Teledyne Continental Motors GTSIO-520 Series Overhaul Manual Download Page 217

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Summary of Contents for GTSIO-520 Series

Page 1: ...OVERHAUL MANUAL FOR GTSIO 520 SERIES AIRCRAFT ENGINES FAA APPROVED MARCH 1981 FORM X 30045A...

Page 2: ...ginal June 1980 Original June 1980 Original June 1980 Original March 1981 Original June 1980 Original March 1981 Original March 1981 Original June 1980 Original PAGE B 1 B 2 B 3 B 4 B 5 B 6 B 7 thru B...

Page 3: ...in the Table of Limits and are referred to as reference numbers i 8 This chapter contains the Difference Data instructions for all engine models as listed in the Table of Contents This chapter consist...

Page 4: ...UIPMENT A 5 1 VI UNPACKING AND PREPARATION FOR SERVICE STORAGE OR SHIPMENT 6 1 Unpacking 6 2 Preparation for Service 6 3 Preparation for Storage VII DISASSEMBLY 7 1 Aircraft Parts and Accessories 7 2...

Page 5: ...A 9 3 9 12 Crankcase A 9 3 9 13 Crankshaft and Propeller Driveshaft A 94 9 14 Crankshaft and Counterweight Bushings A 94 9 15 Camshaft A 9 5 9 16 Connecting Rods A 9 5 9 17 Gears A 9 5 9 18 Pistons a...

Page 6: ...12 1 0 Alternator Assembly 12 11 Oil Cooler 12 12 Magneto and Accessory Drive 12 13 Oil Sump 12 14 Induction System 12 15 Fuel Injection System 12 16 Magneto Drive Gears 12 17 Placing Crankshaft in T...

Page 7: ...1 1 A 4 15 Starter Adapter A4 12 A4 16 Oil Pump Assembly A 4 13 A4 17 Cylinder and Piston Assembly A 4 14 A4 18 Crankcase Assembly A 4 15 A4 19 Camshaft Assembly A 4 17 A 4 20 Crankshaft Assembly A 4...

Page 8: ...A 5 8 Valve Spring Compressor CHAPTER B TABLE OF LIMITS LIST OF TABLES Table No 1 2 3 4 5 6 7 8 9 10 11 12 Table of Limits Tightening Torques General Use Tightening Torques Pipe Plugs Magnetic Partic...

Page 9: ...520 D C 2 1 General Information C 2 2 Detail Engine Specifications C 2 2 Operating Test Limits C 2 4 Major Overhaul Test Run C 2 5 Start Oil Consumption Determination C 2 6 Fuel Injection System C 2...

Page 10: ...moval and Disassembly 4 7 Assembly and Installation C4 7 Oil Cooler 4 7 Removal and Disassembly CA4 7 Assembly and Installation C 4 7 Oil Pump Assembly 4 7 Removal and Disassembly 4 7 Assembly and Ins...

Page 11: ...embly GTSIO 5 20 C C 1 11 C 1 4 Magneto and Accessory Drives GTSIO 520 C C 1 12 C 1 5 Fuel Manifold Valve Fitting Location GTSIO 520 C C 1 13 C 1 6 Control Valve Fitting Locations GTSIO 520 C C 1 14 C...

Page 12: ...ations GTSIO 520 M Fuel Pump Fitting Locations GTSIO 5 20 M Crankcasc Stud Setting Hcights GTSIO 520 M Page C 4 14 C 4 15 C 4 16 C 4 17 C 4 18 C4 19 C 5 8 C 5 9 C 5 10 C 5 1 1 C 5 12 C 513 C 6 8 C 6 9...

Page 13: ...r and Alternator may be obtained from Delco Remy Division General Motors Corporation Anderson Indiana 1 6 DEFINITION OF TERMS Front rear left and right as used in this manual refer to the engine as vi...

Page 14: ...anation in Inches Hex Hexagon hr Hour Left Side Side on which No s 2 4 and 6 cylinders are located Lbs Pounds Lock Wire Soft steel wire used to safety con nections etc Man Manifold or manometer Max Ma...

Page 15: ...e bayonet thermocouple Magneto temperature at coil hold down screw 75F 2400 F 4600 F 170F Installed in tapped holc in bottom of cylinder hcad Applicable only with downdraft cooling system PRESSURE LIM...

Page 16: ...al 18mm helical coil thread inserts are installed in upper and lower spark plug holes Exhaust valves are faced with a special heat and corrosion resistant material The solid valve stem tips are harden...

Page 17: ...struction and operation of the tappets are described in paragraph A 3 1d and figure A 4 10 Current tappets incorporate a new snap ring which is red in color The most discernible difference between the...

Page 18: ...f the adapter and a slot in the bottom of the clutch spring sleeve 5 Each cylinder wall and piston is lubricated by individual oil squirt nozzles These nozzles direct a continuous stream of oil at the...

Page 19: ...nit is enclosed in a shroud and is blast air cooled to help prevent vapor lock A fuel pressure switch connected to the fuel control unit actuates to cause the auxiliary fuel pump to operate at a high...

Page 20: ...mp will operate automatically when the auxiliary fuel pump switch is ON Incorporated on the fuel injection pump is a variable orifice controlled by an aneroid on the pump The aneroid is controlled by...

Page 21: ...SECTION IV ILLUSTRATIONS FIGURE A4 1 CYLINDER NUMBERING DIAGRAM A 4 1 6 4 2 5 3 1...

Page 22: ...FIGURE A 4 2 RIGHT FRONT VIEW GTSIO 520 C FIGURE A 4 3 LEFT REAR VIEW GTSIO 520 D A4 2...

Page 23: ...FIGURE A 44 RIGHT FRONT VIEW GTSIO 520 H FIGURE A 4 5 LEFT FRONT VIEW GTSIO 520 K A 4 3...

Page 24: ...FIGURE A 4 6 RIGHT FRONT VIEW GTSIO 520 L FIGURE A 4 7 RIGHT SIDE VIEW GTSIO 520 M A4 4...

Page 25: ...ump Driven Gear Scavenge Driven Gear Scavenge Driver Gear Idler Gear Assembly 13 14 15 16 17 18 19 20 21 22 23 24 25 Idler Gear Support Pin Left Magneto Drive Gear Right Magneto Drive Gear Starter Wor...

Page 26: ...FIGURE A 4 9 LUBRICATION SYSTEM DIAGRAM A 4 6...

Page 27: ...3 Housing Check Valve 4 Spring Check Valve 5 Plate Check Valve 6 Plunger 7 Socket 8 Ring Retaining 9 Oil Groove Exterior 10 Oil Inlet Body 11 Oil Groove Interior 12 Oil Inlet Plunger 13 Oil Reservoir...

Page 28: ...ock 3 Washer Plain 4 Cover 5 Gasket 6 Nut Hex 7 Washer Lock 8 Washer Plain 9 Nut Hex 10 Washer Lock 11 Washer Plain 12 Adapter Accessory 13 14 15 16 17 18 19 20 21 22 2 3 Gasket Bushing Seal Oil Gear...

Page 29: ...SUMP 1 Gasket Annular 2 Plug 3 Screw Ilex Head 4 Washer Lock 5 Washer Plain 6 Sump Assembly Oil 7 Gasket Oil Sump 8 Screw Hex Head 9 Screw Hex Head 10 Washer Plain 11 Tube Assembly Suction 12 Gasket...

Page 30: ...SSEMBLY Nut Hex Washer Lock Washer Plain Alternator Assembly Complete Gasket Alternator Pin Cotter Nut Slotted Hex 8 Key Woodruff 9 Washer Thrust 10 Gear Assembly Alternator Driven 11 Bushing 12 Sprin...

