Teledyne 0-470-A Overhaul Manual Download Page 272

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Summary of Contents for 0-470-A

Page 1: ...OVERHAUL MANUAL PART NO X30586A O1992 TELEDYNE INDUSTRIES INC MODELS 0 470 A 0 470 B 0 470 E 0 470 G 0 470 J 0 470 K 0 470 L 0 470 M 0 470 P 0 470 R 0 470 S 0 470 U FAA APPROVED OCTOBER 1992 ...

Page 2: ...OCTOBER 1992 THE ORIGINAL DATE OF THIS PUBLICATION IS SEPTEMBER 1988 INSERT LATEST PAGES DESTROY SUPERSEDED PAGES MODELS 0 470 A B E G J K L M P R S U FORM X30586A ii OCTOBER 1992 ...

Page 3: ... and modelof the type certificatedproduct on which the part is eligiblefor installation stamped on the part An FAA Parts ManufacturerApproval FAA PMA is issued under FAR 21 305 The makeand model informationmay be on a tag attachedto the part d By shippingticket invoice or other documentwhich provides evidence that the part was produced by a manufacturer holding an FAA Approved Production Inspectio...

Page 4: ...nd instructions applicable to proper overhaul procedures Prior to overhaul the mechanic must meet requirements of Federal Aviation Regulation 65 and must follow FAR parts 43 91 and 145 as applicable This manual must be used in conjunction with the FAA Advisory Circular 43 13 1A Acceptable Methods Techniques and Practices Aircraft Inspection and Repair aswell asTeledyneContinental Motors 0 470 Seri...

Page 5: ...ngine will be covered inthis System Chapter The major System Chapters are then broken down into Sub system Sections These sections are identified by the second element of the standardized numbering system The number 10 of the basic number series 72 10 00 is for the disassembly of the engine The Subsection is the third element of the standardized numbering system 72 10 12 This number is the final b...

Page 6: ...1 30 00 PRODUCTS 1 30 01 Product List CHAPTER 4AIRWORTH INESS UMITATIONS 4 00 00 Airworthiness Limitations 4 00 03 CHAPTER 5 TIME IIMITS MAINTENANCE CHECKS 5 00 00 GENERAL 5 00 03 5 10 00 TIME LIMITS INSPECTION PROGRAM 5 10 01 5 20 00 SCHEDULED MAINTENANCE 5 20 01 5 20 01 Preflight Inspection 5 20 01 5 20 02 50 Hour Inspection 5 20 01 5 20 03 100 Hour Inspection 5 20 01 5 30 00 UNSCHEDULED MAINTEN...

Page 7: ...stem 72 10 06 72 10 08 Magneto and Accessory Drives 72 10 11 72 10 09 Oil Sump 72 10 12 72 10 10 Oil Cooler 72 10 14 72 10 11 Generator 72 10 17 72 10 11 Alternator Assembly 72 10 18 72 10 12 Starter and Starter Drive Adapter 72 10 20 72 10 13 Oil Pump Assembly 72 10 22 72 10 14 Cylinders and Pistons 72 10 25 72 10 15 Crankcase 72 10 28 72 10 16 Camshaft Assembly 72 10 30 72 10 17 Crankshaft Group...

Page 8: ...soent Particle Inspection 72 30 09 72 30 06 Dimensional Inspection 72 30 09 72 30 07 DimensIonal Urnits 72 30 09 72 30 08 Table of Limits 72 30 11 72 30 09 Original Dimension 72 30 25 72 30 10 Protective Coating 72 30 26 72 30 11 Application of Anodizing 72 30 26 72 30 12 Repair of Adnodized Surfaces 72 30 27 72 30 13 Enamel Coatings 72 30 27 CHAPTER 72 40 SPECIFIC INSPECTIONS 72 40 01 Crankcase 7...

Page 9: ... 72 60 08 72 60 09 03 Cooler 72 60 08 72 60 10 Valve Mechanism 72 60 09 72 60 11 ON Sump 72 60 10 72 60 12 Induction System I 72 60 l0 72 60 13 Carburetor 72 60 11 72 60 14 Magneto Drive Gears 72 60 12 72 60 15 PlacIng Crankshaft inliming Position 72 60 13 72 60 16 Magnetos 72 6014 72 60 17 Ignition Harniess 72 60 14 72 60 18 Fuel Uines 72 60 15 72 60 19 Exhaust System 72 60 15 CHAPTER 72 70 TESTI...

Page 10: ...on 74 00 03 74 00 02 Harness Assembly Installation 74 00 04 74 10 00 IGNIION TROUBLESHOOTING 74 00 06 SUCK IGNITION SYSTEM 74 30 00 GENERAL 74 00 07 74 30 01 Magneto Installation 74 00 07 74 30 02 Harness Assembly Maintenance 74 00 08 74 50 00 IGNITION TROUBLESHOOTING 74 00 10 CHAPTER 75 AIR 75 00 00 GENERAL 75 00 03 CHAPTER 76 ENGINE CONTROLS 76 00 00 GENERAL 76 00 03 76 10 00 CRUISE CONTROL BY P...

Page 11: ...03 80 00 01 Prestarting 80 00 03 80 00 02 Starting 80 00 03 80 00 03 Ground Warm Up 80 8 00 04 80 00 04 Pre takeoff Check 80 00 04 80 00 05 Flooded Engine 80 00 06 80 00 06 Cold Weather Operation 80 00 07 80 0 07 Preheating 80 00 07 80 00 08 Hot Weather Operation 800 00 9 80 00 09 Ground Operating At High Altitude Airports 80 00 10 CHAPTER 81 TURBINES 81 00 00 GENERAL 81 00 02 xi ...

Page 12: ...er 1 20 1 2 Valve Guide Removers 1 20 1 2 Valve Guide Replacers 1 20 1 3 RockerArm BushingRemover InstallerSet 1 20 13 PistonRingCompressors 1 20 13 FloatingHolder 1 20 14 Valve Spring Compressor 1 20 1 4 PushRodHousingSpringCompressor 1 20 14 FlaringTool PushRodHousing 1 20 1 4 Valve Guide Remover 1 20 14 Valve Seat Insert Remover Replacer 1 20 15 Valve Seat Installer 1 20 15 Common Parts Kit 1 2...

Page 13: ...sertTap Spark Plug lnsert Remover Slide Hammer Spark PlugTap osan Lock Ringinstaller Stud Drivers505 Series Scavenge Pump Drill Fixture Drill Fixture CrankcaseSplitter Set Propeller Shaft Oil Seal Installer Oil PressureRelief Spot Facers Runout Block Set PolishingToolsfor Crankshaft Bearings8087 Series Injector NozzleRemoverand Installer CrankcaseThru Bolt Removers Hex Drivefor HexTube Nuts Rotobr...

Page 14: ...inder Assembly Incline Valve Cylinder Assembly Straight Valve Crankcase Assembly Camshaft Assembly Crankshaft Group Exhaust System Crankcase Stud Setting Heights Helical Coil Installation Helical Coil Installation Spark Plug Helical Coil Expanding Spark Plug Helical Coil Removal Spark Plug Cylinder Assembly Dimension Inclined Valve Cylinder Assembly Dimension Straight Valve Valve Rocker Bushing Di...

Page 15: ...ge Torque Sequence 72 60 07 72 60 04 Oi Pump Cover Threading Procedure 72 60 07 72 60 14 Position of Magneto Couplings 72 60 12 72 60 17 Ignition Wiring Diagram 72 60 15 72 70 05 Exhaust Flange Dimensions 72 70 05 72 70 10 Three Quarter Right Front View of Stromberg PSD 5C Carburetor 72 70 06 73 00 00 Three Quarter Left Rear View of Stromberg PSD 5C Carburetor 73 00 06 74 00 04 Coating Insulating ...

Page 16: ...t 3 Table of Limits Chart 4 Table of Limits Chart 5 Critical New Part Dimensions Inspection Chart General Use Tightening Torques Table of Tightening Torques Pipe Plugs Crankcase Assembly Procedure Magneto Timing Overhaul Test Run Standard Acceptance Test Oil Consumption Determination Overhaul Test Run Fuel System Troubleshooting Charts Coupling Nut Torque Values Ignition Troubleshooting Coupling N...

Page 17: ...ns 1 00 03 Service ReportsAnd Inquiries 1 00 04 100 ReplacementParts 1 10 00 DEFINITIONS ABBREVIATIONS 1 10 01 Abbreviations Symbols 1 10 02 Definitions 1 10 03 DescriptionOf EngineModelCode 1 10 04 BasicDesign Features 1 20 00 TOOLS 1 20 01 SpecialTools 1 30 00 PRODUCTS 1 30 01 ProductList ...

