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Continental Motors GO-300-A Overhaul Manual Download Page 1

Publication X30019

©

2011 CONTINENTAL MOTORS, INC.

AUG 2011

GO-300-A, C, D & E

CONTINENTAL

®

 AIRCRAFT ENGINE

 

 OVERHAUL

MANUAL

FAA APPROVED

Summary of Contents for GO-300-A

Page 1: ...Publication X30019 2011 CONTINENTAL MOTORS INC AUG 2011 GO 300 A C D E CONTINENTAL AIRCRAFT ENGINE OVERHAUL MANUAL FAA APPROVED...

Page 2: ...ver 1 A 1 i Blank added 1 ii thru vi 0 1 thru 67 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 Conti...

Page 3: ...INTENTIONALLY LEFT BLANK...

Page 4: ...sembly Repair and Testing of Accessories Testing After Overhaul Table of Limits LIST OF TABLES Purchased Accessories Ignition System Details Characteristics and Dimensions Fuel System Details Temperat...

Page 5: ...rankcase Cover 14 Cylinder Dimensional Drawing 15 Installing Helical Coil Inserts 16 Rocker Arm Bearing Dimensions 17 Measuring of Dampener Bushing 18 Connecting Rod and Bushing Dimensions 19 starter...

Page 6: ...eral Aviation Administration Figure Illustration Propeller End Foot or feet Gallons per minute Water Mercury Inside Diameter Inches Hexagon Hour Side on which No s 2 4 and 6 cylinders are located Poun...

Page 7: ...n cable 6 Oil cooler 19 Carburetor 7 Propeller reduction unit housing 20 Throttle lever 8 Propeller shaft bearing cage 21 No 3 cylinder intake pipe 9 Propeller shaft oil seal 22 No 3 cylinder lower ig...

Page 8: ...rod 11 Nut lockwasher and washer 33 Oil sump 12 Starter 34 Left rear mount bracket 13 Three wire ignition cable bracket 35 No 2 cylinder intake pipe 14 Nut lockwasher and washer 36 Two wire ignition...

Page 9: ...requested that all orders fMsuch publications be placed with these facilities when not immediately available from their stock 1 5 SERVICE BULLETINS 1 6 Important changes in part numbers interchange ab...

Page 10: ...t and upper left side plugs Right magneto fires upper right and lower left side plugs Firing order cylinder numbers Spark plug gap settings SR 87 Permissible R P M spread when switched from Both to ei...

Page 11: ...g factor on all engines having Vernatherm valves installed 2 1 OIL SUPPLY AND MEASUREMENTS 2 2 The capacity of the oil sump is 10 U S quarts The minimum quantity of oil in the sump necessary to adequa...

Page 12: ...y forging is machined on four journals nine cam lobes and the gear mount flange at the rear end The lobes and journals are ground and hardened A groove around the front journal passes engine oil from...

Page 13: ...e rear exit of the gallery is aligned with a passage to the oil pressure relief valve The front exit of the gallery aligns with the entrance to a passage in the reduction unit housing which directs th...

Page 14: ...ears rotates at 1 1 2 engine speed counterclockwise 4 Oil pump drive gear rotates at 1 2 engine speed clockwise 5 Oil pump driven gear rotates at 1 2 engine speed counterclockwise 6 Generator drive ge...

Page 15: ...re drilled to provide an oil passage from the valve lifters to the rocker arm The rocker arms are drilled to provide an oil passage from the push rod end to the rocker arm bearings Oil is sprayed from...

Page 16: ...e aircraft manufacturer 4 9 To install the oil gauge pressure line fitting 8 remove the 1 8 in pipe plug located in the crankcase between No 2 and 4 cylinders Coat the pipe threads of the fitting with...

Page 17: ...s fully engaging the crank shaft gear On all models connect the electrical lead to the starter switch Connect the generator field coil F and armature A electrical leads to the terminals so designated...

Page 18: ...160 24 THREAD 2 TERMINALS jLcd f VACUUM PVMP AETURN 375 18 NPTF i OIL PRESSURE RELIEF VALVE TACH DRIVE ASM TYPE I BALANCE TUBE OIL DILUTION CONNECTION 125 27 ORYSEALl PLUG OIL SUMP MANIFOLD DRAIN CONN...