Page 31: ...Washer Lock Washer Plain Washer Plain Washer Plain O Ring O Ring 11 Washer Plain 12 Bolt 13 Cooler Engine Oil 14 Gasket Oil Cooler to Crankcase 15 Elbow Oil Inlet 16 Nut Hex 17 O Ring 18 Valve Assembl...

Page 32: ...ional 19 Key Woodruff 20 Screw 21 Washer Lock 22 Washer Plain 23 Cover Starter Adapter 24 Spacer 25 O Ring 26 Seal Oil 27 Ring Retaining 28 Gasket Cover to Adapter 29 Adapter Assembly Starter 30 Sprin...

Page 33: ...1 Pin and Plug Assembly By Pass Valve 22 Gear Assembly Oil Pump Driver 23 Pin Dowel 24 Gear Bevel Tach Drive 25 Key Woodruff 26 Body Assembly Scavenge Pump 27 Elbow 28 Plug 29 Gear Scavenge Pump Drive...

Page 34: ...using Nut Flanged Nut Flanged Cylinder Assembly O Ring Cylinder Base Key Valve Spring Retainer Roto Coil Assembly Exhaust Retainer Valve Spring Intake Spring Valve Outer Spring Valve Inner Retainer Va...

Page 35: ...FIGURE A4 18 CRANKCASE ASSEMBLY A 4 15...

Page 36: ...er Plain Nut Hex Washer Lock Washer Plain Screw Hex Head Eye Lifting Spacer Nut Hex Washer Lock Washer Plain Bolt Hex Washer Plain Nut Hex Washer Lock Washer Plain Screw Hex Head Valve Manifold and Br...

Page 37: ...FIGURE A 4 19 CAMSHAFT ASSEMBLY 1 Gear Bevel Governor Drivcn 2 Gear Bevel Governor Drive 3 Key Woodruff 4 Screw Hex Head 5 Gear Cam Cluster 6 Gear Camshaft 7 Camshaft A4 17 2 1...

Page 38: ...17 Screw 31 O Ring 18 Plate Quill Shaft 32 Bearing Prop Shaft 19 Gear Prop Shaft Drive 3 3 Washer Prop Shaft Thrust 20 Shaft Quill Prop Drive Gear 34 Screw Hex Head Drilled 21 Screw Hex Head 35 Gear I...

Page 39: ...FIGURE A 4 21 STUD LOCATION FIGURE A 4 22 INSPECTION RING SIDE CLEARANCE June 1980 A 4 19...

Page 40: ...D DIAMETER INCH ES NEW PARTS SERVICE SIZE MIN MAX LIMIT STANDARD 5 251 5 253 5 256 FIGURE A4 23 CLYINDER MACHINING DIMENSIONS A 4 20 June 1980...

Page 41: ...CAL COIL INSERT FIGURE A 4 25 INSTALLING SPARK PLUG HOLE HELICAL COIL INSERT FIGURE A 4 26 EXPANDING SPARK PLUG HOLE HELICAL COIL INSERT FIGURE A 4 28 VALVE ROCKER BEARING DIMENSIONS A 4 21 THESE SURF...

Page 42: ...EAMING OF REPLACEMENT BUSHING 1 00 L BUSHING 0005 IN MAX TWIST WITH NEW BUSHING BIG END FIGURE A 4 29 CONNECTING ROD AND BUSHING DIMENSIONS AND INSTALLATION 1 Connecting Rod Bushing Removal and Replac...

Page 43: ...SECTION A A FIGURE A 4 30 COUNTERWEIGHT WITH BUSHING FIGURE A4 31 INSTALLING NEW STARTER ADPATER NEEDLE BEARING A 4 23...

Page 44: ...FIGURE A 4 32 EXPLODED VIEW OF IGNITION SYSTEM A 4 24...

Page 45: ...Assembly to No 3 Upper Spark Plug 13 Cable Assembly to No 2 Lower Spark Plug 14 Cable Assembly to No 5 Upper Spark Plug 15 Cable Assembly to No 4 Lower Spark Plug 16 Spring 17 Terminal 18 Sleeve 19 S...

Page 46: ...E A 4 36 CHECKING ROCKER ARM CLEARANCE FIGURE A 4 34 VALVE SPRING INSTALLATION FIGURE A 4 35 ALIGNMENT OF TIMING MARKS FIGURE A 4 37 INSTALLING CYLINDER BAFFLE A 4 26 June 1980 FEELER GAGE 005 035 NOT...

Page 47: ...peat above on cylinders 2 3 8 Repeat above on cylinder 6 9 Tighten bolts No 27 28 44 45 46 47 to 650 in lbs in sequence shown 10 Repeat above on cylinder 1 11 Tighten bolts No 38 thru 61 to specified...

Page 48: ...FIGURE A 440 TIMING MARKS A4 28...

Page 49: ...IGURE A 441 INSTALLING OIL SEAL ON PROPELLER DRIVE SHAFT GEAR FIGURE A 442 PROPELLER DRIVE SHAFT GEAR OIL SEAL INSTALLED WITH RETAINING RING AND SPRING IN CAVITY FI A 429...

Page 50: ...ARTING VIBRATOR IGNITION SWITCH STARTER SWITCH RIGHT MAG SINGLE BREAKER LEFT MAG DOUBLE BREAKER LOWER SPARK PLUGS ENGINE FIRING ORDER 1 4 5 12 36 MAGNETO FIRING ORDER 12 3 4 56 FIGURE A4 43 WIRING DIA...

Page 51: ...azoo Michigan 49007 5 5 Fig A 5 8 depicts Borroughs Tool No 2838A used to compress the valve spring while removing or replacing the valve 5 6 The wrenches shown in Fig A 5 1 facilitate cylinder base n...

Page 52: ...R 52 COLD ROLLED STEEL BAR STOCK SIDE VIEW END VIEW 16 x 450 CHAMFER NOTE ALL DIMENSIONS IN INCHES FIGURE A 5 2 STARTER ADAPTER BEARING INSTALLER FIGURE A 5 3 PISTON RING COMPRESSOR BORROUGH S NO 5201...

Page 53: ...FIGURE A 5 6 SCHEMATIC DIAGRAM OF A DIFFERENTIAL PRESSURE TESTER FIGURE A 5 7 ENGINE TRANSPORTATION STAND FIGURE A 5 8 VALVE SPRING COMPRESSOR BORROUGH S NO 2838A A 5 3 A 5 4...

Page 54: ...d will do no harm hence it does not need to be flushed out b Before installing upper spark plugs coat their 18mm threads with only a film of engine oil After tightening the upper plugs insert the cabl...

Page 55: ...nadvertantly Care should be taken in removing gaskets from aluminum parts by scraping Such removal should be delayed until the part is to be cleaned 7 4 DISASSEMBLY STAND For greatest ease of disassem...

Page 56: ...nter cooler or adapter c Remove attaching parts along with the crankcase breather hose so that the induction system can be lifted off as an assembly and be disassembled on the bench Remove and discard...

Page 57: ...and remove Woodruff key 40 Remove bearing 41 from shaft 42 k See Section VIII to remove needle bearing 43 from adapter 29 7 14 OIL PUMP ASSEMBLY See Fig A4 16 a Loosen oil screen plug 4 4 by pass plu...

Page 58: ...on 7 16 CRANKCASE See Figure A4 18 a Remove oil gauge rod assembly 1 2 Remove one screw 3 and oil gauge rod guide assembly 4 5 6 b Unhook and remove oil cap retainer assembly 7 and gasket 8 Remove the...