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Page 19: ...phasize certaiit instructions or to prevent possible damage to engine or accessories WARNING Information which if disregarded may result in severe damage to or destruction of the engine or endangermentto personnel 1 00 01 RELATEDPUBLICATIONS A EngineManuals 1 Maintenanceand Overhaul Manualfor 0 470 Series Aircraft Engine FormX30586A 2 IllustratedPartsCatalogfor 0 470SeriesAircraft Engine FormX3058...

Page 20: ...l on an annual subscription basis NOTE Teledyne ContinentalBulletinsare easilydistinguished bytheir title color 1 Customer lnformationBulletins Blue 2 Service Bulletins Black 3 MandatoryService Bulletins Red 1 00 03 SERVICE REPORTS AND INQUIRIES If for any reason you have an inquiry or require technical assistance beyond the scope of your service facility contact your local TCM distributor or TCM ...

Page 21: ...l Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All ModelsWhere Applicable All other engine parts components and accessories must be inspected replaced if necessary or overhauled in accordance with applicable manufacturers instructions recommendations and specifications SPECIAL NOTES If for any reason lift...

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Page 23: ...ulations Cubic Feet Per Minute Center of Gravity Cylinder HeadTemperature Counterclockwise Rotation Clockwise Rotation Degreesof Angle Degreesof Fahrenheit ExhaustGasTemperature Figure Illustration PropellerEnd Foot or Feet FullThrottle Foot PoundsTorque Gallons Per Minute Grams Water Mercury InsideDiameter Inches Hexagon Hour InchPoundsTorque Side onwhich Nos 2 4 and 6 cylindersare located Rearto...

Page 24: ...Ambient Temperature or Ambient Pressure Brake Horsepower The power actually delivered to the engine propeller shaft It is called Brake Horsepower because it was formerly measured by applying a brake to the power shaft of an engine The required effort to brake the engine could be converted to horsepower hence brake horsepower Brake Specific Fuel Consumption Fuel Consumption stated in pounds per hou...

Page 25: ...he maximum amount of moisture the air could contain at a given temperature A mechanical device used in some magnetos to retard the ignition timingand providehighervoltage at cranking speedsfor starting The leanest mixture approved for any given power condition It is not necessarily the leanest mixture at which the engine will continue to operate Pressure measured in the intake manifold down stream...

Page 26: ...ression engine A rating of 100 130 denotes performance characteristics of lean 100 and rich 130 mixturesrespectively A term used to describe a process by which a crankcase is made An engine with a permold crankcase has a front right hand mounted gear driven alternator Altitude usually expressed in feet using absolute static pressure as a reference equivalent to altitude above the standard sea leve...

Page 27: ...eat generated which is converted into usefulpower T I T Turbine Inlet Temperature The measurement of E G T at the turbochargerturbine inlet Torque Twistingmoment or leverage stated infoot poundsor inchpounds Turbocharger A device used to supply increased amounts of air to an engine induction system In operation a turbine is driven by engine exhaust gas In turn the turbine directly drives a compres...

Page 28: ...stegate valve closes and causes gas which would go directly overboard to pass through the turbine The wastegate is usually operated by an actuator which gets necessary signals from the turbochargercontroller DEFINITIONOFTERMS Front rear left and right as used in this manual refer to the engine as viewed by the mechanic facing the accessory end Accessory end being the rear and propeller flange bein...

Page 29: ...The desired oil pressure is maintained by a pressure relief valve located In the oil pump housing Engine cranking is accomplished by a geared right angle drive starter adapterand a direct current starter motor The 0 470 series engines have provisions for a beltdriven generator or alternator The engine 1 is equipped with two gear driven magnetos The exhaust system may or may not be supplied with th...

Page 30: ...INSTALLATION DRAWING OF TYPICAL 0 470 ...

Page 31: ...LTOOLS Specific tools illustrated or similar tods marketed by other manufacturers are necessary for service and maintenance of the aircraft engine Tod illustrations shown on the following pages are usedwith the permissionof the respective manufacturers Illustrations in this section show only the general appearance of tods and do not correspond to the actual size or shape Details of special toois f...

Page 32: ...06108 203 528 9821 Fuel PressureTest Equipment Measuringlnstruments PrecisionTools Piston PositionIndicators Printedand StandardCircuits FEDERALTOOL SUPPLYCO INC 10631Capital Oak Park Michigan 48237 800 521 1508 TOLL FREE or 313 543 9300 PrecisionInspection lnstruments SpecialTools OTC TOOLS EQUIPMENT Divisionof OwatonnaTool Company Owatonna Minnesota 55060 507 45 1 5310 PrecisionTools SpecialTool...

Page 33: ...C OTC MCSC SOT ALCOR INC BORROUGHSTOOLAND EQUIPMENTCORP CHAMPION SPARK PLUG CO EASTERNELECTRONICS INC FEDERALTOOL SUPPLY CO INC OTCTOOLS EQUIPMENTCO McMASTER CARRSUPPLY CO SNAP ONTOOLS KTC KELL STROMTOOLCOMPANYINC CODE Numbers referenced in the left hand bottom corner of each picture correspond to the numberslocatedinthe SpecialTool Index WARNING Whenever usingtest equipment keep equipment and per...

Page 34: ... Ring Compressor Ring Compressor Ring Compressor Ring Compressor Floating Holder Valve Spring Compressor Push Rod Spring Compressor Flaring Tool Push Rod Hsg Valve Guide Remover Valve Seat Insert R R Oil Filter Removal 3 to 3 3 8w Oil Filter Removal 3 1 2 to 3 7 8 Oil Filter Removal 4 1 8 to 4 7 16 Oi Filter Sludge inspection Cylinder Removal Cylinder Removal Piston Removal Cylinder Reconditioning...

Page 35: ...der HeatingStand BearingPuller Bearing Puller DifferentialPressureGauge DifferentialPressure CylinderChecker BeltTension Gauge Application Vendor Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cyiinder Reconditioning Cylinder Recon...

Page 36: ...ometers Screw Thread Micrometers Screw Thread Microneiters Depth Micrometers Hydraulic L fter Testing Checking GEN ALT Output Setting Engine Timing Sheave Removal Checking Comp Driver Sheave Alignment Crankcase Modification Vacuum Testing GEN ALT Sheave Removal Journal Bearing Modification Cylinder Reconditioning Crankcase Modification Crankcase Modification Cylinder Reconditioning Cylinder Recond...

Page 37: ...ThicknessGage PrecisionVernier Calipers InsideMeasuringInstrument Alternator Analyzer Voltage RegulatorTester Alternator Regulator BatteryTester Voltage CircuitTester MagnetoTiming tight Timing Indicator Cold CylinderTester Hi VoltageTester Master OrificeTool Alcor PortableDigital EGT Unit Alcor PortableDigitalCHT Unit Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinde...

Page 38: ...as occurred and to inspect for metal or other contaminateswithin the engine oil system Use of the Champion CT470 Oil Filter Can Cutter eases the opening of spin on filters without introducing foreign material into the filter Following is the recommended procedure for inspection of full flow oil filters 3 Using a clean plastic bucket containing approximately 1 pt clean varsol swish filter element a...

Page 39: ...882 2 1 2 hex 3882A 9116 hex 3882 3A 5 8 hex Cylinder BaseNutWrench Special modified 3882 type wrench this special wrench is perfect for those occasional situations when the 3882 wrench won t fit It s a slightly different configuration as shown 80799 16 hex 3882 styleshown in LL I phantom to scale Cylinder Base NutWrench For470 and520Series The special configuration of these wrenches permits acces...

Page 40: ... 5 1 4 Cylinder Hone Expandable racks adjust to cylinder size with universal joint action Optional set for use on TCM cylinders Crankshaft Blade and Dampener BushingRemovers Replacers Back up plates and forcing screws are rugged heat treated alloy steel Be sure to keep forcing screws greased 496M for 5 8 I D Bushing 3604 for 3 4 I D Bushing 3607 for 15 32 I D Bushing 3607 1 for GTSIO 520 8068 for ...

Page 41: ...int showing hole sizes and locations is included with adapters 9 Universal Cylinder Holding Fixture 5221 B This is a heavy duty precision fixture manu factured to extremely close tolerances Suitable for use on vertical mills or drill presses it allows quick indexing of required angles for valve work FEATURES For all Continental Engines Fixture indexes in all present positions required to machine v...

