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CONTINENTAL AIRCRAFT ENGINE C75 Series Maintenance Manual

Standard practice for spark ignited engines
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CONTINENTAL AIRCRAFT ENGINE
MAINTENANCE
MANUAL
STANDARD PRACTICE
FOR SPARK IGNITED ENGINES
Technical Portions Accepted by the Federal Aviation Administration
Publication M-0
CHANGE 2
©
2016 CONTINENTAL MOTORS
SEP 2016

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Summary of Contents for CONTINENTAL AIRCRAFT ENGINE C75 Series

  • Page 1 CONTINENTAL AIRCRAFT ENGINE MAINTENANCE MANUAL STANDARD PRACTICE FOR SPARK IGNITED ENGINES Technical Portions Accepted by the Federal Aviation Administration Publication M-0 CHANGE 2 © 2016 CONTINENTAL MOTORS SEP 2016...
  • Page 2 Supersedure Notice This manual incorporates maintenance and service information contained in Continental Motors Service Documents common to the horizontally opposed, spark ignition, AvGas aircraft engines conforming to Type Certificate held by Continental Motors. This document is supplemental to the Instructions for Continued Airworthiness provided in the manuals listed in Section 1-1.1.
  • Page 3 List of Effective Pages, cont. Page Change Page Change Page Change Page Change 7-8 ........1 A-1 thru A-6 ....0 7-9 ........0 B-1 ....... 1 7-10 ......1 B-2 thru B-7 ....0 7-11 thru 7-23 ....0 B-8 ....... 1 7-24 ......1 B-9 thru B-16 ....
  • Page 4 Intentionally Left Blank Standard Practice Maintenance Manual CHANGE 1 30 May 2016...
  • Page 5 Introduction 1-2.4.1. Service Documents Incorporated in this Manual Applicable technical maintenance and service information contained in the Service Documents listed below, relevant to the engine models covered by this engine manual, have been incorporated in this M-0 Standard Practice Maintenance Manual. This manual supersedes and retires these older Service Documents (where applicable) excluding Mandatory Service Bulletins (MSBs) and Critical Service Bulletins (CSBs) identified with an asterisk below.
  • Page 6 Introduction Table 1-1. Service Documents Incorporated in Manual Service Document Subject Affected Chapter SB96-12, Cylinder Continued Airworthiness Scheduled Inspection 6 & 10 SID97-2B, Design, Operation Maintenance and Engine Maintenance Warranty of Cylinders SID97-3G, Continuous Flow Fuel Injection Systems O p e r a t i o n a l C h e c k s a n d Adjustment Specifications and Instructions...
  • Page 7 Engine Inspection and Service Overhauled or repaired in a manner that is inconsistent with the specifications, • limits, and instructions provided in the CM Instructions for Continued Airworthiness and FAA Airworthiness Directives 6. The “Hobbs Meter” is commonly used by the aviation industry as an acceptable device to record time elapsed while electrical power is applied to the device.

  • Page 8: April

    Engine Inspection and Service Table 6-1. Engine Time Between Overhaul (TBO) HOURS/YEARS ENGINE ENGINE S/N BEFORE S/N 1006000 ENGINE MODEL SEE NOTE 1006000 AND LATER 1200/12 GTSIO-520-F, K 1, 4 GTSIO-520-C, D, H 1600/12 GTSIO-520-L, M, N 1400/12 TSIO-520-B, D, E, J, K, L, N 1, 2 1400/12 1600/12...
  • Page 9 Engine Inspection and Service 6-4.7.1. Fuel Injection System Specifications NOTE: Engines may not reach rated full power RPM during ground run- up due to atmospheric, environmental, or configuration limitations. This condition is normal, occurring most often when operating naturally aspirated engines configured with a fixed pitch propeller. A correction factor must be applied to reduce the fuel pressure to the lower maximum RPM observed during fuel system adjustments on the ground.

  • Page 10: Change

    Engine Inspection and Service Table 6-4. Fuel System Adjustment Values Idle and FULL POWER Fuel Pressures and Flows Manifold Metered Absolute Unmetered Nozzle Fuel Fuel Prop. Pressure Engine (MAP) Pump PSI (lbs/hr) (gal/hr) TSIO-360-JB 6.5 - 7.5 2800 37.0 34.5 - 37.5 16.7 - 19.3 134 - 145 22.8 - 24.7...

