This
represents a point-of-reference for primary
point "E" gap. (See Figure 7.10.5).

-t

Figure 7.10.4
H. Attach coil lead wire to the vertical bronze male
terminal of the primary point assembly. Figure 7.10.5
,-

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
10 530 Blackhawk Park Avenue 8-4 F
01 85 3 1 93
Rockford, Illinois, U.S.A. 61 104
8 1993 Unison Industries
 L-1037
Section 7.10.1 above.
NOTE: THE ACTUAL NUMBER AT B. Adjust tachometerdrivepointsto have anopen-
THE TIMING DISK INDEX MARK IS ing of ,013 (+.002 - .000) with the rotor oriented
NOT CRITICAL. THIS INDEX MARK to the position of maximum cam lift.
WILL BE USED AS A POINT OF C. Tighten the adjusting screws to secure the
REFERENCE FOR SETTING THE points in this position.Torque adjusting screws
RETARD POINTS A SPECIFIED to 18-20 in-lbs.
NUMBER OF DEGREES FROM THE D. Apply cam grease sparingly to each lobe of the
PRIMARY POINTS. cam. (See Figure 7.10.6).
F. Note the lag angle from the magneto dataplate.
G. The ticks on the timing disk each represent 59
To set the timing disk in the proper position,
rotate the timing disk counterclockwise for
left-hand rotation magnetos and clockwise for
right-hand rotation magnetos. Rotate the disk
according to the following chart:

Magneto Retard Number of Ticks

Angle on Timing Disk
5O 1
lo0 2
15O 3
20 O 4 Figure 7.10.6
25 O 5
30 O 6 7.10.4 INSTALL RETARD CONTACT BREAKER LEAD-
35 O 7 RETARD BREAKER MAGNETOS ONLY
40 O 8 A. Insert retard ignitionswitch screw through eye-
let end of retard breaker lead wire.
EXAMPLE: B. Insertretardignitionswitchscrewthrough hous-
Lag angle as noted from dataplate: 25O ing. Secure screw using nut and lockwasher.
Rotation as noted from dataplate: L
To set timing disk, turn the timing disk 5
'11 INSTALL ROTOR GEAR
ticks (5 x 5O = 25O) counterclockwise A. Install rotor gear into rotor. Orientation is not
using scribed mark as reference point. critical.
B. Tap with a light hammer until gear bottoms on
H. Tighten timing disk retaining screws. Reverse
T-125 base and place magneto in it, flange
down (use T-123 timing plug). Remove T-150
" E gap gauge from magneto.
I. Rotate magneto against the direction of
normal rotation (clockwise for left-hand
rotation magnetos and counterclockwise
for right-hand rotation magnetos) until the ROTOR GEAR

magneto bumps against the pin in the T-125

base. The magneto rotor shaft is now retarded
from E-gap position the number of degrees
indicated on the magneto data plate.
J. Using a timing light, adjust the retard contact
points to where they are just opening. Tighten
the adjustingscrews to secure the retard points
in this position. Torque adjusting screws to 18-
20 in-lbs.
K. Apply cam grease sparingly to each lobe of the
cam. (See Figure 7.10.6). Figure 7.11
L. Attach coil lead wire to the male terminal of the
primary point assembly. 7.12 INSTALL CONDENSER
A. Assemble the condenser into the distributor
7.10.3 SET TACHOMETER DRIVE POINTS - housing, being sure to rotate the condenser
TACHOMETER DRIVE MAGNETOS ONLY wire the same rotation as the condenser is
A. Set primary points according to instructions in tightened in the housing. (See Figure 7.12).

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

..-
MO DAY YR YO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 8-5 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61 104
Cg 1993 Unison industries
 BRUSHISPRING ASSEMBLY

MAXIMUM BRUSH EXTENSION

UNDER NO PRELOAD.

Figure 7.13
Figure 7.12
7.14 INSTALL DISTRIBUTOR BLOCK
Retard Breaker Magnetos Only-Ensure A. Assemble the distributor gear in the distributor
retard breaker contact lead is channeled under- block with the L&R facing you.
neath condenser. See Figure 7.12.1. 6. Assemble the bearing bar to the distributor
block as shown in Figure 7.14.

Figure 7.14
Figure 7.12.1
C. Secure the distributor block in the distributor
CAUTION: RETARD BREAKER LEAD housing with the cut-away toward the con-
WlRE MUST BE CHANNELED SE- denser. Use screws and lock washers. Torque
CURELY UNDER CONDENSER. to 18-28 in-lbs. (See Figure 7.14A).
FAILURE TO DO SO MAY CAUSE
THE LEAD WlRE TO INTERFERE
WITH ROTOR GEAR MOVEMENT OR
POINT OPERATION.

