AVSTAR LVC-3-3A Operation & Maintenance Manual

Carburetors

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Fuel System Operation &

Maintenance Manual

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Principal Manual)

Models LVC-3-3A, LVC-3-3PA, LVC-5-4PA, LVC-5-5BPA,

LVC-5-5PA, LHC-6-6BA and LHC-6-6BPA Carburetors

September 25, 2023

Part No. AFS-IOM-01

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Page 1 Fuel System Operation & Maintenance Manual Principal Manual) Models LVC-3-3A, LVC-3-3PA, LVC-5-4PA, LVC-5-5BPA, LVC-5-5PA, LHC-6-6BA and LHC-6-6BPA Carburetors September 25, 2023 Part No. AFS-IOM-01 AVStar Fuel Systems. All Rights Reserved.
Page 2 1365 Park Lane South Jupiter, FL 33458 USA Phone: U.S. and Canada Toll Free: +1 (866) 982-7287 Factory Direct: +1 (561) 575-1560 AVStar’s regular business hours are Monday through Friday from 8:00AM through 5:00PM Eastern Time (-5 GMT). Visit us Online: avstardirect.com...
Page 3: Record Of Revisions
AFS-IOM-01 RECORD OF REVISIONS Revision Revised Revision Date Revision Description Original 9/25/2023 CES Original Release of Manual - Part No. AFS-IOM-01 AVStar Fuel Systems. All Rights Reserved Record of Revisions September 25, 2023 Page i...
Page 5: Service Document List
Lycoming S.L. L114 Engine and Accessory Maintenance Publications Lycoming S.L. L247 Shelf Life Requirements Lycoming S.L. L253 Warranty repair of AVStar Fuel System Lycoming SSP-112-4 Service Bulletins Letters and Instructions Service Table of Limits and Torque Value Lycoming SSP-1776-3 Recommendations AVStar Fuel Systems.
Page 7: Table Of Contents
— Cleaning Guidelines ........................ 13 — Fuel Inlet Strainer........................13 Unscheduled Corrective Maintenance ................ 05-50 — Incorrect Fuel or Fuel Contamination ..................15 — Water Damage ......................... 15 AVStar Fuel Systems. All Rights Reserved Table of Contents September 25, 2023 Page v...
Page 8 — Carburetor Model LVC-3-3PA & 5-4PA Features ..............34 — Carburetor Model LVC-5-5BPA & 5PA Features ..............41 — Carburetor Model LHC-6-6BPA & BA Features ..............45 Table of Contents AVStar Fuel Systems. All Rights Reserved Page vi September 25, 2023...
Page 10: List Of Figures
LHC-6-6BPA TOP VIEW A-20 LHC-6-6BPA SIDE VIEW A-21 LHC-6-6BPA END VIEW A-22 LHC-6-6BPA END VIEW A-23 LHC-6-6BPA SECTION M-M A-24 LHC-6-6BPA SECTION P-P Continued on Next Page List of Figures AVStar Fuel Systems. All Rights Reserved Page viii September 25, 2023...
Page 11 AFS-IOM-01 Fig. No. Figure Title Page A-25 LHC-6-6BPA SECTION R-R A-26 LHC-6-6BPA SECTION T-T A-27 LHC-6-6BPA SECTION U-U A-28 LHC-6-6BPA SECTION V-V A-29 LHC-6-6BPA SECTION W-W AVStar Fuel Systems. All Rights Reserved List of Figures September 25, 2023 Page ix...
Page 13: List Of Tables
AFS-IOM-01 LIST OF TABLES Table No. Table Title Page Part Number Applicability Fault Isolation Guide (Troubleshooting) Carburetor Fuel Pressure Limitations AVStar Fuel Systems. All Rights Reserved List of Tables September 25, 2023 Page xi...
Page 15: Abbreviations And Acronyms
Methyl-Ethyl-Ketone AFS-OM: AVStar Overhaul Manual Part Number Pounds per square inch Society of Automotive Engineers (oil viscosity) Service Bulletin Service Instruction Service Letter Time Between Overhaul AVStar Fuel Systems. All Rights Reserved Abbreviations and Acronyms September 25, 2023 Page xiii...
Page 17: Introduction
AFS-IOM-01 INTRODUCTION The AVStar Carburetor Product Line consists of Models LVC-3-3A, LVC-3-3PA, LVC-5-4PA, LHC-5-5BPA, LVC-5-5PA, LHC-6-6BA and LHC-6-6BPA. All carburetors are equipped with Altitude Mixture Adjustment “A”, and those models designated with a “P” make use of an accelerator pump. All are used on normally aspirated, horizontally opposed, air-cooled engines.
Page 18 AFS-IPC-02 FSM LVC-5-5 AV10-6102 AV10-6108 AV10-4404 AV10-4404-1 LVC-5-5PA AV10-5054 AV10-6035-11 AV10-5256-1 AV10-5280-2 LHC-6-6BA AV10-6001 AV10-5219 AV10-5224 AV10-5230 AV10-5235 AFS-IPC-03 FSM LHC-6-6 AV10-5253 LHC-6-6BPA AV10-5255 AV10-5283 AV10-6019 AV10-6019-1 AV10-6030-1 Introduction AVStar Fuel Systems. All Rights Reserved Page xvi September 25, 2023...
Page 19 Carburetor Model Nomenclature The table below shows the definition of each letter and number. Model Number Meaning Lycoming Vertical/Bottom FAA Certified Flange Size Bore Size Accelerator Pump Altitude Mixture AVStar Fuel Systems. All Rights Reserved Introduction September 25, 2023 Page xvii...
Page 20 Carburetor Model Nomenclature The table below shows the definition of each letter and number. Model Number Meaning Lycoming Vertical/Bottom FAA Certified Flange Size Bore Size Accelerator Pump Altitude Mixture Introduction AVStar Fuel Systems. All Rights Reserved Page xviii September 25, 2023...
