Continental Motors O-200-D Page 75 Installation And Operation Manual Download

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O-200-D & X Series Engine Installation and Operation Manual

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3 January 2017

Figure 3-11. O-200-D Engine Installation Drawing - Detail Views

Summary of Contents for O-200-D

Page 1: ...Publication OI 2 2017 CONTINENTAL MOTORS INC JAN 2017 O 200 D X CONTINENTAL AIRCRAFT ENGINE INSTALLATION AND OPERATION MANUAL FAA APPROVED...

Page 2: ...3 January 2017 Page Change Page Change Page Change Page Change Cover 0 A 0 i viii 0 1 1 thru 1 12 0 2 1 thru 2 32 0 3 1 thru 3 28 0 4 1 thru 4 22 0 A 1 thru A 2 0 B 1 thru B 2 0 C 1 thru C 2 0 Publish...

Page 3: ...rements It is not intended and should not be used by a pilot owner or maintenance personnel Installation and Operation instructions in this manual may be modified or used intact to create the aircraft...

Page 4: ...ii O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Intentionally Left Blank...

Page 5: ...er 2 Engine Description 2 1 General Engine Description 2 1 2 1 1 Engine Model Number Definition 2 2 2 1 2 Cylinder Number Designations 2 2 2 2 Aircraft Interface Requirements 2 3 2 2 1 Crankcase Breat...

Page 6: ...System 2 17 2 3 5 1 Oil Pump 2 17 2 3 5 2 Oil Sump 2 18 2 3 5 3 Oil Pressure Relief Valve 2 18 2 3 5 4 Oil Cooler Adapter 2 19 2 3 6 Ignition System 2 19 2 3 7 Starter Assembly 2 21 2 3 8 Alternator 2...

Page 7: ...In 4 3 4 2 3 1 Engine Break In 4 3 4 2 3 2 Flight Check 4 4 4 3 Normal Operation 4 5 4 3 1 Pre operational Requirements 4 5 4 3 2 Engine Start 4 6 4 3 2 1 Cold Start 4 7 4 3 2 2 Flooded Engine 4 7 4...

Page 8: ...ix A Glossary Appendix B Torque Specifications Appendix C Standard Practices C 1 Handling Parts C 1 C 2 Replacement Parts C 1 C 2 1 Background C 1 C 2 2 Acceptable Replacement Parts C 1 C 2 2 1 Know Y...

Page 9: ...elated Publications 1 11 Table 2 1 Recommended Instrument Range Markings 2 5 Table 2 2 Oil Gauge Rod Error 2 7 Table 2 3 O 200 D Specifications 2 23 Table 2 4 O 200 X Specifications 2 25 Table 2 5 Acc...

Page 10: ...Harness Routing typical 2 20 Figure 2 17 Engine Cooling 2 21 Figure 2 18 Fuel Flow vs Brake Horsepower 2 29 Figure 2 19 Full Throttle and Prop Load Curves 2 30 Figure 2 20 Sea Level Performance 2 31...

Page 11: ...ries including the O 200 A B C model engines engine accessories or the airplane refer to the appropriate manual This document is intended for use only by an OEM or STC customer for assistance in defin...

Page 12: ...ormation in this manual must be incorporated into the applicable aircraft design data and the Airplane Flight Manual Pilot s Operating Handbook AFM POH by the aircraft manufacturer Refer to the AFM PO...

Page 13: ...O 200 D X Series Engine Installation and Operation Manual 1 3 3 January 2017 Introduction Figure 1 1 Figure and Index Reference...

Page 14: ...releases publication changes in the form of either change pages or complete publication revisions depending upon the extent of change Continental Motors issues service documents in the form of Servic...

Page 15: ...riginal publication date and an itemized list of changes issued for the technical manual Figure 1 3 If change pages are issued for the manual the change will be identified with an effective date under...

Page 16: ...1 6 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Introduction Figure 1 3 List of Effective Pages...

Page 17: ...eration of an aircraft persons or property on the ground unless some specific action inspection repair replacement etc is taken by the owner or operator Documents in this category are candidates for i...

Page 18: ...Inspection M 0 SB96 12 Continued Airworthiness for TCM Cylinders Scheduled Inspection M 0 SB97 6B Mandatory Replacement Parts Engine Inspection Assembly M 0 SIL98 9E Time Between Overhaul Periods Eng...

