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IO-520 Overhaul Manual

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IO-520 Overhaul Manual IO-520 CONTINENTAL® AIRCRAFT ENGINE OVERHAUL MANUAL TECHNICAL CONTENT ACCEPTED BY THE FAA Publication X30039 ©2011 CONTINENTAL MOTORS, INC. AUG 2011 Supersedure Notice This manual revision replaces the front cover and list of effective pages for Publication Part No. X30039, dated September 1977. Previous editions are obsolete upon release of this manual. Effective Changes for this Manual 0 .......... September 1977 1 ............ 31 August 2011 List of Effective Pages Document Title: IO-520 Series Engine Overhaul Manual Publication Number: X30039 Initial Publication Date: September 1977 Page Change Page Change Page Change Page Change Cover............................1 A...................................1 i thru v ..........................0 1-1 thru 1-10.................0 2-1 thru 2-10.................0 3-1 thru 3-2...................0 4-1 thru 4-30.................0 5-1 thru 5-12.................0 6-1 thru 6-30.................0 7-1 thru 7-8...................0 8-1 thru 8-20.................0 9-1 thru 9-8...................0 10-1 thru 10-2...............0 Published and printed in the U.S.A. by Continental Motors, Inc. Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601 Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted, republished, broadcast, or otherwise altered without the publisher's written permission. This manual is provided without express, statutory, or implied warranties. The publisher will not be held liable for any damages caused by or alleged to be caused by use, misuse, abuse, or misinterpretation of the contents. Content is subject to change without notice. Other products and companies mentioned herein may be trademarks of the respective owners. A IO-520 Series Engine Overhaul Manual 31 August 2011 i iv October 1978 October 1978 v Intentionally Left Blank SECTION I INTRODUCTION 1-1. SCOPE. This publication comprises 1-5. CYLINDER ARRANGEMENT. Cylinders Overhaul Instructions for the IO-520 Series Aircraft are numbered starting from the rear, with odd Engines. numbers on the right and even numbers on the left. 1-2. RELATED PUBLICATIONS. Detail part 1-6. DEFINITIONS AND ABBREVIATIONS numbers and service assemblies for these engine Term . Explanation models are contained in Parts Catalog X-30040A. A.B.C. After Bottom Center Operating instructions are contained in Operator's Approx. Approximately Handbook X-30041. A.T.C. After Top Center a. Service instructions for Slick Magneto Model Bar. Barometric No. 662 may be obtained from Slick Electro Inc., B.B.C. Before Bottom Center Rockford, Illinois 61100. B.H.P. Brake horsepower B. T.C. Before Top Center b. Service instructions for Bendix Magneto F.A.A. Federal Aviation Administration Model S6RN-201, S6RN-205, S6RN-1201 and C.A.R. Civil Air Regulations S6RN-1205 may be obtained from Bendix c.f.m. Cubic feet per minute Corporation, Electrical Components Division, C.G. Center of Gravity Sidney, New York 13830. Dia. Diameter c. Service instructions for Delco-Remy Starters, ° Degrees of Angle Generators or Alternators may be obtained from °F. Degrees Farenheit Delco-Remy Division, General Motors Corporation, Fig. Figure (Illustration) Anderson, Indiana 96011. Front Propeller End 1-3. SERVICE BULLETINS. Important ft. foot or feet changes and product improvements are covered by G.P .M. Gallons per minute factory service bulletins available for study at all H2O Water Approved Distributors. These Bulletins are also Hg. Mercury available to owners, operators or maintenance I.D. Inside Diameter personnel on an annual subscription basis. in. (") Inches Hex. Hexagon 1-4. SERVICE REPORTS AND INQUIRIES. hr. Hour It is the policy of Teledyne Continental Motors to Left Side Side on which Nos. 2, 4 and handle all reports of service difficulty and requests 6 cylinders are located for information through Approved Distributors. Lbs. Pounds Request for further copies of this or any other Lockwire Soft steel wire used to safety Teledyne Continental Aircraft Engine Service connections, etc. Publication should be made through these facilities. Man. Manifold or manometer There is an Approved Distributor at every major Max. Maximum airport. Min. Minimum 30' thirty minutes of angle (60' equal one degree) N.P.T. National pipe thread (tapered) MAY 1980 1-1 Term . Explanation 1-7. DEFINITION OF TERMS. Front, rear, left and right, as used in this manual, refer to the engine N.C. National Coarse (thread) as viewed by the mechanic in a normal position, N.F. National Fine (thread) facing the accessory end. O.D. Outside Diameter Press. Pressure TABLE III. p.s.i. Pounds per square inch CHARACTERISTICS AND DIMENSIONS Rear Accessory end of engine Right Side Side on which Nos. 1, 3 and DIMENSION VALUE 5 cylinders are located Piston stokes per cylinder............................................4 R.P.M. Revolution per minute Std. Standard Number of cylinders.....................................................6 T.D.C. Top dead center Temp. Temperature Cylinder bore (inches).............................................5.25 Torque Force x lever arm (125 ft.