DISTRIBUTOR GEAR ASSEMBLY

A. Install carbon brush into spring.
1. Insert small end of carbon brush into
tapered end of spring.
2. Turn carbon brush clockwise until the
shoulder of carbon brush seats on the
spring.
B. Install carbon brush assembly into the dis-
tributor gear.
1. Insert the open end of the spring into the
open end of the distributor gear shaft. Figure 7.14A
2. Gently press the carbon brush and spring
assembly into the shaft untilthe springseats 7.15 CONNECT CONDENSER WlRE
on the bottom of the shaft. The top of the A. Connect condenser wire to the remaining
carbon brush should protrudefrom the top terminal of the contact assembly.
of the shaft approximately 114 inch. (See B. Attach the terminal with the lead pointing left.
Figure 7.13). (See Figure 7.15)

1 1 1 1
/
MO

10
ISSUED
DAY

01 85
YR
11 REVISED
MO

05
DAY

01
1 1
YEAR

89
1 Slick Aircraft Products
Unison Industries, Inc.
530 Blackhawk Park Avenue
PAGENO. 1
II
REVISION
~-
.

Rockford, Illinois, U.S.A. 61104

@ 1989 Unison Industries. Inc
 7.16 ALIGN ROTOR GEAR
Align the "L" or "R" (depending on the rotation of
the magneto-look at data plate) on the rotor gear
so that it points up, toward the high tension lead of
the coil. Secure rotor shaft to prevent rotation dur-
ing assembly. Alignment of rotor gear is critical.
(See Figure 7.16)

CONDENSER LEAD WIRE POINTASSEMBLY

Figure 7.15

7.15.1 CONNECT RETARD CONTACT WlRE

A. Connect retard terminal wire to retard contact
points. (See Figure 7.15.1).

Figure 7.16

7.17 ALIGN DISTRIBUTOR GEAR

A. Align the "L" or "R" hole in the distributor gear
with the "L" or "R" in thedistributor block. Use
"C'for left-handrotation and "R" for right-hand
rotation magnetos.
- ' 6. Lock the distributor gear in place with the T-118
timing pin through the appropriate hole in the
Figure 7.15.1 block and gear.
7.15.2 CONNECT TACHOMETER 7.18 ArrACH THE DISTRIBUTOR HOUSING
CONTACT WIRE A. Insert the top boss of the distributor housing
A. Connect wires to tachometer contact points. into its mating pilot on the magneto frame.
(See Figure 7.15.2). B. Gently rotate the distributor housing onto the
magneto frame. (See F~gure7.18).

PIN

Figure 7.15.2

Figure 7.18

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 8-7 F
10 01 85 03 01 93 Rockford, Illinois, U.S.A. 61104
0 1993Unlson lndustr~es
 CAUTION: MAKE SURE THE CAR-
BON BRUSH IS CONTAINED IN THE
DISTRIBUTOR SHAFT DURING
ASSEMBLY. IFTHE CARBON BRUSH
CATCHES ON THE SIDE OFTHE DIS
TRIBUTOR SHAFT, THE COIL STRAP
WILL BE BENT INTO THE WRONG
POSITION DURING ASSEMBLY.

7.19 SECURE DISTRIBUTOR HOUSING

A. Secure the housingwith three screws and one
screw. Torque to 24 in-lbs.

PRESSURIZED MAGNETOS: DUR-

ING RE-ASSEMBLY, PLACE ONE
DROP OF FEL-PRO, PRO-LOCK
BROWN HYDRAULIC SEALANT NO.
51452, INTOTHE TAPPED MAGNETO
FRAME HOLES THAT CORRE-
SPOND TO THE FOUR HOUSING
SCREWS.

B. Remove T-118 timing pin.

CAUTION: DO NOT ROTATE MAG-
NETO ROTOR SHAfT WlTH THE
P-148TIMING PIN INSERTED 1M THE
DISTRIBUTOR BLOCK. IF ROTOR
SHAFT IS ROTATED WlTH TIMING
PIN INSERTED, THE MAGNETO
MUST BE DISASSEMBLED AND IN-
SPECTED FOR DISTRIBUTOR
BLOCK AND GEAR DAMAGE.

