T.0.

8E2-5-3-23

HANDBOOK
OVERHAUL INSTRUCTIONS

AIRCRAFT MAGNETO
TYPE SB9RU-3
(AMERICAN BOSCH)

THIS TECHNICAL ORDER SUPERSEDES THE OVERHAUL PORTION OF

T.O. 8E2-5-3-21 DATED 25 AUGUST 1944

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE

FPS--SM--H-¾-WOO 15JULY195
T.O. 8E2-5-3-23
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T.O. 8E2-5-3-23

TABLE OF CONTENTS

Section Page
I INTRODUCTION.......... ....... 1

II OVERHAUL INSTRUCTONS . . . . . . . . . . . . . . . . . . 1
2-2. Overhaul Tools Required . . . . . . . . . . . . . . . . . 1
2-3. Disassembly ......... ......... 2
2-18. Cleaning ......... . . ....... 5
2-25. Inspection ........ . ......... 5
2-32. Testing ......... ......... 6
2-35. Repair or Replacement . ... .. . . . . . . . . . . 7
2-40. Lubrication .......... . ........ 7
2-41. Reassembly ......... . ......... 8

III TEST PROCEDURE ......... .......... 15

3-1. Magneto Test Runs . . . . . . . . . . . . . . . . . . . . 15
3-2. Booster Current . . . . . . . . . . . . . . . . . . . 16
3-3. Final Inspection After Test Runs. . . . . . . . . . . . . . . . . . . . . 16
Section 1 T.O. 8E2-5-3-23

O.

Figure 1-1. Type SB9RU-3 Aviation Magneto

ii
T.O. 8E2-5-3-23 Sections I-II

SECTION I

INTRODUCTION

1-1. This handbook covers the overhaul instructions use of Difference Data Sheets. The additional models
for the Aviation Magneto, Type SB9RU-3 (see figure included in Section IV will be listed in Section IV.
1-1) manufactured by the American Bosch Corpora-
,
1--4. Overhaul and test procedures for models in-
tion, Springfield, Mass.
cluded in Section IV are the same as the procedures
1-2. The Type SB9RU-3 Magneto is a base-mounted, given in Sections II and III except for the specific
9 cylinder, fixed ignition, polar inductor type magneto. differences noted by the applicable Difference Data
It rotates clockwise (as viewed from the drive end) Sheets.
and is driven through a splined drive coupling. This
is completely TABLE OF LEADING PARTICULARS
magneto radio shielded.
1-3. Sections I, II,
and III of this handbook contain
Capacity 9 Cylinders
overhaul and instructions
test for the Type SB9RU-3 Type Polar Inductor
Magneto. Overhaul and test instructions for addi. Rotation Clockwise
tional models will be provided in Section IV by the Weight 15¼ pounds

SECTION 11

OVERHAUL INSTRUCTIONS

2-1. SPECIAL TOOLS. None required. 2-2. OVERHAUL TOOLS REQUIRED.

AM.BOSCH
PART NO. NOMENCLATURE APPLICATION

TSE 5210 Magnetizing Stand For magnetizing American Bosch Magnetos.

TSE 5212 Spring Scale Registers tension of contact and cam follower springs.
TSE 5213 Feeler Gauge Temporary set of contact opening at overhaul.

TSE 5214 Go and No-Go Gauge Checks air gap between electrodes of distributor block and
distributor rotor.

TSE 5218 Box Wrench For breakers assembly.

TSE 5219 Staking Chisel Staking tool for thrust plate fastening screws.
TSE 5220 Breaker Assembly Fixture Breaker adjusting fixture.
TSE 5225 Drift For distributor gear shaft and inductor rotor.

TSE 5229-99 Dressing Tool For dressing contact points.

TSE 5230 Timing Light Determines exact instant of point opening.

1
Section II T.O. 8E2-5-3-23
Paragraphs 2-3 to 2-7

AM. BOSCH
PART NO. NOMENCLATURE APPLICATION

TSE 5232 Open End Wrench For drive couplings.

TSE 5234 Mounting Block Holds Magneto for installing breaker assembly.
TSE 5236 Box Wrench For breaker assembly.
TSE 5246-1 Magnetizing Jaw Used with TSE 5210.
TSE 5246-2 Magnetizing Jaw Adapter Used with TSE 5210.
TSE 5246-3 Magnetizing Jaw Used with TSE 5210.
TSE 5248-1 Base Plate Used in conjunction with arbor press tools on arbor press.
TSE 5248-2 Pin Set Used with TSE 5248-1.
TSE 5248-3 Post Used with TSE 5248-1.
TSE 5248-4 Plate Used with TSE 5248-1 and TSE 5248-3.
TSE 5248-5 Pressing Tool Pressing tool for oil seal.
TSE 5248-6 Pressing Tool Pressing drive gear on inductor rotor shaft.

TSE 5248-7 Pressing Tool Pressing bearing.

TSE 5248-8 Pressing Tool Pressing bearing.
TSE 5248-9 Drift For removing bearings and drive gear from inductor rotor
shaft.

TSE 5248-10 Base For pressing bearings into gear housings.

TSE 5248-11 Pilot Pin For use with TSE 5248-10.

TSE 5250 Drive Pulley For test purposes.

TSE 5253 Straightedge For internal timing of magneto,

TSE 5260 Adjustable Spark Gap For testing Magneto.

TSE 5261 Bearing Puller Extracting bearings.

TSE 5262 Staking Tool Set Staking distributor rotor fastening screws.

TSE 5276 Compass Determines polarity of Magnets, Magnetos, and TSE 5210.

TSE 5277 Contact Opening Indicator Measures exact amount of contact opening.

TSE 5279 Breaker Plate Adjusting Tool Turning breaker plate in its three slots.

