Lycoming IO-390-D Series Manuals

Manuals and User Guides for Lycoming IO-390-D Series. We have 2 Lycoming IO-390-D Series manuals available for free PDF download: Maintenance Manual, Installation And Operation Manual

Lycoming IO-390-D Series Maintenance Manual (322 pages)

Brand: Lycoming | Category: Engine | Size: 5.48 MB

Airworthiness Limitations
3
Record of Revisions
5
Service Document List
7
Table of Contents
11
Abbreviations and Acronyms
21
Introduction
23
Required Maintenance
27
General
27
List of Tools for Service and Maintenance
27
Time between Overhaul (TBO)
28
Safety Precautions - before Engine Maintenance
29
Maintenance Practices
29
General Engine Inspection Criteria
31
Requirements for Engine Maintenance
31
Approved Parts
31
Unscheduled Corrective Maintenance (Cont.)
31
Time Limits / Service Checks
33
Engine Inspection Schedule for IO-390-D Series Engines
33
Required Engine Inspections for IO-390-D Series Engines
35
Engine Inspections
35
Visual Inspection for IO-390-D Series Engines
35
Operational Leak Check Sheet for IO-390-D Series Engines
41
10-Hour Initial Engine Inspection for IO-390-D Series Engines
42
25-Hour Engine Inspection for IO-390-D Series Engines
43
50-Hour Engine Inspection for IO-390-D Series Engines
46
100-Hour or Annual Engine Inspection for IO-390-D Series Engines
49
400-Hour Engine Inspection for IO-390-D Series Engines
54
500-Hour Engine Inspection for IO-390-D Series Engines
56
1000-Hour Engine Inspection for IO-390-D Series Engines
57
Cleaning
59
Cleaning Guidelines
59
Crankshaft Cleaning
62
Crankshaft Counterbore Cleaning
62
Crankshaft Gear Cleaning
63
Tappet Cleaning
64
Crankcase Cleaning
64
Grit-Blasting
64
Soft Carbon Removal
65
Hard Carbon Removal
66
Cylinder Cleaning
66
Piston Cleaning
67
Injection Nozzle Cleaning
67
Steel, Aluminum, or Magnesium Parts Cleaning
68
Spark Plug Cleaning
69
Lead Deposit Removal
69
Volcanic Ash Removal
69
Cleaning Guidelines for a Soaked Engine
70
Cleaning Method for Non-Destructive Testing
70
Unscheduled Corrective Maintenance
73
Lightning Strike - after a Lightning Strike
73
Engine Overspeed
73
Incorrect Fuel or Fuel Contamination
76
Soaked Engine
77
Engine on Fire or Near a Fire
78
Hydraulic Lock
79
Volcanic Ash/Particulate Contamination
79
Valve Sticking
81
Oil Starvation/Sudden Loss of Oil Pressure
81
Metal Contamination of the Lubrication System
82
Propeller Strike, Sudden Engine Stoppage or Loss of a Propeller Blade Tip
82
Engine Inspection Checklist after Propeller Strike for IO-390-D Series Engines
82
Cleaning Methods for Non-Destructive Testing
90
Servicing - Replenishing
91
Refueling
91
Oil Level Check
91
Oil Consumption
92
Oil Type and Viscosity
92
Add Oil to the Engine
92
Oil Leak Check
93
Oil Servicing Schedule
93
Oil Change Procedure
94
Engine Pre-Oil Procedure
95
Oil Suction Screen Removal/Inspection/Cleaning/Installation
97
Oil Pressure Screen Removal/Inspection/Cleaning/Installation
98
Crankcase Maintenance (Cont.)
98
Electrical System Maintenance (Cont.)
98
Oil Filter Replacement
99
Oil Filter Inspection
99
Identification of Metallic Solids after Oil Servicing
100
Visual Inspection of the Oil Filter Element, Oil Pressure Screen, and Oil Suction Screen
100
Ignition System Maintenance (Cont.)
100
Recommended Corrective Action Options
106
Oil Contamination Check
107
Fault Isolation
109
Recommended Approach to Fault Isolation
109
Fault Isolation Guide
109
Engine Removal and Return to Service
127
Engine Removal Prerequisites
127
Engine Removal Procedure
127
Engine Installation Preparation Requirements
129
Operational Ground Check
130
Idle Speed and Mixture Adjustment
130
Engine Mount Inspection
131
Return to Service Procedure
132
Engine Disassembly
133
Engine Assembly
139
Corrosion Prevention
139
Painting the Engine and Engine Components
139
Limits and Clearances
141
Inspections
141
Engine Assembly Procedure
142
Engine Assembly Checklist
148
Propeller Flange Bushing Replacement
153
Propeller Flange Bushing Removal
153
Propeller Flange Bushing Installation
153
Crankcase Maintenance
155
Crankcase Inspection before Disassembly
155
Connecting Rod Removal
155
Crankcase Disassembly
156
Tappet, Main Bearing and O-Ring Removal
157
Propeller Governor Drive Removal/Disassembly (Engines with Front-Mounted Propeller Governor Drives)
159
Oil Plug Removal
160
Crankshaft Idler Gear Shaft Removal
160
Piston Cooling Nozzle Removal
161
Crankshaft Disassembly
161
Counterweight Removal
162
Crankcase Dimensional Inspection
164
Crankshaft Inspection
166
Alignment Dowel Inspection
175
Crankshaft Bearing Surface Inspection
176
Camshaft Inspection
177
Connecting Rod Inspection
178
Connecting Rod Bushing Replacement
180
Connecting Rod Parallelism / Squareness Check
182
Tappet Inspection
183
Crankshaft Assembly
183
Alignment Dowel Replacement
183
Crankshaft Gear Installation