Page 21 The table below shows the definition of each letter and number. Model Number Meaning Lycoming Vertical/Bottom FAA Certified Flange Size Bore Size Non-standard Bore Accelerator Pump Altitude Mixture AVStar Fuel Systems. All Rights Reserved Introduction September 25, 2023 Page xix...
Page 22 The table below shows the definition of each letter and number. Model Number Meaning Lycoming Horizontal FAA Certified Flange Size Bore Size Non-standard Bore Accelerator Pump Altitude Mixture Introduction AVStar Fuel Systems. All Rights Reserved Page xx September 25, 2023...
Page 23 Refer to any of the latest revisions of the applicable AVStar Service Document List for additional service instructions, as well as any service documents issued by AVStar showing a date after the issue date or current revision date of this manual.
Page 24 As advancements in technological applications on this fuel system continue, AVStar will make future revisions to this manual. However, if more timely distribution is necessary, AVStar posts all pertinent documents to our website under ‘Product Support’. Here you can find all active Service Bulletins (AFS-SB), Operation &...
Page 25 Copyright This publication is a copyrighted work. All rights reserved by AVStar Fuel Systems. Content in this manual cannot be changed or released as a reprint, electronic media output, or web communiqué without written permission from AVStar Fuel Systems.
Page 26 AVStar’s regular business hours are Monday through Friday from 8:00 A.M. through 5:00 P.M. Eastern Time (-5 GMT) Change of Address Notification The owner of the manual is responsible for supplying a change of address to AVStar Fuel Systems. Introduction AVStar Fuel Systems. All Rights Reserved...
Page 28: Airworthiness Limitations
14 CFR §§ 43.16 and 91.403 of the Federal Aviation Regulations (FAR) unless an alternative program has been FAA-approved. 2. Currently there are no Airworthiness Limitations issued. Airworthiness Limitations AVStar Fuel Systems. All Rights Reserved Page xxvi September 25, 2023...
Page 30: General
Tools used for any other Major Repairs and for Overhaul can be found in the applicable overhaul manuals. 2. Fuel Systems can be purchased new directly from AVStar or its authorized distributors A. All maintenance (overhaul, repair, inspection, replacement of parts, or preservation) identified in this manual and within the Service Document List requires persons to be fully trained, qualified, and authorized to approve for return to service.
Page 31: Maintenance Practices
A. Obey all safety precautions B. DO NOT reuse any gasket. You must install a new gasket. C. Be advised the opening of any fuel system voids all applicable AVStar warranties. AVStar cannot restrict certified repairman from performing any repairs, assuming the latest revisions of the proper manuals are followed.
Page 33: Time Limits / Inspections
NOTICE: Inspections in this manual apply to the carburetor and not the engine or aircraft. Refer to the applicable manufacturer’s maintenance manual for inspection information on all other components. 05-10 AVStar Fuel Systems. All Rights Reserved Page | 4 September 25, 2023...
Page 35: Scheduled Maintenance Checks
(6) While unlikely, examine the exterior of the carburetor for cracks and any surface damage. NOTICE: If you find any cracks contact AVStar immediately. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 6...
Page 36 Before flight, make sure that all leaks and problems have been corrected or repaired. (13) Complete all other required inspections in accordance with the Engine or Airframe manufacturer’s instructions prior to installing the cowling on the aircraft. AVStar Fuel Systems. All Rights Reserved 05-20 September 25, 2023 Page | 7...
Page 37: 10-Hour Initial Inspection
CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 8 September 25, 2023...
Page 38: 25-Hour Initial Inspection
CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. AVStar Fuel Systems. All Rights Reserved 05-20 September 25, 2023 Page | 9...
Page 39: 50-Hour Inspection
CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. 05-20 AVStar Fuel Systems. All Rights Reserved Page | 10 September 25, 2023...
Page 40 CORRECT ALL LEAKS. IF FUEL LEAKS ARE NOT CORRECTED BEFORE FLIGHT, THE ENGINE CAN HAVE LOSS OF POWER OR ENGINE FAILURE CAN OCCUR. AVStar Fuel Systems. All Rights Reserved 05-20 September 25, 2023 Page | 11...
Page 42: Cleaning
NOTICE: Disassembly of the fuel system or any modification made by a party other than AVStar Fuel Systems or one of its approved Service Centers voids all applicable warranties. Refer to the AVStar website for a list of all currently authorized Service Centers.
Page 44: Unscheduled Corrective Maintenance
