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Continental Refrigerator CD-170 Operation & Maintenance Manual

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Aerospace Technologies GmbH
Operation & Maintenance
The Operation and Maintenance Manual
must be read completely before operating the
engine, as it contains important safety information
and information about the operation of the engine.
The Operation and Maintenance Manual
must be included at the time of sale
Please report any service difficulties to the
Continental Aerospace Technologies GmbH.
See above for contact information.
Continental
Platanenstraße 14
D - 09356 St. Egidien
Operation & Maintenance Manual - Issue 1 / Revision -
Manual
CD-170
Doc. No.: OM-02-02B
Version: 1/3
CAUTION:
Note:
of the engine / aircraft.
Note:
Technical Support Center at
P/N: 05-7200-H140104
Tel. +49 37204 696-0
Fax +49 37204 696-2912
www.continentaldiesel.com
support@continentaldiesel.com

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  • Page 1 Platanenstraße 14 support@continentaldiesel.com D - 09356 St. Egidien Operation & Maintenance Manual - Issue 1 / Revision - Operation & Maintenance Manual CD-170 Doc. No.: OM-02-02B Version: 1/3 CAUTION:  The Operation and Maintenance Manual must be read completely before operating the engine, as it contains important safety information and information about the operation of the engine.
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  • Page 3 Operation & Maintenance Manual CD-170 OM-02-02B Table of Contents Chapter Description Page Table of Contents ..................1 List of Figures .....................1 List of Revisions ..................1 List of applicable Chapters .................2 Preliminary Remarks ..................3 Introduction ....................1 Accompanying applicable Document ............1 Engine Identification ...................2 Copyright ©...
  • Page 4 Operation & Maintenance Manual CD-170 OM-02-02B Technical Data ..................1 Dimensions and Weights ................1 Performance Data ..................1 Operational Data ..................2 Operation Limits ..................3 3.4.1 Engine Flame Out in Cold Weather Condition .......4 Fuel / Oil / Coolant ..................5 Power Curve ....................7 Operation ....................1...
  • Page 5 Operation & Maintenance Manual CD-170 OM-02-02B Maintenance Schedules ................1 "Pre-flight Check" ..................2 Maintenance Actions based on Operating Hours ........2 6.2.1 After the 3rd - 6th operating hour ..........3 6.2.2 Every 100 operating hours ............4 6.2.3 Every 200 operating hours ............5 6.2.4...
  • Page 6 Operation & Maintenance Manual CD-170 OM-02-02B Emergency Procedures ................1 Power Loss ....................1 FADEC Operation ..................1 Engine System Malfunction ................2 7.3.1 One FADEC light flashing ..............2 7.3.2 Both FADEC lights flashing ............3 7.3.3 Abnormal engine behavior .............3 Restart after Engine Failure ...............4 Fire in the Engine Compartment ..............4...

  • Page 7: Table Of Contents

    Fig. 1.1 Explanation of the chapter numbering system Fig. 1.1 Engine identification Fig. 1.2 Preservation of the engine Gearbox front view of CD-170  Fig. 2.1 (dimensions in mm) Fig. 2.2 Air intake side view of CD-170 (dimensions in mm) Fig.
  • Page 8 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.29 FADEC read-out - Choice screen Fig. 6.30 FADEC read-out - Maintenance data download Fig. 6.31 FADEC read-out - Enter engine specifications Fig. 6.32 FADEC read-out - Perform engine ground run Fig. 6.33 FADEC read-out - Downloading Fig.
  • Page 9 Operation & Maintenance Manual CD-170 OM-02-02B List of Revisions Issue/ Chapter Remark Date Approved by Revision Issue 1 / Revision - 02-OM-00-02 03.08.2020 Hartung 02-OM-01-02 03.08.2020 Hartung 02-OM-02-02 03.08.2020 Hartung Adapted, based on 02-OM-03-02 03.08.2020 Hartung version 02-OM-04-02 03.08.2020 Hartung...
  • Page 10 Operation & Maintenance Manual CD-170 OM-02-02B List of applicable Chapters Document No. Document Issue Revision Date 02-OM-00-02 Lists 21.04.2023 02-OM-01-02 Introduction 03.08.2020 02-OM-02-02 Description and Dimensions of 06.10.2022 the Engine 02-OM-03-02 Technical Data 06.10.2022 02-OM-04-02 Operation 06.10.2022 02-OM-05-02 Airworthiness Limitations 03.08.2020...

  • Page 11: Fig. 1.1 Explanation Of The Chapter Numbering System

    Operation & Maintenance Manual CD-170 OM-02-02B Preliminary Remarks The chapter numbering of the footer is different to the chapter numbering of the remaining manual. See Fig. 1.1. refers to the section of the chapter refers to the chapter Fig. 1.1...
  • Page 12 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Lists Chapter: 02-OM-00-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 21.04.2023...
  • Page 13 Operation & Maintenance Manual CD-170 OM-02-02B Introduction This Operation and Maintenance Manual contains basic information related to the proper operation of the engine in various situations and under different conditions. It also contains instructions for maintenance. The information and descriptions of components and systems in this manual were correct at the time of publication.