184
Expansion Plug Installation
186
Solid-Ring Crankshaft Oil Seal Installation
187
Connecting Rod Installation
189
Counterweight Installation
190
Piston Cooling Nozzle Installation (if Removed)
192
Crankshaft Idler Gear Shaft Installation
192
Oil Plug Installation (if Removed)
193
Tappet Assembly Installation
194
Crankshaft Bearing and O-Ring Installation
194
Propeller Governor Drive Installation (Engines with Front-Mounted Propeller Governor Drives)
195
Camshaft Assembly and Installation
197
Crankshaft Installation
199
Crankcase Assembly
200
Crankshaft Oil Seal Installation
205
Crankshaft Idler Gear Installation
207
Crankshaft Endplay Clearance Check
207
Propeller Oil Control Leak Test
208
Propeller Governor Removal (Engines with Front-Mounted Propeller Governor Drives)
210
Propeller Governor Installation (Engines with Front-Mounted Propeller Governor Drives)
210
Crankshaft-To-Camshaft Timing Check
210
Accessory Housing Maintenance
211
Accessory Housing Removal
211
Oil Pump Removal
212
Oil Pump Installation
212
Fuel Pump Plunger Removal
213
Fuel Pump Plunger Inspection
213
Fuel Pump Plunger Installation
213
Accessory Housing Installation
213
Propeller Governor Replacement (Engines with Rear-Mounted Propeller Governor Drives)
215
Cylinder Maintenance
217
General
217
Visual Cylinder Inspection
217
Cylinder Compression Check
218
Intercylinder Baffle Inspection
223
Cylinder Borescope Inspection
224
Exhaust Valve and Guide Inspection
225
Cylinder Removal
230
Piston Removal
234
Cylinder Assembly Inspection
235
Piston Inspection
239
Piston Ring Replacement
243
Piston Installation
244
Intake Valve Replacement
245
Exhaust Valve Replacement
246
Cylinder Installation
247
Corrective Action for Valve Sticking
253
Intake and Exhaust Valve Guide Replacement
254
Intake and Exhaust Valve Seat Replacement
254
Barrel Glaze and Varnish Removal from Interior Cylinder Barrel
255
Heli-Coil ® Replacement
255
Lubrication System Maintenance
257
Oil Pressure Adjustment
257
Oil System Inspection
257
Oil Line Inspection
257
Oil Line Replacement
258
Oil Level Gage Tube and Assembly Removal
258
Oil Level Gage Tube and Assembly Installation
258
Oil Pressure Relief Valve Removal
259
Oil Pressure Relief Valve Inspection
259
Oil Pressure Relief Vale Installation
259
Oil Cooler Bypass Valve Removal
260
Oil Cooler Bypass Valve Cleaning
260
Oil Cooler Bypass Valve Installation
260
Oil Pressure Screen Housing Removal
261
Oil Pressure Screen Housing Installation
261
Oil Filter Base Removal
261
Oil Filter Base Installation
261
Oil Sump Removal
262
Oil Sump Installation
262
Propeller Governor Oil Line Removal (Engines with Rear-Mounted Propeller Governor Drives)
265
Propeller Governor Oil Line Installation (Engines with Rear-Mounted Propeller Governor Drives)
265
Accessory Drives
267
Accessory Drive Inspection
267
Propeller Governor Drive Replacement (Engines with Rear-Mounted Propeller Governor Drives)
267
Electrical System Maintenance
269
Wiring Inspection
269
Alternator Belt Inspection
269
Alternator Belt Tension Check/Adjustment
269
Alternator and Bracket Removal
272
Alternator and Bracket Installation
272
Alternator Belt Replacement
273
Starter Replacement
273
Starter Ring Gear Support Replacement
274
Starter Ring Gear Replacement
275
Induction System Maintenance
277
Induction System Inspection
277
Intake Pipe Replacement
277
Fuel Drain Valve Adapter Assembly Inspection
278
Engine Fuel and Control - Distribution Maintenance
279
Fuel System Inspection
279
Fuel Line Inspection
281
Fuel Injector Leak Check
285
Fuel System Inspection Checklist
285
Fuel Line Replacement
287
Fuel Injector Replacement
290
Injection Nozzle Replacement
291
Injection Nozzle Fuel Flow Check
293
Fuel Manifold Replacement
293
Fuel Pump Replacement
295
Ignition System Maintenance
297
Spark Plugs
297
Spark Plug Removal
297
Ignition Lead Inspection
298
Spark Plug Inspection
298
Spark Plug Fouling
299
Spark Plug Port Seal Inspection
300
Spark Plug Cleaning
300
Spark Plug Gap Setting
300
Spark Plug Rotation
301
Spark Plug Installation
301
Ignition Harness Removal
302
Ignition Harness Inspection
302
Ignition Harness Installation
303
Electronic Ignition System / Magneto Maintenance
305
Lycoming Electronic Ignition System (EIS)
305
EIS Inspection
305
EIS Replacement
306
EIS Removal
306
EIS Installation
307
Install the Drive Gear (Magneto Gear)
307
Internally Time the EIS
308
Mount the EIS on the Engine
309
EIS Timing Check
310
Traditional Magnetos (Optional)
310
Magneto Inspection
310
Magneto-To-Engine Timing Check
310
Magneto Adjustment Procedure
313
Magneto Replacement Procedure
314
Exhaust System Inspection
317
Stud Replacement
319
Fin Stabilizer Installation
320
Install Stud at Oil Filter Pad (if Required)
321
Install the Fitting for the Manifold Pressure Line in Cylinder #3
322