(b) Drain the carburetor and remove from service in accordance with this manual and the aircraft manufacturer’s instructions. (c) AVStar recommends returning the carburetor to our facility or one of our service centers for detailed evaluation to determine if repair or overhaul is necessary.
Page 45: Volcanic Ash/Particulate Contamination
Refer to the applicable overhaul manual for float height setting requirements, inspection requirements to place a float into service, and testing requirements for proper float operation. 05-50 AVStar Fuel Systems. All Rights Reserved Page | 16 September 25, 2023...
Page 47: Unscheduled Servicing
4. If flooding occured with no other maintenance activity, remove carburetor from service for repair. Continued on Next Page 12-30 AVStar Fuel Systems. All Rights Reserved Page | 18 September 25, 2023...
Page 48 Low Fuel Pressure Wrong fuel pressure Make sure the fuel pressure regulator is operating Engine in the carburetor regulator settings correctly. Maintenance Manual Continued on Next Page AVStar Fuel Systems. All Rights Reserved 12-30 September 25, 2023 Page | 19...
Page 49 Manual(s) Carburetor Hear door not Rig so door goes from full open to full closed. Airframe rigged properly Maintenance Manual Continued on Next Page 12-30 AVStar Fuel Systems. All Rights Reserved Page | 20 September 25, 2023...
Page 50 Manual Maintenance out of adjustment (when Manual applicable) Exhaust bypass bleed Readjust as described in Engine Maintenance Engine bolt improperly adjusted Manual Maintenance (when applicable) Manual AVStar Fuel Systems. All Rights Reserved 12-30 September 25, 2023 Page | 21...
Page 52: Air Intake
AFS-IOM-01 71-60 – AIR INTAKE 1. Refer to the applicable section of the Aircraft Maintenance Manual for Airbox and Carburetor Heat connection details and maintenance. AVStar Fuel Systems. All Rights Reserved 71-60 September 25, 2023 Page | 23...
Page 54: Engine
A. Start the engine and warm up in accordance with the Engine and Airframe Maintenance Manuals. Prevailing winds can affect the load of the propeller and the resulting engine RPM. Therefore, AVStar recommends setting the Idle Speed and Mixture with the aircraft in a crosswind orientation.
Page 56: Engine Fuel System
C. Depending upon the model carburetor to be removed, either four 1/4-20 or 5/16-18 nuts and their applicable washers and lock washers will need to be removed. The torque of these nuts is 96 in-lbs. (for 1/4-20) or 204 in-lbs. (for 5/16-18). AVStar AVStar Fuel Systems. All Rights Reserved...
Page 57: Carburetor Installation Preparation Requirements & De-Preserving
If not certain as to the status of the carburetor being installed and if it has been preserved, AVStar recommends the following procedure as a best practice: Remove the fuel drain plug and drain preservative oil. Remove the fuel inlet strainer and clean in hydrocarbon solvent.
Page 58: Carburetor Storage & Preservation
C. This procedure should be followed anytime the carburetor is anticipated to be inactive for 30 days or more. D. Repeat the process annually when in storage for more than one year. AVStar Fuel Systems. All Rights Reserved 73-10 September 25, 2023...
Page 60: Power Control
AFS-IOM-02 76-10 – ENGINE POWER CONTROL 1. Refer to the applicable section of the Aircraft Maintenance Manual for Throttle and Altitude Mixture Control connection details and maintenance. AVStar Fuel Systems. All Rights Reserved 76-10 September 25, 2023 Page | 31...
Page 62: Carburetor Fuel Pressure Limitations
O-235-K, -L, -M, -N series. For gravity feed systems, minimum fuel pressure is 15.0 inches of fuel differential pressure across the fuel inlet fitting on O-320-D2J. AVStar Fuel Systems. All Rights Reserved APPENDIX A September 25, 2023...
Page 63: Carburetor Model Lvc-3-3Pa & 5-4Pa Features
Refer to the applicable IPC for further details. Models LVC-3-3PA & 5-4PA are very similar except for the throttle flange and bore size, as well as the accelerator pump used. Model LVC-3-3A does not use an accelerator pump. B. Features or Components Indicated by * serve as an inspection point for potential fuel leaks.
Page 70 (5) *The small permanent plug installed at the base of the carburetor bowl, as shown in View K-K, should be inspected for any signs of a fuel leak or stain. Figure A-12, LVC-5-5BPA Front View AVStar Fuel Systems. All Rights Reserved APPENDIX A September 25, 2023...
Page 74 (3) *The bowl drain plug should be inspected for any signs of a fuel leak or stain and that the lockwire is in place and wired properly. Figure A-19, LHC-6-6BPA Top View AVStar Fuel Systems. All Rights Reserved APPENDIX A September 25, 2023...

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Lvc-3-3pa Lvc-5-4pa Lvc-5-5bpa Lvc-5-5pa Lhc-6-6ba Lhc-6-6bpa

AVSTAR LVC-3-3A Operation & Maintenance Manual

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