2-3. DISASSEMBLY. (See figure 2-1.) c. Remove insulation gland (3), low tension termi-
2-4. The fo110wing procedures list the sequence of nal (4) and terminal nut with spring (5),
steps required to disassemble completely the Type 2-6. RADIO SHIELD.
SB9RU-3 Magneto'
a. Remove radio shield elbow (6).
Note b. Open radio shield assembly (10) by withdraw-
To facilitate reassembly of the Magneto, place ing three screws.
the disassembled parts on a clean bench (or in c. Remove two fastening screws (13) holding radio
a clean container) in the order in which they shield to gear housing (63). Also remove two fasten-
are disassembled- ing screws (11) holding radio shield to dust cover
2-5. GROUNDING TERMINAL. (18). Withdraw halves of the assembly.
a. Unfasten lock spring (1). 2-7. DUST COVER.
b. Unscrew low tension outIet nut (2). a. Take off dust cover (18) and booster conductor
2
T.O. 8E2-5-3-23 Section 11
Paragraphs 2-8 to 2-16

(25) by first fastening screws (19).

removing two
CAUTION
b. Separate booster conductor from dust cover by
withdrawing two screws (26).
rotor (40) is held to the dis-
.

The distributor
.

2-8. DISTRIBUTOR BLOCK. tributor gear hub by means of two staked

a. Back off nuts (64) about 3 turns.Pull gear hous. screws (41). Before any attempt is made to
ing ( 63) against nuts. loosen these screws, a No. 31 (0.120-inch
b. Remove two distributor block fastening nuts dia.) drill must be used for spot drilling to re-
move the staked metal on the threaded end
(24). Lift block (23) vertically; remove insulation
plate by hand. of the screws. The ½-inch holes in the gear
hub permit easy insertion of the drill for this
2-9. COIL ASSEMBLY. . operation. Use a few drops of any heavy oil
a. Loosen screw in cable clamping block on side of on the end of the drill.
coil (28) and disconnect the primary breaker cable.
-
a. Place wrench TSE >232 on flats of splined drive
coupling to prevent distributor rotor from turning
CAUTION and withdraw the screws (41). These screws are to
be scrapped. Remove the apron fastening screws (44).
Do not try to remove cable by prying open Withdraw the rotor and apron as a unit.
terminalpost with a screw driver.
b. Measure the backlash of gears with a suitable
dial gauge. The backlash as measured on periphery
b. Remove coil by withdrawing
. .

coil hold-down
of teeth on distibutor gear and with inductor held in a
screws (29 and 34). 4xed position, must not exceed 0.010 inch. If the
Note backlash exceeds 0.010 inch, replace both the distribu-
It is not necessary to place a keeper across tor gear (70) and drive gear (80).
the pole shoe extensions while the Magneto c. Check the distributor gear ball bearing radial
is disassembled· play by measuring it at the center of cam surface.
2-10. INSULATION PLATE. Replace those distributor gear ball bearings (67) hav-
ing a radial play exceeding 0.0025 inch total indicator
a. Remove the insulation plate (35) under coil
reading.
and primary cable holding clip (39) by withdrawing
three screws (36)· 2-14. GEAR HOUSING.
2-11. BREAKER COVER. a. Remove four nuts (64) securing the gear housing
a. Remove the two screws (47) securing the breaker to the magneto housing (88).
cover (46) to the gear assembly housing (63). Take
off the breaker cover. Note
Magnetos have two slots between magneto
2-12. BREAKER ASSEMBLY.
and gear housing to permit prying the hous-
a. Remove cam fastening nut (54) using a ¾ inch ings apart by two screw drivers.
socket wrench. Hold inductor rotor shaft stationary,
placing wrench TSE 5232 in position on the splined
drive coupling (71). 2-15. DISTRIBUTOR GEAR.
,

b. Remove timing collar (53), steel washer (55), To remove distributor gear shaft from gear hous-
a.
compensating cam (56), Woodruff key (57) and static ing, screw drift tool TSE 5225 on end of shaft until it
washer (58). bottoms.
c. Remove the screws (60). The entire breaker as- b. Place tool TSE 5248-1 on arbor plate and insert
sembly can be pulled out, guiding the primary cable two pins TSE 5248-2 in proper holes.
with the protecting sleeve (49) through the hole in c. Align gear housing assembly so that the two pins
the gear housing. TSE 5248-2 slide through the two holes in the gear
d. Disassemble all component parts of the assembly hub.
from the breaker plate as shown in figure 2-2. d. With arbor ram pressing against TSE 5225 push
e. Withdraw the cam lubricator screws (51, figure length of distributor gear shaft through gear housing.
2-1) and lock washers (52) and remove the cam e. Remove bearings (67) from gear housing by
lubricator (50). means of puller TSE 5261.
Note f. Remove spacer (68) and spacing washer or wash-
Discard the cam lubricator. A new one is to
ers (69).
be installed at assembly. 2-16. INDUCTOR ROTOR.
2-13. DISTRIBUTOR ROTOR AND INSULATION a. Hold splined drive coupling (71) stationary with
APRON. wrench TSE 5232 and use a ½-inch socket wrench.
3
©

13
12

2
29 3
-4
9 o-30
20 34 -3\
10 47

25

40
43

65 6

7 74 75

8
9
87

Figure 2-1. Exploded View of Type SB9RU-3 Magneto

T.O. 8E2-5-3-23 Section 11
Paragraphs 2--17 to 2-27

Legend for Figure 2-1

1. Lock spring 23. Distributor block assembly 45. Lock washer 67. Ball bearing
2. Nut 24. Nut 46. Breaker assembly cover 68. Spacer
3. Insulation gland 25. Booster conductor assembly 47. Screw 69. Shim washer
4. Terminal 26. Screw 48. Lock washer 70. Distributor gear assembly
5. Terminal assembly 27. Lock washer 49. Tubing 71. Drive coupling
6. Elbow 28. Coil assembly 50. Cam lubricator 72. Cotter pin
7. Screw 29. Screw 51. Screw 73. Castle nut
8. Lock washer 30. Lock washer 52. Shakeproof washer 74. Lock washer
9. Plain washer 31. Plain washer 53. Timing collar 75. Washer
10. Radio shield 32. Bushing 54. Nut 76. Thrust plate
11. Screw 33. Insulation washer 55. Washer 77. Screw
12. Lock washer 34. Screw . 56. Cam 78. Oil seal
13. Screw 35. Insulation assembly 57. Woodruff key 79. Ball bearing
14. Lock washer 36. Screw 58. Spring contact washer 80, Drive gear
15. Plug 37. Lock washer 59. Breaker assembly 81. Woodruff key
16. Lock washer 38. Plain washer 60. Screw 82. Insulation disc
17. Plain washer 39. Clip 61. Lock washer 83. Washer
18. Dust cover assembly 40. Distributor rotor 62. Plain washer 84. Inductor rotor assembly
19. Screw 41. Screw 63. Gear housing assembly 85. Ball bearing
20. Lock washer 42. Lock washer 64. Nut 86. Nameplate
21. Plain washer 43. Apron - 65. Plain washer 87. Screw
22. Sleeving 44. Screw 66. Cotton sleeving 88. Magneto housing assembly