Page 19: ...rt a copy of the service document behind the last page of this section Make pen ink corrections where appropriate to the original text in the manual with a citation to the service document i e see SB9...

Page 20: ...letin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sections Title Bulletin Number Release Date Affected Sectio...

Page 21: ...ccess our web site to confirm and review the latest revision of this manual If you have not subscribed to Internet service and are using printed manuals contact using the Contact Information in Sectio...

Page 22: ...service If customers have an inquiry or require technical assistance they should contact their local Continental Motors distributor or field representative To contact a factory representative refer t...

Page 23: ...ped with carburetors and an updraft induction system The engines are designed with a wet sump positive displacement oil pump installed in the accessory case When properly maintained under normal opera...

Page 24: ...he rear of the engine is the accessory end Viewed from the rear of the engine the left side cylinders are designated by even num bers 2 4 with Cylinder 2 being closest to the rear The right side cylin...

Page 25: ...on Audit The purpose of the audit is to review compliance with the minimum requirements set forth within this document Satisfactory completion of the audit is required before Continental Motors will d...

Page 26: ...embly and the aircraft air filter and the alternate air system in compliance with the applicable regulations The engine induction air system consists of individual tubes connected between the cylinder...

Page 27: ...fuel flow values Minimize fuel line lengths to decrease residence time of the fuel Minimize elevation changes Minimize the number of bends and fittings Route fuel lines away from heat generating comp...

Page 28: ...Fuel Boost Pump An aircraft boost pump can aid starting and vapor suppression on a carburetor equipped engine The airframe manufacturer must ensure the minimum and maximum fuel pressure at the carbur...

Page 29: ...ground attitude oil levels in the POH should be increased by 0 5 quarts 2 2 6 4 Oil Filter The O 200 D X series engines are fitted with a spin on full flow oil filter with integral bypass as standard...

Page 30: ...al connector for grounding the magneto through a switch In cases where only the left magneto is equipped with an impulse coupling the right magneto must be grounded when the starter is energized Groun...

Page 31: ...opeller and spinner exhaust system and all accessories required for operation 2 2 11 Propeller System O 200 D X series do not provide hydraulic control for propeller pitch control A fixed pitch propel...

Page 32: ...acked crankshaft main bearing inserts are line bored through web bosses Camshaft bearings are bored directly in the case metal Bearings are divided equally by the parting surface camshaft bearings bei...

Page 33: ...r of each case casting affords an engine mounting point The arm bosses of the crankcases are bored through and counterbored for mount bushing assemblies The flange surrounding the rear end of the cran...

Page 34: ...s a propeller mount flange forged on the front end with six tapped holes in the flange Six bolts screwed into the propeller flange clamp the propeller between a loose front flange and the propeller fl...

Page 35: ...amshaft main journals are supported in the crankcase by machined bearing saddles Hydraulic tappets move inward and outward in their bores following the eccentric shape of the cam lobes Four unequally...

Page 36: ...t side of the accessory case for installation of a non adjustable oil pressure relief valve Oil pump gear chambers are machined in the interior of the accessory case The oil pump drive gear shaft hole...

Page 37: ...ber for an optional primer jet which may be installed by the owner The port is sealed by a pipe plug from the factory An external base flange below the cylinder barrel fins is mounted flat and drilled...

Page 38: ...he hydraulic valve tappet lifter provides an interface between the camshaft lobe and the remaining valve train Hydraulic valve tappets ride on the eccentric cam lobes opening and closing the intake an...

Page 39: ...2 13 consists of two meshed steel gears that revolve inside the oil pump cavity machined in the accessory case The camshaft drives the oil pump drive gear which drives the oil pump driven gear The oi...

Page 40: ...on The upper section features a rib reinforced crankcase mounting flange and a boss for the pressed oil gauge rod and extension tube assembly The lower oil sump body is fitted with a threaded drain pl...

Page 41: ...inental Motors magneto model number identifies the key features of each magneto model as shown in Figure 2 15 The magnetos generate and distribute high voltage ignition pulses through high tension lea...

Page 42: ...Magneto one drive two output distributors Cylinders Fired 4 Four Cylinders 6 Six Cylinders 8 Eight Cylinders Rotatlon Viewed Looking in to Drive End L Left counterclockwise R Right clockwise Designato...