Page 59: ...18 CRANKSHAFT ASSEMBLY See Figure A4 20 a Use wooden blocks under front and rear main journals of crankshaft during disassembly b Remove cotter pin 1 slotted nut 2 bolt 3 and separate connecting rod c...

Page 60: ...ation of stress at the scratch and may cause fatigue failure e Various hot and cold working solutions have been marketed for loosening carbon Any of these may be employed for that purpose if they do n...

Page 61: ...aft is rotated in a lathe at approximately 100 R P M First use crocus cloth moistened in kerosene then dry crocus cloth 8 7 CRANKCASE If possible the oil passages should be pressure flushed with the u...

Page 62: ...oxides do not form continuous cover or protect under lying metal thus oxidation of steel parts is progressive and destructive j PITTING OR SPALLING Small deep cavities with sharp edges may be caused i...

Page 63: ...s Chapter B and to Limits and Lubrication Chart to locate the reference number of each fit and the acceptable limits assigned to it Limits under the column heading New Parts are manufacturing limits A...

Page 64: ...r and vigorous brushing 9 10 ENAMEL COATINGS Ferrous parts when painted with gold enamel will be baked with infrared equipment for 15 minutes at 275 2850 F following application of each coat Magnesium...

Page 65: ...in the vee blocks and check the oil seal bearing surface gear propeller flange and all points of importance in accordance with the Table of Limits If it is necessary to replace the oil transfer tube...

Page 66: ...ird ring groove it is not necessary to remove light scores or discoloration from the exterior surfaces and it is not advisable to use abrasive including crocus cloth on the skirt since the cam ground...

Page 67: ...ny lifter body which exhibits any of these faults To test roughly for excessive diametrical clearance between hydraulic unit plunger and cylinder and to check valve wear in cylinder start dry plunger...

Page 68: ...cticut The manu facturer s Bulletin No 650 R lists both manual and power driven installing tools tang break off tools special taps and plug gauges A tap drill bulletin is also available from the manuf...

Page 69: ...tion use long nose pliers to bend the driving tang back and forth across the hole until it breaks off at the notch Coat a Heli Coil Corporation No 520 2 expanding tool threaded end with Alcoa thread l...

Page 70: ...flush with the rocker hub after dipping it in clean lubricating oil Ream the new bushing to the specified diameter It is advisable to plug the oil holes with beeswax before reaming Be sure to remove...

Page 71: ...ust face must be parallel to the parting surface within 0 002 inch full indicator reading CA UTION Before boring a new bushing plug its oil holes with beeswax to exclude chips from the adapteroil groo...

Page 72: ...ceed in consecutive order around the plates As each cable is inserted through the outlet plate 1 it must pass through a ferrule 2 The cable will then pass through the grommet 3 and into the eyelet 23...

Page 73: ...plied 11 3 FINAL CLEANING Immediately before assembling a group of parts they should be washed in or sprayed with a clean solvent and dried with dry compressed air 11 4 LUBRICATION Immediately after f...

Page 74: ...gasket 28 and cover assembly 23 26 27 32 on adapter and secure with attaching parts 20 21 22 Install O ring 25 spacer 24 and Woodruff key 19 then place torsional damper 18 over shaft and key Attach w...

Page 75: ...crankpins in accordance with position number stamped on bolt bosses Start with No 1 at the end opposite the flange and proceed in numerical order Obtain a set of 12 new crankpin bearing inserts and ma...

Page 76: ...ng inserts Install main bearings so that bearing ends project equally 11 14 FUEL INJECTION CONTROL AND AIR THROTTLE BODY ASSEMBLY See Figure A 4 44 CA UTION Use only a fuel soluble threadlubri cant on...

Page 77: ...bearings with clean engine lubricating oil d Install mount brackets on the left crankcase and attach assembly to engine stand Place a support under the casting 12 3 CRANKSHAFT ASSEMBLY a Lift cranksha...

Page 78: ...t not exceed those specified in the Table of Limits Chapter B c Place the idler gear in the left crankcase Apply clean engine lubricating oil liberally to all bare steel surfaces journals bearings and...

Page 79: ...this time Install the gasket 8 and oil filler cap assembly 7 m Apply a film of Tite Seal compound on gasket 15 and install with cover 14 Secure with four sets of attaching parts 11 12 13 n After cylin...

Page 80: ...ARTER ADAPTER See Figure A 4 15 a Coat gasket 1 1 on both sides with a film of Tite Seal compound and install it on crankcase studs b Install adapter assembly and secure with two sets of attaching par...

Page 81: ...e certain that adapter with studs on the adapter pad is positioned on the 1 3 5 crankcase Attach both adapters to crankcase with plain washers lock washers and nuts 6 7 8 9 10 11 12 13 OiL SUMP See Fi...

Page 82: ...ressure is felt on the thumb No 1 cylinder is coming up on the compression stroke b Remove plug 1 17 Figure A 4 18 from crankcase between fuel manifold valve and No 6 cylinder Rotate the crankshaft sl...

Page 83: ...cylinders Tighten to torque specified in Section VII NOTE Before final installation coat spark plug 18 mm threads with a film of thread lubricant d Install ignition harness assembly Insert ter minals...

Page 84: ...Hold down the socket with a pushrod or other ball end tool until the snap ring has been removed c Invert the tappet and catch the socket as it drops out d Insert a finger into the plunger and with dr...

Page 85: ...r and valve assembly into its bore The plunger will go in easily until its inner end has passed the lower body oil hole Unless it is very badly worn or the check valve is leaking it will stop there In...

Page 86: ...ee bolts washers and nuts The adapter may incorporate the two gauges It may be made of steel plate and standard iron pipe fittings The cleaning solution should enter through the normal cooler outlet p...

Page 87: ...lding rod 6 Remove all traces of welding flux by wiping all accessible areas with a clean cloth wet with hot water then scrub with a stiff bristle brush and hot water and wipe again with a wet hot clo...

Page 88: ...Remy Prestolite Accessory Manufacturer Address Alternator Teledyne Teledyne Continental Motors Crittenden P 0 Box 90 Mobile Alabama 36601 Magnetos Bendix United Motors Service General Motors Building...

Page 89: ...rubber mount bushing dimensions shown in the installation drawings The crankshaft should be at least five feet above the cell floor so that the club will not cause excessive air disturbance at floor...

Page 90: ...upper elbow projection from left side of fuel pump shroud Connect fuel pump to supply tank return line to upper elbow projecting from right side of fuel pump Connect fuel pressure gauge line to the fi...

Page 91: ...rhaul with the engine installed in the aircraft using a flight propeller has become evident and we therefore propose the following 1 In hot weather select the coolest time of day for both ground run i...

Page 92: ...ring in groove Side Clearance Third piston ring standard gap Tension Fourth piston ring in groove Side Clearance Fourth piston ring standard gap Tension Fifth piston ring ingroove Side Clearance Fifth...

Page 93: ...ndicator reading Camshaft gear on camshaft flange Dameter Governor drive gear on camshaft Diameter CRAN KCASE Thru bolts incrankcase Diameter Hydraulic lifter incrankcase Diameter Governor drive shaft...

Page 94: ...eal in fuel pump adapter Diameter GEAR BACKLASH Crankshaft gear and camshaft gear Backlash Prop drive shaft and prop reduction gear Backlash Crankshaft gear and idler gear Backlash Idler gear and magn...

Page 95: ...le Limit 46 5 lbs 5 0 lbs 73 lbs 40 lbs 118 lbs 46 lbs New Parts 120 F 168 F 49 6 lbs 5 3 lbs 78 lbs 43 lbs 126 lbs 49 lbs Use 0 005 inch oversize pistons and 0 005 inch oversize rings Clearances for...