b. Remove cotter pin (72), castle nut (73), lock 2--20. DISTRIBUTOR BLOCK AND DISTRIBU-
washer (74) and recessed washer (75). TOR ROTOR.
c. Remove the four screws (77) securing ball bear- a. Remove carbon deposits and clean electrodes
ing thrust plate (76), which contains oil seal (78), to with fine emery cloth.
magneto housing. Take two of these screws and insert b. Clean distributor block and booster conductor
them in the two unused, threaded holes in the thrust cable holes.
plate. Tightening of the two screws will provide the c. Clean insulation plate with a cloth dipped in
equivalent of a puller and will withdraw the thrust
light engine oil and wipe with a clean cloth.
plate from the magnetohousing.
d. Remove inductor rotor by screwing drift tool 2-21. INSULATION PARTS.
TSE 5225 firmly on rotor shaft and tapping end of a. Clean all insulation parts, such as insulation
drift with rawhide mallet. apron, insulation bushings, insulation blocks, and in-
e. Place tool TSE 5248-1 on arbor plate so that there sulation washers, with a cloth dipped in clean light
is free space below the slot in this tool. Slide rotor engine oil. Then wipe dry with a clean cloth.
shaft into slot which is shaped so that it will just clear
2-22. COIL ASSEMBLY
steel washer (83) on inductor rotor when insulation
disc (82) is pressed against seating surface of the tool, a. Clean with an oily cloth and wipe dry.
Use pressing tool TSE 5248-9 on shaft end to press 2-23. BALL BEARINGS.
shaft through ball bearing (79) drive gear (80) and
insulation disc (82). Now remove Woodruff key (81) a. Clean with approved cleaning solvent, Federal
and steel washer (83). Specification P-S-661.
2-17. MAGNETO HOUSING. 2-24. BREAKER ASSEMBLY.
a. Tap out ball bearing (85) by means of fibre rod. a. Clean all component parts of the breaker assem-
2-18 bly. Wipe primary condenser (20, figure 2-2) with
CLEANING
a cloth dipped in clean light engine oil.
2-19. METAL PARTS.
a. Wash all metal parts in solvent, Federal Specifi- 2-25. INSPECTION.
cation P-S-661 and dry with compressed air· 2-26. METAL PARTS.
b. If it is
necessary to remove the varnish finish on a. Examine magneto housing, gear housing, radio
the inside of the magneto housing, dust cover, etc., shield, and dust cover for cracks, loose inserts, and
use only an approved thinner. Follow by coating the loose studs.
exposed metal surface with an approved bakelite var-
b. Inspect all tapped holes.
nish to prevent rusting.
2-27. DISTRIBUTOR BLOCK AND DISTRIBU-
CAUTION TOR ROTOR.
a. Check for cracks and loose inserts.
Do not use a hot, caustic solution. b. Check insulation plate for cracks.
5
Section II T.O. 8E2-5-3-23
Paragraphs 2-28 to 2-33

18

1. Breaker assembly plate 9. Insulation block 17. Lever and spring follower
2. Bracket 10. Insulation bushing 18. Cotter pin
3. Screw I1. Spacer shim 19. Follower lever washer
4. Shakeproof washer 12. Spacing washer 20. Condenser
5. Primary cable 13. Breaker spring 21. Screw
6. Short circuiting spring 14. Nut 22. Washer
7. Spring supporting place 15. Shakeproof washer
8. Nut 16. Bolt

Figure 2-2. E×pioded View of Breaker Assembly

2-28. COIL ASSEMBLY. b. A definite voltmeter reading must be obtained

a. Examine coil for cracked end plates. which will be somewhat less than the battery voltage,
depending on sensitivity of the meter. If continuity of
b. Check all soldered connections.
secondary winding is checked with an ohmmeter, re-
2-29. BALL BEARINGS. sistance should be between 3900 and 6000 ohms,
a. Inspect for rough, loose, or worn bearings.
COlL SECONDARY TERMINAL
2-30. GEARS.
a. Check distributor gear assembly and the rotor
gear for burrs, excessive wear, or other defects.
2-31. BREAKER ASSEMBLY.
a. Examine points for wear,
b. Examine the bakelized, linen cam follower block
for wear.
coRE VOLTMETER
2-32. TESTING.
2-33. COIL ASSEMBLY.
a. Check continuity of secondary winding by con- Il
necting coil in series with battery and sensitive volt- BATTeny
meter of suitable range for low voltage battery being
used. (See figure 2-3.) Figure 2-3. Coi! Test Diagram
T.O. 8E2-5-3-23 Section 11
Paragraphs 2-34 to 2-40

2-34. PRIMARY CONDENSER. amperes. Remagnetize only by using a mag-

a. Preheat primary condenser
82-93°C (180-220°F) netizing stand of proper strength (TSE 5210,
to
and test on a 500-volt d.c. megger tester. If a reading or equivalent).
of 1 megohm or more is obtained, the condenser is a. Find south pole of magnet using compass TSE
satisfactory.
5276.
2-35. REPAIR OR REPLACEMENT. b. Hold magnetizingjaw adapter TSE 5246-2 to
2-36. DISTRIBUTOR BLOCK AND DISTRIBU- magnetizing jaw TSE 5246-1 by inserting adapter
TÒR ROTOR. pilot pins into mating holes on jaw. Place the base
of the magneto housing in the magnetizing jaw
a When visual inspection indicates that electrodes
adapter
,

