Continental Motors GTSIO-520 SERIES Operator'S Manual Download Page 1

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Publication X30079

CONTINENTAL MOTORS, INC.

AUGUST 2011

GTSIO-520-D

CONTINENTAL® AIRCRAFT ENGINE

OPERATOR’S

MANUAL

FAA APPROVED

Summary of Contents for GTSIO-520 SERIES

Page 1: ...Publication X30079 CONTINENTAL MOTORS INC AUGUST 2011 GTSIO 520 D CONTINENTAL AIRCRAFT ENGINE OPERATOR S MANUAL FAA APPROVED...

Page 2: ...1 A 1 i 1 ii thru iv 0 1 thru 40 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 In...

Page 3: ...WITH ALL INSTRUC TIONS CONTAINED HEREIN FAILURE TO SO COMPLY WILL BE DEEMED MISUSE RELIEVING THE ENGINE MANUFACTURER OF ANY RE SPONSIBILITY THIS MANUAL CONTAINS NO WARRANTIES EITHER EXPRESS OR IMPLIE...

Page 4: ...scending and Landing 21 7 Stopping Engine 22 TROUBLE SHOOTING 22 Trouble Shooting Chart 23 INSPECTION AND MAINTENANCE 30 1 General 30 2 Daily Inspection 30 3 50 Hour Inspection 31 4 100 Hour Inspectio...

Page 5: ...stributors are regularly supplied with Service Bulletins which are available for study by engine owners and other interested parties These bulletins may also be obtained on an annual subscription basi...

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Page 7: ...RES 1 GENERAL The engines have overhead valves air cooled horizontally opposed cylinders with 5 25 inch bore 4 00 inch stroke 520 cubic inch displacement and a compression ratio of 7 5 1 The cylinders...

Page 8: ...ngines per pound of weight is achieved by utilization of carefully selected high strength materials by improvements in design calculated to make the optimum use of these high quality materials and by...

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Page 11: ...Teledyne Continental Motors GTSIO 520 D H E7CE Individual cylinders horizontally opposed 7 5 1 1 4 5 2 3 6 460 F 380 F 6 1 3 5 2 4 6 5 250 4 000 520 Rated Maximum Continuous Operation 375 Rated Maxim...

Page 12: ...hr Maximum Continuous Operation Normal Cruise 60 MC Power Best Power Normal Cruise 60 MC Power Best Economy Oil Specification Above 40 F Below 40 F Below 40 F Oil Pressure Minimum Idle psi t Cruising...

Page 13: ...agneto degrees BTC 008 75 F 240 F 170 F Minimum oil level for satisfactory oil cooling IS indicated by LOW mark on oil level gauge ACCESSORIES Magneto 2 Spark Plugs Fuel Injector Pump Turbocharger Alt...

Page 14: ...ludes lubrication system accessory drives starter adapter intake system mounting brackets cylinders six pendulum type dampers and a viscous damper Turbocharger Spark Plugs 12 Magnetos 2 Ignition Assem...

Page 15: ...plugs are provided for use in changing oil at the recommended intervals The main oil pressure pump picks up oil from the sump and discharges it through a passage to the oil filter and oil cooler and t...

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Page 17: ...heel compressor wheel and interconnecting drive shaft comprise one complete assembly and the only moving part in the turbocharger The thrust bearing and two journal type main bearings are pressure lub...

Page 18: ...UCTION SYSTEM FIG 6 The turbocharger supplies intake air to the induction system and supplies the necessary combustion air when it is needed most i e on take off climb and during flight at high altitu...

Page 19: ...N VARIABLE SETTING ABSOLUTE PRESSURE CONTROLLER I I I I I TO CABIN Figure 6 Induction System LEGEND RAM AIR AIR EXHAUST GAS HYDRAULIC OIL COMPRESSOR TURBINE...

Page 20: ...ed shielded conduit assemblies 7 FUEL SYSTEM The fuel injection system is of the multi nozzle continuous flow type which controls fuel flow to match engine air flow Any change in air throttle position...

Page 21: ...e fuel air control unit a The air throttle assembly includes a butterfly valve which controls the amount of air entering the intake manifold This valve is controlled by a lever which is connected to t...

Page 22: ...switch ON or as instructed by aircraft manufacturer CAUTION If engine is hot press starter button first then turn auxiliary fuel pump switch ON or as instructed by aircraft manufacturer g When fuel p...

Page 23: ...use 3 WARM UP a Maintain engine speed at approximately 900 to 1000 crankshaft RPM for at least one minute in warm weather and as required during cold weather to prevent cavitation in the pressure oil...