Page 96: ...61 FIGURE B 1 LIMITS CHART CHART 1 B 5...

Page 97: ...FIGURE B 2 LIMITS CHART CHART 2 B 6 JUNE 1980...

Page 98: ...82 83 84 T 12 FIGURE B 3 LIMITS CHART CHART 3 B 7...

Page 99: ...1067 81 107 FIGURE B4 LIMITS CHART CHART 4 B 8 74...

Page 100: ...gasket 1 3 4 16 1 500 520 41 6 43 3 Alternator mounting nut 5 16 18 4 150 180 12 5 1 5 0 Alternator shaft nut 5 8 32 1 450 500 37 5 41 7 T11 1 Spark plugs 18 mm 12 300 360 25 0 30 0 T12 3 Starter shaf...

Page 101: ...at low limit and tighten nut to first hole beyond this torque However on connecting rod nuts the torque limits must be maintained Replace nut and repeat as required In no case shall con necting rod nu...

Page 102: ...inal drilled hole edges Fatigue cracks Piston pin Circular or 1000 Shear planes ends Fatigue cracks Longitudinal center Rocker arms On Conductor Bar 1000 Pad socket under Fatigue cracks and Single Bet...

Page 103: ...Bearing Diameter Hole for Transfer Sleeve Small Outside Diameter Large Inside Diameter Journal Diameter Camshaft Bearing Diameter Crankshaft Bearing Diameter Reduction Gear Bearing Diameter Prop Shaft...

Page 104: ...urled Drum Diameter Clutch Drum Support Diameter Outside Diameter Inside Diameter Sleeve Front End I D Inside Diameter Shaft Diameter Shaft Hole Diameter Driven Gearshaft Diameter Driver Gearshaft Hol...

Page 105: ...ess caused by burning Cracks and broken areas If attaching nuts were found loose at dis assembly test for flatness of mounting face SPECIAL CONSIDERATIONS Sec Paragraph 6 6 Defects not permissible aft...

Page 106: ...hrough stellite face of exhaust valve or entered rounded edge on intake valve hood Use height gauge to detect stretch and check for reduction due to tip grinding Scoring Obstruction Side clearance bet...

Page 107: ...out at center journal end wobble on face of flange Teeth Attempt to hand only pull out by Burning scoring wear enough to alter profile Damaged or dirty threads Diameters ing scoring burn Thickness ex...

Page 108: ...ugh to alter profile Diameter scoring Roughness wear in tang notches Diameter scoring fit of rear bearing between camshaft flanges Inspect visually galleries main and camshaft bearing supply holes usi...

Page 109: ...toolmaker s square to check studs suspected of being bent Inside diameter scoring Roughness or excessive play Attempt to rock and pull out by hand only Look for bent blade obliterated FULL and LOW ma...

Page 110: ...rtion Look for damaged corners Damaged threads dented tube cracks in tube distorted or plugged filter Cracks scratches on machined surfaces restrictions in oil holes Look for scoring meas ure diameter...

Page 111: ...centered and aligned Damaged threads punc tured screen out of round pilot cup Cracks scratches on machined surfaces Measure diameters and compare with bushing diameters Scoring burning or wear enough...

Page 112: ...seness Cracks scratches on machined surfaces da maged mounting holes Look for scoring Measure diameter See that oil seal was removed without damage to casting Visual for damage and obvious leakage Sco...

Page 113: ...Measure outside diameter and compare with bore diameter Make sure that new plug was installed after mag netic particle inspection of gear and visual inspection for cleanliness of center bore Check fo...

Page 114: ...ng Look for damaged corn ers Check for freedom of rotation Visually inspect for any signs of damage Measure bore diameters Observe that old oil seal has been removed without damage to casting bore Loo...

Page 115: ...TIFICATION TYPICAL PITCH DIA OF MARKS ON COARSE THREAD END COLOR TYPICALCOARSE THREAD PART NO inches STAMPED MACHINED CODE XXXXXX STANDARD NONE NCNE XXXXXXP003 003 RED XXXXXXPOO6 006 BLUE XXXXXXP009 0...

Page 116: ...x 5 16 24 11 16 4 17 5 16 18 x 5 16 24 3 4 2 18 5 16 18 x5 16 24 7 8 4 19 3 8 16 x 3 8 24 1 3 16 2 20 Idler Pin Pad 1 4 20 x 1 4 28 5 8 2 21 Starter Drive Pad 5 16 18 x 5 16 24 13 16 2 22 Fuel Pump P...

Page 117: ...iameter TABLE 11 CRANKSHAFT AND CRANKCASES ENGINE MODEL GTSIO 520 C GTSIO 520 D GTS IO 520 H Crankcase Studding Assembly 642132 642133 GTSIO 520 L 642135 GTSIO 520 M GTSIO 520 N 643724 Crankshaft Damp...

Page 118: ...fied Flushing of oil cooler Engine storage MATERIAL OR TRADE NAME Corrosion preventive compound Molyshield grease Thread lubricant and sealing compound Grade 30 Aviation lubricating oil Dry lubricant...

Page 119: ...ratio Specific differences are the induction system and fuel injection system While certain parts may have a different part number and different physical characteristics for example the reduction gear...

Page 120: ...epower at 3200 RPM 2400 Prop RPM Limiting Manifold Pressure Sea Level Inches Hg at 3200 RPM Critical Altitude Inches Hg Maximum Recommended Cruise Horsepower at 2800 RPM 2100 Prop RPM Limiting Manifol...

Page 121: ...Drive Autopilot 1 5 1 Rotation Counterclockwise Propeller Governor Drive Ratio to Crankshaft 0 809 1 Rotation Clockwise Spark Plug See Service Bulletin M77 10 Spark Occurs Degrees BTC Both Magnetos 22...

Page 122: ...r Engine Intake Air Temperature S C Inlet s Oil Pressure at Maximumi Rated Power Engine Oil Temperature 1750 185 F Oil Pressure at Idle Engine Oil Temperature 140 150 F t Timing of Engine and Toleranc...

Page 123: ...op engine drain oil weigh in oil for propeller transfer tube during all testing oil consumption determination and replace in engine START OIL CONSUMPTION DETERMINATION Time Minutes 10 30 5 10 RPM 3200...

Page 124: ...t Removal and replacement of any of these parts could allow small metal shavings to become lodged in the equipment causing a malfunction If it should be necessary to replace any connection or fitting...

Page 125: ...ining two hoses 11 and clamps 10 over the ends of tubes 15 16 Slide tube assemblies 5 12 13 in place space hoses and tighten clamps g Slide hose clamp sleeve 2 over each end of flexible hose 4 Install...

Page 126: ...inlet adapter P N 628675 replaced by steel adapter P N 640793 IMPROVED VALVE STEM AND GUIDE LUBRI CATION To provide better lubrication to exhaust valve stems and exhaust valve guides improved exhaust...

Page 127: ...15 Washer Wave 16 Rod Link 17 Screw 18 Shroud Top 19 Screw 20 Washer Tab 21 Control 22 Bumper Shroud 23 Shroud Bottom 24 Nut Tinnerman 25 Grommet 26 Throttle Body 27 Nut Castle 28 Pin Cotter 29 Screw...

Page 128: ...amp Hose 15 Tube Assembly Intake Manifold No 1 Cylinder 16 Tube Assembly Intake Manifold No 2 Cylinder 17 Tube Assembly Intake Manifold No 3 and 4 Cylinders 18 Clamp Hose 19 Hose Balance Tube 20 Tube...