  • Page 14: Fig. 1.1 Engine Identification

    Operation & Maintenance Manual CD-170 OM-02-02B Engine Identification The serial number of the engine is provided on the data plate on the crankcase near the starter flange.  Example: Fig. 1.1 Engine identification  Note: When making inquiries, always have the serial number of the engine ready.
  • Page 15 Operation & Maintenance Manual CD-170 OM-02-02B Safety Recommendations The following symbols and warning signs are used in the manual. They must be heeded strictly to prevent personal injury and material damage, to avoid impairment of the operational safety of the aircraft and to rule out any damage to the aircraft as a consequence of improper handling ...
  • Page 16 Operation & Maintenance Manual CD-170 OM-02-02B Packaging and Transport The engine has been packaged at the factory for transport as follows: • Mounted on a support in a wooden crate • Supplied with drying agent • When the engine is transported by ship, it is packed seaworthy ...
  • Page 17 Operation & Maintenance Manual CD-170 OM-02-02B Scope of Supply The scope of supply is specified in Chapter 2, Section 2.2, Page 1 of this Manual. 1.10 Qualifications of the Operating and Maintenance Personnel All tasks and checks described in this manual should only be performed by persons authorized through the competent authority of the respective country.
  • Page 18 Operation & Maintenance Manual CD-170 OM-02-02B 1.13 Safety Information  WARNING: Any Aircraft Engine Ground Run must be conducted in a secure area that is protected from the unauthorized movement of personnel! Any rotating propeller is a potential safety hazard that can cause severe personal injuries or even death! •...
  • Page 19 Operation & Maintenance Manual CD-170 OM-02-02B • Improper installation, the use of non-suitable lines for the fuel, cooling and oil circuits, and operation with non- approved fuels or lubricants/oils absolves the manufacturer from any liability. • Any unauthorized modifications made to the engine or the aircraft absolve the manufacturer from liability for related damages.
  • Page 20 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Introduction Chapter: 02-OM-01-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date:...
  • Page 21 CD-170 (TAE 125-02-125) Description and Standard Production Version The Continental Diesel CD-170 is a liquid-cooled 4-cylinder in-line four-stroke diesel engine with DOHC (double overhead camshaft). The valves are activated by cam followers. The operation of the direct diesel-injection engine is based on the common-rail technique and is turbo charged.
  • Page 22 Operation & Maintenance Manual CD-170 OM-02-02B Engine Views Gearbox front view CD-170 30.5 30.5 Gearbox front view of CD-170  Fig. 2.1 (dimensions in mm) Air intake side view CD-170 Fig. 2.2 Air intake side view of CD-170 (dimensions in mm)

  • Page 23: Fig. 2.3 Exhaust Side View Of

    Operation & Maintenance Manual CD-170 OM-02-02B Exhaust side view CD-170 Fig. 2.3 Exhaust side view of CD-170 (dimensions in mm) Overhead view CD-170 Fig. 2.4 Overhead view of CD-170 (dimensions in mm) Description and Dimensions of the Engine Chapter: 02-OM-02-02...
  • Page 24 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Description and Dimensions of the Engine Chapter: 02-OM-02-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 06.10.2022...
  • Page 25 Operation & Maintenance Manual CD-170 OM-02-02B Technical Data  Note: All speed-related data in the operation and maintenance manual refer to propeller speeds if not otherwise explicitly specified as engine speeds.  Note: The performance and operational data refer to sea level at 15°C and 0% relative humidity.
  • Page 26 Operation & Maintenance Manual CD-170 OM-02-02B Operational Data Speeds: Idling speed..............890 rpm Oil pressure: Normal operating pressure.......... 2.3 - 6 bar min. 1.0 bar / max. 6.5 bar Oil temperature: Optimum operating temperature ....approx. 90°C - 110°C min. for starting -25°C min.
  • Page 27 Operation & Maintenance Manual CD-170 OM-02-02B Operation Limits Min. oil temperature OT (starting) ........-25°C Min. oil temperature OT (opening-up) ........50°C Max. oil temperature OT ............120°C Min. coolant temperature CT (starting) .......-25°C Min. coolant temperature CT (opening-up) ......60°C Max. coolant temperature CT..........105°C Max.