Page 19: ...ler and replace it with a plug and gasket Disconnect the oil pressure gauge tube remove its connector and replace it with a l 8 in pipe plug Disconnect the intake manifold pressure gauge line from the...

Page 20: ...rference with other members e Inspect all hoses and clamps for tightness of jOints and general appearance Ascertain that tighten ing of hose clamps at the jOints has not deformed in take manifold part...

Page 21: ...ontrols and removing the four nuts washers and lock washers which attach the carburetor to the sump To drain the fuel from the float chamber remove the pipe plug at the bottom of the rear Side below t...

Page 22: ...a Remove three sets of nuts lock washers and plain washers attaching the adapter to crankcase cover studs b Remove a nut lock washer and plain washer from the bolt that passes through the adapter cra...

Page 23: ...ushrod housings until clear of the pushrod housing flange f Remove cylinder base nut locks and flange nuts starting with lower ones first g Support the cylinders in either arm pull it straight outward...

Page 24: ...djusted Remedy Place mixture control in IDLE CUTOFF position Switch ignition off Open throttle wide Turn propeller several revolutions Prime more In cold weather draw plunger slowly back push hard Che...

Page 25: ...s in carburetor air intake Restrictions in carburetor jets low float level plugged fuel screen Idle setting too lean Remedy Use full rich mixture for all ground operation Remove and clean Adjust gaps...

Page 26: ...an fuel air mixture Valve spring broken Valve warped or burned Hydraulic tappet dirty or worn Throttle not opening wide Spark plugs fouled or im properly gapped Carburetor air heat valve open Incorrec...

Page 27: ...ne solids Scored pressure pump Defective pressure gauge Remedy Overhaul and adjust carbure tor Top overhaul Top overhaul Refer to Table IV for correct fuel octane rating On ground and in flight below...

Page 28: ...peller shaft oil seal Damaged gasket pushrod housing Cylinder wall worn out of round Intake valve guides worn Valve faces and seats worn Piston rings excessively worn Cylinder barrel worn out of round...

Page 29: ...d remove gasket 8 b Disconnect ignition cables from spark plugs Detach ignition cable brackets and remove band clamp 16 Mark the magneto outlet of each cable as it is removed from the magneto c Remove...

Page 30: ...le pushing the piston pin sideways until free of the connecting rod The pin should be kept with the piston in its normal position 38 42 35 39 e J 41 3 7 I 40 19 20 1 Deleted 16 Washer 31 Needle bearin...

Page 31: ...27 No 5 cylinder upper cable 45 Nut 9 Rivet 28 No 5 cylinder lower cable 46 Generator gear 10 Clamp bracket 29 Nail 47 Sleeve gen coupling 11 Clamp bracket 30 Connector 48 Coupling bushings 12 Clamp...

Page 32: ...ert 7 Plug 20 Lockwasher 33 Copper asbestos gasket 46 Diffuser ring 8 Nut 21 Washer 34 Plug 47 Diffuser tube 9 Screw 22 Hose clamp 35 Copper asbestos gasket 48 Retaining ring 10 Clamp 23 pose 36 Plug...

Page 33: ...18 Valve spring seat 19 Outer valve spring 20 Inner valve spring 21 Intake valve spring retainer 22 Exhaust valve spring retainer 23 Exhaust valve 24 Intake valve 25 Exhaust valve guide 26 Intake val...

Page 34: ...MBLY 7 17 CRANKCASE See figure 11 a With the aid of a pushrod push the complete hy draulic valve lifter up until it is free of the lifter guide Use extreme caution when removing the lifters as the pus...

Page 35: ...r 68 Ball bearing 90 Plug 15 Lockwasher 43 Shaft propeller drive 69 Accessory drive 91 Plug 16 Washer 44 Nut cage 92 Plug 17 Gasket 45 Lockwasher 70 Accessory drive 93 Ball 18 0 ring 46 Washer cover 9...

Page 36: ...38 Washer 60 Thread insert 16 Washer 39 Right rear mount bracket 61 Plug 17 Deleted 40 Right front mount bracket 62 0 ring 18 Flanged nut 4I Left front mount bracket 63 Oil gauge rod 19 Washer 42 Left...

