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Manuals and User Guides for Continental Refrigerator IO-240-B. We have
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Continental Refrigerator IO-240-B manual available for free PDF download: Installation And Operation Manual
Continental Refrigerator IO-240-B Installation And Operation Manual (146 pages)
AIRCRAFT ENGINE
Brand:
Continental Refrigerator
| Category:
Engine
| Size: 3 MB
Table of Contents
Table of Contents
9
Chapter 1. Introduction
15
Scope and Purpose of this Manual
15
1-1.1. Effectivity Symbols
15
1-1.2. Advisories
15
1-1.3. Using this Manual
15
Figure 1-1. Figure and Index Reference
16
Publications
17
1-2.1. Service Documents
17
1-2.2. Related Publications
18
Table 1-1. Related Publications
18
1-2.3. Publication Access
19
1-2.4. Publication Changes
19
1-2.4.1. Update/Change Distribution
19
1-2.4.2. Suggestions and Corrections
21
Figure 1-3. List of Effective Pages
21
Contact Information
22
Chapter 2. Engine Description
23
General Engine Description
23
2-1.1. Engine Model Number Definition
24
2-1.2. Cylinder Number Designations
24
Figure 2-1. Engine Model Definition
24
Figure 2-2. Cylinder Number Designation
24
Detailed Engine Description
25
2-2.1. Crankcase
25
Figure 2-3. IO-240 Crankcase Features
25
Engine Drive Train
26
2-2.2.1. Crankshaft
26
2-2.2.2. Connecting Rods
27
Figure 2-5. Crankshaft
27
Figure 2-6. Connecting Rod
27
2-2.2.3. Camshaft
28
Figure 2-7. Camshaft
28
2-2.4. Cylinders
29
Figure 2-8. Accessory Case Features
29
Figure 2-9. Cylinder Features
30
2-2.4.1. Pistons
31
2-2.4.2. Hydraulic Valve Tappets
31
Figure 2-10. Piston Features
31
2-2.5. Lubrication System
32
Figure 2-11. IO-240-A Lubrication
32
2-2.5.1. Oil Pump
33
Figure 2-12. IO-240-B Lubrication
33
2-2.5.2. Oil Sump
34
2-2.5.3. Oil Pressure Relief Valve
34
2-2.5.4. Oil Cooler Adapter
34
Figure 2-13. Oil Pump
34
Figure 2-14. IO-240-A Oil Cooler Adapter
35
Figure 2-15. IO-240-B Oil Cooler Adapter
35
Figure 2-16. IO-240-B Oil Cooler/Filter Adapter
35
2-2.6. Ignition System
36
Figure 2-17. Continental Motors Magneto Part Number Structure
36
Figure 2-18. Continental Motors Ignition Distribution
37
Figure 2-19. Slick Ignition Distribution
37
2-2.7. Fuel System
38
2-2.7.1. Fuel Pump
38
Figure 2-20. IO-240 Standard Fuel Injection System
38
Figure 2-21. Standard Fuel Pump
39
Figure 2-22. Altitude Compensating Fuel Pump
39
2-2.7.2. Fuel Injectors
40
2-2.8. Starter Assembly
40
2-2.9. Alternator
40
Figure 2-23. Fuel Injector
40
2-2.10. Engine Cooling
41
Figure 2-24. Engine Cooling
41
2-2.11. Induction System
42
Figure 2-25. IO-240-A Induction System
42
Figure 2-26. IO-240-B Crossflow Induction System
42
Engine Specifications and Operating Limits
43
Table 2-1. IO-240-A Specifications and Operating Limits
43
Table 2-2. IO-240-B Specifications and Operating Limits
45
2-3.1. Accessory Drive Ratios
47
2-3.2. Performance Data
47
Table 2-3. Accessory Drive Ratios
47
2-3.2.1. IO-240-A Performance Charts
48
Figure 2-27. IO-240-A Fuel Flow Vs. Brake Horsepower
48
Figure 2-28. IO-240-A Sea Level Performance
49
2-3.2.2. IO-240-B Performance Charts
50
Figure 2-29. IO-240-B Fuel Flow Vs. Brake Horsepower
50
Figure 2-30. IO-240-B Sea Level Performance
51
Chapter 3.Engine Installation
53
Engine Installation
53
3-1.1. Common Tools and Consumable Supplies Required
53
3-1.2. Engine Receipt and Handling
53
3-1.2.1. Uncrating the Engine
54
3-1.2.2. Crating an Engine for Shipping
54
3-1.2.3. Acceptance Inspection
54
3-1.3. Engine Transport
54
Installation Procedures
56
3-2.1. Prepare the Airframe for Engine Installation
56
3-2.2. Prepare the Engine for Installation
56
3-2.3. Installation Sequence
57
3-2.3.1. Engine Pre-Oiling
59
3-2.3.2. Fuel Purge and Leak Check
60
3-2.4. Installation Inspection
61
3-2.5. Preflight and Run-Up
61
Engine Installation Drawings
63
3-3.1. IO-240-A Installation Drawings
63
Figure 3-1. IO-240-A Top View
63
Figure 3-2. IO-240-A Left Side View
64
Figure 3-3. IO-240-A Front View
65
Figure 3-4. IO-240-A Rear View
66
3-3.2. IO-240-B Installation Drawings
67
Figure 3-5. IO-240-B Top View
67
Figure 3-6. IO-240-B Left Side View
68
Figure 3-7. IO-240-B Front View
69
Figure 3-8. IO-240-B Rear View
70
Figure 3-9. IO-240-B W/Optional Oil Cooler-Filter Adapter Top View
71
Figure 3-10. IO-240-B W/Optional Oil Cooler-Filter Adapter Left Side View