-
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
MO DAY YR MO DAY YEAR Unison lndustries
10 01 85 3 1 530 Blackhawk Park Avenue 8-8 F
93
Rockford, Illinois, U.S.A. 61 104
Q 1993 Unison Industries
 8.0 POST-ASSEMBLY TESTING 2. Regular and consistent firing of the spark
gaps is required during the entire test.
Complete Magneto Reassembly, Section 7.0. B. 6200 Series Magnetos
Ensure that the T-118 Timing Pin has been 1. Test run the magneto for a minimum of three
removed. hours. Operate the magneto at 3000 RPM
for the first two hours and 4500 RPM for the
8.1 PRE-TEST PREPARATION remaining hour.
A. Mount the magneto on a suitable test stand in 2. Regular and consistent firing of the spark
the same position as installed on the engine. gaps is required during the entire test.
B. Install a Slick High-Temperature Ignition
Harness on the magneto and connect each 8.6 TEMPERATURE TEST
output lead to a 5mm spark gap. Measure the temperature on the outside surface of
the magneto frame during the long term test at the
highest RPM setting. The magneto will generate
MAGNETO UNLESS THE IGNITION heat during normal operation. Maximum tempera-
HARNESS IS INSTALLED AND THE ture on the outside surface of the magnetoframe is
OUTPUT LEADS ARE CONNECTED 175O F when tested at room temperature.
8.7 REPEAT IMPULSE COUPLING TEST
8.2 IMPULSE COUPLING Repeat impulsecoupling test (Section 8.1) following
A. Rotate the test stand drive pulley in the same the temperature test detailed above.
direction of rotation as stated on the magneto 8.8 PRESSURE TESTING-PRESSURIZED
data plate.
B. The impulse coupling should engage the stop MAGNETOS ONLY
pin in the magneto frame below approximately After magneto reassembly, install a pressurized
200 RPM. If the impulse coupling pawls slip harness cap and apply 15 psi filtered air to the inlet
past the stop pin or engage intermittently, the nozzle of the magneto. Air flow at 15 psi is not to
impulse coupling is not operating properly. exceed 40 standard cubic feet per hour (SCFH). If
flow is excessive, reposition gaskets and retorque
8.3 COMING-IN SPEED housing and harness cap screws. Screws should
A. Determine the lowest speed at which the be torqued to 18-20in. Ibs. (See Figure 8.8 for Test
magneto can be turned and still spark all 5mm Apparatus Details). Testing should be conducted
gaps without missing. with magneto at room temperature.
B. The test gap must fire consistently at 200 RPM
on non-impulse magnetos and 350 RPM on MAX. FLOW OF40 SCFH
impulse coupled magnetos. b AT15PSI
I

8.4 HIGH-SPEED TEST

A. 4200 Series Magnetos
1. Operate the magneto at 1000, 2000 and
3000 RPM for five minutes at each speed
-
AIR SUPPLY
-
REGULATOR
4%
I
FLOW METER

setting.
2. Observe sparking regularity at the spark FILTER
gaps. Magneto must produce a consistent -
spark at all speed settings. TO MAGNETO
B. 6200 Series Magnetos PRESSURE GAUGE
1. Operate the magneto at 1000, 2000, 3000
and 4000 RPM for five minutes at each
speed setting. Figure 8.8
2. Observe sparking regularity at the spark
gaps. Magneto must produce a consistent
spark at all speed settings.
8.5 LONG-TERM TEST - OPTIONAL
A. 4200 Series magnetos
1. Test run the magnetofor a minimum of three
hours. Operate the magneto at 1725 RPM
for the first two hours and 3400 RPM for the
remaining hour.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industriles
530 Blackhawk Park Avenue 9-1 F
10 01 85 03 01 93
Rockford, Illinois, U.S.A. 61104 I

O 1993 Unison Industries

THIS PAGE LEFT BLANK INTENTIONALLY
 9.0 MAINTENANCE CHECKLIST

AIC Type Engine MakeIModel

N# Total Time on Engine
Magneto PIN Total Time on Magneto
Magneto SIN Date

EVERY 100 HOURS

ADJUST TIMING TO ENGINE Sec. 3.2.1
INSPECTIONS
fl Wiring Conditions and Connections Sec. 3.2.2
Vent Holes-Non-Pressurized Magnetos Sec. 3.2.3
P-Lead Attachment Sec. 3.2.4
Turbo Filter (Pressurized Mags Only) Sec. 3.2.5
fl Inlet Nozzle (Pressurized Magnetos Only) Sec. 3.2.6
Orifice Vent (Pressurized Magnetos Only) Sec. 3.2.7

EVERY 500 HOURS

GENERAL CLEANING Sec. 3.3.1
0INSPECTIONS-ALL MAGNETOS
Ball Bearing Assembly Sec. 3.3.2
Impulse Coupling Sec. 3.3.4
Coil Sec. 3.3.5
Condenser Sec. 3.3.7
Contact Points Sec. 3.3.6
El Carbon Brush Assembly Sec. 3.3.9
Distributor Block Assembly Sec. 3.3.8
INSPECTIONS-PRESSURIZED MAGNETOS Sec. 3.4
Inlet Nozzle Sec. 3.4.1
3 Orifice Vent Sec. 3.4.2
3 Turbo Filter Sec. 3.4.3
3 Frame Gasket Sec. 3.4.4
3 Screw Gaskets Sec. 3.4.4
I Harness Cap 0-Ring Sec. 3.4.5
I Magneto Interior-Check for Turbocharger Sec. 3.3.3-3.3.1 0
Contaminants

~1 Pressure Testing Sec. 8.8.

