Today's Message Index:
----------------------
1. 01:14 AM - SV: IO-240 alternator drive coupling (Hans Christian Erstad)
2. 01:16 AM - Additional owners and builders added to the list (mark_trickel)
3. 04:21 AM - Re: Additional owners and builders added to the list (William Schertz)
4. 05:08 AM - IO-240 alternator drive coupling (Owen Baker)
5. 11:59 AM - SV: IO-240 alternator drive coupling (Hans Christian Erstad)
Message 1
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Subject: | IO-240 alternator drive coupling |
Thanks John
I am starting to think that the best solution is to convert to the older
coupling mechanism (P/Nos 531325, 530407, 632050, 653982 and 653983)
Aircraft spruce have these parts new, but it add up to $900.... so
thanks
for the sky-craft link !
This add to the list of modifications and repairs that have been done to
my
IO-240 due to mistakes/quality problems by TCM:
1. The oil channel that were missing on the first IO-240, and had to be
drilled by a TCM employed mechanics that traveled to Norway to fix one
engine(mine)
2. The TCM starter motor that failed after 20 h and I replaced with a
B&C
(at my own cost)
3. The Intake valve seal that was incorreclty fitted at the factory (a
blind worker maybe?). I had to remove one cylinder, remove valve and
fit a
new seal (again at my own time and cost)
Hans Christian
_____
Fra: owner-kis-list-server@matronics.com
[mailto:owner-kis-list-server@matronics.com] P=E5 vegne av JOHN JACKSON
Sendt: 2. mars 2013 21:50
Til: kis-list@matronics.com
Emne: Re: SV: KIS-List: IO-240 alternator drive coupling
Hans
Mine failed at 220 Hrs. I fitted P/Nos 531325, 530407, 632050, 653982
and
653983. Now have 405 hrs so i guess it's too early to tell if it was
totally successful. However, my 'new' coupling has a mechanical linkage
with rubber shock absorbtion so I don't see how the design can fail.
I got my parts 'used' from Skycraft in the UK. I've just looked at
their
website and they may have the part you are looking for. Check here
under
'Gear'
http://www.sky-craft.co.uk/acatalog/Skycraft_New_Used_Continental_Engine_
Par
ts.html
John
From: Hans Christian Erstad <hans-chr.erstad@c2i.net>
Sent: Saturday, 2 March 2013, 18:24
Subject: SV: KIS-List: IO-240 alternator drive coupling
<hans-chr.erstad@c2i.net>
No, I did not know that was an option. Thanks.
That is probable how Continental fiexed the problem instead of fixing
the
part.
Hans Christian
-----Opprinnelig melding-----
Fra: owner-kis-list-server@matronics.com
[mailto:owner-kis-list-server@matronics.com] P=E5 vegne av Mark
Kettering
Sendt: 2. mars 2013 19:15
Til: kis-list@matronics.com
Emne: Re: KIS-List: IO-240 alternator drive coupling
Have you thought about converting to a front belt mount alternator? I
think
the newer versions (B?) do this.
Mark
-----Original Message-----
From: Hans Christian Erstad
Sent: Mar 2, 2013 12:55 PM
Subject: KIS-List: IO-240 alternator drive coupling
I have read several
postings about early failure of the IO-240 alternator drive coupling
(P/N
635796).
The coupling failed
now at 337 hours in my IO-240 powered KIS. From other postings, it seems
like this part never reaches 500 h, and cost a fortune to buy new (more
than
$2000), but may be overhauled for $600.
The failure rates
indicate to mee that this part (too) is a bad design.
Apparently it is
possible to replace the one piece coupling, with one that contain of
several
parts (531325, 530407, 632050, 653982, 653983) and have been used on
other
Continental (e.g. O-200).
What have the
experience been for you that have IO-240 ?
Any suggestion for
best place to get the one-piece overhauled? or suggestions for where to
buy
the serveal-piece alternative?
Regards
Hans Christian
Erstad
Message 2
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Subject: | Additional owners and builders added to the list |
As the propeller turns -
The search for the KIS fleet continues and our efforts were rewarded this week
with 3 flying TR-1s added and 3 other TR-1s confirmed to the KIS builders and
owners list.
Jay Johnson, Daytona Beach, FL, USA - This builder was airworthy in early 2000
and is still the owner.
Robert Hadley, Yorba Linda, CA, USA - owns a build by Vic Stanley, This build first
flew in late 1997.
