Continental Motors C-125 Manual Download Page 1

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Publication X30013

2011 CONTINENTAL MOTORS, INC.

AUG 2011

C-125
C-145

O-300

CONTINENTAL

AIRCRAFT ENGINE

OVERHAUL

MANUAL

FAA APPROVED

Summary of Contents for C-125

Page 1: ...Publication X30013 2011 CONTINENTAL MOTORS INC AUG 2011 C 125 C 145 O 300 CONTINENTAL AIRCRAFT ENGINE OVERHAUL MANUAL FAA APPROVED...

Page 2: ...Change Cover 1 A 1 B blank added 1 ii thru iv 0 1 thru 61 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...

Page 3: ...Intentionally Left Blank...

Page 4: ...hauls These and the overhaul instructions in Sections 10 11 and 12 are intended to cover adequately the work involved If additional information is re quired an inquiry should be addressed to the neare...

Page 5: ...ement and Minor Repair 18 1 Carburetor 18 2 Magneto Installation and Timing to the Engine 18 3 Ignition Wiring 18 4 Starter 18 5 Generator 19 OVERHAUL INSTRUCTIONS Section 10 Disassembly Cleaning and...

Page 6: ...cker Shaft Bushings Measurement of Dampener Bushings Installing Cam Follower Body in Crankcase Installing Crankshaft Thrust Washer Installation of Starter Pinion Pivot Installation of Crankshaft and C...

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Page 10: ...o U 300 A B 0 300 C D E C125 C145 Starter 0 300 A B C 0 300 D E C125 C145 Generator 0 300 A B C D 0 300 E Generator 0 300 C D E Alternator Opt All Carburetor Feature Left magneto fires lower plugs Rig...

Page 11: ...l All C125 C145 0 300 A B C D 0 300 E 0 300 C D E C125 C145 0 300 A B C 0 300 D E All OIL VISCOSITY GRADES SAE Grade SAE No 20 SAE No 40 When operating oil temperatures overlap above column ranges use...

Page 12: ...ermanent plug at the rear and a re movable plug at the front providing an oil passage to the shaft endfor hydraulic actuation of the controllable propeller The letter D in a C 145 serial No de notes a...

Page 13: ...attached by crankcase studs and sealed by a thick reinforced gasket Drain plugs are installed in front of and behind the carburetor mount pad in the sump floor From the carburetor pad the intake air p...

Page 14: ...and the length of which is auto matically adjusted so that each camshaft cycle gives zero lash 9 LUBRICATING SYSTEM To reduce the number of external oil lines an oil sump is attached directly to the...

Page 15: ...ar is driven by the crankshaft gear 1 at 1 2 crankshaft speed 3 The right and left magneto drive gears driven by the camshaft gear 2 turn in a clockwise direction at 1 50 1 crankshaft speed 4 The oil...

Page 16: ...all requirements of these engines It is advisable to use good quality tools and to keep them dry and clean to avoid damage and injury 4 Engine parts and accessories required for mainten ance work mus...

Page 17: ...atment described in the preceding paragraph should be repeated at intervals of not over 30 days during storage 5 PREPARATION OF ENGINES FOR SERVICE AFTER STORAGE a Engines prepared for storage in acco...

Page 18: ...LATOR TO OIL TEMP GAGE Figure 6 Typical Installation Diagram I 679 Om 1 r 1679 002 DRILL 257 DEPTH 81 C SINK Iloox 34 DIA TAP 3125 18NC 4 DEPTH 62 PD 2764 2779 4 VIEW A A D Figure 7 Installation Drawi...

Page 19: ...HOMETER DRIVE S A E STD 1 2 ENGINE SPEED D GENERATOR E SUCTION OIL SCREEN F PRESSURE OIL SCREEN G OIL FILLER H ENGINE MOUNT BRACKETS J OIL SUMP DRAIN K NO 10 SPLINE TYPE SHAFT L CARBURETOR MARVEL M OI...

Page 20: ...SPACED 14 j 5 16 LENGTH CLEARANCE REQUIRED TO REMOVE STARTER AND GENERATOR 0 1 _ 9 5 S u I i _ 1 _ I 2217 32 5 251 5 249 6 1 2 DIA j VIEW B B 18bi 32 2 4 EXHAUST PORTS 2 4 1 8 PIPE TAP FOR MANIFOLD PR...

Page 21: ...on versus both magnetos is no longer a sound criteria for evalua tion of magneto operation Therefore all magneto checks should be performed on a comparative basis between individual Right and Left mag...

Page 22: ...TART a Lack of Fuel 1 Check whether there is sufficient gasoline in airplane tank and a definite flow of gasoline to the carburetor 2 Check gasoline shut off valve for being in the FULL OPEN pOSition...