1 LUBRICATION

EVERY 1000 HOURS

Replace Ball Bearing Assembly

+
1 1 1 11 1 1 1
MO

10
ISSUED
DAY

01
YR

85
MO

05
REVISED
DAY

01
YEAR

89
Slick Aircraft Products
Unison Industries, Inc.
530 Blackhawk Park Avenue
PAGE NO. I REVISION

Rockford, Illinois, U.S.A. 61104

@ 1989 Unison Industries, Inc.
THIS PAGE LEFT BLANK INTENTIONALLY
 10.0 TROUBLESHOOTING
10.1 TROUBLESHOOTING GUIDE
The following charts are intended to be used as a
guide only. Many non-ignitionfactors influence the
performance of aircraft ignition systems and the
replacement or repair of ignitioncomponents may
not remedy problems in all cases. After verifying
that all non-ignition related causes for possible
problems have been explored, then proceed to use
this troubleshooting guide.

I. OPERATIONAL PROBLEMS

PROBLEM POSSIBLE CAUSE REMEDY

HARD STARTING Incorrect external timing to engine. Consult engine manufacturer's specifications for
ignition timing. Correct as required.
Incorrect internal timing. Consult Slick Manual L-1037,Section 7.10,for
internal timing specifications. Correct as required.
Point gap setting incorrect. Consult Slick Manual L-1037,Section 7.10,for
point gap specifications. Correct as required.
Faulty impulse coupling. Consult Slick Manual L-1037,Section 3.3.4,for
impulse coupling specifications and inspection
procedures.
Overtorqued impulse coupling nut. Torque nut to 120-320in-lbs. on magnetos with
attached drive gears. There must be ,010to -020
play between drive gear and impulse coupling.
Correct as necessary.
Worn pawls or stop pin. Inspect pawls and stop pin for wear. Correct as
necessary.
Impulse coupling fails to return to Inspect impulse coupling nut for torque.
unwound position.
Fouled spark plugs. Clean spark plugs according to manufacturer's
specifications.
Incorrect spark plug gap. Regap spark plug to manufacturer's
specifications.
faulty ignition switch. Inspect ignition switch for possibility of inter-
mittent grounding and proper operation. Repair
or replace as necessary.
Corrosion on harness lead contacts. Consult Manual L-1177for proper cleaning and
inspection procedures. Correct as required.