Page 43: ...ailed description of Continental Motors alternators refer to Continental Motors Alternator Service Instructions 2 3 9 Engine Cooling The engine cylinders are cooled by transferring heat from the cylin...

Page 44: ...he intake manifold is attached to two studs on the lower crankcase flange The carburetor is attached to the bottom of the intake manifold with a gasket and four fasteners Air passage through the manif...

Page 45: ...Power WOT 1 88 bhp 2450 rpm Fuel System Specifications Fuel Minimum Grade3 100 100LL conforming to ASTM D910 Fuel Grade People s Republic of China4 RH 95 130 conforming to GB 1787 Minimum fuel pressu...

Page 46: ...of rear accessory case Below crankshaft centerline Beside crankshaft centerline toward 1 3 side 14 55 0 96 0 06 369 60 24 40 1 50 1 Performance is based on sea level standard day zero water vapor pre...

Page 47: ...2450 rpm Fuel System Specifications Fuel Minimum Grade3 100 100LL conforming to ASTM D910 Fuel Grade People s Republic of China4 RH 195 130 conforming to GB 1787 Minimum fuel pressure at the carburet...

Page 48: ...d of rear accessory case Below crankshaft centerline Beside crankshaft centerline toward 1 3 side 14 55 0 96 0 06 369 60 24 40 1 50 1 Performance is based on sea level standard day zero water vapor pr...

Page 49: ...ximum Torque in lbs Maximum Overhang Moment in lbs Cont Static Magneto CW 1 1 Starter Motor CW 35 7 1 Alternator gear driven CCW 2 035 1 60 600 100 Mass Flow Sea level standard day conditions 100 bhp...

Page 50: ...X configuration as cafeteria type selections Performance specifications for both engine models are identical WARNING The performance charts included in this manual indicate uninstalled engine perform...

Page 51: ...iption 2 4 5 1 O 200 D X Performance Charts Figure 2 18 Fuel Flow vs Brake Horsepower 20 25 30 35 40 45 50 55 60 50 55 60 65 70 75 80 85 90 95 100 Fuel Flow lbs hr Corrected Brake Horse Power Data Mea...

Page 52: ...Rich Fuel Mixture Minimum Engine 0 45 0 50 0 55 0 60 0 65 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Brake Specific Fuel Consumption lb hphr Engine Speed rpm Prop Load Full Throttle Data Measu...

Page 53: ...ermine actual HP 1 Locate RPM Pm on Alt Perf Chart Pt A 2 Locate RPM Pm on Sea Level Perf Chart Pt B 3 Transfer CBHP equal to Pt B on Sea Level Chart to Alt Perf Chart Pt C 4 Draw line from Pt C to Pt...

Page 54: ...mponents provided by the aircraft manufacturer Table 2 6 O 200 D X Accessory Weights Accessory Weight lbs Model Specification D1B D2B D3B D4B X2B Basic Engine Weight 158 2 Starter Skytec 12V 9 2 X X X...

Page 55: ...3 Engine Transport Stand 4 Oil conforming to SAE J1966 break in oil non dispersant mineral oil or MIL C 6529 Type II Fly away oil or 5 MIL P 46002 Grade 1 oil 6 100 100LL aviation fuel conforming to A...

Page 56: ...and inspect the desiccant bag through the plastic shipping bag Desiccant bag is attached to the engine mount at the rear of the engine 5 Inspect the engine according to the Acceptance Inspection crite...

Page 57: ...on 3 2 2 Prepare the Engine for Installation b If damage or corrosion is discovered contact the supplier of the engine for disposition Do not install a damaged or corroded engine or place it in storag...

Page 58: ...recommends hose replacement coincident with engine overhaul to avoid immediate contamination or failure at a later date 2 Replace all aircraft flexible oil and fuel hoses according to the aircraft ma...

Page 59: ...nstructions in Section C 3 of M 0 Standard Practice Maintenance Manual 9 Install all aircraft manufacturer required components according to the aircraft manufacturer s instructions including the follo...

Page 60: ...aft manufacturer s instructions 8 Install the propeller according to the aircraft and propeller manufacturer s instructions 9 Perform the Engine Pre oiling procedure according to the instructions in S...

Page 61: ...or valve to the ON position 3 Allow a minimum of one quart 0 94 liter of fuel to flow through a paper filter until the fuel is free of contaminants 4 Position the fuel selector valve to the OFF positi...