Page 24: ...observed when operating on either magneto alone switch circuit should be inspected for loose connections 2 Check throttle and propeller operation a Slowly move propeller governor control toward low RP...

Page 25: ...rce air between the cylinder fins Proper cooling also depends on operation practices Fuel and air mixture ratio also affects cylinder temperature Excessively lean mixture causes overheating even when...

Page 26: ...periods 3 Set auxiliary pump switch as instructed by aircraft manufacturer see Note 3 NOTE 2 The turbocharger lag may boost the manifold pressure 2 to 3 inches between run up and ground breaking spee...

Page 27: ...ly eliminate excess vapor c When an economy setting step b above is in use and a change of power setting is to be made it is recommended that the mixture control be returned by gauge to approximately...

Page 28: ...position because the engine could KICK as the result of auto ignition of a small amount of fuel remaining in the engine TROUBLE SHOOTING The trouble shooting chart which follows discusses symptoms wh...

Page 29: ...VE ACTION a No fuel gauge pressure I a Check fuel control pump ON and op filters open and tank No fuel to engine b Have gauge pressure I b engine flooded Turn off auxiliary throttle to FULL O c Have g...

Page 30: ...lugs c Discharge nozzle air c Check for bent or l vent manifolding re connections Check tv stricted or defective defective component d Restricted fuel nozzle d Remove and clean al 4 Engine has a Idle...

Page 31: ...g Replace defective spa d Check operation li operation of waste g defects Tighten loos a Check manifold con connections Check setting and adjustme for dirt Check for p pump if defective b Remove and c...

Page 32: ...s carbon deposits ero adjusted electrode g plugs for regular damaged or misfirin 0 015 to 0 019 inch c Check for full travel travel of throttle co has automatic con connections and r adjustment of tra...

Page 33: ...CTION g Check for unusual malfunction is suspec inlet connections an possible rubbing in defective bearings Rep noted h Inspect exhaust syste cylinder exhaust port turbine inlet flanges e Ia Check mix...

Page 34: ...embly Defective relief valve I b operation in fuel injector pump Restricted recirculation I c passage in fuel injector pump Air leakage in fuel gauge d vent pressurization line a Vapor in fuel system...

Page 35: ...c tion Restricted screens and filter 11 Poor engine Ia Engine getting fuel idle cut off 12 Bla ck exhaustIa Turbo coking oil smoke forced through seal turbine housing CORRECTIVE ACTION c Check for res...

Page 36: ...yne Continental Motors Engineering and Field Service Departments as minimum requirements to maintain the engine in dependable operating condition 2 DAILY INSPECTION a Make sure the throttle can be mov...

Page 37: ...nstruments or gauges for possible irregularities inperformance at various power settings 3 50 HOUR INSPECTION a Change filter or clean oil screen Change oil if full flow filter is not used See Service...

Page 38: ...looseness of clamps and attaching hardware Hoses must not exhibit any signs of deterioration Check turbocharger mounting bolts for looseness f If a malfunctioning turbocharger is suspected remove the...

Page 39: ...n the principle that for any given airflow through a fixed orifice a constant pressure drop across that orifice will result The restrictor orifice dimensions for Continental aircraft engines should be...

Page 40: ...an air approximately 100 120 psi to the tester d Install an adapter in the spark plug bushing and connect the compression tester to the cylinder e Adjust the pressure regulator to obtain a reading of...

Page 41: ...stuck or worn piston rings j If leakage is still occurring after a recheck it may be possible to correct a low reading by staking the valves This is accomplished by placing a fiber drift on the rocker...

Page 42: ...a visual inspection reveals damage or green stain indicating plugging has occurred When necessary to remove the nozzles a standard half inch spark plug socket is the correct tool to use Slosh the noz...

Page 43: ...travel a minimum of 0 09 inch between120 F and 170 F Replace the valves which do not pass this test k The idle mixture adjustment is the locknut at the metering valve end of the linkage between the me...

Page 44: ...LOCKNUT FOR IDLE MIXTURE ADJUSTMENT WHEN THROTTLE LEVER IS 020 FROM STOP SPRING LOAD TO BE 8 LBS CONTROLLER AT FULL POWER POSITION IDLE SPEED ADJUSTMENT Figure 8 Idle Adjustment Points 38...

Page 45: ...hing ignition cables to spark plugs inspect leads and cable terminal parts for cracks and deformation Magnetos are normally inspected at each 200 hour period unless there is reason to suspect ignition...

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