TSE 3246-2 so that the two exposed lower-

are excessively worn or burned, replace both the
distributor block and
pole-shoe surfaces firmly contact the magnetizing jaw
the distributor rotor.
adapter. Slide magnetizing jaw TSE 5246-3 into the
2-37. OIL SEAL, space between pole shoe extensions until contact is
a. Replace oil seal (78, figure 2-1) if it shows evi. made with the upper. pole shoes.
dence of wear or leakage. c. Place magneto and jaws on magnetizing stand
2-38. TSE 5210 with south pole of magneto toward north
BREAKER ASSEMBLY.
pole of magnetizing stand.
a. Remove the peaks appearing on the contact sur-
d. Apply two charges of four to five seconds dura-
face of the points. Take care in dressing points using
tion each. Turn the inductor rotor one-quarter of a
tool TSE 5229-99, to obtain a flat square surface.
revolution between charges. This allows saturation of
Note both magnets in turn.
It is not necessary to remove enough of the e. Remove magnetizing jaw adapted plate TSE
platinum points to cause small pits or craters 5246-2 from magnetizing jaw TSE 5246-1 and reverse
to disappear completely unless they collec. position of magnetizing jaw TSE 5246-3 on magnetiz-
tively cover an excessive part of the contact ing stand pole. This will leave two straig,ht jaw sur-
surface. faces.
, ,
f. Place magnetizing jaw TSE 5246-1 against bot-
-
CAUTION tom of magneto housing underneath lower pole shoes.
Place magnetizing jaw TSE 5246-3 across upper pole
Do not use file for dressing points. shoe extensions. With jaws held on same poles of
magnetizing stand as in step d., apply two additional
2-39. REMAGNETIZATION OF MAGNET. charges of four to five seconds duration each. This
time is sufficient to allow magnetizing current to build
Note
up to its full value for saturation of the magneto cir-
Do not attempt to remagnetize the magnet
cuit
unless the primary current as obtained under
Test Procedure Section III is less than 1.65 2-40. LUBRICATION.

TABLE I
LUBRICATION REQUIREMENTS

PART LUBRICANT APPUCATION

Ball bearing Grease, MIL-L-3545 See paragraphs

2-44a and
2-451.

Surface of distributor Approx. ¼ ounce At assembly

gear teeth grease, MIL-L-3545
Follower lever post Grease, MIL-L-3545 At assembly
and follower spring
post
Inner circumference Lubricating oil, At assembly
of oil seal grade 1120,
AN-VV-O-446
Cam surface Cam lubricator Continual
Section 11 T.O. 8E2-5-3-23
Paragraphs 2-41 to 2-43

2-41. REASSEMBLY. 2-43. BREAKER ASSEMBLY.

2-42. Torque values to be maintained during reas¯ a.Place breaker plate (1, figure 2-2) on Breaker
sembly are given in Table II. Allowable mechanical Assembly Fixture TSE 5220 and secure with three
tolerances are listed in Table III screws and washers.

TABLE 11 b. Mount contact point bracket (2) and secure

to plate (1) with enlarged-head screw (3) and shake-
TORGUE TABLE proof lock washer (4). Do not tighten screw (3) too
securely as further adjustment is necessary.
TOROUE in inch-pounds
NOMENCLATURE OF PART c. Fit together the following parts: Fastening bolt
Minimum Maximum
(16), lock washer (15), spacing washers (12), contact
Breaker Cover Fastening Screws 40 50 point spring (13), three shims (11), insulation block
(9) and insulation bushing (10). Put bolt and insula-
Gear Housing Fastening Nut 60 70 tion bushing into assembly supporting post on breaker
Breaker Assembly Bolt Nut 17 22 plate. Over protruding end of bolt (16), slide insula-
tion block (9) and fasten to supporting post with
Cam Locking Nut 130 -

150 square nut (8). Apply a liberal film of grease,

Specification MIL-L-3545 to follower lever and
Distributor Rotor Fastening Screws 40 50
spring supporting posts. Mount follower lever and
Distributor Block Stud Nuts 30 40 spring (17), washer (19), and cotter pin (18). Make
certain that washer (19) has smooth rotary freedom.
Coil Fastening Screws 25 30
Remove excess grease from top of follower lever
bushing. Apply a single drop of Grade 1120 oil,
Specification No. AN-VV-O-446, to cam contact sur-
face of follower lever.
TABLE III
ALLOWABLE MECHANICAL TOLERANCES d. Shift contact point spring (13) on its elongated
hole so that both contact points are in perfect align-
ment. Now tighten assembly securely to bolt (16).
PERMISSIBLE TOLERANCE
DESCRIPTION Minimum Maximum e. Turn dummy cam of breaker assembly fixture so
that follower will rest on higher part of cam. Loosen
Breaker spring tension (measure 20 ounces 28 ounces screw (3) and move contact point bracket (2) by means
as shown in figure 2-4) of eccentric head stud, until Feeler Gauge TSE 5213,
inserted between points, just becomes free, indicating
Cam follower spring tension 14 ounces 18 ounces an opening of 0.008 to 0.010 inch. Tighten enlarged
(measure as shown in figure head screw (3) securely.
2-5)
f. Check tension of contact point spring (13), using
Breaker point opening .008 inch .010 inch Spring Scale TSE 5212. Hook of scale must be held
adjacent to point as iridicated in figure 2-4. Spring
Gear backlash (measured on --
.010 inch tension must be 20 to 28 ounces at instant points open.
periphery of distributor gear) This instant can be detected by connecting Timing
Light TSE 5230 across points. Timing light will register
Clearance between automatic 3/32 inch --

the exact instant of pomt openmg For a

.

and closing.
grounding spring and gear
spring tension reading of more than 28 ounces, decrease
housing rim.
the tension by adding one shim (11, figure 2-2). For
Clearance between top of cam .014 inch spring tension reading less than 20 ounces, increase
follower and breaker spring the tension by removing one shim. When adding or
with follower at its lowest removing shims, all parts of the bolt (16) assembly
position must be removed and replaced in their proper sequence
on supporting post. Readjust points and check spring
Distance between distributor .015 inch .063 inch tension.
rotor and distributor block
electrodes g. Using Feeler Gauge TSE 5213, check clearance
between cam follower (17) and contact point spring
"E" gap .098 inch 2.5 mm (13). This clearance must not be less than inch .014

(2.5 mm) when follower is at its lowest position.