  • Page 28: Fig. 3.5 Diagram: Outside Temperature Range

    Operation & Maintenance Manual CD-170 OM-02-02B Engine Flame Out in Cold Weather Condition  3.4.1 (only applicable for version 1 engines):  WARNING: If continuous monitoring of MAT in-flight is not possible, engine operation in the red area of Fig. 3.5 should be avoided, due to the risk of an engine flame out! Approved &...
  • Page 29 Operation & Maintenance Manual CD-170 OM-02-02B Fuel / Oil / Coolant  CAUTION: Use of non-approved fuel / oil / coolant can lead to dangerous malfunctions of the engine. Fuel ............JET A-1 (ASTM D 1655) Jet Fuel No. 3 (GB6537-2018) Alternative fuel ...........
  • Page 30 Operation & Maintenance Manual CD-170 OM-02-02B Coolant:....Use of Ready Mix ratio 50:50 is recommended  Note: If Ready Mix is not available please use concentrate and distilled water in a ratio of 50:50 to ensure an ice flocculation point at ...
  • Page 31 Operation & Maintenance Manual CD-170 OM-02-02B Power Curve The values refer to 0% relative humidity. Fig. 3.6 Power curve of CD-170 (TAE 125-02-125) Technical Data Chapter: 02-OM-03-02 Issue: Issue date: 03.08.2020 Revision no.: Page: Revision date: 06.10.2022 Content:...
  • Page 32 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Technical Data Chapter: 02-OM-03-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 06.10.2022...
  • Page 33 Operation & Maintenance Manual CD-170 OM-02-02B Operation  WARNING: No coolant loss may occur during operation! Any coolant loss must immediately be followed by a technical inspection by an authorized person. Coolant loss could result in engine malfunction, which can lead to engine failure! ...
  • Page 34 Operation & Maintenance Manual CD-170 OM-02-02B Start-up  WARNING: Any Aircraft Engine Ground Run must be conducted in a secure area that is protected from the unauthorized movement of personnel! Any rotating propeller is a potential safety hazard that can cause severe personal injuries or even death! ...
  • Page 35 Operation & Maintenance Manual CD-170 OM-02-02B Engine Warm-up • Allow the engine to warm up for approximately 2 minutes at idle speed. • Then increase the propeller speed to 1400 rpm until the oil temperature has reached 50°C and the coolant temperature has reached 60°C.
  • Page 36 Operation & Maintenance Manual CD-170 OM-02-02B The A light extinguishes, idle speed is reached; the test is completed. Release test button.  WARNING: If there are prolonged engine misfires or the engine shuts down during the test, do not attempt a takeoff with the airplane.
  • Page 37 Operation & Maintenance Manual CD-170 OM-02-02B 4.4.2 Engine test run for maintenance purposes (Real Time Log File (RTLF), Internal Data Logger (IDL), Event Log (EL)) Make sure that the Force B switch is in the automatic position. Warm-up (in accordance with Section 4.3, Page 3 of this Chapter) •...
  • Page 38 Operation & Maintenance Manual CD-170 OM-02-02B • Move the Force B switch to the FADEC B position. Move the load selector to the full-load position. The propeller must accelerate smoothly and steadily to the following propeller speed limits (rpm): Single-engined ......2240 rpm to 2300 rpm Twin-engined......
  • Page 39 Operation & Maintenance Manual CD-170 OM-02-02B 4.4.3 FADEC-Reset (from Software 2.7 on and following) In case of a FADEC-warning, one or both FADEC warning lamps are flashing. If the "FADEC" test button then is pressed for at least 2 seconds, the following possibilities will occur:...
  • Page 40 Operation & Maintenance Manual CD-170 OM-02-02B Possible reasons for activation of FADEC-Warnings are: a) Category LOW, temporary failure (one time reset is possible) - Engine_Speed ............High or Low - FADEC switchover due to FADEC A/B ....RPM difference - MAP ................High or Low - MAP max.
  • Page 41 Operation & Maintenance Manual CD-170 OM-02-02B b) Category HIGH, steady failure or high category failure (no reset possible by FADEC-Test Knob) - Engine Speed max. tolerated difference ECU A/B ..Exceeded - Injector ................. Error - Injector or InjectorPower........... Overcurrent - Mapping ................
  • Page 42 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Operation Chapter: 02-OM-04-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 06.10.2022...
  • Page 43 Operation & Maintenance Manual CD-170 OM-02-02B Airworthiness Limitations AIRWORTHINESS LIMITATIONS APPROVAL SHEET (EASA) This Airworthiness Limitations Section is EASA approved and mandatory. It specifies required maintenance unless an alternative program has been EASA approved. AIRWORTHINESS LIMITATIONS APPROVAL SHEET (FAA) The Airworthiness Limitations section is FAA approved and specifies maintenance required under Sec.
  • Page 44 Operation & Maintenance Manual CD-170 OM-02-02B 5.1.2 Every 600 operating hours • Replace high-pressure pump (refer to Chapter 6, Annex 1 of this Manual) • Replace rail pressure valve • Replace Injectors 5.1.3 Every 1200 operating hours • Replace engine shock mounts •...
  • Page 45 Operation & Maintenance Manual CD-170 OM-02-02B Claimable Exceeds of Maintenance Actions  CAUTION: Exceedings must not be cumulated! 5.2.1 Maintenance Actions based on operating hours Claimable Exceeding of Operating Hours Intervals the Basic Interval up to and including 100 operating ±...
  • Page 46 Operation & Maintenance Manual CD-170 OM-02-02B 5.2.3 Examples Limited intervals based on operating hours • Maintenance action due on:  300 operating hours (100 hours check) • Maintenance action must be performed between:  290 and 310 operating hours The maintenance action is performed at the latest at 310 operating hours.
  • Page 47 Operation & Maintenance Manual CD-170 OM-02-02B Log of Revisions to Airworthiness Limitations Issue / Revision Description of Revision 1 / - first publication Airworthiness Limitations Airworthiness Limitations Chapter: 02-OM-05-02 Issue: Issue date: 03.08.2020 Revision no.: Page: Revision date: Content:...
  • Page 48 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Airworthiness Limitations Chapter: 02-OM-05-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date:...
  • Page 49 Operation & Maintenance Manual CD-170 OM-02-02B Maintenance Schedules The specified maintenance schedule applies to all aircraft regardless of type and ensures the reliability of the engine. The maintenance work on Continental Aerospace Technologies GmbH engines must be carried out after specific time intervals or upon reaching a specific number of operating hours.
  • Page 50 Operation & Maintenance Manual CD-170 OM-02-02B "Pre-flight Check" • All switches - "OFF" • Check the engine oil level (refer to IM-02-02, Chapter 4 for filling quantities)  CAUTION: When checking the engine oil level screw in the dipstick completely! ...
  • Page 51 Operation & Maintenance Manual CD-170 OM-02-02B 6.2.1 After the 3rd - 6th operating hour • Check the oil system for leakage  (refer to Annex 2 of this Chapter) • Check the fuel system for leakage (refer to Annex 2 of this Chapter) •...
  • Page 52 Operation & Maintenance Manual CD-170 OM-02-02B 6.2.2 Every 100 operating hours • Visual inspection of the air filter • Visual inspection of the oil system (refer to Annex 2 of this Chapter) • Visual inspection of the fuel system (refer to Annex 2 of this Chapter) •...
  • Page 53 Operation & Maintenance Manual CD-170 OM-02-02B • Exchange the engine oil and the oil filter  (refer to Annex 5 of this Chapter)  Note: A sample of the oil and the used oil filter must be labeled, stored clean...
  • Page 54 Operation & Maintenance Manual CD-170 OM-02-02B 6.2.4 Every 300 operating hours • Carry out all steps described in Section 6.2.2, Page 4 of this Chapter. 6.2.5 Every 600 operating hours • Carry out all steps described in Section 6.2.4, Page 6 of this Chapter.
  • Page 55 Operation & Maintenance Manual CD-170 OM-02-02B 6.2.7 Every 1200 operating hours or every 24 months, whichever occurs first • Exchange coolant (refer to Chapter 6, Annex 14, Page 50 of this Manual) 6.2.8 Every 1500 operating hours • Carry out all steps described in Section 6.2.4, Page 6 of this Chapter.
  • Page 56 Operation & Maintenance Manual CD-170 OM-02-02B Maintenance Actions based on Time  WARNING: Under extreme conditions such as low usage combined with operation in a salt-water environment, or in a very dusty and sandy environment, shorter maintenance and inspection intervals are recommended for your own safety.
  • Page 57 Operation & Maintenance Manual CD-170 OM-02-02B 6.3.3 Every 24 months • Exchange coolant  (refer to the engine manufacturer's specifications) 6.3.4 Every 60 months • Replace all fuel, oil and cooling system lines  Note: Flexible hose / hose assemblies replacement times are in- service times.

