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IO-240 alternator drive coupling

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hans-chr.erstad(at)c2i.ne
Guest

Posted: Sat Mar 02, 2013 9:55 am Post subject: 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

  

  

   [quote][b]

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mantafs(at)earthlink.net
Guest

Posted: Sat Mar 02, 2013 10:14 am Post subject: 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



--

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bakerocb

Joined: 15 Jan 2006
Posts: 727
Location: FAIRFAX VA

Posted: Sun Mar 03, 2013 5:08 am Post 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’t 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.

  

 ‘OC’

  

 '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



To: kis-list(at)matronics.com (kis-list(at)matronics.com)



Subject: 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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