. h. Fasten primary condenser (20) to breaker plate
Radial movement of cam shaft .000 mch .0025 inch
(1) with two screws (21) and lock washers (22).

8
T.O. 8E2-5-3-23 Section 11
Paragraph 2-44

Figure 2-4. Contact Spring Tension Check Figure 2-5. Following Lever Spring Tension Check

i. Assemble supporting plate (7), short circuiting

spring (6), primary cable (5), and primary condenser , CAUTION
lead (20) to bolt (16) and fasten with elastic stop nut
(14). Remove breaker assembly from Fixture TSE Do not overgrease ball bearings as the surplus
5220. grease will be thrown onto adjacent parts. To
properly pack a bearing, work the grease into
j. Check cam follower lever spring tension with
the spaces around the balls. Then, holding the
Spring Scale TSE 5212 (see figure 2-5). Tension must
inner race, spin the outer race. This will cause
be between 14 and 18 ounces at instant top of follower .

any surplus grease to work out. Agam work

block touches contact point spring, otherwise follower
the grease around the balls and spin the outer
lever and spring assembly must be replaced by a new
race. Working the grease around the balls
one.
two or three times, spinning the outer race
k. Mount a new cam Iubricator (50, figure 2-1) on each time, will insure the correct amount of
breaker (59) and secure with two screws (51) and grease being applied to the bearing. Wipe
countersunk shakeproof lock washers (52) off excess grease with the finger so that the
1. Breaker assembly is now ready for assembly in bearing is not over one-half to three-quarters
magneto. full.
2-44. MAGNETO HOUSING AND INDUCTOR b. Insert drive end of inductor rotor into hole "C"
ROTOR- of tool 5248-1 which is placed on arbor plate so that
a. Irisert post TSE 5248-3 in hole "C" of TSE free space exists below hole "C." Assemble steel washer
5248-1. Place plate TSE 5248-4 on end of post. Slide (83), Woodruff key (81) and insulation disc (82) on
magneto housing (88) over plate TSE 5248-4, which gear end of inductor rotor shaft.
fits into the tunnel between the pole shoes. With c. Before pressing drive gear (80) on to the in-
sealed end of bearing facing the inside of magneto ductor rotor shaft, heat the drive gear to a tempera-
housing, press bearing (85) into housing with large 121°C (250°F).
ture of The gear may be heated by
end of tool TSE 5248-8 until it seats firmly· placing it on the Acme three-heat unit 9 to 12 inch,
Note 220-880 watt electric griddle or equivalent.
All ball bearings must be packed with grease d. After the drive gear is heated to a temperature
121°C
Specification MIL-L-3545. of (250 F), press it on inductor rotor shaft.
9
Section II T.O. 8E2-5-3-23
Paragraph 2--45

Using tool TSE 5248-6 press drive gear into place, with Note
flat surface of gear resting against insulation plate It is imperative that these two bearings be
With sealed end of bearing (79) facing drive gear, clean and free from grease and oil during the
press bearing on inductor rotor shaft with tool TSE complete operation outlined in this para-
5248-7. graph.
Note d. Lift the gear housing clear of the pilot pin and
Be sure that the keyway in drive gear is base, holding it level to avoid lateral displacement or
aligned with Woodruff key slipping of the shortened spacer and shims. Insert
Drift Tool TSE 5225 from under side (breaker com-
e. Insert pressing tool TSE 3248-7 into hole "D"
partment side) of gear housing. Drift should now oc-
of plate TSE 5248-1. Place inductor rotor shaft in an
cupy the same relative position, recently held by pilot
upright position by placing bearing (79) into recess of
pin. The shortened spacer and shims are no longer
tool TSE 5248-7. Slide magneto housing over drive liable to slip off center. Screw shaft of distributor gear
end of shaft as far as it will go. Using large end of
(70) firmly into Drift Tool TSE 5225 and guide gear
tool TSE 5248-8 on ball bearing (85) m magneto
shaft through bearing and spacer assembly in gear
housing, press housing on shaft until bearing seats housing. Now remove drift tool from distributor gear
on shoulder of inductor rotor shaft.
shaft. Withdraw pilot pin from BASE TSE 5248-10
f. If oil seal is worn or shows sign of leakage, and locate gear housing, breaker side down, on Base
replace it as follows: Place thrust plate (76) in hole TSE 5248-10. Using Bearing Pressing Tool TSE 5248-7
A of tool TSE 5248-1 and use small end of tool TSE against hub of distributor gear, press gear into place.
5248-5 for pressing out worn seal. Now turn thrust e. Assemble static washer (58), compensating cam
plate over and place it in hole "B" of tool TSE 5248-1- (56), timing collar (53) and cam locking nut (54).
Metal supported side of new seal must face toward f. Using Spanner Wrench TSE 5231 on hub of
inside of magneto when thrust plate is installed. Use distributor gear and a ¾ inch socket wrench on cam
large end of tool TSE 5248-5 to press seal into place,
locking nut, tighten cam locking nut to a torque of
making certain that the seal is properly seated in
130 to 150 inch-pounds. Using suitable dial indicator,
thrust plate. Assemble thrust plate with oil seal in check for radial play. Cam shaft radial movement must
magneto housing, using four screws (77). Tighten
not exceed 0.0025 inch. It is desirable to hold this cam
screws gradually and evenly, and stake screw heads shaft radial movement to zero without overloading the
with tool TSE 5219.
bearings
2-45. GEAR HOUSING ASSEMBLY. g. Should the radial movement exceed 0.0025 inch,
substitute progressively thinner shims, according to
a. Locate gear housing assembly (63), with breaker
5248-10. chart below, until cam shaft radial movement is re-
compartment up, on large end of Base TSE
duced to between 0.000 and 0.0025 inch. Several trials
Place the small end of Base TSE 3248-10 in position
may be required before the desired result is obtained.
on Plate TSE 5248-1. With open end of ball bearing
(67) facing down, press bearing into gear housing h. The various shim combinations obtainable and
the equivalent thickness of each combination are given
(63) using small end of Bearing Pressing Tool TSE
5248-8. in the following table:

b. Remove gear housing from Base TSE 5248-10 SHIM COMBINATION TOTAL THICKNESS
and insert Pilot Pin TSE 5248-11, narrow end up, 2-WA 1313 .036 inch
into hole in base. Place gear housing over this tool
"
1-WA 1313 and 1-WA 1312 .034

breaker compartment facing down· 1-WA "

assembly, with 1313 and 1-WA 1311 .032

The pressed-in ball bearing (67) should now 1-WA "

recently 1313 and 1-WA 1310 .030

rest on the slight projection on the wide face of Base "