  • Page 58: Fig. 6.1 V-Ribbed Belt

    Operation & Maintenance Manual CD-170 OM-02-02B Annex 1 Inspecting the V-Ribbed Belt This is a general visual inspection. The v-ribbed belt is to be checked for indications of wear such as abrasion and cracks.  The v-ribbed belt tension is determined by spring pressure automatically.
  • Page 59 Operation & Maintenance Manual CD-170 OM-02-02B Annex 2 Inspecting the Oil and Fuel System for Leakage This is a visual inspection. Check all pipes, pipe joints, supply connections and engine housing separation points (e.g. cylinder head gasket, cylinder head cover gasket) for leakage, seepage points and correct routing.

  • Page 60: Fig. 6.3 Cooling System

    Operation & Maintenance Manual CD-170 OM-02-02B Annex 3 Inspecting the Cooling System for Leakage This is a visual inspection. The pipes, pipe joints and supply connections are inspected for leakage and seepage points.  WARNING: No leakage and seepage points are permitted! No coolant loss...
  • Page 61 Operation & Maintenance Manual CD-170 OM-02-02B Annex 4 Engine Test Run Check the starting behavior:  CAUTION: Do not overheat the starter. Do not operate the starter for more than 10 seconds. After operating the starter, let it cool down for 20 seconds.
  • Page 62 Operation & Maintenance Manual CD-170 OM-02-02B Annex 5 Exchanging the Engine Oil and Oil Filter Allow the engine to warm up, refer to Chapter 4.2 and Chapter 4.3 of this manual.  WARNING: The engine warm-up must be conducted in a secure area that is protected from the unauthorized movement of personnel!...