Page 23: ...aks exist in in duction system at any point that would allow unfiltered air into engine 2 lOO HOUR INSPECTION a Remove and inspect general condition of engine cowling b Wash the exterior of the engine...

Page 24: ...inter visible through the inspection window in the top of the magneto case This places the magneto in No l firing position b Turn the crankshaft forward until No 1 piston is on its compression stroke...

Page 25: ...ide of the lever to ob tain this adjustment It is also important that the lever whether operated by cable or wire have a spring with sufficient tension to return the lever to its fully released positi...

Page 26: ...remove the three cap screws from each of the two intake mani folds and remove the manifolds b Oil Sump and Oil Screens Remove the two oil screens from the bottom of the crankcase cover Remove 3 hex he...

Page 27: ...4 inch cap screws holding the cam gear to the camshaft and remove gear 5 Remove the four 1 4 inch cap screws holding the crankshaft gear to crankshaft and remove gear 6 Remove all 1 4 inch nuts from...

Page 28: ...free from grit and foreign particles 6 Pistons and Piston Pins Do not use wire brushes or scrapers of any kind Soft and moderately hard carbon deposits may yield to solvent action which should be trie...

Page 29: ...ust be free of carbon and oil 2 Crankshafts and piston pins must be polished be fore inspection 3 All parts should be inspected for forging laps seams and grinding cracks which may have opened in serv...

Page 30: ...spect valve spring retainer locks for wear and b Cylinder Barrels Inspect cylinder barrel flange galling on outside diameter and for wear and fit on for nicks evenness and for condition of cylinder va...

Page 31: ...neto starter generator oil pump camshaft and crankshaft gears for cracks nick burrs wear and proper fit Inspect camshaft gear crankshaft gear and magneto gears by Magnaflux for fatigue cracks Section...

Page 32: ...der bores which are slightly cor roded scored or pitted by honing Cylinder wall finish should be as specified in Section 13 If the maximum allowable bore diameter taper or out of roundness is exceeded...

Page 33: ...efacing machine for condi tioning valve contact faces and lap into valve seats d Crankshaft and Connecting Rods 1 Before Magnaflux inspection polish journals crank pins and oil seal race Stone any nic...

Page 34: ...acturer protects all aluminum alloy castings sheet metal and tubing from corrosion by treating all surfaces of the parts with Alodine 1200 American Paint and Chemi cal Company Ambler Pennsylvania m AP...

Page 35: ...hey are only pressed into the rocker box and are easily bent Any bending or misalign ment will result in an oil leak b Connecting Rods and Crankshaft 1 Install new bearings inserts of standard or unde...

Page 36: ...rs until pins lie within case notches Lubricate washers See Fig 20 30 Figure 20 Installing Crankshaft Thrust Washer 3 Check crankshaft end clearance between either washer and shaft flange c Assembly o...

Page 37: ...holes utilize other suit able means suchas a proper wedge between the teeth of the crankshaft and cam gears to prevent the gears from rotating when the cap screws are tightened Be sure the wedge does...

Page 38: ...ulic Units and Pushrod Housing Flanges 1 Rotate engine stand so that crankcase is in flight position Oil hydraulic units with thin coat of light oil NOTE Be sure that the hydraulic unit is working pro...

Page 39: ...d clamps down over pushrod housing flange 10 Assemble the remaining cylinders in the same man ner as described above 11 Test crankshaft for free rotation g Installing Air Intake System 1 Place gaskets...

Page 40: ...les refer to Fig 10 11 or 12 and check connections from magneto terminals to spark plugs by position and length of wires Radio shielded cable assemblies should be new complete assemblies For Bendix S6...

Page 41: ...ull Throttle Hr Fuel Pressure psi Inlet Carburetor Max Allowable Min Allowable Recommended Flight Minimum Engine Intake Air Temperature Manifold Vacuum at Full Throttle Manifold Vacuum at Idle Oil Gra...

Page 42: ...rmination 7 5 Warm up to rated RPM minimum 1200 RPM 8 30 2450 See Note B 9 5 500 25 Idle cooling period 3000 max C H T before shut down Stop engine drain and weigh oil See Note C A Magneto drop and sp...

Page 43: ...NOTES 37...

Page 44: ...NOTES 38...

Page 45: ...ain bearings Dia CONNECTING RODS Bearing and bushing twist or convergence per inch of bearing length Bearing on crankpin Bushing in connecting rod Piston pin in conn rod bushing CAMSHAFT Dia Dia Dia C...

Page 46: ...g Ring 4th oil control CYLINDERS AND VALVES Valve seat to valve guide axis Valve guides in cylinder head Cylinder bore standard Cylinder bore 0 015 oversize Gap Gap Gap Gap Tension Tension Angle Dia C...