Page 62: ...ct the oil cooler and oil filter for signs of leaks or physical discrepancies 5 Check the following on the engine for physical damage a External cylinder barrels b Cylinder barrel fins c Areas between...

Page 63: ...g Handbook POH Perform a flight check before releasing the engine for normal service to ensure the installed engine meets the aircraft manufacturer s performance and operational specifications WARNING...

Page 64: ...p gaskets for oil leaks c Inspect oil sump for cracks d Inspect cylinder head exhaust gaskets for evidence of exhaust leaks e Inspect oil return hoses and air inlet for evidence of chafing from oil co...

Page 65: ...d to assist the aircraft manufacturer determine appropriate fittings and fasteners for aircraft interconnect requirements Pay particular attention to the engine models depicted when referencing drawin...

Page 66: ...3 12 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Engine Installation Figure 3 3 60 Amp Alternator Detail Figure 3 4 50 Amp Alternator Detail...

Page 67: ...O 200 D X Series Engine Installation and Operation Manual 3 13 3 January 2017 Engine Installation Figure 3 5 Engine Mounts...

Page 68: ...3 14 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Engine Installation Figure 3 6 Starter Connection Details...

Page 69: ...0 D X Series Engine Installation and Operation Manual 3 15 3 January 2017 Engine Installation Figure 3 7 Ignition Distribution Champion Slick Magnetos Figure 3 8 Ignition Distribution Continental Magn...

Page 70: ...3 16 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Engine Installation Figure 3 9 Ignition Switch Connections to Magneto...

Page 71: ...O 200 D X Series Engine Installation and Operation Manual 3 17 Reverse Blank 3 January 2017 3 3 2 O 200 D Installation Drawings Figure 3 9 O 200 D Engine Installation Drawing Left Side and Rear Views...

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Page 73: ...O 200 D X Series Engine Installation and Operation Manual 3 19 Reverse Blank 3 January 2017 Figure 3 10 O 200 D Engine Installation Drawing Front and Top View...

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Page 75: ...O 200 D X Series Engine Installation and Operation Manual 3 21 Reverse Blank 3 January 2017 Figure 3 11 O 200 D Engine Installation Drawing Detail Views...

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Page 77: ...O 200 D X Series Engine Installation and Operation Manual 3 23 Reverse Blank 3 January 2017 3 3 3 O 200 X Installation Drawings Figure 3 12 O 200 X Engine Installation Drawing Left Side and Rear Views...

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Page 79: ...O 200 D X Series Engine Installation and Operation Manual 3 25 Reverse Blank 3 January 2017 Figure 3 13 O 200 X Engine Installation Drawing Top and Front Views...

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Page 81: ...O 200 D X Series Engine Installation and Operation Manual 3 27 Reverse Blank 3 January 2017 Figure 3 14 O 200 X Engine Installation Drawing Detail Views...

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Page 83: ...r aircraft operating procedures 4 2 Flight Prerequisites Perform the sequential tasks listed in the Engine Operational Check instructions in Section 6 3 6 of the Maintenance and Overhaul Manual M 2 on...

Page 84: ...of an engine the first time high power is applied If the aircraft is inadvertently serviced with the incorrect grade of aviation fuel or jet fuel the fuel system must be completely drained and the fu...

Page 85: ...to prevent undesirable engine cooling If power must be reduced for long periods adjust the propeller to minimum governing RPM if equipped to obtain desired performance levels If outside air temperatur...

Page 86: ...ure to drop below 300 F 149 C 5 Descend at low power cruise settings Avoid long descents with engine speed below 1500 RPM Carefully monitor engine instrumentation to maintain levels above the minimum...

Page 87: ...een completed in addition to the aircraft manufacturer s instructions found in the AFM POH Operation of a malfunctioning engine can result in additional damage to the engine bodily injury or death Sup...

Page 88: ...r Verify the tasks listed in Table 4 2 Flight Prerequisites have been completed in addition to those required by the aircraft POH aircraft manufacturer or Supplemental Type Certificate STC holder Note...

Page 89: ...arts and runs smoothly at idle indicated oil pressure is greater than 10 psi If the engine fails to start refer to the troubleshooting instructions in Chapter 8 of the Maintenance and Overhaul Manual...