1-WA 1313 and 1-WA 1309 .028

TSE 5248-10- 1-WA and.1-WA "

1311 1310 .026

2-WA 1310
"
c. Insert two spacing washers (shims) (69) and the .024

1-WA "
ball bearing spacer (shortened spacer) (68). These 1309 and 1-WA 1310 .022

2-WA "
parts slip over the pilot pin and are centered. Place 1309 .020

1-WA "
other bearing (67) over pilot pin, open side down, and 1313 .018

1-WA "
press into position with small end of Bearing Pressing 1312 .016

1-WA "
Tool TSE 5248-8. 1311 .014

1-WA 1310 .012

"
Note 1-WA 1309 .010
"
Bearings must be tightly and evenly sealed in
bore of gear housing. If looseness or an egg- The shims in the above table are illustrated in fig-
shaped fit exists, a new bearing must be tried. ure 2-6. The part number thickness and identifying
If condition still prevails, gear housing must holes are given. Also shown is the standard (old style)
be replaced with a new one. spacer, and the shortened (new) spacer for use in

10
T,O. 8E2-5-3-23 Section 11
Paragraph 2-46

OLD STYLE SPACER-CADMlUM PLATED

SHORTENED SPACER-BLACK

NUMBER OF HOLES INDICATES THICKNESS AND PART NUMBER

495 450 SHIM SHIM SHIM SHIM SHJM

493 .448" WA 1313 WA 1312 WA 13LI WA 13|O WA 1309
OLDSTYLE *
THICK THICK THICK THICK .OIO THICK
SHORTENED -018 ·016 -014' .012

SPACER SPACEA
SR 52ll SR 5273

Figure 2-6. Spacer and Shim Identification

controlled spacing. The two spacers are easily dis- 2-46. MOUNTING GEAR HOUSING ASSEMBLY
tinguished, as the standard spacer SR 5211 is cadmium TO MAGNETO HOUSING.
plated, while the shortened spacer SR 5273 is black' a. Guide the gear housing (63) part way on to the
i. It is extremely important that the ball bearings studs of magneto housing.
(67) are not loaded by this controlled spacing. If the
spacing has been correctly accomplished, a torsional · · · · . . . . . . .

load of 1 to 3 ounces, as measured at the radius of the CAUTION

distributor gear teeth should rotate the distributor gear
when gear is supported by the ungreased ball bearings To obtain correct internal timing of the mag-
j. Prepare to make a torsional load check as fol- neto, make sure that the distributor gear is
lows: Form a small loop at one end of a length of properly meshed with the drive gear. The dis-
string. Near the other end attach three 1-ounce weights tributor gear tooth marked with a white dot
spaced about one inch apart. Engage the loop in the on side facing ball bearing should go between
teeth of the distribution gear and pass the string com- the two drive gear teeth marked with red
pletely around the gear. Rest the weights on a table lines. (See figure 2-9.)
or bench and position the gear so that when the gear
housing is raised the gear can rotate through a full b. Turn the floating inductor rotor ball bearing (79,
360 degrees. (See figure 2--7.) figure 2-1), until the edges of one of the two slots are

Note aligned with the two red marks on drive gear teeth.
There MUST be a torque of 130 to 150 inch-
This facilitates seating the bearing against the bearing
retainmg spring in gear housing. Undue pressure on
pounds on the cam locking nut during each
retaining spring results if bearing must relocate itself.
torsional load check.
Gear teeth mesh can be seen through observation hole
k. Raise the gear housing slowly until the first on breaker side of gear housing. To permit checking
weight is drawn into the air. The gear should rotate the gear mesh from either side of gear housing, place
within the torsional load limits given in step i above. pencil marks on top of the two drive gear teeth having
1. When the ball bearing spacing is adjusted to the red lines and on rotor side of the distributor gear
bring the radial movement within the permissible tooth having the white dot.
limits at the required torques, remove the cam locking
is obtained, use rawhide
c. After correct gear mesh
nut, timing collar, washer, cam, static washer, distribu¯ magneto
mallet to tap gear housing firmly against
tor gear, ball bearings, spacers and shims. Pack both
housing. Secure with washers (65) and nuts (64) and
bearings (67, figure 2-1) with high temperature torque between 60 to 70 inch-pounds.
grease, Specification MIL-L-3545. Reassemble the dis-
tributor gear (70), ball bearing (67), proper shims d. With fingers, apply approximately ¼ ounce of
(69), spacer (68), static washer (58), and Woodruff grease, Specification MIL-L-3545 to surface of dis-
key (57), to gear housing (63). , tributor gear teeth.
Section II T.O. 8E2-5-3-23
Paragraph 2-46

STRING LOOPING GEAR

OZ. WEIGHT

1 OZ. WEIGHT

1OZ.WElGHT

Figure 2-7. Torsional Load Check

2-47. Providing Timing Marks on a New Gear Hous- As the white mark on the distributor geat approaches
ing. To install a new gear housing follow all assembly the mark on the red pad, insert a No. 40,
white .098 inch
steps listed in the preceding paragraphs. Replacement (or a 2.5 millimeter) drill shank between the laminated
gear housings do not come with timing marks. Locate sector on inductor rotor and the left (facing drive shaft
and make timing marks as follows: end of magneto) edge of the upper pole shoe. When
a. Turn magneto drive shaft in normal direction pressure on the drive shaft is released, the drill shank
(clockwise facing magneto drive shaft) until the white will be cIamped between the faminated-inductor-rotor
dot on distributor gear approaches the white mark on sector and the pole shoe edge. (See figure 2-9.) The
red pad which is on the inner surface of gear housing. drill shank should be leaning slightly toward the pole
(See figure 2-9.) At the same time, the distributor shoe edge. Place straightedge TSE 5253 across step
gear tooth having the white marker on the breaker side of timing collar and draw a highly sharpened pencil
should be between the two drive gear teeth with the point along edge nearest the step of timing collar.
red marks. This setting can be seen through the obser- This makes two Ane marks on the gear housing. Fig-
vation hole on the breaker side of the gear housing. ures 2-8 and 2-9 show position of the straightedge as
T.O. 8E2-5-3-23 Section 11
Paragraphs 2-48 to 2-49