ISSUED REVISED Slick Aircraft P~roducts PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue 11-1 F
10 01 85 3 1 93
Rockford, Illinois, U.S.A. 61 104
0 1993 Unlson lndustr~es
 1 PROBLEM / POSSIBLE CAUSE I REMEDY
HARD STAITING Magneto Internal Component Failure: Consult Manual L-1037, Section 3, for
specifications and inspection procedures.
Points lnspect for excessive burning, pitting, corrosion,
gap setting and general operation. Replace as
necessary.
Cam lnspect cam for excessive wear or unevenness
that could cause "point spread." Correct as
necessary.
Condenser lnspect for faulty P-lead connection, P-lead stud
for overtorqued condition, damaged pigtail
connector and damaged grounding. Replace as
necessary.
Coil lnspect for cracks, damage to high tension strap
or pigtail connector and integrity of windings.
Replace as necessary.
Distributor Gear lnspect electrode finger for looseness, gear teeth,
shaft. lnspect carbon brush for damage. Replace
as necessary.
Distributor Block Inspect distributor towers for evidence of abrasion
or excessive burning. Examine rotor gear
bushings for wear. Replace as necessary.
Incorrect or non-standard starting Consult engine operation's manual for proper
procedures. operation and performance. Correct as required.
Faulty fuel delivery system. Consult engine manufacturer'smanual for speci-
fications and operation. Correct as required.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries, Inc.
530 Blackhawk Park Avenue 11-2 E
10 01 85 05 01 89
Rockford, Illinois, U.S.A. 61104
e 1989 Unison Industries. Inc.
 PROBLEM 1 POSSIBLE CAUSE I REMEDY
ROUGH RUNNING Incorrect external timing to engine. Consult engine manufacturer's manual for
specifications of ignition timing. Correct as
required.
Incorrect internal timing. Consult Slick Manual L-1037, Section 7.10, for
internal timing specifications. Correct as required.
Fouled spark plugs. Clean spark plugs according to manufacturer's
specifications.
Incorrect spark plug gap. Regap spark plug to manufacturer's
specifications.
Faultv .
., mark -
.olua. Test spark plug according to manufacturer's
specifications.
Faulty ignition lead. Consult Slick Harness Maintenance Manual
L-1177, Section 5, for ignition lead troubleshooting
information. Correct as required.
Faulty ignition switch. Inspect ignition switch for possibility of inter-
mittent grounding and proper operation. Repair
!
or replace as necessary.
Magneto Internal Component Failure: Consult Manual L-1037, Section 3, for
specifications and inspection procedures.
Points Inspect for excessive burning, pitting, corrosion,
gap setting and general operation. Replace as
necessary.
Cam Inspect cam for excessive wear or. unevenness
that could cause "cam spread." Correct as
necessary.
Condenser Inspect for faulty P-lead connection, P-lead stud
for overtorqued condition, damaged pigtail
connector and damaged grounding. Replace
as necessary.
Coil Inspect for cracks, damage to high tension strap
or pigtail connector and integrity of windings.
Replace as necessary.
Distributor Gear Inspect electrode finger for looseness, gear teeth,
shaft. lnspect carbon brush for damage. Replace
as necessary.
Distributor Block Inspect distributor towers for evidence of abrasion
or excessive burning. Examine rotor gear
bushings for wear. Replace as necessary.
Excessive heat. Inspect baffling or cooling air duct. Correct as
necessary.
Faulty fuel delivery system. Consult engine operation's manual for proper
operation and performance. Correct as required.
Faulty induction system. Inspect for leaks and faulty valve operation.
Consult engine manufacturer's specifications for
proper operation and performance.
Faulty exhaust system. Inspect for obstructions in exhaust pipes and
mufflers, faulty valve operation. Consult engine
manufacturer's specifications for proper operation
and performance.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries, Inc.
530 Blackhawk Park Avenue 11-3 E
10 01 85 05 01 89
Rockford, Illinois, U.S.A. 61104
a 1989 Unison Industries. Inc.
 PROBLEM POSSIBLE CAUSE REMEDY
ROUGH RUNNING Propeller out of track or imbalanced. Consult propeller manufacturer's manual for
OR VIBRATION specifications. Correct as necessary.
IN SPECIFIC Propeller imbalanced or installed Correct as necessary.
RPM RANGE incorrectly.
Propellerlengineharmonic resonance. Consult airframe manufacturer's operations
manual. Correct as necessary.
Magneto Internal Component Failure: Consult Manual L-1037, Section 3, for
specifications and inspection procedures.
Points lnspect for excessive burning, pitting, corrosion,
gap setting and general operation. Replace as
necessary.
Cam lnspect cam for excessive wear or unevenness
that could cause "cam spread." Correct as
necessary.
Condenser lnspect for faulty P-lead connection, P-lead stud
for overtorqued condition, damaged pigtail
connector and damaged grounding. Replace as
necessary.
Coil lnspect for cracks, damage to high tension strap
or pigtail connector and integrity of windings.
Replace as necessary.
)I Distributor Gear lnspect electrode finger for looseness, gear teeth,
shaft. lnspect carbon brush for damage. Replace
I as necessary.
j

1 1 Distributor Block / orInspect distributor towers for evidence of abrasion

I
excessive burning. Examine rotor gear
bushings for wear. Replace as necessary.
Faulty fuel delivery system. Consult engine manufacturer's manual for
specifications and operation. Correct as required.
Faulty induction system. lnspect for leaks and faulty valve operation.
Consult engine manufacturer's specifications for
proper operation and performance. Correct as
required.
Faulty exhaust system. lnspect for obstructions in exhaust pipes and
mufflers, faulty valve operation. Consult engine
manufacturer's specifications for proper operation
and ~erformance.