Page 90: ...rtently start and cause personal injury or death This condition must be corrected prior to continued aircraft operation CAUTION Do not underestimate the importance of the magneto check When operating...

Page 91: ...ight Magneto channel drop results Maximum allowable RPM drop spread between magneto channels is 75 RPM CAUTION Do not operate the engine at speeds in excess of 2000 RPM longer than necessary to comple...

Page 92: ...t take off Determine cause and take corrective action necessary to maintain airworthiness Supplement the AFM POH take off procedures with these engine settings 1 Mixture FULL RICH 2 Cowl Flaps per AFM...

Page 93: ...esired altitude has been reached supplement the AFM POH instructions with these steps 1 Adjust the throttle for the desired cruise power settings 2 Monitor Engine Instruments Allow engine temperatures...

Page 94: ...in Section 6 5 3 of M 0 Standard Practice Maintenance Manual Supplement the AFM POH with the following 1 Descend at cruise power settings with mixture control positioned for smooth engine performance...

Page 95: ...NOTE The difference between magnetos individual operation should not exceed 75 RPM Maximum RPM drop for either magneto is 150 RPM Observe engine smoothness during magneto switching If the engine runs...

Page 96: ...specific steps in addition to the AFM POH requirements when responding to emergency conditions If a malfunction should occur in flight certain remedial actions may eliminate or reduce the severity of...

Page 97: ...4 4 2 Engine Roughness WARNING If roughness is severe or the cause cannot be determined engine failure may be imminent Follow the AFM POH emergency procedures and LAND AS SOON AS POSSIBLE 5 Upon land...

Page 98: ...speed If the overspeed event duration is less than ten seconds perform a Category I Overspeed Inspection according to instructions in Section 6 5 3 of M 0 Standard Practice Maintenance Manual If the o...

Page 99: ...e indication may be caused by a faulty gauge or thermocouple If oil temperature drops as temperature increases 1 Cowl Flaps OPEN if equipped 2 Airspeed Increase 3 Reduce Power if steps 1 and 2 do not...

Page 100: ...1 4 OPEN 3 Ignition Switch START hold until engine starts 4 Mixture Control Advance slowly until proper proper fuel air mixture is reached 5 Throttle Adjust for desired RPM 4 4 8 Engine Fire In Flight...

Page 101: ...to the Engine Preheating instructions in Section 7 4 1 1 of M 0 Standard Practice Maintenance Manual 4 5 1 1 1 Engine Preheat with a Combustion Heater Refer to the Engine Preheat with a Combustion He...

Page 102: ...and fuel vapor Until the entire fuel system becomes filled with liquid fuel difficult starting and unstable engine operation can be expected Hot weather operation situations requiring special instruc...

Page 103: ...following engine run up face the aircraft into the wind with the engine idling at 900 1000 RPM 4 5 2 3 Take off and Initial Climb Out in Hot Weather 1 Mixture control FULL RICH NOTE Under extreme cond...

Page 104: ...equired during takeoff If higher than desired temperatures are experienced during the climb phase establish a lower angle of attack or higher climb speed consistent with safe operating practices to pr...

Page 105: ...O 200 D X Series Engine Installation and Operation Manual A 1 3 January 2017 Glossary Appendix A Glossary Refer to Appendix A in M 0 Standard Practice Maintenance Manual...

Page 106: ...A 2 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Glossary Intentionally Left Blank...

Page 107: ...O 200 D X Series Engine Installation and Operation Manual B 1 3 January 2017 Torque Specifications Appendix B Torque Specifications Refer to Appendix B in M 0 Standard Practice Maintenance Manual...

Page 108: ...B 2 O 200 D X Series Engine Installation and Operation Manual 3 January 2017 Torque Specifications Intentionally Left Blank...

Page 109: ...e Manual C 2 4 Mandatory Overhaul Replacement Parts Refer to Appendix C 2 4 in M 0 Standard Practice Maintenance Manual C 2 5 Authorized Oversize Undersize Parts Refer to Appendix C 2 5 in M 0 Standar...

Page 110: ...pendix C 9 in M 0 Standard Practice Maintenance Manual C 10 Gasket Installation Refer to Appendix C 10 in M 0 Standard Practice Maintenance Manual C 11 Hose and Tubing Installation Refer to Appendix C...

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