Page 42: ...ing Checker 7521 A Per Continental Bulletin M74 1 6 Check valve spring quickly and easfly Hy draulically actuated extremely accurate readout 0 160 pounds Includes step gauges for all required dimensions 7521 Checker Isless step gauges Max spring dimensions Ht 2 1 2 O D 2 Heat Shrink Type I Valve Guide Removers Cold Force Removal Type Tough heat treated steel 3611 375 I D Guide 2874 436 438 Il D Gu...

Page 43: ...ies also available individually The 8098 10 Base must be used with 8118G 81IH 81185 and 8118K Driver and Adapter Assemblies Makes rocker arm bushing removal installation fast and easy All components of 8118 set are alsoavailableindividually PistonRingCompressors FlexibleBandType 4901 for 3 7 8 and4 1 6 boreengines 2839 for 5 and 5 1 4 boreengines 3618 for 4 7 16 boreengines TaperedType 49016 for 3...

Page 44: ...pring loaded tubes The 68 3compresses the spring which can then be removedwithfurnished clips Eliminates wiring springs together to install simply insert spring then pull off clip includes instructions FlaringToolfor Push RodHousing 4951A For A C Series expanding ball type tod Balls rotate inside housing expanding it into aluminumboss ValveGuideRemover4981 Removes guides by heat shrink method Cyli...

Page 45: ...50 Set includes 1 Handle leverassembly 12 Puller heads size to fit all Continentalengines 10 Installerpilots 1 Remover plug 6 feet of super flexible hose to attach to water supply Instructions Storage case Tool is rigged for removal Center is plugged to route water Tool is rigged tor replacement Guide on end of tool slips out thru small holes in rim of removing head into valve stem hole for perfec...

Page 46: ...TS AND GUIDES CAN BE RE ALIGNED QUICKLY Here s how It s done Step 1 Removed old guides and seats Step 2 Install Expanding Guide Body into valve seat boss Step 3 Place Boring Bar into Guide Bore valve guide boss concentric and perpendicular to valve seat Follow up with Reamner SlING SOLT VALVE GUIDE BORE CIN VRED SL EEVE Step 4 Use your drill press for bore or ream operations as shown in this pictu...

Page 47: ...speed M2tool steel precision Valve GuideBoss Takes placeof ground 4914 and 4943 Series reameis Reamers Tool No Hole Dia BoringBars Tool No Hole Dia Example Use 811CC6B Boring Bar to bore hole to 555 then finish with 8116 SR Reamerto 561dia Expanding Minimum Maximum Bodv No RetractedDia Expanded Dia Expanding Guide Bodies ...

Page 48: ...5 10 Exh 1 798 010 522515 Exh 1 808 015 5225 20 Exh 1 808 O W 522530 Exh 1 818 O W StepSide Cutters Small Large Small Large Part No Diameter Diameter Q Part No Diameter Diameter Q STD 8138 3 005 8136 4 010 8138 5 015 8138 020 8138 1 030 8138 2 STD 8138 3 005 803 4 010 8138 5 osan Stud Remover This stud remover is for use in extracting studs 1 from cylinder assemblies using o s a n t y p e Studs Us...

Page 49: ...as a dial indicator reading in ten thou sandths of an inch 0001 The gauge body is lapped into the mating bushing for accurate readings Instructionsare included Adapter Kits 8042Cfor 520 470 ESeries 1 125 8072Cfor 0 200 O 300 360 1 00 922 w 6 J Base Retainer K i t 811lA Reamers ConnectingRodBushing High speed steel reamers with 3 4 diameter pilot Use with 8111A Base Retainer K i and properAdapter K...

Page 50: ...s all pilotsand cutters also fits your d d cutters By using the 8122A with the proper pilot from below you may choose to pilot into valve stem hde or valve guide boss I Pilots 812 2 Handle Pilot All pilots are hardened and precision ground for cutter accuracy Two choices pilot into valve stem hdeor valve guide boss Pilot Choice No 1 Pilot lntoValve Stem Hole On new installation8only PartNo Pilot D...

Page 51: ...Once the bushing is removed or installed a turn of thevalve returnsactuatorfor another cycle 807714includes 10 000 p s i pump and cylinder 5 ton output cylinder 3 ft long flex hydraulic hose all adapters to f i t 0300 and 360 470 and 520 Series 8077B lesshydraulics includes Items shown above in 8077A except no hydraulics are furnished The actuator head has 1 4 NPT female port for connecting to you...

Page 52: ...nting plate also rotates 360 and locks inplacewith heat treatedlock pin flange holder is predrilied to accept all Con tinental engines Threaded adapters included to mount nonRanged crankshafts Shipping weight 400ibs Tork BandTensionAdjuster 7726 Adjust belt tension without damage to compo nents Use on atternators compressors etc Allows grabbingdifficultroundcomponents GeneratorDriveHolder Hdd driv...

Page 53: ...3 6 PropaneHosesw fittings PropaneRegulator Controls I Y Connector 1 Stand 2 Cylinder Risers All screws nuts and washers needed and instructions Blind Needle Bearing8093C Puller 20 Ib Propane Tank Use to remove 5 8 1 D needle bearings in 470 and 520 Series engines Use with 8054 Slide Hammer Starter Clutch Shaft BearingPullers W D for removing3 4 1 D bearings Use with 8054 Slide Hammer Febnrary1989...

Page 54: ...sure maximum belt and bearing life The proper belt tension eliminates slippage and increasesefficiencyof beltdriven opponents Compact only 3 1 4 wide to fit in crowded areas Easy to use just apply gauge to belt release ball handle and read tension on rotating dial Calibrated for A section V belts 3 8 to 1 2 top width and K section 45 and 6 rib poly V belts Range 30 to 180 Ibs and 130 to 800 newton...

Page 55: ...r protected Two point hook up field term and cigarette lighter EngineTimingDisc 3608A For all engines universal application from J3 to DC3 Fastens to prop tip and accurate to 1 4 degree Includespistonstop3608A 15 PulleyHolder 4974 For hdding 2 1 2 to 3 1 2 dia pulleys grip in pulleygroove PulleyAlignment Gage Bar 8082 The 8082 gage bar allows a quick and easy alignment check between driver sheave ...

Page 56: ...d operation Heavy steel wall 0 30 in Hg nozzlefits several sizes of tubing Generator PulleyPuller 61 5 Quick removes pulleys from 2 1 2 to 5 diameter Applies even pressure on outside of pulley in pulley groove All components are tough heat treatedalloy steel Bearing and Bushing8094B Drill Fixture Per Continental Bulletin79 10 Use to reqork your present stock of main journal bearings and starter sh...

Page 57: ...t dowel boss prior to inserting improved thru bolt with O ringseal Spark PluglnsertTap 504 1 Use on all engines Spark PlugInsertRemover 4919 Use on all engines Slide Hammer 8054 Heavy duty slide hammer features 2 1 2 lb slide and 5 8 18 thread 24 long overall Use with 8114 Series removers Spark PlugTap 445 18millimeterthreads High speedsteel February 1989 1 20 27 ...

Page 58: ... Pump per Continental BulletinM72 8 Drill Fixture 8025 For drilling and installing piston oil squirt nozzles in 0470V engines converting to O 470VO per Continental Bulletin M75 13 10 470 to IO4700S Includes all drills drill bushings and stops requiredto a fast and efficientjob CrankcaseSplitter Set L423 Makes splitting Continental crankcases easier and faster Prevents crankcase damage Puller assem...

Page 59: ...emoval Cutter blades are heat treated highspeedsteel 8048 Spot Facerfor 470 and 520 RunoutBlockSet 8177A Use this set to check runout on crankshafts etc up to 4 diameter Blocks are aluminum alloy with Teflon bearing surfaces Approx size 4 w x 8 1x 5 h each PolishingTools for Crankshafts Bearings Dial indicator not included Special aluminum frame and felt polishing surfaces 808719 1 718 to 2 114 di...

Page 60: ...f heat treated steel for durability Torque input and output ismarkedon extension Installer is special thin walled 6 pt 1 2 hex socket CrankcaseThru Bolt Removers Use with 8054 Slide Hammer to remove stubborn bolts 8114 8 Remover 1 2 20 threads 8114 7 Remover 7 16 20 threads 8114 6 Remover 3 8 24 threads Hex Drivefor HexTubeNut 7912A ubing nut wrench set for fuel systems ydraulic systemsand brakes ...

Page 61: ...Pullers These pullers provide a more controlled method to remove press fit parts ...

Page 62: ...side of holes to outside edges DialBoreGages Dial Bore Gages used for large volume go no go inspections or for determination of actual dimensions Three point contact two guide pins and one interchangeable rod assure alignment within bore Zero point may be set with ring gage micrometer height master or gage Mocks NOTE All precision measuring devices must have a current calibration that is traceable...