  • Page 63: Fig. 6.5 Oil Drain Plug, Depending On The Oil Pan 2 Different Designs

    Operation & Maintenance Manual CD-170 OM-02-02B Replace the seal ring at the drain plug. Refit the drain plug and tighten it up to the specified tightening torque, see Fig. 6.5. Tightening Torque: 20 Nm (177 inch-lbs.) / 30 Nm (266 inch-lbs.) Secure the drain plug with a locking wire/locking sheet.
  • Page 64 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.6 Oil filter assy a Screw cap, P/N 05-7253-K00030x b O-ring, part of P/N 05-7253-K0044 01 c Oil filter cartridge, P/N 05-7253-K0044 01 Refit the screw cap (b) and tighten it up to the specified tightening torque.
  • Page 65 Operation & Maintenance Manual CD-170 OM-02-02B Annex 6 Cleaning the Engine The engine must be cleaned with care. If leakage points are found, their positions must be clearly identified before they are cleaned. The engine must be cleaned only when it is cooled down.

  • Page 66: Fig. 6.7 Coolant Temperature Sensor

    Operation & Maintenance Manual CD-170 OM-02-02B Annex 7 Checking the FADEC Sensors This is a visual inspection. Check whether the plug connections of the sensors are firmly in place. In addition, the wiring harness has to be checked for indications of abrasion. ...
  • Page 67 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.9 Air temperature sensor and MAP connections of the intake manifold a FADEC connection for MAP sensor b Air temperature sensor Fig. 6.10 Camshaft sensor 1 a Camshaft sensor FADEC A (1 of 2)
  • Page 68 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.11 Camshaft sensor (TWIN CAM) Fig. 6.12 Camshaft sensor 2 a Camshaft sensor 2 FADEC B (2 of 2) Fig. 6.13 Camshaft sensor (TWIN CAM) Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020 Page: Revision no.:...
  • Page 69 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.14 Crankshaft sensor 1 a Crankshaft sensor FADEC A (1 of 2) Fig. 6.15 Crankshaft sensor 2 a Crankshaft sensor FADEC B (2 of 2) Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020 Revision no.:...
  • Page 70 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.16 Gearbox temperature sensor a Gearbox temperature sensor Fig. 6.17 Oil pressure- and oil temperature sensor a Oil pressure sensor b Oil temperature sensor Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020 Page: Revision no.:...

  • Page 71: Fig. 6.18 Position Of The Oil Filter Cap

    Operation & Maintenance Manual CD-170 OM-02-02B Annex 8 Exchanging the gearbox oil filter Item Part Number Description 1 Description 2 Quantity 03-7212-K004001 Filter element DIN 3771-25x2,5- NM-0000-0150401 O-Ring 80FKM610 Loosen the filter cap of the gearbox oil filter and remove it.
  • Page 72 The o-ring is part of the new oil filter. Fig. 6.19 Mounting direction of the oil filter Fig. 6.20 Gearbox oil filter assembling (CD-170) a Filter element with o-ring b O-ring c Filter cap with spring Maintenance Schedules...

  • Page 73: Fig. 6.21 Lock Wiring Between Oil Drain Plug And Oil Filter Cap

    Operation & Maintenance Manual CD-170 OM-02-02B Attach the new o-ring to the filter cap. See Fig. 6.20.  Note: Make sure that the spring in the filter cap is fixed. Remount the filter cap and tighten it to the specified tightening torque.
  • Page 74 Operation & Maintenance Manual CD-170 OM-02-02B Annex 9 Checking the level of the gearbox oil Gearbox with oil cooler: Item Part Number Description 1 Description 2 Quantity Required if oil needs to be refilled: NM-0000-0021701 Sealing Ring DIN 7603-A18x24-Al  CAUTION: Only use gearbox oil specified in Chapter 3, Section 3.5 of this...