Page 47: ...4 7 16 20 7 16 20 3 8 24 1 4 28 Cylinder base studs Cylinder base studs Crankcase tie bolts and stud Crankcase tie bolts Gears to crankshaft and camshaft SPRING PRESSURES New Parts Service Limit Min M...

Page 48: ...42 PRESSURE OIL DRAINOIL SECTION A A SECTION B B Figure 27 Lubrication Chart Lateral Section Front View...

Page 49: ...6 14 PRESSURE OIL DRAIN OIL Figure 28 Lubrication Chart Longitudinal Sectional View Schematically shown 51 47 43...

Page 50: ...SECTION THROUGH OIL PRESSURE RELIEF VALVE SECTION THROUGH HIGH AND LOW PRESSURE 01 L SCREENS 44 t f PRESSURE OIL SCAVENGER OIL DRAIN OIL Figure 29 Lubrication Chart Accessory Cover Section T7 55...

Page 51: ...num throttle body and bowl cover and a cast aluminum fuel bowl and air entrance c OPERATION 1 Idle System 4 Fig 32 With the throttle fly slightly open to permit idling the suction or vacuum above the...

Page 52: ...VE BOWL DRAIN IDLE TUBE IDLE FUEL ORIFICE MIXT RE MET RING SLEEvE THROTTLE FLY CRUISING POSITION Figure 32 Cutaway Views of MA 3PA Carburetor MAXIM M PUMP INLET SCREEN PUMP INLET SCREEN HOUSING PUMP I...

Page 53: ...o the mixing chamber Air passing through the nozzle air vent channels sweeps fuel from the nozzle well and nozzle bore under very low suction and therefore satisfies any sudden demand for nozzle fuel...

Page 54: ...not to damage the idle needle seat by turning the idle adjusting needle too tightly against seat as damage to this seat will make a satisfactory idle ad justment very difficult 9 Float Height 3 Fig 32...

Page 55: ...at the points arejust opening on the No I cylinder Secure the magneto in this position and recheck the adjustment IWARNING I Do not fail to remove the paper strip from the magneto after the timing is...

Page 56: ...ce should be checked each time installation is made This check should be made without oil in the unit 6 Proper oil supply must be maintained Oil must be supplied to the hydraulic tappets with at least...

Page 57: ...tappet is working properly there will be almost no shock felt Once this comparison is made there will be no question about its finality thereafter If it is found that one unit has a tendency to stick...

Page 58: ...using and insert over pinion pivot Place the 006 inch thick gasket over the three 5 16 studs being careful that the top end of gasket is kept in place Assemble starter and adapter over 3 16 studs and...

Page 59: ...d against the commutator with a stick while the cranking motor is operated NEVER OPERATE MORE THAN 30 SECONDS AT A TIME TO AVOID OVERHEATING AND NEVER USE EMERY CLOTH TO CLEAN COMMUTATOR If the commut...

Page 60: ...oss the generator This will assure an adequate flow of air through the generator and proper generator ventilation 54 Specifications are as follows Clockwise rotation viewing drive end Cold output 13 a...

Page 61: ...round b If the generator is not grounded check field for open circuit c If this field is not open check for shorted field Field draw at 12 volts should be 1 62 to 1 69 amperes Excessive current draw i...

Page 62: ...sure the insulators are correctly assembled 3 With a low battery and a low or no charging rate check the circuit for loose connections frayed or damaged wires High resistance resulting from these con...

Page 63: ...drum e Remove retaining ring 34 bearing 35 and worm drive shaft assembly Remove worm gear 36 spring 37 and Woodruff key 38 from shaft 39 AND ADAPTER 4 CLEANING a Use a fortified mineral spirit solvent...

Page 64: ...Lock washer Flat washer Cover Gasket Bolt Lock washer Flat washer 0 rmg Figure 37 Starter and Adapter 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Oil seal Stud Pin Bushing Adapt S...

Page 65: ...lign ment measurements This will be accomplished by using standard measuring instruments s Jch as mi crometers telescoping gauges and dial indicators 6 REPAIR AND REPLACEMENT a The parts listed in the...

Page 66: ...is worn to 75 RMS replace sleeve 13 From centerline of worm gear shaft to starter adapter thrust pads 14 Needle bearing in starter adapter Dia 15 Ball bearing in starter adapter Dia 16 Worm gear shaf...

Page 67: ...L 0 0065L 21 Starter drive tongue to shaft drive slot side clear 0 030L O OlOL 0 021L 22 Needle bearing to worm gear shaft Dia 0 0031L 0 0005L 0 0029L 23 Starter gear to crankshaft gear back lash 0 01...

Page 68: ...www continentalmotors aero Continental Motors Inc...

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