Page 63: ...eV Anvil Type 60 degree V Anvil and Conical Spindle are made of high grade special steel hardened and precisionground Depth Micrometers The Depth Micrometer is one of the basic measuringtoois selected by machinists Rachet stop for consistent and repetitive measurements NOTE All precision measuring devices must have a current calibration that is traceable to the National Bureauof Standards February...

Page 64: ...9 1 5129 2 786 Pilot 5129 4 818 Finishing Usewith 5129 1 5129 3 815 Pilot 51245 833 Finishing Usewith 5129 1 5129 2 5129 3 5129 4 815 Pilot Reamer Rocker Shaft Bushing 5130 751 Std 707 Pilot Reamer RockerArm Bushing 7232 751 Std 732 Pilot Reamers Valve Guide Boss Useat 275 RPM maximum USE MORSE ADAPTER 4914 1HS 537 005 O S 53lV Pilot 2689 4914 2HS 542 010 O S 534 Pilot 2689 4914 3HS 552 020 O S 53...

Page 65: ...e usedto check for new limits andservice limits where applicable Gaugesare heat treatedalloy steel precisionground 2848 1 436 I D Guide 2848 2 438 I D Guide 3615 37 I D Guide Suggestions For Reaming ValveGuideStem Holes 1 Use highquality cutting oil 2 Reamersare madeto cut right hand onlydo notturn backwards evena partialturn 3 If usingpower runhigh speed reamersat 400 RPMmaximum and carbidetipped...

Page 66: ...he Englishand Metric Measure Inside Measuring Instruments Three measuring surfaces are lapped parallel to the longitudinal axis of the Micrometer and stay aligned with the bore while measurements are taken Large ratchet stop provides constant measuring pressure to the wall surface and insures repet itive reading to 0002 or 0001 smaller ranges NOTE All precision measuring devices must have a curren...

Page 67: ...ors regulators batteries on 12 and 24 volt systems with currents up to 32 volts DC Has a pointer zero adjustment screw on the face of the instrument Circuitry is entirely solid state and no battery or power source is required Power for the unit isderivedfrom the systems under test MultipleVoltage Circuit Tester For 12 24 Volts _C__1 Model29 Designed to test continuity of circuits shorts diodes liv...

Page 68: ...ircraftTiming Indicator ModelE25 Improves the accuracy and speeds up the process of timing an aircraft magneto to the engine Easily attached to the propeller spinner with mounting bands Has top dead center locator Cold Cylinder Test ModelEl0 Attach one wire with an alligator clamp and use another cable with a hand held probe to test comparative temperatures from cylinder to cylinder in a matter of...

Page 69: ...t insulation for leak Built in continuity lamp provides handy test of electrical connections Uses two c cell flashlight batteries Includes top grain cowhide carrying case Master OrificeTool P N 646953 Attach to differential cylinder pressure tester to check calibration and determine the low leakage limit Ref TCM Service bulletin M84 15 February 1989 f 20 39 ...

Page 70: ...t 9 volt LCD unit with a disposable battery TemperatureRange 1000 1 800 F u Part Number85328 Alcor Portable DigitalCHT Unit This device is used with Type J Thermocouple It is a lightweight 9 volt LCD unit with disposable battery TemperatureRange200 600 F Indicationfrom 32 6000 Part Number85329 WARNING Keep equipment and personnel clear of prop area ...

Page 71: ...on TSIOILTSIO 360 At EngineAssembly e Idler Gear and Pin Which useGrade 50 Oil Grade50 MHS27 0 Connecting Rod Bearings o Prop Driver Driven Gears 0 CamshaftBearings 0 AccessorySpur GearTeeth 0 Quill Shaft Splines 0 Starter Cone Bushing and February 1989 1 30 01 ...

Page 72: ...ethreads only e Thrust Washer e Oil FilterAdapter Seals mI m e PressureRegulatorThreads e Exhaust Studs nut end All Class 4 Studs RfaEWNE 0 Ringson FuelPumps coKMEjNa4LMCJTORS AkxottRoducts Mixture ShaftBushing Crankcase Threading Pro a 1 30 02 February 1989 ...

Page 73: ...3M Brand e MagnetoFlanges lara6 285 6 320 WTELEWNE c 3mmml AbwcrftRoducts e RockerCover Gaskets e Gasket Idler Pin e Gasket IntakeManifold e Oil DrainBackTubes e Gasket Oil Filter Neck Area of 3 way Joints ModelsTS10360A February 1989 1 30 03 ...

Page 74: ...IRTELEWUE CON17NEKG9LMCrTORS 646944 Primer 1 30 04 February 1989 ...

Page 75: ... ReleaseagenS1 Mold Release RELEASEAGEN INC Oil Preservative DaubertChemical Inc Pennsylvania RefiningCo TCM PIN 626531 2 Interior and Exterior Aluminum Parts February 1989 1 30 05 ...

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Page 77: ...CHAPTER 4 AIRWORTHINESS LIMITATIONS ...

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Page 79: ...tins issued after the date of certification inspections mandated by the FAA under Parts 43 and 91 of the FederalAviation Regulationsare requiredfor type certification 3 Other Related Procedures Subject to additional information contained in FAA Approved Mandatory Service Bulletins issued after the date of certification the 0 470 engines do not have any inspection related or replacement time relate...

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Page 81: ...INTENANCE CHECKS 5 00 00 GENERAL 5 10 00 TIME LIMITS INSPECTION PROGRAM 5 20 00 SCHEDULED MAINTENANCE 5 20 01 Preflight Inspection 5 20 02 50 Hour Inspection 5 20 03 100 Hour Inspection 5 30 00 UNSCHEDULED MAINTENANCE 5 00 01 ...

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Page 83: ... inspection guide to assist the owner or operator in meeting their responsibilities This inspection guide is not intended to be all inclusive no guide can replace the good judgement of a certified airframe and power plant mechanic in the performance of his duties As the one primarily responsible for the air worthiness of the airplane the owner or operator should select only qualified personnel to ...

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Page 85: ...l dressing dusting or spraying we recommend a maximum of 1200hoursTBO or lessat operators discretion Applies to new and rebuilt 0 470 U Spec 11 12 13 14 17 and 18 0 470 engines other than those listed above may be made eligible for the TBO increase 2000 hours by installing P N M267A2 cylinder and valve assembly P N 646280 piston P N 639565199 ring set P N 646277 lifter in the exhaust position P N ...

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Page 87: ...ed 2 Oil Filter Replacefilter inspect cartridge 3 Oil Change oil if integralscreen or smallfilter is used 4 Air Filter Inspectand clean or replaceas necessary 5 HighTension Leads Inspectfor chafingand deterioration 6 Magnetos 7 Visual Check and adjust only if non conformities were notedinStep 1 Check hoses lines wiring fittings baffles etc for general condition properrouting positioning 8 ExhaustS...

Page 88: ...e and effort required to check and adjust the magnetos to specifications is slight and the operator will be rewarded with longer contact point and spark plug life smoother engine operationand lesscorrective maintenancebetweenroutine inspections NOTE At each 500 hours the magnetos should bedisassembledand inspectedaccording to Magneto Service Manual 9 Air Filter Inspectand cleanor replaceas necessa...

Page 89: ...form service as required on any items that are not within specifications Perform complete run up Check engine for fuel or oil leaksbeforereturningto service NOTE Refer to this Manual or applicable Service Bulletins for proper procedures and limits ...

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Page 91: ... replacement and repair top overhaul etc can be found in Related Publications listed in Chapter 1 No unscheduled maintenance of the categories listed above should be attempted without consultingthe applicablerelated publications NOTE In case of engine overspeed refer to the current Overspeed Limitations Service Bulletins ...

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Page 93: ...ENERAL 70 10 00 LOCKWIRE PROCEDURE 70 20 00 CRANKCASETHREADING PROCEDURE 70 30 00 APPLICATION OF ADHESIVES 70 40 00 INSTALLATIONOF GASKETS 70 50 00 CYLINDER LEAKAGE CHECK 70 50 01 LeakageChecks 70 50 02 Equipment 70 50 03 Performing The Check ...

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Page 95: ... with the dust caps in the tube ends If anything is dropped into the engine work should be stopped immediately and the item removed even if considerabletime and labor is required Insureall partsare thoroughly clean beforeassembling especiallyduring engine build up All lockwire and cotter pins must fit into a recess of the nut with the other end bent such that one leg is back over the stud and the ...