ISSUED REVISED Slick Aircraft Products

Unison Industries, Inc.
10 01 85 05 01 530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
@ 1989 Unison Industries, Inc
 PROBLEM POSSIBLE CAUSE I REMEDY
EXCESSIVE RPM Incorrect external timing to engine. Consult engine manufacturer's manual for
DROP DURING specifications of ignition timing. Correct as
MAGNETO CHECK required.
Incorrect internal timing. Consult Slick Manual L-1037, Section 7.10, for
internal timing specifications. Correct as required.
Fouled spark plugs.
specifications.
Incorrect spark plug gap. Regap spark plug to manufacturer's
specifications.
Faulty spark .plug.
- Test spark plug according to manufacturer's
I
- ~

specifications.
Faulty tach. I Confirm tach accuracy at RPM where mag drop
p
Faulty ignition lead. / Consult Slick Harness Maintenance Manual
ignition lead troubleshooting
as reauired.
1 Corrosion on harness lead contacts. Consult Manual L-1177 for proper cleaning and
ins~ection~rocedures.Correct as reauired. 1
PROBLEM POSSIBLE CAUSE REMEDY I
MAGNETO WILL Faulty ignition switch. Inspect ignition switch for possibility of inter-
NOT FIRE mittent grounding and proper operation. Repair
or replace as necessary.
Faulty condenser. Consult Slick Manual L-1037, Section 3.3.7.
lnspect for faulty P-lead connection, broken
P-lead stud, damaged pigtail connector, and
damaged grounding. Replace as necessary.
Faulty coil. Consult Slick Manual L-1037, Section 3.3.5.
lnspect for cracks, damage to high tens~onstrap
or pigtail connector and integrity of windings.
1 Replace as necessary.
Point gap
- . setting
- incorrect. I Consult Slick Manual L-1037, Section 7.10, for
I 1 point cia^ specifications. Correct as required. I
MAGNETO "HOT" Faulty ignition switch. Inspect ignition switch for possibility of inter-
mittent grounding and proper operation. Repair
or replace as necessary.
Broken "P"-lead wire. Repair as necessary.

I I lncorrect external timing to engine. Consult engine manufacturer's manual for specifi-
-
cations of ignition -
timina. Correct as reauired.
Faulty tach. Consult engine manufacturer's manual for specifi-
cations of ignition timing. Correct as required.

.
/

ISSUED REVISED Slick Aircraft Products 1 PAGE NO. 11 REVISION I

Unison Industries, Inc.
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
0 1989 Unison Industries, Inc
11. PHYSICAL DAMAGE

/ PROBLEM POSSIBLE CAUSE 1 REMEDY

MOUNTING Hold-down clamp over-torqued. Torque hold-down clamps to 190-220 in-lbs.
FLANGE
,
. Hold-down clamps torqued unevenly. When magneto is reinstalled, be sure clamps are
tightened with even pressure.
Magneto gasket residue on accessory Be sure mounting face is free of gasket residue.
case mountins pad.

POINTS BURNED
EXCESSIVELY
/ Faulty condenser. Consult Manual L-1037, Section 3.3.7, for testing
Drocedure. Reolace as necessarv.
I lmproper spark plug gap. Regap plugs according to manufacturer's
s~ecifications.
1 Fouled spark plug. Clean spark plug according to manufacturer's
s~ecifications.
/ Excessive heat. lnspect baffling or cooling air duct. Correct as
necessarv. I
HIGH TENSION Improper tension between high tension Consult Manual L-1037, Section 7.7, for high
LEAD ON COIL lead and carbon brush. tension lead loading specifications.
WORN OR
BURNED
THROUGH

COlL CRACKEC) Faulty coil. Consult Manual L-1037, Section 3.3.5, for specifi-
OR ARCING cations and inspection procedures. Replace as
IN CASE necessary.
Improper spark plug gap. Regap spark plug to manufacturer's
specifications.
Fouled spark plug. Clean spark plug according to manufacturer's
specifications.
Faulty spark plug. Inspect spark plug according to manufacturer's
/ specifications.
Excessive heat. 1 Inspect baffling or cooling air duct. Correct as
necessary.

ELECTRODE Timing pin wedged between electrode Consult Manual L-1037for proper timing
FINGER LOOSE and distributor block during timing procedures. Replace block and gear assembly.
ON DISTRIBUTOR process.
GEAR

DISTRIBUTOR Electrode finger contacting towers. Inspect and replace as necessary.

BLOCK TOWERS
SCORED OR
EXCESSIVELY
BURNED 3

DISTRIBUTOR Improper lubricationof bushings. Consult Manual L-1037, Section 3.3.8, for proper
GEAR BUSHIN(;S maintenance procedures.
EXCESSIVELY
WORN

BEARING BAR
BURNED
Carbon tracking due to excessive carbon
brush wear. / Consult Manual L-1037, Section 7.7, for high
tension lead loadina s~ecificafions.

ISSUED REVISED Slick Aircraft Products

Unison Industries, Inc.
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
@ 1989 Unison Industries. Inc.
1- PAGE NO. REVISION
SPUN BEARING Bearing not updated to correct Consult Manual L-1037, Section 3.3.2 and 7.1, for
configuration. proper maintenance procedure.
Improper bearing installation. Consult Manual L-1037, Section 3.3.2 and 7.1, for
proper maintenance procedure.