Page 129: ...IGURE C 1 3 CRANKCASE ASSEMBLY 1 Clamp Breather Hose 2 Hose 3 Hose 4 Tee Breather 5 Screw 6 Nut 7 Washer 8 Spacer 9 Eye Engine Lifting Front 10 Bolt 1 1 Nut 12 Washer 13 Eye Engine Lifting Rear C 1 11...

Page 130: ...VES Nut Hex Washer Lock Washer Plain Cover Gasket Nut Hex Washer Lock Washer Plain Nut Hex Washer Lock 11 Washer Plain 12 Adapter Accessory 13 Gasket 14 Bushing 15 Seal Oil 16 Gear 17 Bushing Coupling...

Page 131: ...FIGURE C 1 5 FUEL MANIFOLD VALVE FITTING LOCATIONS A B I c D E GTSIO 520 C PLUG 90 Elbow 1800 NIPPLE UNION 45 0 EIbow C 1 13...

Page 132: ...6 CONTROL VALVE FITTING LOCATIONS C 1 14 A B C D E Mixture Fuel Inlet Return and Fuel To Pump Pressure Conn Outlet 9 0 Elbow 180 TEE 180 NIPPLE GTSIO 520 C PLUG NIPPLE PLUG NIPPLE REDUCER RED UCER CON...

Page 133: ...FIGURE C 1 7 FUEL PUMP FITTING LOCATIONS C 1 15 F A C 0 B E A B C D E F 900 Elbow 900 Elbow 900 Elbow GTSIO 520 C 75 90 Elbow 90 285 345 PLUG 9 0 Elbow 0 Connector Connector Connector...

Page 134: ...ETTING HEIGHTS Setting Location Thread Sizes Heights Model C 1 Magnego Accessory Drive Adapter 5 16 18 x 5 16 24 3 4 6 2 Magncto Accessory Drive Adapter 3 8 16 x 3 8 24 13 16 2 3 Engine Mount Legs 3 8...

Page 135: ...37847 632590 633091 632188 633274 4 635089A1 633090 3 637847 633091 636414 632188 633274 4 634735A1 4 637847 633090 636414 632188 633274 4 635089A1 3091 633090 5 637847 633091 632188 633274 4 634735A1...

Page 136: ...ion Looking Forward Propeller Attachment Flange Bore Inches Stroke Inches Displacement Cubic Inches Compression Ratio Turbosupercharged Maximum RPM Oil SAE Number Above 400 F Below 400 F Oil Sump Capa...

Page 137: ...l Pressure Lbs Per Sq Inch Unmetered 450 Propeller RPM 6 0 PSI Auxiliary Pump Resistor 450 Propeller RMP 5 5 25 PSI Maximum Metered Fuel Pressure 3 9 5 Hg MP 2 275 Propeller RPM 16 0 17 0 PSI Metered...

Page 138: ...at Maximum Rated Power Engine Oil Temperature 1750 185 F Oil Pressure at Idle Engine Oil Temperature 140 1500 F S Timing of Engine and Tolerance t u v W T C Air Inlet Air Filter Pressure Drop T C Air...

Page 139: ...3200 8 5 3400 25 100 Power 42 0 43 0 9 5 3000 68 5 Power 257 BHP 34 8 35 8 10 5 2600 44 8 Power 168 BHP 33 5 34 5 11 10 600 25 Idle Cooling Period NOTE Engine oil pressure must be supplied to NOTE St...

Page 140: ...5 compared to the 1 31 for the old pump g Pump and shroud parts 53 thru 64 were original equipment on specifications 1 thru 10 If it is neccssary to replace a pump of this type with the latest pump it...

Page 141: ...t it is possible to crack the turbocharger oil inlet adapter Teledyne Continental Motors P N 628675 and cause an oil leak by improperly torqueing the retaining bolts or by overtorqueing the steel inle...

Page 142: ...tinuous Feed Lifters Exhaust New Style P N 640941 These new parts went into production on the following engine serial numbers and all subsequent The change in the exhaust rocker arm is in the angle of...

Page 143: ...dapter Elbow 25 Retainer 26 Shroud Bottom 27 Bumper Rubber 28 Control Assembly 29 Screw 30 Washer 31 Controller 32 Gasket Controller 33 Bushing 34 Lever 35 Pin Tubular 36 Air Throttle 37 Screw 38 Nut...

Page 144: ...ve 13 Insulator 14 Inter cooler 15 Seal 16 Bracket 17 Manifold Intake 18 Clamp 19 Hose 20 Nut Plain Hex 21 Washer Lock 22 Washer Plain 23 Tube intake 24 Flange Intake 25 Gasket Intake 26 Tube Air Fuel...

Page 145: ...27 FIGURE C 2 3 FUEL MANIFOLD VALVE FITTING LOCATIONS C 2 11 1800 C Do 1800 I A lI B I I DI I GTSIO 520 03 900 Elbow 3400 1900 Elbow 200 iNIPPLE UNION 1450 Elbow 1900 Elbow 110c...

Page 146: ...ITTING LOCATIONS C 2 12 2700 90 B 161 1 A S C 0 E Mixture Fuel Inlet Return and Fuel To Pump Pressure Conn Outlet 900 Elbow 1800 NIPPLE GTSIO 520 D PLUG ADAPTER PLUG EE CON9NECTOR ADAPTER 450 Elbow 3Q...

Page 147: ...0a FIGURE C 2 5 FUEL PUMP FITTING LOCATIONS June1980 C 2 13 27 n0 1800 D E 1800 I I Al B Ic D E GTSIO 520 D TEE 300 450 Elbow 00 CONNECTOR PLUG 900 Elbow 00...

Page 148: ...8 5 Power RPM 3000 10 Flow Limits 137 144 lbs hr 44 8 Power RPM 2600 10 Flow Limits 90 96 lbs hr a This chart is based on 701F injector fuel temperature For every 100 F increase in injector inlet fuel...

Page 149: ...S 1 Obtain actual maximum rated RPM 2 Determine fuel pressure limits for 100 maximum power by reading directly above actual maximum rated RPM point EXAMPLE 100 Power Fuel Pump Pr Limits 3400 10 RPM 30...

Page 150: ...ctly above the actual maximum rated RPM point 3 Determine metered fuel pressure limits for 100 68 5 and 44 8 maximum power by reading directly above actual maximum rated RPM point EXAMPLE 100 power 34...

Page 151: ...ame as the procedures for the basic GTSIO 520 except for the specific differences noted by this Difference Data FOR THE MODEL GTSIO 520 H Section The fuel injection system and the induction system for...

Page 152: ...ve Ratio Propeller Shaft Rotation Looking Forward Propeller Attachment Flange Bore Inches Stroke Inches Displacement Cubic Inches Compression Ratio Turbosupercharged Maximum RPM OilSANumber Above 40 F...

Page 153: ...7 0 018 Firing Order 14 5 2 3 6 Fuel Pressure Lbs Per Sq Inch Unmetered 450 Propeller RPM 6 0 PSI Auxiliary Pump Resistor 450 Propeller RMP 5 5 25 PSI Maximum Metered Fuel Pressure 39 5 Hg MP 2275 Pro...

Page 154: ...e at Maximum Rated Power Engine Oil Temperature 175 185 F Oil Pressure at Idle Engine Oil Temperature 140 150 F s Timing of Engine and Tolerance t u v w T C Air Inlet Air Filter Pressure Drop T C Air...

Page 155: ...25 100 Power 68 5 Power 257 BHP 44 8 Power 168 BHP Idle Cooling Period T C Outlet Pr Hg Reference 42 0 43 0 34 8 35 8 33 5 34 5 NOTE Engine oil pressure must be supplied to propeller transfer tube dur...