-lbs. Piston stroke (inches) .............................................4.00 force applied one ft. from bolt center or 62-1/2 lbs. applied TABLE IV. TEMPERATURE LIMITS 2 ft. from center) INDICATED CONDITION MIN. MAX. TABLE I. PURCHASED ACCESSORIES Oil temperature at takeoff 75°F-- ACCESSORY QTY Oil temperature in flight -- 240°F. Magneto.......................................................................2 Cylinder head temperature Starter ..........................................................................1 (bayonet thermocouple)* -- 460°F. Alternator .....................................................................1 Magneto temperature (at coil hold-down screw) -- 170°F. Generator.....................................................................1 * Installed in tapped hole in bottom of cylinder head. Oil Cooler.....................................................................1 Fuel Pump....................................................................1 TABLE V. PRESSURE LIMITS Spark Plugs................................................................12 INDICATION MIN. MAX. Oil pressure (idling) 10 psi -- TABLE II. IGNITION SYSTEM DETAILS Oil pressure (in flight) 30 psi 60 psi FEATURE VALUE Oil pressure (with cold oil) -- 100 psi Left Magneto Fires ...............................Lower No. 1-3-5 And Upper No. 2-4-6 plugs TABLE VI. VISCOSITY OIL GRADES Right Magneto Fires.............................Upper No. 1-3-5 OIL OPERATING OIL And Lower No. 2-4-6 plugs TEMPERATURE GRADE Firing order (cylinder numbers)....................1-6-3-2-5-4 Below 40°F. 30 OR 10W-30 Permissible RPM spread when Above 40°F. 50 Switched from “Both” to either Ambient air temperature is the controlling factor on all “Left” or “Right” magneto............................................50 engines having oil temperature control valves installed. 1-2 1-8. OIL SUPPLY AND MEASUREMENT. 1-10. OIL CONSUMPTION. 1-9. The capacity of the oil sump is 12 U.S. quarts. 1-11. When operated on a rigid test stand at cruise The oil filler cap is attached over the oil filler neck power settings and operating within specified limits on top of the left crankcase. The oil sump is oil consumption shall not exceed 1 quart per hour equipped with an oil level gauge notched and and one –half. stamped with numerals representing quarts. FIGURE 1-1. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-A,E,F & K. (SANDCAST CASE) FIGURE 1-2. THREE-QUARTER REAR VIEW OF THE IO-520-A & F. (SANDCAST CASE) 1-3 FIGURE 1-3. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-B. (PERMOLD CRANKCASE) FIGURE 1-4. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-B. (PERMOLD CASE) 1-4 FIGURE 1-5. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-C. (PERMOLD CASE) FIGURE 1-6. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-C. (PERMOLD CASE) 1-5 FIGURE 1-7. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-D. (SANDCAST CRANKCASE) FIGURE 1-8. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-D. (SANDCAST CRANKCASE) 1-6 FIGURE 1-9. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-J. (SANDCAST CRANKCASE) FIGURE 1-10. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-L. (SANDCAST CRANKCASE) 1-7 FIGURE 1-11. INSTALLATION DRAWING FOR THE IO-520-A,D,E,J,K & L. FIGURE 1-12. INSTALLATION DRAWING FOR THE IO-520-B. 1-8 FIGURE 1-13. INSTALLATION DRAWING FOR THE IO-520-C. 1-9/1-10 Intentionally Left Blank SECTION II GENERAL DESCRIPTION 2-1. SIGNIFICANT DIFFERENCES. Specific Gear trains and lubricating systems as well as other detail parts differences in the IO-520 Series will be less noticeable parts are likewise different in the noted in the Parts Catalog. Significant configuration two crankcases. differences in the IO-520 Series are primarily related to the two different crankcases. Other configuration differences not related to the crankcase are the oil sump, either cast aluminum or The SAND CAST CRANKCASE has provision for stamped aluminum sheet metal; the engine a belt driven generator (or alternator) located at the mounting legs, either attached to the sump, the accessory end of the engine. The oil cooler is in crankcase bottom or the crankcase accessory end; front of the number 5 cylinder and an integral type and various induction systems, balance tubes and oil screen is incorporated in the oil pump. fuel injection assemblies. 2-2. GENERAL. The arrangement and appearance of the engine components are indicated in Figures 1-1 through 1-10. Additional information will be found in installation drawings.
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