PRESSURIZED Faulty pressurization system. Consult engine manufacturer's manual for

MAGNETOS ONLY: pressurization system specifications.
INTERNAL
CONTAMINATION
AND CORROSION

ALL MAGNETOS: Excessive or improper solvents or Consult Manual L-1037 for proper cleaning pro-
INTERNAL cleaning agents. cedures. Correct as necessary.
CONTAMINATION
AND CORROSION

Slick Aircraft Products PAGE NO. 11

II
REVISION
Unison Industries, Inc.
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61104
0 1989 Unlson Industr~es.Inc.
THIS PAGE LEFT BLANK INTENTIONALLY
 TABLE ONE
4200 SERIES OVERHAUL PARTS
REPLACEMENT LIST
The following parts must be replaced at overhaul. Additional
parts may require replacement depending on conditions as
determined during magneto inspection. Install only Slick
Replacement Parts.
SLICK AUTHORIZES THE USE OF ONLY SLICK
REPLACEMENT PARTS IN THE OVERHAUL OF SLICK
AIRCRAFT PRODUCTS EQUIPMENT. USE OF PARTS OR
FASTENERS NOT MANUFACTURED OR APPROVED BY
SLICK VOIDS ANY AND ALL WARRANTIES AND MAY
ADVERSELY AFFECT THE PERFORMANCE AND
JEOPARDIZE THE AIRWORTHINESS OF THE
MAGNETO.

Fig. Qty.
Condenser 28 1
Double Shielded Bearing 10 1
Bearing Cap Assembly 12 1
Coil 21 1
Impulse Coupling 4 1
Oil Seal 5 1
Contact Point Kit 15 1
Rotor Gear 16 1
Distributor Block & Gear 29 1
*Reference TableTwo "Parts Listing"forcorrect part number
for a specified model magneto.

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

MO DAY YR MO DAY YEAR Unison Industries
530 Blackhawk Park Avenue T- 1 F
10 01 85 3 1 93
Rockford, Illinois, U.S.A. 61104
0 1993 Unlson lndustr~es
 TABLE TWO
EXPLODED PARTS DIAGRAM

ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION

-
YO DAY YR MO DAY YEAR
Unison Industries, Inc.
10 01 85 05 01 89 530 Blackhawk Park Avenue T-2 E
Rockford, Illinois, U.S.A. 61104
0 1989 U n ~ s o nIndustr~es,Inc.
 TABLE THREE
4200 SERVICE PARTS LIST

2 Nul, ImpulseCoulpllng ............................. M3019

1 1
3 Washer, Impulse CoupHng ....................... M3172 1
4
I Impulse Coupling Assembly ...................... M W 7 I
5. 011 Seal ..............
......................... MU62
I1 1

.- I - . .I1017 1 L a 0*7 1
iv~~orr IWI~X,
ib. nolor bear ................................................. 1 FJ3P.27

17. Cam .....................

.............................. M3611 M3611 M3611 M3611
18. WoodruUKey ............................................. M2536 M2536 M2536 M2536
19. Coll Wedg M3040 M M O M3040 M3040
20. Screw ........................................................ M3020 M3020 M30M M3020
M3975 M3975 W3975 M3975
M2555 M2555 M2555 M2555
- - - -
24. Pressure Tube FlHlng ................................ - - -
25. Air Vent wllh Hwd .................................... M3DB4 M3084 M3M4 M3084
26. SUEW .................... ............................... M3015 M3015 Ma15 M3015
27. Houslng. Dlslrlbulor .................................. M3681 M3599 M3599 M3599
28. Capscltor.......... .
..................... K3984 K3984 K3984 K3984

29. Dlslrlbulor Block & Gear Assembly ........... K38Z K

38Z K3822 K38D
30. Screw ....................
........................... M3021 M W 1 M3021 M W 1
31. Carbon Brush ............................................ M3215 M3215 M3215 M3215
I
32. Washer ................
...... .....................
I M2532 M2532 M2532 M2532