Page 156: ...ent parts In the event the pump must be replaced the fuel pump drive gear will have to be C 3 6 replaced and the coupling will have to be added It will also be necessary to change the crankcase mounti...

Page 157: ...established at final assembly IMPROVED VALVE STEM AND GUIDE LUBRICATION To provide better lubrication to exhaust valve stems and exhaust valve guides improved exhaust rocker arms and exhaust lifters...

Page 158: ...perly torqueing the retaining bolts or by overtorqueing the steel inlet oil line fitting To preclude the possibility of this occurring the adapter material has been changed from aluminum to steel and...

Page 159: ...25 27 5 19 j 23 FIGURE C 3 1 FUEL INJECTION SYTEM C 3 9 2...

Page 160: ...Assembly Screw Nut Type J 39 Screw 40 Washer Tab 41 Shroud Assembly Top 42 Adapter Elbow 43 Retainer 44 Shroud Assembly Bottom 45 Bumper Rubber 46 Control Assembly 47 Screw 48 Washer Lock 49 Controlle...

Page 161: ...13 Insulator 14 Inter cooler 15 Seal 16 Bracket 17 Manifold Intake 18 Clamp 19 Hose 20 Nut Plain Hex 21 Washer Lock 22 Washer Plain 23 Tube Intake 24 Flange Intake 25 Gasket Intake 26 Tube Air Fuel No...

Page 162: ...ROL VALVE FITTING LOCATIONS C 3 12 2700 B 2700 1800O A B C D E Mixture Fuel Inlet Return and Fuel To Pump Pressure Conn Outlet 900 Elbow 18O 0 NIPPLE GTSIO 520 H PLUG TEE 30 PLUG TEE ADAPTER eeConnect...

Page 163: ...FIGURE C 3 4 MANIFOLD VALVE FITTING LOCATIONS C 3 13 no nO A 1800 2700 E i 800 I I Al 81 cD E GTSIO 520 H 900 Elbow 434Q0 900 Elbow 200 NIPPLE UNION 450 Elbow 900 Elbow i 1100...

Page 164: ...00 Do A D B I0 70 2700 90go EE FIGURE C 3 5 FUEL PUMP FITTING LOCATIONS C 3 14 B 10 E...

Page 165: ...injector fuel temperature For every 101F increase in injector inlet fuel temperature subtract 1 lb of fuel from the curve value For every 101F decrease in injector inlet fuel temperature add 1 lb of f...

Page 166: ...INSTRUCTIONS 1 Obtain actual maximum rated RPM 2 Determine fuel pressure limits for 100 maximum power by reading directly above actual maximum rated RPM point EXAMPLE 100 Power Fuel Pump Pr Limits 340...

Page 167: ...ual maximum rated RPM point EXAMPLE 100 power 3400 10 Metered Fuel Pr Limits 16 5 17 5 PSI hIi fiT K Mjatorc ri Pii Proq c iiro I imitc nt tArY 9F RPPA IH rIp Pl 4a0 P S I L 6 0 Z d57 60 22 10 07_0_ 0...

Page 168: ...MODEL GTSIO 520 K Overhaul and test procedures for the model covered in this section are the same as the procedures for the basic GTSIO 520 except for the specific differences noted by this Difference...

Page 169: ...uous flow a complete exhaust system DETAIL ENGINE SPECIFICATIONS Rated Maximum Take off Horsepower 435 Rated Maximum Continuous Horsepower 435 Rated Speed Crank RPM 3400 Rated Speed Prop RPM 2265 Rate...

Page 170: ...tation Counterclockwise Propeller Governor Drive Ratio To Crankshaft 0 809 1 Rotation Clockwise Firing Order 14 5 2 36 Oil Pressure PSI Normal 30 60PSI Maximum 100 PSI Idling Minimum 10 PSI Oil Temper...

Page 171: ...ted power engine oil temperature 1400 1500 F 30 psi minimum Timing of engine and tolerance Left 200 BTC 10 Right 200 BTC 10 Turbocharger air inlet air filter pressure drop 6 0 H2 0 max Turbocharger ai...

Page 172: ...peller transfer tube during all testing engine START OIL CONSUMPTION DETERMINATION Time Minutes 10 30 5 10 145 RPM Warm Up 3400 25 2400 900 25 Power 100 Power See a Check Magnetos See b Idle Cooling A...

Page 173: ...of nozzles should not be attempted unless flow test equipment is available NOTE Air throttle assembly and controller assembly are calibrated as an integral unit They should not be disassembled unless...

Page 174: ...ler 8 b Remove spacers 3 4 O ring 12 two gaskets 1 and spacer 2 c Remove oil temperature control valve 20 d Remove bolt 7 and washer 6 and separate turbo mounting bracket from crankcase ASSEMBLY AND I...

Page 175: ...lbow and Riscr Assembly 3 Elbow Assembly 4 Exhaust Riser Assembly 5 Exhaust Riser Assembly 6 Exhaust Riser Assembly 7 Exhaust Riser Assembly 8 Packing 9 Clamp Assembly 10 Adapter 11 Bolt 12 Washer 13...

Page 176: ...NT 1 Electric Heater Assembly 2 Heating Element Housing 3 Tube Assembly 4 Primer Nipple Assembly 5 Tee 6 Solenoid Valve 7 Mounting Bracket 8 Washer Lock 9 Screw 10 Nipple 11 Hose Assembly 12 Clamp Ass...

Page 177: ...ter Washcr Washer Wave Nut Elastic Stop Rod End Special 13 14 15 16 17 18 19 20 21 22 23 24 Nut Spring Rod and Link Assembly Gasket Controller Controller Washer Screw Bushing Lever Pin Tubular 0 Ring...

Page 178: ...FIGURE C44 INDUCTION SYSTEM CA 1l...

Page 179: ...4 Flange Intake Manifold 35 Tube Intake Manifold 36 Washer Plain 37 Washer Lock 38 Nut Plain Hex 39 Hose 40 Clamp 41 Tube Assembly Air 42 Sleeve Assembly Injection Nozzle 43 Seal Compression 44 Washer...

Page 180: ...I 10 11 FIGURE C 4 5 OIL SUMP 1 Gasket 2 Tube Assembly 3 Washer 4 Bolt 5 Bolt 6 Gasket 7 Spacer 8 Gasket 9 Sump Assembly 10 Washer 11 Washer Lock 12 Screw 13 Gasket 14 Plug C 4 13 14...

Page 181: ...2 Spacer 3 Washer 4 Washer 5 Bracket Turbocharger Mounting 6 Washer Lock 7 Screw 8 Oil Cooler 9 Washer 10 Washer Lock 11 Nut 12 O Ring 13 Bolt 14 Bolt 15 Nut 16 Elbow 17 Nut 18 O Ring 19 Gasket 20 Va...

Page 182: ...per 17 Nut Adj usting Screw 18 Valve Oil By Pass 19 Spring Oil By Pass 20 Gasket Copper 21 Plug and Pin Assembly Oil By Pass 22 Shaftgear 23 Pin Dowel 24 Key Woodruff 25 Body Scavenge Pump 26 Gear Dri...

Page 183: ...18 x 5 16 24 1 1 64 1 3 Oil Cooler Mount Pads 5 16 18 x 5 16 24 4 15 16 1 4 Oil Cooler Mount Pads 5 16 18 x 5 16 24 4 7 16 1 Early crarnkcaiss cidntifled by PIN 640034 steel stamped above the crankcas...