Lycoming IO-390-D Series Installation And Operation Manual (78 pages)

Brand: Lycoming | Category: Engine | Size: 1.23 MB

Record of Revisions

3
Service Document List

5
- Table of Contents
  7
Table of Contents

11
List of Figures

11
List of Tables

13
Abbreviations and Acronyms

15
Introduction

17
System Description ________________________________________________________________

21
- System Description
  21
- Cylinders
  21
- Crankcase
  22
- Ignition System
  23
- Starter
  23
- Fuel Injection System
  24
- Lubrication System
  25
- Cylinder Number Designations
  26
Engine Reception and Lift

27
Requirements for Engine Installation

29
Section

37
Engine Installation

37
Field Run-In

45
- Field Run-In Procedure
  45
Engine Initiation

47
Section

55
Engine Operation

55
- Step 1. Pre-Flight Check
  55
- Step 2. Engine Start
  55
- Step 3. Engine Run-Up
  57
- Step 4. Engine Operation
  58
  - Operation in Flight
    58
  - Fuel Mixture Leaning
    58
- Step 5. Engine Stop
  59
Engine Conditions

61
- Action for Engine Conditions
  61
  - Apply Heat to a Cold Engine
    62
  - Cold Weather Engine Start
    63
  - Engine Operation in Hot Weather
    63
  - Volcanic Ash
    64
  - Overspeed
    64
  - Low Oil Pressure During Flight
    65
Engine Preservation and Storage

67
Appendix________________________________________________________________________

71
- Appendix Aengine Specifications and Operating Limits
  
  71
- Appendix Bperformance Data
  
  75

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More Lycoming Manuals

Lycoming IO-390-D Series Manuals

Lycoming IO-390-D Series Maintenance Manual (322 pages)

Table of Contents

Lycoming IO-390-D Series Installation And Operation Manual (78 pages)

Table of Contents

Record of Revisions

Service Document List

Table of Contents

List of Figures

List of Tables

Abbreviations and Acronyms

Introduction

System Description ________________________________________________________________

Engine Reception and Lift

Requirements for Engine Installation

Section

Engine Installation

Field Run-In

Engine Initiation

Section

Engine Operation

Engine Conditions

Engine Preservation and Storage

Appendix________________________________________________________________________

Appendix Aengine Specifications and Operating Limits

Appendix Bperformance Data

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Lycoming Categories