  • Page 75: Fig. 6.23 Gearbox Oil Filler Screw And Inspection Glass

    Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.23 Gearbox oil filler screw and inspection glass a Oil filler screw b Oil level inspection glass Fill in the new gearbox oil until the oil level reaches the top border of the oil level inspection glass (marking line in Fig.
  • Page 76 Operation & Maintenance Manual CD-170 OM-02-02B Secure the oil filler screw with a lock wire. See Fig. 6.24. Fig. 6.24 Lock wiring the oil filler screw 10. Do an Engine Test run according to Annex 4 of this Chapter. 11. Do a visual inspection and a check for leaks.
  • Page 77 Operation & Maintenance Manual CD-170 OM-02-02B Annex 10 FADEC Read-out General The FADEC service tool is designed to provide the user access to Real time data, the onboard logger system as well as the event log information available from the Continental...
  • Page 78 Operation & Maintenance Manual CD-170 OM-02-02B  Note: Please use a compressed file format such as .zip to send any data. This greatly reduces transfer times and facilitates data handling on both sides. The tool offers this function automatically for the regular maintenance download and the extended download.
  • Page 79 Operation & Maintenance Manual CD-170 OM-02-02B Generating a Real Time Log File  Note: The Tool gives the user the capability to generate a Real Time Logfile separately. This is not generally necessary, as the tool provides all necessary files in a single download. Please proceed to section 4 of this annex.

  • Page 80: Fig. 6.26 Fadec Read-Out - Enter Engine Specifications

    Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.26 FADEC read-out - Enter engine specifications c) Enter the engine S/N and engine run time in the fields provided. Select OK. The window at the bottom right of the screen will indicate that the logging function is active by showing the file name in blue text.