Page 37: ...lts 19 Left crankcase 7 Crankshaft 20 Cotter pin 8 No 5 connecting rod 21 Nut 9 Crankshaft oil 22 Connecting rod bolt transfer tube 23 Crankcase support 10 Crankshaft counterweight 24 No 4 connecting...

Page 38: ...ng 21 Plunger 22 Nut 23 Lock washer 24 Gasket 25 Cap 26 Oil Seal 27 Tachometer drive housing 28 Screw 29 Tab washer 30 Oil pump cover Used only on GO 300 D E engines Figure 13 Crankcase Cover o 8 VJ 3...

Page 39: ...ats 18 springs 19 20 and retainers 21 22 g Grasp valve stems and lift cylinder from sup port Lay cylinder on its Side stone down any burrs on valve stems then remove valves 23 24 7 21 CRANKCASE COVER...

Page 40: ...carbon deposits since they loosen by dissolving adheSive rosins which cannot be dissolved after they have been carbonized by heat 8 7 VariOUS blasting techniques can be employed to remove hard carbon...

Page 41: ...other coarse abrasives Vapor blasting may be employed if bushings and bear ing slots are protected from the abrasive Discolora tion need not be removed from piston pin bushings and no abrasive cloth o...

Page 42: ...visual inspection the engine parts should be in three groups apparently serviceable parts repairable parts and parts to be discarded 9 5 MAGNETIC PARTICLE INSPECTION TABLE IX MAGNAFlUX INSPECTION DAT...

Page 43: ...Fatigue cracks Continuous Wet Teeth drum shaft Fatigue heat cracks Continuous between spur gear Fatigue cracks and drum Wet Slotted end Fatigue cracks Continuous around key slot Wet Teeth Fatigue cra...

Page 44: ...ird ring grooves width Fourth ring groove width Outside diameter Length including plugs Bushing bore diameter Bushing center to crankpin center Main journal diameter Crankpin diameter Damper pin bushi...

Page 45: ...r main journal in order to detect excessive bending 2 247 2 248 0 8120 0 8130 2 247 2 248 9 16 CAMSHAFT Inspect the journals for scoring corrosion and overheating and lobes for pitting atthe toes and...

Page 46: ...ed up by the piston head to a point in line with the base flange 9 20 CYLINDERS Measure the barrel bore near the top of the ring travel limit and at the open end in the thrust direction and at right a...

Page 47: ...t lard oil and two parts kerosene to prevent overheating the metal and tearing the thread 10 7 To remove a damaged helical coil use the pro per size extracting tool speCified for the nominal thread si...

Page 48: ...Crankcase breather pad 1 4 20 x 1 4 24 0 75 2 10 98 Crankcase breather pad 1 4 20 x 1 4 24 0 62 2 10 99 Oil cooler pad 1 4 20 x 1 4 24 0 75 8 10 100 Vacuum pump drive cover pad 1 4 20 x 1 4 24 0 62 4...

Page 49: ...with a hard Arkansas stone or a fine India stone The face must never run into the roundecf edge of the head Discard valves which must be ground to this condition to clean up 10 13 After the valve seat...

Page 50: ...e any nicks on finished surfaces 42 b If damper pin bushings in shaft or counterweights are worn drive out or press out old bushings and drive or press in replacements which have been chilled Be sure...

Page 51: ...drive and pump cover renders this part unserviceable unless the parting surface can be lapped smooth and perfectly flat 10 23 IGNITION CABLES Normally all ignition cable assemblies or both harness as...

Page 52: ...or of an Alodized part may vary from light gold to dark brown When a part is treated with Alodine 1200 the thickness of the film or buildup on the mating or bearing sur faces is so fine that the effec...

Page 53: ...d dried with de hydrated compressed air 11 5 LUBRICATION Immediately after final clean ing and before installation coat all bare steel surfaces and journals with clean engine lubricating oil except wh...

Page 54: ...d be found on original cylinders but they must be stamped on new parts Mter assembly cylinders should be laid on the bench in a row in the order of position numbers a Spread a film of Lubriplate No 70...

Page 55: ...se then twist the seal and slide it over the propeller shaft with the felt side toward the flange See figure 22 Bring the ends back together h Pass the spring around the propeller shaft on the recesse...