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Page 97: ...NS I1 LOCKWIRE 2 INSERTING WIRE 3 BENDING WIRE HOLES PARALLEL AROUND BOLT I6 BENDING WIRE AROUND BOLT 7 TWISTING WIRE 4 TWISTING WlRE 5 PULLING WlRE 8 BENDING TWISTED WIRE 9 CUTTING EXCESS WIRE a Steps in applying satety wire b Typical satety wire patterns ...

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Page 99: ...ion beforethreading 3 Apply Permatex to all areas listed in paragraph 2 above on the non threaded crankcase half usingthe same technique as in paragraph 2 4 Apply grade D silk thread P N 641543 as shown in illustration being sure that free ends are covered by gaskets except at oil seal 5 Assemble crankcase halves using bolts for alignment to prevent movement of the thread and torque all bolts in p...

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Page 101: ...ealantsand Lubricants Gasket Maker is an easily workable tacky gel which can be extruded onto one side of a flange surface from a tube and evenly spread or small parts can be covered adequately by pressing them into a saturated polyester urethane sponge or by roll coating them with a short pan roller Once Gasket Maker has been applied evenly torque assembly into place Excess material can be cleane...

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Page 103: ...asket Gasket surfaces must be clean and free of oils and grit Apply a thin coat of TCM Copper Coat 642188 to both sides of gasket unless otherwise specified Refer to Item No 10 in Chapter 1 Sealants and Lubricants for application of Copper Coat Once Copper Coat has been applied position gasket with the Copper Coat to its respective side according to Chapter 1 Sealantsand Lubricants Evenlytorque as...

Page 104: ...INTENTIONALLY LEFT BLANK ...

Page 105: ...ect cylinder leakage check results caused by improper use of test equipmentand or bythe use of faulty test equipment To help you accurately accomplish a leakage check we submit the following information on leakage and use of the Master Orifice tool Ref Figure 70 50 01 to calibrate the leakage checkingequipment used on Teledyne Continentalengines FACTORY CALIBRATED ORIFICE an with soft brush Do Not...

Page 106: ...leakage can vary from engine to engine by the cylinder displacement cylinder choke ring end gap and pistondesign 70 50 02 EQUIPMENT Testing equipment must be kept clean and checked periodically for accuracy as follows Using a line pressure of 100 to 120 p s i close the cylinder pressure valve then set the regulator pressurevalve to 80 p s i The pressure in both gages should stabilizewith no leakag...

Page 107: ...lfrom your cylinder adapter A schematicdiagramof atypical differentialpressuretester isshown in Figure70 5003 FIGURE70 50 03 DIFFERENTIALPRESSURETESTER 70 50 03 PERFORMINGTHE CHECK The following procedures are listed to outline the principles involved and are intended to supplementthe manufacturer s instructionsfor the particulartester being utilized WARNING Magnetos and fuel must be shut off prio...

Page 108: ...flow sound at the exhaust or induction system cylinder port When checking for cylinder head to barrel leakage use a soapy solution between the fins and watch for bubbles Use a soapy solution also around both spark plugseals for leakage NO LEAKAGE ISALLOWED INSTATICSEALS h If leakage is occurring in the intake or exhaust valve areas it may be possible to correct a low reading by staking the valves ...

Page 109: ...20 p s i and working piston through TDC several times bringing the piston to TDC in the normal direction of engine rotation Adjust regulated pressure to 80 psi and determine amount of loss If the gage reading is higher than the previously determined master orifice calibratedreading proceedto next cylinder to betested NOTE Piston ring rotation within the ring land is a normal design characteristic ...

Page 110: ...In Exhaust Port STATIC SEAL NO LEAKAGE PERMISSIBLE Replace Cylinder Replace Cyl nder SECOND CHECK CHECK FOR DYNAMIC SEAL Replace Cyl nder ...

Page 111: ... Crankcase 72 00 03 Crankshaft 72 00 04 Connecting Rods 72 00 05 Camshaft 72 00 06 Pistons 72 00 07 Ufters 72 00 08 Cylinders 72 00 09 Gear Train 72 00 10 Lubrication System 72 00 11 Valve Mechanism 72 00 2 Induction System 72 00 13 Exhaust System 72 00 14 IgnItion System 72 00 01 ...

Page 112: ...nentalMotors Model 0 470 Cylinders Arrangement Individualcylinders ina horizontallyopposed position Compression Ratio 0 470 A E J K L R S 7 1 0 470 B G M 8 1 0 470 U 8 6 1 FiringOrder 1 6 3 2 5 4 Cylinder HeadTemperatureMaximumAllowable 0 470 G J K L R S U 460 F 0 470 A E 450 F 0 470 B M 475OF Indicatestemperature measuredby Bayonet Thermocouple AeronauticalStandard AS234 element or equivalent ins...

Page 113: ...system as noted DOES NOT INCLUDE Cylinder baffling prop governor airframe to engine control cables attaching hardware hose clampsandfittings airframesuppliedaccessories OPERATING LIMITS ENGINEMODEL RATEDMAX CONT BHP REC MAX CRUISE BHP CrankshaftSpeed RPM RatedMaximumContinuousOperation All 0 470 s except J U 2600 0470J 2550 0 470 U 2400 RecommendedMax for Cruising 75 Power 0 4704 J K R S U 2300 04...

Page 114: ...r engine inspectioncompleted Oii First 25 hoursof operation Mineral non detergent oil or Corrosion PreventiveOil Correspondingto MIL C 6529Type I1 Oit Specification MHS 24 or MHS 25 Normal Service All Temperatures 15W 50 20 W 50 Below50 F Ambient Air Sea Level SAE30 or 1OW 30 Above 30 F Ambient Air Sea Level SAE50 Oi Sump Capacity See Operating LimitsSection77 00 03 Max Oil Consumption Models O 47...

Page 115: ...88D A88 SR88 SR88D SR83P SR93 SR87 HSR87 HS88 SR831R HSR831R SR88 SR87 HSR 87 HSR88 SH 2M SH20A SH15 SHlSR SH200A SH26 SH 260 SH150 BG 7065 RB 4855 BG919SK BG919SR5 BGRB955S EM41 E RC26 S C27 S EM41N REM39M RHM39M RHD39M REM40E RHMNE EM42E HM41E REM38W RHM38W REM38P RHM38P REM385 RHM385 SE190 SJ190 SE230 SJ230 RSE233R RSH23 3R RSE233R 1 RSH23 3R 1 626363 635861 626362 539433 539432 625351 625350 6...

Page 116: ...62 627449 627450 635610 635611 649911 649913 649914 632507 632508 632511 632512 632513 632514 630574 627342 530892 626026 626761 627643 627978 635151 635012 632572 628325 630049 635013 646629 646630 642097 642098 646091 646092 627892 632461 632462 632463 635146 635147 MODELS 0470 U Auburn AC271 AC273 AC291 AC281 AC283 AC293 AC2811R AC2831R 273 Autdite SL360 PL350 Champion RHB32M RHB36W RHB32P RHB3...

Page 117: ... is pressed into the right crankcase to the right of the rear mainbearing to support thefront end of the starter shaftgear B Cylinder mounting pads on the left crankcase are farther forward than the corresponding pads on the right crankcase to permit each connecting rod to work on a separate crankpin Each pad has six studs and two through bolts for attaching cylinder base flanges The propeller gov...

Page 118: ... pressure from the governor through an interior groove in the front main and thrust bearing 41 see figure 720004 to the center of the propeller hub On some 0 470 models an oil transfer collar encompassing the crankshaft between the front and rear halves of the main thrust bearing transfers the governor controlled oil from the crankcase passage to the crankshaft interior The crankshaft gear is heat...

Page 119: ...s screwed and shrunk onto an externally finned steel alloy barrel to make the permanent head and barrel assembly Heat treated nitralloy and prefinished aluminum bronze valve guides are pressed into the cylinder assembly Special 18mm helical coil thread inserts are installed in upper and lower spark plug holes Smaller helical coils are installed in exhaust manifold attaching stud holes Both intake ...

Page 120: ...essed into the gear center hole prevents excessive distortion of the rubber bushings betweenwhich the driving lugs onthe magnetoimpulsecouplingfi The electric starter 17 is mounted on a right angle drive adapter which is attached to the rear end of the crankcase The tongue end of the starter shaft mates directly with the grooved end of the worm shaft The worm shaft is supported between a needle be...

Page 121: ...gear 1 0 5 10 Tachometerdriie bevel gear 1 0 5 11 Tachometerdrive bevel gear shaft 1 0 5 12 Tachometerdrive shaft assembly 1 0 5 13 Idler gear assembly 1 0 652 14 Idler gear support pin 15 Left magnetodrive gear 1 1 5 16 Right magnetodrive gear 1 1 5 17 Electric starter 4 8 1 18 Starter coupling 19 Worm drive shaft 4 8 1 20 Worm shaft spring 21 Starterworm gear 4 8 1 22 Starter worm wheel 2 1 23 S...