well as the 2.5 millimeter "E" gap. Make the timing in gear hub and rests against threaded end of rotor
marks permanent by using a small, sharp chisel. A fastening screw.
sharp chisel, having one flat and one tapered side, maY 3) Insert the other staking tool, TSE 5262-1, into
be used directly in place of the pencil for marking the opposite ½ inch hole in gear hub. Two or three rea-
gear housing rim- sonably sharp hammer blows on this tool will flatten
2-48. screw threads.
DISTRIBUTOR ROTOR.
4) Repeat
operation outlined in paragraph 3)
a. Re-install apron (43, figure 2-1) and distributor
rotor (40) as a unit. Do not fasten apron screws until using tool marked TSE 5262-2. Three-sided point on
distributor rotor is in proper position over the gear tool will stake this screw securely.
hub. When apron and rotor are in proper position, 5) Reverse position of magneto and stake second
secure apron and rotor fastening screws (41 and 44) screw in the same manner.
firmly. While tightening the rotor screws, prevent the
distributor rotor from turning 2-49. INSTALLING BREAKER ASSEMBLY IN
by using wrench TSE
5232 on flats of the drive coupling. MAGNETO.
a. Remove couplitig and insert drive shaft into small
Note
hole of mounting block TSE 5234.
The rotor fastening screws must be staked
before the magneto is returned to service. To b. Lead primary cable with protecting sleeve (49)
avoid the necessity of removing staked screws, from breaker assembly (59) through hole in gear hous-
if the magneto should fail to pass final test, ing assembly and slots in apron. Mount breaker assem-
delay staking until it is evident that the dis- bly to gear housing by three fastening screws (60), lock
tributor rotor will not have to be removed (spring) washers (61) and plain washers (62). Locate
again. screws approximately in the centers of the three slots
but do not tighten firmly.
b. When final tests show magneto performance to c. Install a temporary ground wire as follows: Insert
be satisfactory, thoroughly retighten the two distribu¯ wire through low tension outlet nut (2), through in-
tor rotor fastening screws and stake as follows: sulation gland (3), through insulated terminal (4),
1) Place one of the two staking tools, TSE 5262-1, and connect to terminal nut assembly (5). Insert this
horizontally in a vise- assembly of parts into terminal bushing located on top
2) Hold magneto so that the pointed end of this of gear housing. Fasten with low tension outlet nut,
staking tool is inserted into one of the ½ inch holes tightening nut until a clearance of at least ½a inch

Figure 2-8. Straightedge on Timing Lines Figure 2-9. Timing Dots Aligned
13
Section H T.O. 8E2-5-3-23
Paragraph 2-50

is obtained between short circuiting spring and wall of between coil core and primary
lead clamp assembly.
gear housing. Lock low tension outlet nut in place Assemble lock (spring)
washer, plain washer, and in-
with lock spring (1). sulation bushing on screw (29). Fasten coil to pole
d. Slide contact washer (58) over distributor gear shoe extensions using short screw (34) with lock
shaft until it rests against bearing (67) Mount cam (spring) washer and plain washers to tighten right-
(56) with Woodruff key (57) and plain washer (55) hand side of coil (viewed from drive end of magneto).
on shaft of distributor gear. Connect primary cable to terminal block of coil.
e. Press timing collar (53) into place in the cam
slots. The timing collar will fit in one position only- I CAUTION
Use wrench TSE 5232 on temporarily installed drive
coupling to prevent distributor gear shaft from turn- Do not pry slot open with screw driver,
ing. Tighten hex nut (54) firmly by applying an even where primary cable is inserted into the
pressure on ¾ inch socket wrench (box spanner)· terminal post.
f. Turn magneto in normal direction as indicated by
arrow on cam until the cam follower is in cam dwell b. After providing distributor block with temporary
preceding number 1 cam lobe. Connect timing light test cables, install insulation plate by hand. Mount
TSE 5230. Place straightedge across step of timing distributor block (23) to magneto frame and secure
collar. Continue turning magneto in normal direction with fastening nuts (24). Check air gap between elec-
until number 1 cam lobe just begins to open points as trodes of distributor rotor and electrodes of distributor
shown by timing light. block with gauge TSE 5214.
g. Check that the straightedge is aligned with tim- c. At overhaul stage, with magneto being pre-
ing marks "T" on rim of housing. If it is not, loosen pared for reinstallation on engine, air gap between
three fastening screws (60) and turn entire breaker electrodes should not be less than 0.015 inch, nor greater
plate in its slots, using adjusting tool TSE 5279. Place than 0.063 inch. If the air gap is greater than 0.063
long narrow slot over the stationary post which sup- inch, replace the distributor rotor. If visual inspection
ports the cam follower spring and the short, wide slot shows that distributor block electrodes are worn or
over breaker-plate fastening screw nearest the post. burned excessively, replace both the distributor block
Turn the handle until correct position is obtained. Sev- and the distributor rotor.
eral trials may be necessary. Now tighten screws (60) d. Test the magneto as outlined under Test Pro-
firmly. Check breaker point setting by using contact cedure, Section III.
opening indicator TSE 5277. Pointer should rest in e. Assuming that the tests are completed, that the
the calibration marked "9," thus assuring a perfect temporary ground wire and testing cables are re-
contact setting. If pointer does not rest on the "9," moved, that the distributor block is reinstalled and
loosen screw (3, figure 2-2) and slightly move contact that the primary cable is connected to the terminal
bracket with point (2) by turning eccentric head stud- block of the coil, complete assembly as follows:
Continue adjusting until the correct opening is ob- 1) Secure dust cover (18), including the booster
tained assembly (25) to magneto housing with screws (19),
Assemble radio shield and secure with screws (11 and
CAUTION 13).
. .
Note
Screw (3) must be tightened firmly after Screws (13) holding shield to gear housing
adjustment. must be tightened before screws (11) hold-
ing shield to dust cover are inserted.
2-50. COMPLETING THE ASSEMBLY. 2) Mount radio shield elbow (6) to radio shield
a Fasten insulation plate (35, figure 2-1) and pri. using screws (7).
mary cable which is held in place by clip (39) to mag- 3) Assemble drive coupling (71), recessed washer
neto housing with screws (36). Mount coil (28) on (75), lock (spring) washer (74), castle nut (73), and
pole shoe extensions, with high tension electrode in- cotter (split) pin (72) to the drive end of inductor rotor
serted into distributor rotor. Place one plain washer shaft. Magneto is now ready for reinstallation on
under insulation washer and insert both into space engine.