Page 56: ...th two sets of attaching parts 37 36 35 e Turn crankcase halves over so parting flanges are up Wipe out each bearing boss carefully f Install the main bearing inserts 43 44 45 g Position the crankcase...

Page 57: ...ube Align the quill shaft relief with the crankshaft mark and insert the quill shaft into the crankshaft f Observe on the front of the quill shaft that two splines are punch marked and on the front en...

Page 58: ...ntil the dowel hole in its flange is located in the specified relationship to the parting line of the cage halves See Figure 5 Push the subassembly into the housing meshing the propeller drive gear wi...

Page 59: ...uds For current model sumps install a new 0 ring 18 Install manifold riser 16 and secure it with four sets of attaching parts 14 13 12 f Place a new hose 23 and two hose clamps 22 on the longest side...

Page 60: ...n washer on the stud install the three wire cable bracket 9 figure 2 and secure with attaching part 10 d Place the two wire cable bracket 5 on the lifting 52 eye front bolt and secure with a lock wash...

Page 61: ...surface layer or unless unit produces an excessive dry lash wherever it is installed in an engine c Check roughly for diametrical clearance and check valve wear in hydraulic unit by starting dry plung...

Page 62: ...leakage d To test for invisible leaks block either oil port with a gasket and adapter plate through which com pressed air may be introduced into the other port 54 and attach a compressed air hose to...

Page 63: ...during this test flight Do a normal pre flight run up in accordance with the aircraft flight manual Conduct a normal take off with full power and monitorthe fuel flow RPM oil pressure cylinder head te...

Page 64: ...ngine or both to a common ground A Delco Remy generator regulator designed for a 12 volt system should be connected to the generator A armature and F field coil terminals the latter of which is neares...

Page 65: ...change oil Install dehydrator plugs in the spark plug holes which are in the top positionwhen the engine is mounted in the shipping base Seal all other openings leading to the interior of the engine w...

Page 66: ...Period Time Minutes RPM 1 5 900 Warm Up 2 5 1200 3 10 1500 4 10 1800 5 10 2000 6 10 2200 7 10 2400 8 10 2600 9 15 2800 10 15 2900 11 15 3000 12 10 600 25 Idle Cooling Period Following period No 12 sto...

Page 67: ...e Front Cage In Housing Dia Accessory Dri ve Gear In Bearing Ball Dia Accessory Dri ve Front Cage Check Thrust Pad For Wear From Gear From Flange to Thrust Pad Dimension Bushing In Housing Check For W...

Page 68: ...arance Gear To Camshaft Pilot Dia PUSHRODS Pushrod Length to theoretical New Parts Minimum 0005L 003 L 0005T 001 T 000 2 247 1 936 000 0015T 004 0015T 729 729 4916 826 001 L 004 L 001 L 000 0005L 002...

Page 69: ...Oil Seal In Tachometer Drive Housing Dia Crankshaft Gear On Shaft Dia STARTER ADAPTER Starter Shaft Gear In Bushing Dia Starter Shaft Gear Front Journal Dia Starter Shaft Gear In Needle Bearing Dia Cl...

Page 70: ...ner Spring No 625957 Compressed to 1 10 inch length load Valve Outer Spring No 625958 Compressed to 1 559 inch length load Valve Outer Spring No 625958 Compressed to 1 168 inch length load Vernatherm...

Page 71: ...85 21 2 23 8 310 350 25 8 29 2 NOTE Torque loads are listed for use with oil on threads except for studs Stud driving torques apply when the threads are coated with Alcoa thread lube if hole is blind...

Page 72: ...64 12 11 E SECTION D D Figure 25 Limits and Lubrication Chart PRESSURE OIL DRAIN OIL...

Page 73: ...SECTION E E Figure 26 Limits and Lubrication Chart 65...

Page 74: ...SECTION F F Figure 27 Limits and Lubrication Chart 66...

Page 75: ...ER MOUNT PAD 6616710681 0171 P 6 P 7 61 SECTION 6 6 60 59 49 48 109 lOS 104 TO CRANKCASE OIL GALLERY SECTION G G RIGHT CRANKCASE GALLERY DRAIN TO SUMP FRONT PRESSURE OIL SCREEN P 1 FROM PUMP 74 84 SEC...

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