  • Page 81: Fig. 6.28 Fadec Read-Out - Stop Real Time Log File

    Operation & Maintenance Manual CD-170 OM-02-02B d) Conduct the engine ground run according to the operating manual.  Note: During the ground run, the user should verify that engine parameters are to spec.  Compare the values of Map to MapTar, Prop RPM to PrSpdTar and PRail to PRaTar to determine any discrepancy.
  • Page 82 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.29 FADEC read-out - Choice screen f) Select the action you wish to perform: • Open Explorer at Logfile's location to locate the file just created • Create E-Mail with logfile attached if you wish to send the mail •...
  • Page 83 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.30 FADEC read-out - Maintenance data download Fig. 6.31 FADEC read-out - Enter engine specifications b) If not already active, establish CAN communication with the FADEC by following the steps on the screen. Enter the required engine S/N and engine run time.
  • Page 84 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.32 FADEC read-out - Perform engine ground run c) Follow the instructions on the screen, performing the engine ground run according to Chapter 4, Section 4.4.2 of this Manual. Press Continue. The following screen will appear: ...
  • Page 85 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.33 FADEC read-out - Downloading d) When the download is completed, the following screen will appear: Fig. 6.34 FADEC read-out - Choice screen e) Select the action you wish to perform: • Open Explorer at Logfile's location to locate the file just created •...
  • Page 86 Operation & Maintenance Manual CD-170 OM-02-02B • Exit to return to the main screen  Note: The files generated from this download will include a real time log file, the event log, logger files and a zip file containing all of the above.
  • Page 87 Operation & Maintenance Manual CD-170 OM-02-02B Clearing Diagnostic Warnings Should the diagnostic warning lights be active, they must be cleared after the discrepancy has been diagnosed and resolved before the aircraft can be released for service. a) Menu FADEC => Clear Warnings. The following screens will appear: Fig.
  • Page 88 Operation & Maintenance Manual CD-170 OM-02-02B b) Enter the Password, select OK. The following screen will appear: Fig. 6.38 FADEC read-out - Enter password successfully c) Cycle ECU power and ensure that the lights on the panel have extinguished. Selecting Different Screens...
  • Page 89 The high-pressure pump must be delivered to Continental Aerospace Technologies GmbH for maintenance.  To remove and install the high-pressure pump, refer to RM-02-02. High-Pressure Pump  Fig. 6.40 CD-170 R1 High-Pressure Pump  Fig. 6.41 CD-170 R2 Maintenance Schedules Chapter:...
  • Page 90 Operation & Maintenance Manual CD-170 OM-02-02B Annex 12 Replacing the Alternator The alternator must be delivered to Continental Aerospace Technologies GmbH for maintenance.  To remove and install the alternator, refer to RM-02-02. Fig. 6.42 Alternator Maintenance Schedules Chapter: 02-OM-06-02...
  • Page 91 Operation & Maintenance Manual CD-170 OM-02-02B Annex 13 Exchanging the gearbox oil and the gearbox oil filter Gearbox with oil cooler: Item Part Number Description 1 Description 2 Quantity 03-7212-K004001 Filter element DIN 3771-25x2,5- NM-0000-0150401 O-Ring 80FKM610 NM-0000-0021701 Sealing Ring...
  • Page 92 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.43 Overview of the gearbox inspection points a Oil filler screw b Oil level inspection glass c Oil filter cap d Oil drain plug Check the magnet of the oil drain plug for chips.
  • Page 93 Operation & Maintenance Manual CD-170 OM-02-02B Remount the oil drain plug with a new sealing ring and tighten it to the specified tightening torque. Tightening Torque: 25 Nm  CAUTION: The sealing ring has 2 different sealing surfaces. The plane surface of the sealing ring must face the magnet.
  • Page 94 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.45 Removal of gearbox oil filter Insert the new gearbox oil filter. For mounting direction see Fig. 6.46 and Fig. 6.47.  CAUTION: Only use an original Continental Aerospace Technologies GmbH gearbox oil filter.
  • Page 95 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.47 Gearbox oil filter assembling a Filter element with o-ring b O-ring c Filter cap with spring Attach the new o-ring to the filter cap. See Fig. 6.47.  Note: Make sure that the spring in the filter cap is fixed.
  • Page 96 Operation & Maintenance Manual CD-170 OM-02-02B Remount the filter cap and tighten it to the specified tightening torque. Tightening Torque: 30 Nm 10. Loosen the oil filler screw and remove it. See Fig. 6.44. 11. Fill in the new gearbox oil according to the following details: •...
  • Page 97 Operation & Maintenance Manual CD-170 OM-02-02B 15. Secure the oil filler screw with a lock wire. See Fig. 6.49. Fig. 6.49 Lock wiring the oil filler screw 16. Do an Engine Test run according Annex 4 of this Chapter. 17. Do a visual inspection and a check for leaks.
  • Page 98 Operation & Maintenance Manual CD-170 OM-02-02B Annex 14 Exchanging the Coolant  WARNING: Risk of scalding! The cooling system may be pressurized. Carefully release the pressure before opening the drain plug.  CAUTION: Do not drain the coolant if its temperature is above 40°C.
  • Page 99 Operation & Maintenance Manual CD-170 OM-02-02B Annex 15 Inspecting the Gearbox The gearbox must be delivered to Continental Aerospace Technologies GmbH for inspection.  To remove and install the gearbox, refer to RM-02-02. Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020...
  • Page 100 Operation & Maintenance Manual CD-170 OM-02-02B Annex 16 Replacing the Excitation Battery  CAUTION: Never connect a voltage to the alternator when the lines to the excitation battery are not connected. The line to the excitation battery carries a voltage from the alternator and must therefore not come into contact with a ground connection or similar.
  • Page 101 Operation & Maintenance Manual CD-170 OM-02-02B Annex 17 FADEC Software Update Hardware Requirements This software has been designed for Microsoft Windows 2000/XP/Vista. For proper functionality, the Microsoft .Net framework version 3.5 or newer is required (Windows Vista already contains this). If you don‘t have a proper .NET version...
  • Page 102 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.51 Start Update Current firmware, mapping and serial number of the FADEC as well as information about the aircraft type is displayed. Also, for each FADEC an update status is displayed. See Fig. 6.52.
  • Page 103 Operation & Maintenance Manual CD-170 OM-02-02B The current update status is displayed in the lower left corner. See Fig. 6.53. Fig. 6.53 Update progress After a successful update, the following message will appear. Please press "OK" to proceed to the next step....