A build by William Madden, new owner unknown but is now located in Middleburg Heights,
OH, USA. First flown in early 1999.
A build by Doyle Reed, new owner unknown but is now located in Pocahontas, AK,
USA. First flown in late 1994.
Now confirmed but not sure if she is airworthy, a TR-1 by Dennis Griswold is located
in Oconomowoc, WI, USA.
Charles Carlsen, Tehachapi, CA, USA, is now the owner of a build by Bill Arnold
and Dave Klink from Ft.Collins, CO. First flown in mid 1996.
As time permits we will reach out to these builders and owners and try to establish
contact with them. I am sure they could add important experience to this
ongoing project. I will send out updated copies of the list to those who already
have received it once these airplanes are added to it. Any other builders and
owners who do not have the list are entitled to receive this list, just let
me know. Totals as of now are TR-1s 79 of 130, TR-4s 53 of 66, seeking 64 missing
kits.
Mark Trickel
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=395482#395482
Message 3
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Subject: | Re: Additional owners and builders added to the list |
Mark,
I would like the list and updates as they come in.
Bill Schertz
#4045 TR-4
First flight 2009, 88 hours on it now.
-----Original Message-----
From: mark_trickel
Sent: Sunday, March 03, 2013 3:16 AM
Subject: KIS-List: Additional owners and builders added to the list
As the propeller turns -
The search for the KIS fleet continues and our efforts were rewarded this
week with 3 flying TR-1s added and 3 other TR-1s confirmed to the KIS
builders and owners list.
Jay Johnson, Daytona Beach, FL, USA - This builder was airworthy in early
2000 and is still the owner.
Robert Hadley, Yorba Linda, CA, USA - owns a build by Vic Stanley, This
build first flew in late 1997.
A build by William Madden, new owner unknown but is now located in
Middleburg Heights, OH, USA. First flown in early 1999.
A build by Doyle Reed, new owner unknown but is now located in Pocahontas,
AK, USA. First flown in late 1994.
Now confirmed but not sure if she is airworthy, a TR-1 by Dennis Griswold is
located in Oconomowoc, WI, USA.
Charles Carlsen, Tehachapi, CA, USA, is now the owner of a build by Bill
Arnold and Dave Klink from Ft.Collins, CO. First flown in mid 1996.
As time permits we will reach out to these builders and owners and try to
establish contact with them. I am sure they could add important experience
to this ongoing project. I will send out updated copies of the list to those
who already have received it once these airplanes are added to it. Any other
builders and owners who do not have the list are entitled to receive this
list, just let me know. Totals as of now are TR-1s 79 of 130, TR-4s 53 of
66, seeking 64 missing kits.
Mark Trickel
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=395482#395482
Message 4
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Subject: | IO-240 alternator drive coupling |
3/3/2013
Hello Hans Christian, I am sorry to read of your alternator drive
coupling problem. The attached copy of TCM SB95-3B provides some
relevant information.
I think that you have a very good grasp of the four solutions to the
problem. They are: a) purchase and install the multi piece coupling, b)
convert to a front drive alternator, c) purchase and install a one piece
coupling from CMI (Continental Motors Inc. -- new name), purchase and
install an aftermarket rebuilt one piece coupling.
Regarding each solution:
a) The multi piece coupling was replaced by the one piece coupling as
the one piece coupling was considered superior. That point may be
debated.
b) The IO-240 B3B engine in the Diamond DA 20-C1 airplane uses the front
mounted alternator. One could maybe source the parts needed from a
Diamond aircraft dealer. I don=99t know if that model airplane was
ever introduced outside of the USA and Canada. In addition to obtaining
and installing the front of the engine parts needed one would also have
to seal off the left open alternator drive access hole in the rear of
the engine.
c) Purchase a one piece coupling from CMI. The most expensive initial
course of action.
d) The aftermarket one piece coupling can be purchased from these
people:
http://www.qualityaircraftaccessories.com/Default.aspx?A=ProductSearch&
ID=/search-results&SE=True&q=635796
for an initial cost of $1,095.00 US. They are supposed to refund $500 US
of that when they receive your returned old one piece core.
Please let me know if I can be of further help.
=98OC=99
'O C' Baker says "The best investment you can make is the effort to
gather and understand information."
=
From: Hans Christian Erstad
Sent: Mar 2, 2013 12:55 PM
Subject: KIS-List: IO-240 alternator drive coupling
I have read several
postings about early failure of the IO-240 alternator drive coupling
(P/N
635796).