Page 184: ...00 00 FIGURE C 4 9 FUEL PUMP FITTING LOCATIONS I III A I B I CI D E I CONNECTOR 900 Elbow 1200 450 Elbow 113 0 P 900 Eibow 900 450 Elbow 1800 C 4 17 00 C 2 70 I I c...

Page 185: ...fib FIGURE C4 10 FUEL MANIFOLD FITTING LOCATIONS C 4 18 1800 1800 A B C D E 900 Elbow 900 900 Elbow 3300 NIPPLE UNION 450 Elbow 900 Elbow 2050...

Page 186: ...Do FIGURE C 4 11 AIR THROTTLE CONTROLLER FITTING LOCATIONS C4 1 9 C4 20 00...

Page 187: ...L GTSIO 520 L Overhaul and test procedures for the model covered in this section are the same as the procedures for the basic GTSIO 520 except for the specific differences noted by this Difference Dat...

Page 188: ...GINE SPECIFICATIONS Rated Maximum Take off Horsepower 375 Rated Maximum Continuous Horsepower 375 Rated Speed Crank RPM I 33 50 Rated Speed Prop RPM 22 33 Rated Manifold Pressure in Hg 39 0 Propeller...

Page 189: ...Rotation Counterclockwise Propeller Governor Drive Ratio To Crankshaft 809 1 Rotation Clockwise Firing Order 14 5 2 3 6 Oil Pressure PSI Normal 30 60 PSI Maximum 100 PSI Idling Minimum 10 PSI Oil Tem...

Page 190: ...ure at Maximum Rated Power Engine Oil Temperature 175 185 F Oil Pressure at Idle Engine Oil Temperature 140 150 F s Timing of Engine and Tolerance t u v w T C Air Inlet Air Filter Pressure Drop T C Ai...

Page 191: ...200 1500 2100 2600 2800 3000 3200 3350 3040 2600 700 25 100 Power 75 Power 282 BHP Idle Cooling Period r c Outlet PR Hg Reference 41 5 42 5 3 5 0 36 0 NOTE Engine oil pressure must be supplied to prop...

Page 192: ...to bracket with insulator 10 sleeve 9 washer 8 and screw 7 C place tubes Install new seal 35 on sleeves 34 and on nozzle Attach sleeves to air manifold 26 Install rubber washer 37 and plain washer 36...

Page 193: ...se studs Lubri cate coupling 34 and install in fuel pump drive gear Mesh fuel pump 33 with coupling and mount on crankcase studs Secure with two sets of attaching parts 3 0 31 3 2 e Install copper was...

Page 194: ...17 Clamp 18 I ose 19 Nut 20 Lockwasher 21 Washer 22 Flange 23 Tube 24 Tube Cyl 5 25 Gasket 26 Air Manifold Tube 27 Air Manifold Tube 28 Seal 29 Air Manifold Tube 30 Seal 31 Tube Assy 32 Seal 33 Junct...

Page 195: ...Link Assy 14 15 16 17 18 19 20 21 22 23 24 25 26 Nut Elastic Stop Washer Rod End Spring Rod and Link Assy Screw Tab Washer Control Assy Screw Lock Washer Controller Assv Gasket Bushing 27 28 29 30 3 1...

Page 196: ...C FIGURE C 5 3 MANIFOLD VALVE FITTING LOCATIONS C 5 10 nO A 1800 00 270 E 1800 I I AlI B I c I I EI GTSIO 520 L 900 Elbow 34Q0 1900 Elbow 20 1 NIPPLE UNION 450 Elbow 90 low 1100 I on...

Page 197: ...IGURE C 54 CONTROL VALVE FITTING LOCATIONS C 5 11 2700 C U 1800 A B C D E Mixture Fuel Inlet Return and Fuel To Pump Pressure Conn Outlet GTSIO 520 L PLUG TEE 1800 450 Elbow 900 Elbow 450Elw i2700 225...

Page 198: ...SIO 520 L SPEC 1 90 Elbow 2980 900 Elbow 2840 Adapter Tee 00 450 Elbow 1050 90 Elbow 900 900 Elbow 0 SPEC 2 A 90 Elbow 2980 B 900 Elbow 284 C Adapter Tee 0 D 900 Elbow 900 E 900 Elbow 900 F 900 Elbow...

Page 199: ...FIGURE C 5 6 CRANKCASE STUD SETTING HEIGHTS June 1980 C 5 13 Setting Location Thread Sizes Heights Model L 1 Fuel Pump Mount Pads 5 16 18 x 5 16 24 25 2 2 Oil Pump Mount Pads 5 16 18 x 5 16 24 6 1 4 1...

Page 200: ...00 Power RPM 3350 t1 10 Flow Limits 255 265 Lbs hr 75 Power RPM 3040 110 Flow Limits 176 186 lbs hr a This chart is based on 700 F injector fuel temperature For every 101F increase in injector inlet f...

Page 201: ...TRUCTIONS I Obtain actual maximum rated RPM 2 Determine fuel pressure limits for 100 maximum power by reading directly above actual maximum rated RPM point EXAMPLE 100 Power Fuel Pump Pressure Limits...

Page 202: ...vation as the manifold gage and without influence of differential head in gage line NOTE Tolerance on metered fuel pressure 0 30 PSI Check at 17 12 8 PSI and Idle 18 ___ a_ 16_ _ _ _ _ __ _ _ __ _ NOT...

Page 203: ...EL GTSIO 520 M Overhaul and test procedures for the model covered in this section are the same as the procedures for the basic CTSIO 520 except for the seific differences noted by this Difference Data...

Page 204: ...the engine DETAIL ENGINE SPECIFICATIONS Model GTSIO 520 M Rated Maximum Take off Horsepower 375 Rated Maximum Continuous Horsepower 375 Rated Speed Crank RPM 3 350 Rated Speed Prop RPM 2233 Rated Man...

Page 205: ...ump Drive Autopilot 1 14 1 Rotation Counterclockwise Propeller Governor Drive Ratio To Crankshaft 809 1 Rotation Clockwise Firing Order 14 5 2 3 6 oil Pressure PSI Normal See Operating Limits Maximum...

Page 206: ...e Desired Range r Oil Pressure at Maximum Rated Power Engine Oil Temperature 1750 1850 F Oil Pressure at Idle Engine Oil Temperature 1400 1500 F s Timing of Engine and Tolerance T C Air Inlet Air Filt...

Page 207: ...0 2600 5 10 2800 6 10 3000 7 10 3200 8 5 3350 9 5 3040 10 5 2600 11 10 700 NOTE Engine oil pressure must be supplied to propeller transfer tube during all testing RPM 100 Power 75 Power 282 BHP Idle C...

Page 208: ...take manifold with nuts 7 and washers 6 Secure to bracket 8 with nut and washer 10 9 c Install new seal 35 on sleeves 34 and place on nozzle Attach sleeves to air manifold tubes 26 Install rubber wash...

Page 209: ...ase studs Lubricate coupling 34 and install in fuel pump drive gear Mesh fuel pump 3 3 with coupling and mount on crankcase studs Secure with two sets of attaching parts 30 31 32 e Install copper wash...

Page 210: ...Hose 19 Nut 20 Lockwasher 21 Washer 22 Flange 23 Tube 24 Tube Cyl 5 25 Gasket 26 Air Manifold Tube 27 Air Manifold Tube 28 Seal 29 Air Manifold Tube 30 Seal 31 Tube Assy 32 Seal 33 Junction Assy 34 Sl...