  • Page 11: Standard Practice Maintenance Manual 30 Sep

    Engine Inspection and Service Table 6-4. Fuel System Adjustment Values Idle and FULL POWER Fuel Pressures and Flows Manifold Metered Absolute Unmetered Nozzle Fuel Fuel Prop. Pressure Engine (MAP) Pump PSI (lbs/hr) (gal/hr) TSIO-520-BE 5.5 - 7.0 2600 38.0 25.0 - 28.0 12.7 - 14.1 214 - 224 36.5 - 38.2...

  • Page 12: C-19

    Engine Inspection and Service Table 6-4. Fuel System Adjustment Values Idle and FULL POWER Fuel Pressures and Flows Manifold Metered Absolute Unmetered Nozzle Fuel Fuel Prop. Pressure Engine (MAP) Pump PSI (lbs/hr) (gal/hr) 8.0 -10.0 IO-550-C 2700 31.6 - 37.8 17.6 - 19.6 152 - 160 25.9 - 27.3...

  • Page 13: Change

    Engine Inspection and Service 6-4.7.3. Oil Pump Operational Check 1. Perform a Maintenance Preflight Inspection according to Section 6-4.7.2. 2. Perform a normal “Engine Start” according to instructions in Section 7-3.2 and “Ground Run-up” according to Section 7-3.3 to allow the engine to warm to normal operating temperatures.
  • Page 14 Engine Inspection and Service Hoses of sufficient length to allow personnel and equipment to perform the test at a • safe distance from the propeller arc and blast area. A digital hand-held tachometer, capable of verifying aircraft tachometer accuracy • prior to fuel system adjustment.
  • Page 15 Engine Inspection and Service 6-4.7.4.3. Fuel System Operational Checkout Procedure Procedure 1. Set the aircraft brakes and block the aircraft main landing gear tires. 2. Verify the accuracy of the tachometer, manifold pressure gauge, and fuel flow gauges prior to making any adjustments; replace faulty gauges. 3.
  • Page 16 Engine Inspection and Service WARNING Do not operate the engine at speeds above 1700 RPM until the oil temperature reaches minimum takeoff temperature (100°F (38°C) for turbocharged engines or 75°F (24°C) for naturally aspirated engines) and oil pressure is within the normal operating range.
  • Page 17 Engine Inspection and Service 20. Inspect the wastegate controller and fittings for physical condition and security. If the wastegate controller exhibits physical damage, replace the wastegate controller with a new, rebuilt, or serviceable unit. Inspect the wastegate controller hoses, or tubes, for chafing, nicks, cuts or leaks;...
  • Page 18 Engine Inspection and Service 6-4.22. Alternator Inspection Frequency During 500-hour inspection Procedure 1. Remove engine cowling and aircraft components necessary to gain access to the alternator. 2. Remove the alternator according to instructions in Section 10-4.1.1 or Section 10- 4.1.1. Perform the “Alternator Drive Hub Inspection” in Section 6-4.22.1 or Section 6-4.22.2 on all gear driven alternators.
  • Page 19 Engine Inspection and Service torque or less. Replace the drive hub if slippage occurs under 100 inch pounds of torque. 4) Install the serviceable drive hub on the alternator according to instructions in Section 10-4.2.3. b. Inspect the multi-part drive coupling: 1) Secure the alternator coupling gear (Figure 6-99) (5) in the jaws of a padded vice, leaving the gear section free.
  • Page 20 Engine Inspection and Service 6-5. Unscheduled Maintenance 6-5.1. Propeller Strike A propeller strike is any incident (whether or not the engine is operating) in which the propeller contacts a foreign object that 1)results in the necessity to repair the propeller blade(s) (other than minor blade dressing) or 2)results in loss of engine RPM at the time of contact.
  • Page 21 Troubleshooting Fuel Injector Operational Remove fuel injectors from the fuel lines. Check, cont. Connect clear tubing to the fuel lines and terminate the tubing in catch cans: Master Power Switch……..ON Fuel Selector Valve………...ON Flow Boost Pump….……………...ON consistent and Throttle……………………….Wide Open equal Fuel Flow……….……………Check Boost Pump….……………...OFF...