I I II "No1 supplied by Slick

 TABLE THREE
6200 SERVICE PARTS LIST
-
Ref. my.
No. Description 6210 6214 6220 6224 6250 6251 6252 6255 6280 6290 Used
-
"
1 CollerPin ...................
. ...,.,...~..... M2556 M2556 M2556 1
2 Nut. Impulse Coulplln@......................,,..... M3019 M3019 M3019 M3019 1
3 Washer. Impulse Coupllng ........................ M3172 M3172 M3172 - 1
4 Impulse Coupllng Assembly ...................... M3050 M3089 M3050 - 1
5. 011Seal ........................................... M3062 M3062 M3062 M3331 1
- -
-
1
M1293 MI077 1
M3346 M3553 1
- - 1
M r n M r n 1
-
M3047 M3117 1
M3485 M3630 1
MaiB Uai8 2
M3221 M322l 2
M3081 M3637 1
- M3740 1
-
M3828 M3828 1
M3611 M3611 1
M2536 M2536 2'
M3040 M3040 2
M3020 M3020 2
-
M3975 M3975 1
M2555 M2555 1
- - 4
- - 1
M3084 M3084 I
-
M3015 M3015 3
M r n Mrn1 1
K3984 K3984 1
K3823 KX23 ' 1
M3021 M3021 2
-
M3215 M3215 1
M2532 M2532 1
'Models 6210,6214,6220,6224,6267 and 6280 use Qty. 1 Woodruff Key
-
*" '-t supplied by Slick
/
 TABLE FOUR
6200 SERIES OVERHAUL PARTS
REPLACEMENT LIST
The following parts must be replaced at overhaul. Additional
parts may require replacementdepending on conditions as
determined during magneto inspection. Install only Slick
Replacement Parts.
SLICK AUTHORIZES THE USE OF ONLY SLICK
REPLACEMENT PARTS IN THE OVERHAUL OF SLICK
AIRCRAFT PRODUCTS EQUIPMENT. USE OF PARTS OR
FASTENERS NOT MANUFACTURED OR APPROVED BY
SLICK VOIDS ANY AND ALL WARRANTIES AND MAY
ADVERSELY AFFECT THE PERFORMANCE AND
JEOPARDIZE THE AIRWORTHINESS OF THE
MAGNETO.

Description Fig.
-
Condenser 28
Double Shielded Bearing 10
Bearing Cap Assembly 12
Coil 21
Impulse Coupling 4
Oil Seal 5
Contact Point Kit 15
Rotor Gear 16
Distributor Block & Gear 29
PRESSURIZED MAGNETOS: In addition to above parts
the following components
must be replaced at every
overhaul.
Round Head Screw 22 1
Round Head Screw 26 3
Frame Gasket 9 1
Housing Screw Gaskets 23 4
Harness Cap '0' Ring 1
*ReferenceTableTwo"Parts Listing"forcorreclpart number
for a specified model magneto.

ISSUED I/ REVISED Slick Aircraft Products PAGE NO. 1) REVISION

-/ MO I DAY I YR 11 MO I DAY 1 YEAR Unison Industries II
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61 104
Q 1993 Unison Industris
THIS PAGE LEfT BLANK l N f ENTIONALLY
 TABLE FIVE
d
SERVICE LIMITS
SERVICE TORQUE SPECIFICATIONS:
Primary/Retard Point 15- 18 in-lbs
Contact Point 15- 18 in-lbs
P-Lead Nut 13- 15 in-lbs
Air Vent Body 80- 90 in-lbs
Air Vent Body 80- 90 in-lbs
Harness Cap Screw 18- 28 in-lbs
Magneto Mounting Clamp 190-220 in-lbs
Air Vent Hood Screw 5- 7 in-lbs
Housing Screw 18- 28 in-lbs
Housing Screw 18- 28 in-lbs
Impulse Coupling Nut 120-320 in-lbs
Contact Point/Coil Ground 20- 24 in-lbs
Distributor Block Screw 18- 28 in-lbs
Harness Adapter Screw 18- 28 in-lbs
Air Inlet Nozzle 80- 90 in-lbs
Capacitor 150-160 in-lbs
Bearing Cap Screw 20- 24 in-lbs
If cotter pin will not align with pin hole within the speci-
fied torque range, remove nut and lightly lap the bottom
surface of the nut with a piece of emery cloth.

LUBRICATION:
M-1827 Cam Grease - For Rotor Cam
M-3306 or Exxon Teresstic 100 Oil -
For Distributor
Block and Gear Assembly Oilite Bearings

TOLERANCES:
Primary Coil .50-1.2 ohms
Secondary Coil 13,000-20,500 ohms
Condenser +
.35 MFD 10%

/ -
ISSUED REVISED Slick Aircraft Products PAGE NO. REVISION
uo DAY YR MO DPY YEAR Unison Industries
530 Blackhawk Park Avenue T-5 G
10 01 85 09 15 94
Rockford, Illinois, U.S.A. 61104
0 1993 Unison Industrie!~
 fiJ Slick Aircraft Products
Unison Industries
530 Blackhawk Park Avenue
Rockford, Illinois, U.S.A. 61 104
Phone: (815)965-4700 Fax: (815)965-2457
Telex: 910-3808038

Form No. L-1037