Page 211: ...g Adjustment Spring Rod and Link Assy 14 Nut Elastic Stop 15 Washer 16 Rod End 17 Spring 18 Rod and Link Assy 19 Screw 20 Tab Washer 21 Control Assy 22 Screw 23 1Lock Washer 24 Controller Assy 25 Gask...

Page 212: ...nO A FIGURE C 6 3 MANIFOLD VALVE FITTING LOCATIONS C 6 10 18001 2700 E 1800 A I I C I D I E GTSIO 520 M 900 ElIbow 3400 9 0 El bow 120 1NIPPLE UNION 450 7Elbow 90 Elbow 1100...

Page 213: ...URE C 64 CONTROL VALVE FITTING LOCATIONS C 6 11 B IC LI 1800 A B C D E Mixture Fuel Inlet Return and Fuel To Pump Premure Conn Outlet GTSIO 520 M PLUG TEE 1800 900Elbow 900 Elbow 80 450 Elbow f 1900 3...

Page 214: ...F rTTIN G go T 1800 FITTING ORIENTATION FIGURE C 6 5 FUEL PUMP FITTING LOCATIONS A 900 Elbow 2980 B 900 Elbow 2840 C Adapter Tee 00 D 900 Elbow 900 E 900 Elbow 900 F 900 Elbow 00 C 6 12...

Page 215: ...2 1 FIGURE C 6 6 CRANKCASE STUD SETTING HEIGHTS June1980 C 6 13 Setting Location Thread Sizes Heights Model M 1 Fuel Pump Pad 5 16 18 x 5 16 24 3 4 2 2 Oil Cooler Mount Pad 5 16 18 x 5 16 24 6 1 4 1...

Page 216: ...RPM point EXAMPLE GTSIO 520 M 100 Power RPM 3350 10 Flow Limits 255 265 Lbs hr 75 Power RPM 3040 1 0 Flow Limits 176 186 lbs hr a This chart is based on 701F injector fuel temperature For every 10OF i...

Page 217: ...ge ventedtoatmospheric pressure CHART INSTRUCTIONS 1 Obtain actual maximum rated RPM 2 Determine fuel pressure limits for 100 maximum power by reading directly above actual maximum rated RPM point EXA...

Page 218: ...d without___ influence of differential head in gage line NOTE Tolerance on metered fuel pressure I0 30 PSI Check at 17 12 18 _ 8 PSI and Idle a 16_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ LU NOTE Specific we...

Page 219: ...O 520 N Overhaul and test procedures for the model covered in this section are the same as the procedures for the basic GTSIO 520 except for the specific differences noted by this Difference Data Sect...

Page 220: ...ferenced to compressor discharge absolute pressure Fuel metering is accomplished by engine speed pump output and throttle position The fuel control unit is mounted on the throttle body The metering va...

Page 221: ...ction Magneto Drive Ratio to Crankshaft 1 5 1 Magneto 1 Drive Direction Clockwise Tachometer Drive Ratio To Crankshaft 5 1 Rotation Clockwise Starter Drive Ratio To Crankshaft 32 1 Rotation Counterclo...

Page 222: ...el Grade to be used k Idling RPM and Tolerance l Manifold Pressure Maximum Rated Power Idle m Magneto Check at 2100 RPM n Crankcase Pressure 2 Hrs 25 Min 3350 See Graph C 7 1 See Graph C 7 2 See Graph...

Page 223: ...bove Ambient Max Cylinder Head Temperature 4600 F Maximum At Bayonet Thermocouple Normal Rated Power 375 BHP at 3350 RPM Power Correction for Intake Air Temperature 1 per 60 F Correct H P for T C Inle...

Page 224: ...RPM WARM UP 3350 t2400 700 25 100 POWER CHECK MAGNETOS IDLE COOLING PERIOD T C OUTLET PR HG Reference NOTE STOP ENGINE DRAIN OIL WEIGH AND RECORD ENGINE OIL CONSUMPTION OIL CON SUMPTION AT A RATE OF...

Page 225: ...and 14 thru 18 c Bend up ears of tab washers 20 and remove screws 19 and tab washers Separate control assembly 21 from throttle body d Remove attaching parts 22 23 and separate controller assembly 24...

Page 226: ...d install rubber washer and plain washer 37 36 Figure C 7 1 and seat on sleeve Connect fuel discharge tubes 1 to nozzles and fuel manifold valve 5 Install a clamp 2 on each tube and insert spring legs...

Page 227: ...1 39 a 32 FIGURE C 7 1 INDUCTION SYSTEM OCTOBER 1980 C 7 9...

Page 228: ...USTM ENT 12 SPRING 13 ROD AND LINK ASSY 14 15 16 17 18 19 20 21 22 23 24 25 26 NUT ELASTIC STOP WASHER ROD END SPRING ROD AND LINK ASSY SCREW TAB WASHER CONTROL ASSY SCREW LOCK WASHER CONTROLLER ASSY...

Page 229: ...OIL 2700 90w BR 18 0 VIEW H H ROTATED 250 CW FIGURE C 7 3 MANIFOLD VALVE FITTING LOCATIONS A FITTING B FITTING C BRACKET D FUEL P DRAIN PART HORIZ MANIFOLD PORT NO ORIENT ORIENT ASSY ORIENT MS20822 12...

Page 230: ...BO DISCHARGE PRESSURE REF C FITTING FUEL OUTLET 0 FITTING RETURN TO TANK 90 g0o TEE FITTING ORIENTATION ELBOW FITTING ORIENTATION FIGURE C 7 4 FUEL CONTROL FITTING LOCATIONS C 7 12 OCTOBER 1980 00 180...

Page 231: ...FIGURE C 7 5 FUEL PUMP FITTING LOCATIONS FITTING FITTING PART A B NO ORIENT ORIENT 643715 1 I 6846 0 I1 3o OCTOBER 1980 C 7 13 TING D PRESSURE A PUMP F UEL...

Page 232: ...FIGURE C 7 6 CRANKCASE STUD SETTING HEIGHTS LOCATION THREAD SIZES HETINGHT MODEL N 1 FUIEL PUMP MOUNT PADS 5 16 18 X 5 16 24 25 2 2 OILPUMPMOUNTPADS 5 1 18X 5 16 24 6 1 4 1 C 7 14 OCTOBER 1980 2...

Page 233: ...255 265 LBS HR 75 POWER RPM 3040 10 FLOW LIMITS 157 167 LBS HR a THIS CHART IS BASED ON 70F INJECTOR FUEL TEMPERATURE FOR EVERY 10 0 F INCREASE IN INJECTOR INLET FUEL TEMPERATURE SUBTRACT 1 LB OF FUEL...

Page 234: ...IONS 1 OBTAIN ACTUAL MAXIMUM RATED RPM 2 DETERMINE FUEL PRESSURE LIMITS FOR 100 MAXIMUM POWER BY READING DIRECTLY ABOVE ACTUAL MAXIMUM RATED RPM POINT EXAMPLE 100 POWER FUEL PUMP PRESSURE LIMITS AT 33...

Page 235: ...D WITHOUT INFLUENCE OF DIFFERENTIAL HEAD IN GAGE LINE NOTE TOLERANCE ON METERED FUEL PRESSURE 0 30 PSI NOTE SPECIFIC WEIGHT OF GASOLINE 5 87 LB U S GAL 6 J E 1i iO 14U 7 180 FU EL FLOW LBS HR I I I GR...

Page 236: ...essure set fuel flow at 255 to 265 lbs hr if maximum RPM cannot be achieved statically set fuel flow to 255 to 260 lbs hr at maximum static RPM Monitor fuel flow during roll out when maximum RPM of 22...

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Teledyne Continental Motors GTSIO-520 Series, Overhaul Manual

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