Page 122: ...oil is directed to the camshaft passage A groove around the front of the camshaft directs oil to the front camshaft bearing and left crankcase oil gallery C Lubricating oil is directed to the governer drive bearing and propeller governer through passages off the left oil gallery Oil is channeled through a discharge port to the crankshaft oil transfer collar which directs it to the crankshaft inter...

Page 123: ...I 0 0 0L I FIGURE 72 00 10 LUBRICATION SYSTEM DIAGRAM 72 00 13 ...

Page 124: ...e of body picks up oil from crankcase supply hole From the exterior groove oil is directed to interior body groove 11 through hole 1 and from the interior groove through the hole to the reservoir 12 Oil is withheld from reservoir 15 by check valve ball 5 which is supported by a spring 4 and retainer 3 The check valve is opened by outward motion of the plunger under pressure of the expanding spring...

Page 125: ...uces the current for the upper spark plugs of the left side cylinders and lower spark plugs of the right side cylinders The high tension cables pass through braided flexible shielded conduit assemblies which are connected to the magnetos by coupling nuts and to the spark plugs by elbows The magnetos are driven through impulse couplings which incorporate springs and counterweighted latches When cra...

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Page 127: ...o be Discarded PreliminaryCleaning IgnitionSystem FuelPump InductionSystem Magnetoand Accessory Drives Oil Sump Oil Cooler Generatorand AlternatorAssemblies Starterand Starter DriveAdapter Oil PumpAssembly Cylindersand Pistons Crankcase CamshaftAssembly CrankshaftGroup ExhaustSystem ...

Page 128: ...INTENTIONALLY LEFT BLANK ...

Page 129: ...n plugandtighten 3 Disconnectthe battery ground cable 4 Disconnectthe starter cable 5 Tag and disconnect the enginewiring bundlefrom the following components a Magnetos b Alternator c Tach Generator d OilTemperature Bulb e Cylinder HeadTemperatureBulb f Remove all clamps attaching engine wire bundle to engine components and route clear of the engine 6 Disconnect propeller throttle and mixture cont...

Page 130: ... PRELIMINARY CLEANING Spray or brush with a solvent used for general cleaning of engine parts Remove caked dirt on bolt heads and nuts At the same time the oil sump drain plugs should be removedto drainany remainingoil C A W O N Do not use a caustic or even mild alkaline cleaning solution for ertemal precleaning these solutiorts will remove the a1odized finishof aluminumparts 72 10 05 IGNITIONSYST...

Page 131: ...Cable Assy to No 4 Lower Spark Plug Coupling Nut Brass Washer Cable Piercing Screw Two Wire Cable Bracket Round Head Rivet Spark Plug Terminal Sleeve Approved Spark Plug Brace Assembled on Crankcase Clip Lockwasher Round Head Screw Magneto Gasket 28 29 30 3 1 32 33 34 35 36 37 38 39 40 4 1 42 43 44 45 46 47 48 49 SO a 52 Magneto Magneto HoldingWasher Lockwasher Plain Hex Nut Spring Lockwasher Fill...

Page 132: ...replacement by detaching the air scoop shutting off the fuel supply and detaching the fuel supply tube at the carburetor inlet Disconnect the throttle and mixture controls by removing the four nuts washers and bolts which attach the carburetor to the riser manifold To drain the fuel from the float chamber of the carburetor remove the pipe plug at the bottom of the fuel side below the mixture contr...

Page 133: ...in Sleeve Carburetor Mounting Gasket Carburetor Clamp Hose Clamp Hose Clamp Assembly Hose Hose Riser to Elbow Tube Elbow Hose lntakeManifold Tube Assembly lntake Tube Assembly lntake Tube Assembly lntake Tube Assembly lntake Bolt Washer Lock Washer Plain Gasket lntakeManifold Seal lntakeManifold Washer lntake Manifold Spring lntake ManifoldTube Tube Assembly Balance Screw Hex Head Washer Lock Wash...

Page 134: ...del PSD 5C carburetor address Service Department Bendix Products Division of Bendix Aviation Corpora tion South Bend Indiana Carburetorsare identified bythe manufacturer s part number 72 10 07 CARBURETOR AND INDUCTION SYSTEM 0 470 8 E M See Figure72 10 07B A Loosen the manifold riser to intake elbow hose clamps 15 and slide the connecting hoses 13 back onthe elbows untilthey clear thejoints B Loos...

Page 135: ...ube and Valve Assembly Ring Internal Retaining Valve Manifold Drain Clamp Balance Tube Washer Lock Screw Machine Bracket Balance Tube Bracket Balance Tube L H Washer Tab Bolt Tube Elbow LIH Tube Elbow RIH Bracket Carburetor Support Bolt Nut Self Locking Bushing Support Bracket Bracket Support R H Bracket Support L H Washer Plain Nut Self Locking Gasket Carburetor Carburetor Nut Hex Washer Lock Was...

Page 136: ...so that engine is inverted B Remove four sets of nuts I two clamps 2 then loosen two clamp assemblies 4 and pull off balance tube 3 C Loosen plug 8 to facilitate later removal then loosen clamps 11 work hoses 12 clear of joints Remove attaching parts 5 6 7 and pull rear manifold 9 from oil sump studs D Remove four sets of intake tube attaching parts 13 14 15 from each cylinder and lift off tubes h...

Page 137: ...er 22 C Remove attaching parts 8 9 10 and lift cover 11 and gasket 12 Remove oil seal 14 from adapter 17 FIGURE 72 10 08 MAGNETO ACCESSORY DRIVES Nut Plain Hex Washer Lock Washer Plain Nut Plain Hex Washer Lock Washer Plain Adapter Assembly Nut Plain Hex Washer Lock Washer Plain Cover Accessory Drive 12 13 14 15 16 17 18 19 20 2 1 22 Gasket Gasket Seal Oil Bushing Adapter Stud Adapter Gear Assembl...

Page 138: ...rd to remove tap with a soft rubber or rawhide mallet Do not pry Removeand discard gasket 7 B Remove bolt 9 and washer 10 to withdraw oil suction tube assembly 11 and remove gasket I 2 FIGURE 72 10 09A OIL SUMP 0 470 A B E J K L M R S U 1 Plug Oil Drain 2 Gasket Annular 3 Screw Hex Head 4 Washer Lock 5 Washer Plain 6 Sump Assembly Oil 7 Gasket Oil Sump 8 Bolt 9 Bolt 10 _Washer 11 Tube Assembly Suc...

Page 139: ...arburetors see applicable manual distributed by the Marvel Schebler Division Borg Warner Corporation for the Model MA 4 5 carburetor This manual will cover the carburetor disassembly inspection cleaning testing and reassembly For parts list and overhaul instructions pertaining to Bendix Stromberg Model PSD 5C carburetor address Service Department Bendix Products Division of Bendix Aviation Corpora...

Page 140: ...nd washers then withdraw the oil cooler from the crankcase studs D Take off the cooler to cylinder baffle and the cooler gasket FIGURE 72 10 10A OIL COOLER 0 470 A E J K 1 Oil Cooler 2 Nut Plain Hex 3 Lockwasher 4 Plain Washer 5 Gasket 72 10 10 OIL COOLER 0 470 G L P R S U See Figure 72 10 10B A Remove five hex head bolts three plain hex nuts lockwashers and plain washers Remove oil cooler assembl...

Page 141: ...10 108 O I L COOLER 0 470 G L P R S U 4 Oil Cooler 2 Bolt 3 Lockwasher 4 PlainWasher 5 Nut 6 Gasket Cooler to Plate 7 Plug 8 PlateOil Cooler Adapter 9 Nut 10 Lockwasher 11 PlainWasher 12 Gasket Plate to Crankcase ...

Page 142: ... PlainWasher 5 Gasket Cooler to Plate 6 Plug 7 PlateCooler to Crankcase 8 Nut 9 Lockwasher 10 PlainWasher 11 Gasket Plate to Crankcase 1 12 Gasket Cooler to Crankcase 8 13 PlateOil CoolerAdapter 14 OilTemperatureControlValve a 15 Gasket 16 Gasket Plate to Crankcase 017 Plug ...