  • Page 104 Operation & Maintenance Manual CD-170 OM-02-02B Fig. 6.55 Previously failed update Fig. 6.56 Form One 11. Please save the Form 1. Fig. 6.57 CRC checksums Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 21.04.2023...
  • Page 105 Operation & Maintenance Manual CD-170 OM-02-02B 12. If both firmware and mapping have been updated, a second Form 1 will be presented when closing the first one (see step 11). 13. After comparing the checksums you may close the FADEC Updater.
  • Page 106 Operation & Maintenance Manual CD-170 OM-02-02B Annex 18 Inspecting the Fuel Feed Pump The fuel feed pump must be delivered to Continental Aerospace Technologies GmbH for inspection. To remove and install the fuel feed pump, refer to RM-02-02. Fig. 6.59...
  • Page 107 Operation & Maintenance Manual CD-170 OM-02-02B Annex 19 Inspecting the V-Ribbed Belt Pulleys This is a visual inspection.  Check all pulleys for leakage, pulleys must not show any signs of damage. Damaged or leaking pulleys must be replaced. For more details see RM-02-02.
  • Page 108 Operation & Maintenance Manual CD-170 OM-02-02B Inspecting the V-Ribbed Belt Pulleys  Fig. 6.62 NOT OK - needs to be replaced Maintenance Schedules Chapter: 02-OM-06-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 21.04.2023...
  • Page 109 Operation & Maintenance Manual CD-170 OM-02-02B Annex 20 Inspection of common rail clamps This is a visual inspection.  Check the rail clamps for cracks and damage. If cracked, the rail must be replaced. For more details see RM-02-02. Fig. 6.63...
  • Page 110 Operation & Maintenance Manual CD-170 OM-02-02B Annex 21 Perform an Engine Oil Analysis The following limit values must be observed, otherwise contact Continental Aerospace Technologies GmbH. Ingredient Unit Threshold value Standard Iron mg/kg ASTM D6595 Chrome mg/kg ASTM D6595 Aluminum...
  • Page 111 Operation & Maintenance Manual CD-170 OM-02-02B Emergency Procedures  CAUTION: If the FADEC has been operated by the battery only, a temporary decrease of the rotational speed is possible by switching on the Alternator. In any case leave the Alternator switched on.
  • Page 112 Operation & Maintenance Manual CD-170 OM-02-02B Engine System Malfunction  Note: The FADEC consists of two components that are independent of each other: FADEC A and FADEC B. In case of malfunctions in the active FADEC, it automatically switches to the other.
  • Page 113 Operation & Maintenance Manual CD-170 OM-02-02B 7.3.2 Both FADEC lights flashing  Note: The Load Display may not correspond to the current value. Press FADEC-Testbutton at least 2 seconds (refer to Chapter 4, Section 4.4.3, Page 7 of this Manual)
  • Page 114 Operation & Maintenance Manual CD-170 OM-02-02B Restart after Engine Failure Try to determine the reason for engine malfunction.  Note: The propeller probably continues to windmill. A stopped propeller may indicate a major mechanical defect. In this case use starter assisted restart with extreme caution.
  • Page 115 Operation & Maintenance Manual CD-170 OM-02-02B Air in the Fuel System (During Flight) Move the fuel tank selector to a tank with sufficient fuel Electric fuel pump (if installed) - "ON" Engage the starter  WARNING: If there is air in the fuel system, the engine stalls within a few seconds.
  • Page 116 Operation & Maintenance Manual CD-170 OM-02-02B This page intentionally left blank Emergency Procedures Chapter: 02-OM-07-02 Issue: Issue date: 03.08.2020 Page: Revision no.: Content: Revision date: 06.10.2022...
  • Page 117 Change of Hands FOBL E8-01 Change of Hands Continental Aerospace Technologies GmbH Platanenstraße 14 D-09356 St. Egidien GERMANY Dear Engine Owner, To enable a smooth supply of instructions for continued airworthiness, we kindly request you to fill out this form, when you sell your engine or aircraft. Please send this form by e-mail, fax or post to Continental Aerospace Technologies GmbH.
  • Page 118 Inspection of the timing chain FOBL E8-06 Inspection of the timing chain Continental Aerospace Technologies GmbH Platanenstraße 14 D-09356 St. Egidien GERMANY Dear Engine Owner, To enable a continuously improvement of our product, we kindly request you to fill out this form, when you perform an inspection of the timing chain ...
  • Page 119 Operation & Maintenance Manual CD-170 OM-02-02B Engine Maintenance Checklist  - After the 3rd - 6th operating hour General Enter the applicable data in the blocks below: Engine Type Designation: Serial number: Hours, TTSN/STSO: Aircraft Manufacturer: Type: Registration: Operating Hours:...
  • Page 120 Operation & Maintenance Manual CD-170 OM-02-02B Inspection Items Initials Perform an engine test run according to Chapter 4, Section 4.4.2, Page 5 of this Manual, read out the FADEC. E-mail both the Real Time Log Files and Event Log Files to Continental Aerospace Technologies...
  • Page 121 Operation & Maintenance Manual CD-170 OM-02-02B Engine Maintenance Checklist  - General General Enter the applicable data in the blocks below: Engine Type Designation: Serial number: Hours, TTSN/STSO: Aircraft Manufacturer: Type: Registration: Operating Hours: Check (100, 200, 300, 400hr..., Annual Inspection)
  • Page 122 Operation & Maintenance Manual CD-170 OM-02-02B Interval (Engine operation hours) Inspection Items Initials Visual inspection of the engine mount for chafe marks Visually inspect the air filter Visual inspection of the cooling system Check the mixture ratio of the coolant Test the cooling system under pressure at 2.3 bar ...
  • Page 123 Operation & Maintenance Manual CD-170 OM-02-02B Interval (Engine operation hours) Inspection Items Initials Exchange the engine oil and the oil filter (refer to Chapter 6, Annex 5 of this Manual);  A sample of the oil and the used oil filter should be...
  • Page 124 Operation & Maintenance Manual CD-170 OM-02-02B Interval (Engine operation hours) Inspection Items Initials Replace Injectors (refer to RM-02-02) Inspect the dual mass fly wheel (refer to RM-02-02, Chapter 72-10.19) Replace engine shock mounts Inspect fuel feed pump  (refer to Chapter 6, Annex 18 of this Manual) Exchange coolant...
  • Page 125 Operation & Maintenance Manual CD-170 OM-02-02B FINAL INSPECTOR in block letters date, signature Engine Maintenance Checklist - General Chapter: Checklist Issue: Issue date: 25.09.2020 Revision no.: Page: Revision date: 21.04.2023 Content:...
  • Page 126 Operation & Maintenance Manual CD-170 OM-02-02B this page is intentionally left blank Engine Maintenance Checklist - General Chapter: Checklist Issue: Issue date: 25.09.2020 Page: Revision no.: Content: Revision date: 21.04.2023...

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