72
Figure 3-11. IO-240-B W/Optional Oil Cooler-Filter Adapter Rear View
73
3-3.3. IO-240 Common Installation Drawings
74
Figure 3-12. Propeller Flange
74
Figure 3-13. Exhaust Flange Dimensions
75
Figure 3-14. Standard Fuel Pump Installation
75
Figure 3-15. Standard Fuel Pump Adjustments
76
Figure 3-16. IO-240-B Altitude Compensating Fuel Pump Adjustments
76
Figure 3-17. Throttle Lever Installation
77
Figure 3-18. Oil Cooler Adapter Connections
77
Figure 3-19. Oil Cooler Adapter Connections
78
Figure 3-20. Oil Cooler-Filter Adapter Connections
78
Figure 3-21. IO-240-A Air Intake Flange
79
Figure 3-22. Alternator Connections
79
Figure 3-23. Engine Mounts
80
Figure 3-24. Continental Motors Magneto Ignition Schematic
81
Figure 3-25. Champion (Slick) Magneto Ignition Schematic
81
Figure 3-26. Airframe Ignition Switch Connections to Magneto
82
Chapter 4. Engine Operation
83
Introduction
83
Flight Prerequisites
83
4-2.1. Oil Change Interval
84
4-2.2. Engine Fuel Requirements
84
4-2.3. Flight Check and Break-In
84
4-2.3.1. Engine Break-In
85
Table 4-1. IO-240 Operating Limits
86
4-2.3.2. Flight Check
87
Normal Operation
89
4-3.1. Pre-Operational Requirements
89
4-3.2. Engine Start
90
4-3.2.1. Cold Start
91
4-3.2.2. Flooded Engine
92
4-3.2.3. Hot Start
92
4-3.3. Ground Run-Up
92
4-3.4. Taxi Preparation
94
4-3.5. Power Control
94
4-3.6. Take-Off
95
4-3.7. Climb
96
4-3.8. Cruise
97
4-3.9. Descent
98
4-3.10. Landing
98
4-3.11. Engine Shutdown
99
Emergency Operation
100
4-4.1. Engine Fire During Start
100
4-4.2. Engine Fire During Flight
100
4-4.3. In-Flight Restart
101
4-4.4. Engine Roughness
101
4-4.5. High Cylinder Head Temperature
101
4-4.6. High Oil Temperature
102
4-4.7. Low Oil Pressure
102
Engine Operation in Abnormal Environments
103
4-5.1. Engine Operation in Extreme Cold
103
4-5.1.1. Engine Preheating
104
4-5.2. Engine Operation in Hot Weather
108
4-5.2.1. Cooling an Engine in Hot Weather
108
4-5.2.2. Engine Restart in Hot Weather
109
4-5.2.3. Ground Operation in Hot Weather
109
4-5.2.4. Take-Off and Initial Climb out in Hot Weather
109
4-5.3. Ground Operation at High Density Altitude
110
Troubleshooting
110
Glossary
112
Appendix A. Glossary
115
Appendix B.torque Specifications
115
General Information
115
B-1.1. Torque Tips
115
Cylinder Torque Procedure
116
Torque Wrench and Extension Calculations
117
Figure B-1. Torque Wrench
117
Figure B-2. Drive Extensions
117
Figure B-3. Extension Increases Applied Torque
118
Figure B-4. Extension Decreases Applied Torque
118
Table B-1. General Torque Specification
119
Table B-3. Hose Fitting ("B" Nut) Torque Specification
120
Table B-2. Tube Fitting Torque Specifications
120
Table B-4. Component Specific Torque Specifications
121
Table B-5. Specific Torque for Non-Lubricated Hardware
124
Appendix C.standard Practices
125
Handling Parts
125
Replacement Parts
126
C-2.1. Background
126
C-2.2. Acceptable Replacement Parts
126
C-2.2.1. Know Your Supplier
127
C-2.3. 100% Parts Replacement Requirements
127
C-2.4. Mandatory Overhaul Replacement Parts
128
C-2.5. Authorized Oversize/Undersize Parts
128
Torque
128
Figure C-1. Right-Hand-Thread Safety Wire Installation
129
Safety Wiring Hardware
129
Figure C-2. Safety Wire Patterns for Right-Hand Threads
130
Figure C-3. Tab Washer Installation
131
Tab Washer Installation
131
Helical Coil Insert Replacement
132
C-6.1. Helical Coil Removal
133
Figure C-4. Helical Coil Extraction Tool
133
C-6.2. Helical Coil Insertion
134
Figure C-5. Installing a Helical Coil Insert
134
Stud Replacement
135
C-7.1. Stud Removal
135
C-7.1.1. Size-On-Size Rosan® Stud Removal
135
C-7.1.2. Step-Type Rosan® Stud Removal
136
Figure C-6. Rosan® Stud Removal Tool
136
Figure C-7. Rosan® Stud Removal Tool Installed on Stud
136
C-7.2. Stud Installation
137
Figure C-8. Stud Sizes
137
C-7.2.1. Rosan® Stud Installation
138
Figure C-10. Rosan® Stud Installation Dimensions
138
Figure C-9. Minimum Material Thickness for Helical Coil Insertion
138
Cotter Pin Installation
139
Figure C-11. Cotter Pin Installation
139
Fuel System Service
140
C-9.1. Fuel System Purge
140
C-10. Gasket Maker® Application
141
C-11. Gasket Installation
142
C-12. Hose and Tubing Installation
143
Figure C-12. Installing Hoses and Fittings
143
C-13. Harness Routing
144
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