14
T.O. 8E2-5-3-23 Section Ill
Paragraph 3--1

SECTION III

TEST PROCEDURE

3-1. MAGNETO TEST RUNS. grade a.c. ammeter, such as Weston Model 528 (0 to 2.5
a. Mount magnetato suitable test bracket and at- ampere scale) to coil terminal block and ground the
tach pulley(TSE 5250 to rotor shaft using special nut other ammeter lead to the magneto frame.
supplied wi Test stand must be equipped g. If the magneto is properly magnetized and the
with 3-point adjustable spark gaps TSE 5260, or equiv- electrical performance of the coil is satisfactory, a min-
alent, and have a variable speed range up to 3000 rpm, imum reading of 1.65 amperes will be obtained at a
magneto drive shaft speed. magneto drive shaft speed of 400 rpm. If this reading
b. Turn magneto drive shaft by hand to make sure is lower than 1.65 amperes, the magnetizing stand
inductor rotor turns freely. Run magneto at various should be checked by investigating battery condition
speeds and check mechanical operation. Hold breaker and leads from battery to magnetizing stand. If the
points open and note sound of gears and bearings. Shut battery is in good condition and properly connected to
off power and listen for any unusual noises as magneto the stand, the magneto should be correctly remagnet-
comes to a stop. ized with a charger of sufficient strength to completely
c. Set the needle-pointed, three electrode test gaps
saturate the "Alnico" magnet. Magnetizing stand TSE
at nine millimeters. Connect high-tension test tables 5210 is recommended for this purpose.
from magneto to spark gaps. (See figure 3-1.) h. In order to check the insulation of the coil when
the magneto has reached operating temperature, set
the spark gaps at 10 mm after the magneto has run
approximately 30 minutes. Magneto must be capable
of firing the 10 mm pointed, 3-electrode spark gaps
without missing, at any magneto drive shaft speed be-
ooa"
3"^"" ^2 tween 200 and 3000 rpm. If missing occurs, check
.oti" :
AS AEQUIRED magneto with coil of known quality. Should this
check show that missing occurs due to difficulties other
than coil failure, then cable connections, breaker point
adjustment, distributor block and distributor rotor
HIGH TENSION electrode clearance, and primary current must be in-
ELECTRODE toNIZING GAP
GROUND ELECTRODE vestigated. Any faulty conditions thus determined
o
must be corrected.
i. Check coming-in speeds, or low speed at limiÃ
which inductor rotor must be turned to produce con-
sistent sparking at the specified air gaps. The maxi-
mum allowable speeds at the specified aff orapark
gaps are as follows:
65 rpm with 7 mm gaps
Figure 3-1. Spark Gap Test
100 rpm with 9 mm gaps

d. Operate magneto at 2000 rpm drive shaft speed j. If magneto fails to meet these limits, faults may
for 30 minutes. While running, short-circuit the mag- be caused by the following:
neto primary approximately 50 times in rapid suc- Improper breaker point adjustment.
cession by means of the grounding terminal. This Improperly seated or damaged coil.
procedure reduces the magnetization (of the newly re- Weak or faulty primary condenser.
magnetized magneto) to a stable value. Néak magnet.
e. After stabilization magneto must be capable of Cables from distributor block to spark gaps not
firing (without missing) the 9-mm test gaps at all making proper contact.
speeds between 100 and 3000 rpm. Suggested testing Excessive clearance between distributor rotor and
speeds are 100, 1500, 2200 and 3000 rpm magneto drive distributor block electrodes.
shaft speed. Magnetizing stand of insufficient strength to re-
f. The magnetic strength of the stationary magnet magnetize "Alaico" magnet.
is tested by measuring the primary current ouptut. To k. Check the possible causes of failure listed in step
do this, disconnect primary cable from terminal block i above, and by a process of elimination, find and cor-
on primary side of coil. Connect one lead from a high- rect the trouble.

15
Section III T.O. 8E2-5-3-23
Paragraphs 3-2 to 3-3

3-2. BOOSTER CURRENT. b. Check to see that straightedge, placed on top of

a. Run magneto at 100-200 rpm magneto drive timing collar, coincides with timing marks at instant
shaft speed with grounding terminal grounded and the points open on No. 1 cam lobe
high-tension cable from booster unit connected to Note
booster assembly terminal. Use seven-millimeter, Straightedge must line up with timing marks
pointed, three-electrode test gaps for checking spark at instant points open on No. 1 cam lobe.
of booster. Booster spark follows the magneto spark.
c. Stake distributor rotor fastening screws as de-
3-3. FINAL INSPECTION AFTER RUNNING scribed in paragraph 2-48b.
TESTS. d. Upon completion of final inspection, complete
a. Remove magneto from test stand and check the reassembly as instructed in paragraph 2-50e.
period of opening of breaker points using contact f. Table IV summarizes the electrical measurements
point opening indicator TSE 5277. to be observed during test.

TABLE IV
ELECTRICAL MEASUREMENTS

PERMISSIBLE TOLERANCE
DESCRIPTION Minimum Maximum

Condenser test on 500 volt 1 megohm

megger tester

Primary current of magneto at 1.65 amp.

400 rpm
Coming-in speeds
(low speed limits)
1. Seven-millimeter gap. 65 rpm
2. Nine-millimeter gap. 100 rpm

16