Page 143: ... loosen the three generator retaining bolts Push the generator inward Remove the vee belt and the upper retaining bolt C Remove the two pivot bolts and pull generator free FIGURE 72 10 11A GENERATOR 0 470 A B E G J K M P R 1 Belt Generator 2 Spacer Sheave 3 Sheave 4 Generator 5 Bolt 6 Washer 7 Bolt 8 Nut 9 Washer 10 Bolt 11 Washer 12 Arm Adjusting 13 Bracket 14 Bracket ...

Page 144: ...ts and one bolt Push alternator inward and remove vee belt and upper retaining bolt C Remove two nuts pivot bolt washers spacers and alternator from engine FIGURE 72 10 11B ALTERNATOR OPTIONAL EQUIPMENT ALL MODELS Alternator Fan Alternator Sheave Bracket Bracket Pivot Bolt Bracket Bracket Bolt Washer Bushing Washer Nut Bushing Bushing Washer Tab Screw Idler Kiss Nut Elastic Stop Belt Nut Sheave Re...

Page 145: ...INTENTIONALLY LEFT BLANK ...

Page 146: ...h a pin punchall around I Use a wheel puller or an arbor press to press the shaftgear 34 from the drum 33 and bearing 31 after removingthe wormwheel J To remove the clutch spring clamp the drum flange between lead shielded vise jaws Remove the retaining screw 28 and washer 29 Rotate the spring until its depressed rear end lies across the upper 1 4 inch hole in the flange Insert a 3 16 inch wide sc...

Page 147: ...over Lockwasher Plain Washer Woodruff Key Gask 470 A 25 Sleeve 26 Oil Seal 27 Retaining Ring 28 Bolt Spring Retaining 29 Tab Washer 30 Clutch Spring 31 Bearing 32 0 Ring 33 Starter Worm Wheel Clutch Drum 34 Starter Shaft Gear 35 Retaining Ring 36 Starter Worm Gear 37 Spring 38 Bearing 39 Woodruff Key 40 Worm Drive Shaft 41 Bearing 42 Stud 43 Adapter T44 Gear Starter Worm Wheel 45 Dowel Stepped OD ...

Page 148: ...ilter 43 or 50 and gasket 51 E Remove attaching hardware 1 2 3 and oil pump tach drive cover 41 or 42 as applicable F Remove tach drive housing assembly seal gasket thrust washer and tach drive shaft iems 4 thru 11 Figure 72 10 13B from oil pump tach drive cover 41 or remove attaching hardware 20 21 22 25 26 27 Figure 72 10 138 covers gaskets oil seal and tach drive shaft items 8 19 23 24 12and 17...

Page 149: ...ief Valve Plunger Relief Valve Spring Relief Valve Gasket Cap Relief Valve Valve Bypass Spring Bypass Gasket Pin and Plug Assy Bolt Filter Bypass Spring Filter Bypass Gasket Plug Filter Bypass Gear and Bushing Assembly Bushing Oil Pump Gear Gear Assy O P Tach Drive Dowel Gear Bevel Tach Drive Gear Bevel Tach Drive Cover Oil Pump Mech Tach Cover Oil Pump Elec Tach Filter Oil Tube Perforated Bolt Dr...

Page 150: ...aft 15 Dowel 16 Shaft Gear Assy 17 Washer Thrust 18 Gasket Annular 19 Housing Assembly Tach 20 Seal Oil Seal Oil Stud Washer Plain Washer Lock Nut Plain Gear Bevel Tach Drive Gasket Cover Tach Gearbox Washer Plain 21 Washer Lock 22 Screw 23 Gasket 24 Cover Tach Drive Pad 25 Washer Plain 26 Washer Lock 27 Nut Plain ...

Page 151: ...fters be replaced at each major overhaul regardlessof condition H While the engine remains in the inverted position remove the base nuts from the attach ingstudsandthe throughbolt on the sump side of the cylinder baseflange I Turnthe engineto the upright position J Turn the crankshaft until piston in cyiinder being removed is at top dead center Remove the base nuts from the three top attaching stu...

Page 152: ... Outer Spring lnner Retainer Valve Spring lnner Valve lntake Valve Exhaust Shaft Valve Rocker Rocker Assembly lntake Bushing Screw Rocker Assembly Exhaust Bushing Screw Washer Thrust Screw Washer Plain Cover Rocker Screw Washer Lock Washer Plain Gasket Rocker Cover Washer Pushrod Housing Packing Pushrod Housing Spring Pushrod Housing Housing Pushrod Pushrod Nut Gasket Exhaust Flange Packing Cylind...

Page 153: ...lve Spring Valve lntake Valve Exhaust Shaft Valve Rocker Screw Washer Lock Washer Plain Rocker Assembly lntake Bushing Screw Rocker Assembly Exhaust Bushing Rocker Screw Cover Rocker Screw Washer Lock Washer Plain Gasket Rocker Cover Nut Gasket Exhaust Flange Washer PushrodHousing Packing PushrodHousing Packing Pushrod Housing Housing Pushrod Spring Pushrod Housing Pushrod Packing Cylinder to Cran...

Page 154: ...rnor driien gear the idler gear assembly then the assembly of crankshaft connecting rods gearsand oil seal I Detach the left engine mount brackets from the assembly stand and lift off the left crankcasesubassembly NOTE Do not remove the upper flange attaching bolt and washer 69 These two parts are installed before the nearest magneto attaching stud and cannot be removed before removal of that stud...

Page 155: ...d IdentificationBand 0 Ring Packing Through Bolt Through Bolt Through Bolt Through Bolt ldler Gear Assembly Crankshaft Main Bearing CrankshaftThrust Bearing Thrust Washer PlainHex Nut Lockwasher PlainWasher Mount Bracket Plain Hex Nut Lockwasher PlainWasher Fuel Pump Pad Cover Fuel Pump Pad Gasket Plain Hex Nut Lockwasher Plain Washer Spacer Governor Pad Cover Governor Pad Gasket Oil Cap Retainer ...

Page 156: ...in wood blocks Stand these edgewise on the bench and lay the front and rear shaft journals inthe notches B Detach and remove the connecting rods Rotate and remove their crankpin bearing inserts Loosely reassemblethe rods cap boltsand nutswith positionnumbers matched C With Truarc No 1 or No 21 pliers compress the internal retaining rings then remove the retainingplatesand pinsfromthe counterweight...

Page 157: ...ssembly Counterweight Assembly Bushing Counterweight Pin Plate Snap Ring Plug Oil Control Thrust Washer Bearing Main Front Bearing Main Seal Assembly Spring Seal Dowel Gear Crankshaft Screw Drilled Hex Head Gear ldler Bushing ldler Connecting Rod Bushing Bolt Nut Slotted Cotter Pin Bearing ...

Page 158: ...72 10 18 EXHAUSTSYSTEMS A Exhaust systems for the 0 470 series engines are supplied by the airframe manufacturer For maintenanceproceduresreferto the applicableairframe manufacturer sinstructions ...

Page 159: ...ake Manifold 72 20 11 Castings 72 20 12 Stud Replacement 72 20 13 Helical Coil Insert Installation 72 20 14 Spark Plug Hole Helical Coil Inserts 72 20 15 Fin Repairs 72 20 16 Valve Guides 72 20 17 Valve Rockers 72 20 18 Hydraulic Valve Lifters 72 20 19 Connecting Rods 72 20 20 Piston Pin Bushing Replacement 72 20 21 Crankshaft Assembly 72 20 22 Wider Gear 72 20 23 Magneto and Accessory Drive Adapt...

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Page 161: ...rreassembly No polishing compound abrasive paste or powder is needed for cleaning engine parts Scraping and abrasion with wire brushes sandpaper abrasive cloth and buffing wheels are dangerous methods to use on soft metals like aluminum Scratches resultingfrom such methods allow concentratedstressat the scratchand may causefatiguefailure Blasting techniques can be employed to remove hard carbon de...

Page 162: ...ion polish the steel bearing surfaces with crocus cloth moistened with kerosene thenwith dry crocus cloth 72 20 06 PUSHRODS VALVE ROCKERS AND SMALL STEEL PARTS Degreasethese partswith mineral spirit solvent Give special attention to removal of sludge from all oil passages Blow com pressedair thru pushrod 72 20 07 CAMSHAFT AND CRANKSHAFT All parts must be degreased by brushing or spraying with mine...

Page 163: ... studs which cannot be gripped by drilling on center to the correct diameter for unscrewing them with a splined stud extractor Splined extractors and drills are usuaHy sold in sets Examine the course thread end of the damaged stud before discarding it to determine its size Standard studs have no marking For oversize stud identification refer to Fig 72 20 12A Clean the casting tapped hole with solv...

Page 164: ...FIGURE 72 20 12A STANDARD AND OVERSIZE STUD IDENTIFICATION Identification ...