  • Page 22 Troubleshooting 8-4. Charging System Refer to the aircraft and alternator manufacturer’s applicable charging system trouble- shooting instructions. If troubleshooting indicates the alternator is faulty, remove and replace the alternator according to the instructions in Section 10-4. 8-5. Starting System Engine Will Not Start When Ignition Switch Engaged.
  • Page 23 Non-Overhaul Repair and Replacement 10-4. Alternator Replacement Replace the alternator when it fails to deliver the correct voltage and amperage to the aircraft electrical system. If electrical malfunctions are isolated to the alternator, physical inspection of the alternator must be accomplished before replacement. The engine may be equipped with a direct drive alternator, a belt-driven alternator, or both.
  • Page 24 Non-Overhaul Repair and Replacement 6. Remove and discard the gasket (1); clean any remaining gasket residue from the crankcase flange with lacquer thinner. 7. Place the alternator in a horizontal position, rotate the shaft in both direction. If the shaft does not turn freely, rotor friction or bearing stress is indicated, or noticeable shaft displacement is detected during rotation, replace the alternator.
  • Page 25 Non-Overhaul Repair and Replacement 10-4.1.2. Alternator Drive Hub Removal Applicable Engines: IO-520-B, BA, BB, C, CB, M, MB, NB, TSIO-520-B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB, IO-550-A, B, C, G, N, P, R, IOF-550-N, P, R, TSIO-550-B, C, E, G, K, N, TSIOF-550-D, J, K, P, TSIOL-550, A, B, C 1.
  • Page 26 Non-Overhaul Repair and Replacement 4. Install the drive hub assembly (5), and new thrust washer (6) on the alternator shaft. 5. Install the castellated nut (4) on the shaft. Secure the drive hub with an Alternator Drive Hub Spanner Wrench (see Section 2-1, “Special Tools”.) and torque the castellated nut (4) to the minimum value specified in Appendix B.
  • Page 27 Non-Overhaul Repair and Replacement 10-4.1.5. Gear Driven Alternator Installation Applicable Engines: IO-520-B, BA, BB, C, CB, M, MB, NB, TSIO-520-B, BB, BE, D, DB, E, EB, J, JB, K, KB, L, LB, N, NB, UB, VB, WB, IO-550-A, B, C, G, N, P, R, IOF-550-B, C, N, P, R, TSIO-550- B, C, E, G, K, N, TSIOF-550-D, J, K, P, TSIOL-550, A, B, C Prior to alternator installation, perform an “Alternator Drive Hub Slippage Inspection”...
  • Page 28 Non-Overhaul Repair and Replacement 10-4.2. Gear Driven Alternator Replacement, Aft Mount Applicable Engines: C-75, C-85, C-90, C-115, C-125, C-145, E-165, E-185, E-225, GO-300, GIO-300, O-300, IO-240, IOF-240, and all IO-360, LTSIO-360, TSIO-360 10-4.2.1. Gear Driven Alternator Removal WARNING Turn the Ignition Switch OFF and disconnect engine electrical power before commencing maintenance or inspections.
  • Page 29 Non-Overhaul Repair and Replacement Figure 10-6. Alternator and Drive Hub Typical for C-75, C-85, C-90, C-115, C-125, C-145, GO-300, GIO-300, O-300, IO-240, IOF-240 Alternator Castellated Nut Washer Terminal Nut Woodruff Key Cotter Pin Lock Nut Washer Drive Hub (single piece) Gasket Washer Terminal Nut...
  • Page 30 Non-Overhaul Repair and Replacement 10-4.2.2. Alternator Drive Hub Removal Applicable Engines: C-75, C-85, C-90, C-115, C-125, C-145, E-165, E-185, E-225, GO-300, GIO-300, O-300, IO-240, IOF-240, and all IO-360, LTSIO-360, TSIO-360 1. Remove the alternator according to the instructions in Section 10-4.2.1. 2.
  • Page 31 Non-Overhaul Repair and Replacement 8. Install a new cotter pin (4) through the nut and alternator shaft according to the instructions in Appendix C-7. Cut and bend the cotter pin according to the instructions in Figure 10-4 to avoid interference with mating surfaces when installing the alternator on the engine.
  • Page 32 Non-Overhaul Repair and Replacement 10-4.2.4. Gear Driven Alternator Installation Applicable Engines: C-75, C-85, C-90, C-115, C-125, C-145, E-165, E-185, E-225, GO-300, GIO-300, O-300, IO-240, IOF-240, and all IO-360, LTSIO-360, TSIO-360 WARNING Turn the Ignition Switch OFF and disconnect engine electrical power before commencing maintenance or inspections.

This manual is also suitable for:

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