The coupling failed
now at 337 hours in my IO-240 powered KIS. From other postings, it seems
like this part never reaches 500 h, and cost a fortune to buy new (more
than
$2000), but may be overhauled for $600.
The failure rates
indicate to mee that this part (too) is a bad design.
Apparently it is
possible to replace the one piece coupling, with one that contain of
several
parts (531325, 530407, 632050, 653982, 653983) and have been used on
other
Continental (e.g. O-200).
What have the
experience been for you that have IO-240 ?
Any suggestion for
best place to get the one-piece overhauled? or suggestions for where to
buy
the serveal-piece alternative?
Regards
Hans Christian
Erstad
Message 5
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|
Subject: | IO-240 alternator drive coupling |
Thanks OC
Yes, it sound like I have identified all options - and there are quite a
few.
Looking at the failed on-piece coupling, I think it is not designed to
last,
only to make money :-)
I think the best option is to find used parts for the multi piece
coupling,
but buy new the bushing and retainer that according to SB95-3B is to be
replaced every 500h.
This Service Bulletin have been useful providing information on part
numbers, torque etc. However it seems like the one-piece coupling never
reaches 500h, so the SB is to no help there, apart from stating "The one
piece coupling may be substituted for the coupling assembly shown in
Figure
1." Maybe they issued the SB to infrom about this substitution when
they
realized that the one-piece is flawed.
The SB calls for the couling to be tested for 100 inch punds of torque.
Probably all 500h couplings will fail this test? and will require
replacement with the substitute. Anyone know about a 500h coupling that
have
passed the test?
Regards
Hans Christian
_____
Fra: owner-kis-list-server@matronics.com
[mailto:owner-kis-list-server@matronics.com] P=E5 vegne av Owen Baker
Sendt: 3. mars 2013 14:08
Til: ERSTAD HANS-CHRISTIAN; KIS-LIST MATRONICS
Emne: KIS-List: IO-240 alternator drive coupling
3/3/2013
Hello Hans Christian, I am sorry to read of your alternator drive
coupling
problem. The attached copy of TCM SB95-3B provides some relevant
information.
I think that you have a very good grasp of the four solutions to the
problem. They are: a) purchase and install the multi piece coupling, b)
convert to a front drive alternator, c) purchase and install a one piece
coupling from CMI (Continental Motors Inc. -- new name), purchase and
install an aftermarket rebuilt one piece coupling.
Regarding each solution:
a) The multi piece coupling was replaced by the one piece coupling as
the
one piece coupling was considered superior. That point may be debated.
b) The IO-240 B3B engine in the Diamond DA 20-C1 airplane uses the front
mounted alternator. One could maybe source the parts needed from a
Diamond
aircraft dealer. I don=92t know if that model airplane was ever
introduced
outside of the USA and Canada. In addition to obtaining and installing
the
front of the engine parts needed one would also have to seal off the
left
open alternator drive access hole in the rear of the engine.
c) Purchase a one piece coupling from CMI. The most expensive initial
course
of action.
d) The aftermarket one piece coupling can be purchased from these
people:
http://www.qualityaircraftaccessories.com/Default.aspx?A=ProductSearch
<http://www.qualityaircraftaccessories.com/Default.aspx?A=ProductSearch
&ID=/
search-results&SE=True&q=635796>
&ID=/search-results&SE=True&q=635796
for an initial cost of $1,095.00 US. They are supposed to refund $500 US
of
that when they receive your returned old one piece core.
Please let me know if I can be of further help.
=91OC=92
'O C' Baker says "The best investment you can make is the effort to
gather
and understand information."
=
From: Hans Christian Erstad
Sent: Mar 2, 2013 12:55 PM
Subject: KIS-List: IO-240 alternator drive coupling
I have read several
postings about early failure of the IO-240 alternator drive coupling
(P/N
635796).
The coupling failed
now at 337 hours in my IO-240 powered KIS. From other postings, it seems
like this part never reaches 500 h, and cost a fortune to buy new (more
than
$2000), but may be overhauled for $600.
The failure rates
indicate to mee that this part (too) is a bad design.
Apparently it is
possible to replace the one piece coupling, with one that contain of
several
parts (531325, 530407, 632050, 653982, 653983) and have been used on
other
Continental (e.g. O-200).
What have the
experience been for you that have IO-240 ?
Any suggestion for
best place to get the one-piece overhauled? or suggestions for where to
buy
the serveal-piece alternative?
Regards
Hans Christian
Erstad
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