Page 165: ...8 Magnetoand accessory drive adapter pad 5 16 18 x 5 16 24 3 4 6 9 3 8 16 X 3 8 24 13 16 2 10 Idler pin pad 1 4 20 x 1 4 28 1 2 10 1 4 20 x 1 4 28 5 8 2 11 Starter drive pad 5 16 18 x 5 16 24 13 16 2 12 Fuel pump pad 5 16 18 x 5 16 24 29 32 4 5 16 18 x 5 16 24 1 5 16 4 13 Oil pump pad 1 4 20 x 1 4 28 2 9 32 2 14 1 4 20 X 1 4 28 7 8 1 15 1 4 20 x 1 4 28 2 13 16 2 16 1 4 20 x 1 4 28 3 1 8 5 Cylinder...

Page 166: ... to class 3 fit with standard bolt threads or class 4 tight fa with standard size studs The difference in fit is due to a difference in pitch diameters of bolts and studs so that only one set of helical coil special taps is required for installation of these inserts in both bolt holes and stud holes Tap drilling depths and tapping depth for helical coil inserts to be installed in blind holes shoul...

Page 167: ...88 7 724 7N 528 7N 1195 7 1227 16 18mm 520112 C2 52 718 723 2 22 2 21 2 1 543 1227 16 C Notes For aluminum alloy castings For numbers of taps designed for steel refer to the manu facturer s Bulletin No 650 R T C M Part Numbers to basic part number add B for phosphor bronze or Cfor stainless steel add 1 1 5 or 2 for length equal to nominal diameter times 1 1 1 2 or 2 respectively All T C M furnishe...

Page 168: ...NSERT FIGURE 72 20 14A INSTALLSPARK PLUG HOLE HELICALCOlL INSERT A INTERNAL CHAMFER ONLY AS RECEIVED INSTALL AT OUTER END THESE SURFACES MUST BE SQUARE WITHIN 002 IN F U L L INDICATOR READING SECTION A A FIGURE 72 20 14B EXPANDINGSPARK PLUG HOLE HELICALCOlL INSERT FIGURE 72 20 17 VALVE ROCKER BEARING DIMENSIONS ...

Page 169: ...FOR IDIAMETER Dimensions shown are finished after FIGURE72 20 15A CYLINDER ASSEMBLY DIMENSIONS INCLINEDVALVE OCTOBER 1992 72 20 11 ...

Page 170: ...ston ring gaps given in the table of limits MUST be maintained Whenengineis beingoverhauled TCM REQUIRESthat all parts be brought backto newparts limits by rework or replacement installedparts should never exceed Service Limits See Section 72 30 07 New Parts and Service Limits SERVICELlMiTS FOR X DIAMETER FIGURE72 20 158 CYLINDER ASSEMBLY DIMENSIONS STRAIGHTVALVE 72 20 12 OCTOBER 1992 ...

Page 171: ...tted drill bushing to f i over the fin and a 3 16 inch twist drill may be used to cut the notch Its apex must be rounded and the edges should also be rounded If such repairs and previous breakage have removed as much as 10 of the total head fin area the cylinder assembly has reachedthe limit of its repairand the cylinder must be replaced 72 20 16 VALVE GUIDES REMOVALAND INSTALLATION Use heavy duty...

Page 172: ...body 8 hold plunger down fully and scrape out carbon deposit If this obstruction cannot be removed or if plunger is seized by score marks the entire assembly must be replaced Remove spring 7 by turning as if to unwind it while pulling outward Be careful not to stretch spring out of shape Remove check ball 4 from plunger by removing retainer 6 liftingspring 5 and ball 4 NOTE If major engine overhau...

Page 173: ...val These operations should precedemagnetic particleinspection WARNING Do not punch mark or mar the crankshaft or counterweights as a means of identification for re assembly Usetag ink stamps dye etc Hardened steel bushings in the crankshaft blades must be removed and replaced if excessively worn It is recommended that these bushings be replaced during major engine overhaul regardless of condition...

Page 174: ... its oil holes with beeswax to exclude chips from the adaptergr oove Be sure to remove the wax completely after the operation The old seal may be driven out with a 1 8 inch diameter pin punch inserted through the four oblique oil holes In the bushing boss alternately If the seal Istoo tight for that method drill and tap two opposite machine screw holes Inthe exposed flange of the seal case to matc...

Page 175: ...erior side of each outlet plate adjacent to the No 1 cable outlet hole Refer to Fig 72 20 27 and observe that the numerals appearing at magneto ends of the high tension cables correspond to the consecutive order of outlet plate cable holes while the relative positions of spark plug elbows indicate the installed position of the cables Install cable assemblies 3 through 14 Fig 72 10 05 in the indica...

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Page 177: ...ction 72 30 04 Ultrasonic Inspection 72 30 05 Flouirescent Particle Inspection 72 30 06 Dimensional Inspection 72 30 07 Dimensional Umits 72 30 08 Table of Umits 72 30 09 Original Dimension 72 30 10 Protective Coating 72 30 11 Application of Anodizing 72 30 12 Repair of Anodized Surfaces 72 30 13 Enamel Coatings 72 30 01 ...

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Page 179: ...softer metal beingtorn away and welded to the harder metal INDENTATION Dentsor depressionsina surface caused by severe blows OXIDATIONS Chemical combining of a metal with atmospheric oxygen Aluminum oxide forms a tough hard film and protects the surface from further decomposition however iron oxides do not form a continuous cover or protect underlying metal Therefore the oxidationof steel parts is...

Page 180: ...ble before dimensional inspection The Magnaglow method is recommended whenever the necessary equipment is available This method employs magnetic particles coated with a flourescent organic material which may be illuminated with a black light as in the Zyglo process to amplify an indication of weakness If a crankshaft is doubtful after a circular magnetization and inspection demagnetize and remagne...

Page 181: ...rArms Gearsto 6 lnch Diameter On Conductor Bar 1000 Pad socket under and single sidearmsand boss BetweenHeads 800 Fatiguecracks Circular or on 1000to Teeth Splines Center Conductor 1500 Keyways Fatiguecracks Gears over 6 lnch Diameter Shaft Circular 1000to Teeth Splines Teeth Between 1500 HeatTwo Times 9 0 Fatiguecracks Shafts Circularand 1000to Splines Keyways Longitudinal 1500 Changeof Section F...

Page 182: ...Wedge 45 K B Cat MSWS X W 028 KrautKramer Branson Stratford Connecticut 3 ReferenceBlock TCM Part 643901 4 Couplant SAE50 weight lubricatingoil D CALIBRATION 1 Connect instrument to 120V AC source or note that self contained rechargeable battery is at recommendedlevel 2 Liiinstrumentface cover and turn on by pullingthe On Off swtich 3 Turn gateoff by pushingbuttonswitch on side of instrument 4 Ins...

Page 183: ... criteria the following additional steps should beaccomplished a Ascertain the heat code on the crankshaft The code is alpha numeric and consists of three digits i e X45 N78 This code can be found on the number 1 3 4 or 9 cheekdepending on crankshaft part number b Ascertain if the crankshaft is made from air melt steel or vacuum arc remelt steel WAR Crankshafts made from air melt steel have no spe...

Page 184: ... difficult or the patterns displayed on the screen differ from the original pattern Replacethe shoefor correction Replace probe lead when it becomes stiff or frayed to avoid electrical noise and spurious signals 3 Signal Base It is important to distinguish between valid signals displayed on the CRT screen indicating a discreet reflector in the material and a spurious signal caused by electrical no...

Page 185: ...dial type cylinder boregage is preferred ratherthantools not specifically designed for this purpose 72 30 07 DIMENSIONALLIMITS TCM provides a limited number of parts dimensions and assembly clearances in its publications which are considered essential to perform a quality overhaul of its engines These values are termed New Parts Limits taken from parts drawings in effect at the time of publication...

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Page 187: ... GEAR BACKLASH 1 Crankshaft Gear and Camshaft Gear 0 016 0 008 0 012 2 Crankshaft Gear and IdlerGeac 0 016 0 008 0 012 3 IdlerGear and Magneto DriveGear 0 016 0 008 0 012 Leftand Right 4 Starter Shaftgear and Crankshaft Gear 0 0 16 0 008 0 0 12 5 Cam Gear Clusterand Fuel Pump DriveGear 0 016 0 008 0 012 ...

Page 188: ...FIGURE 72 30 08 TABLE OF LIMITS CHART 2 72 30 12 MARCH 1991 ...

Page 189: ...ceand noarea shall exceed one inchinany direction Cylinder bore surface rougness Cermicrome Finish pitting is undesierableif present it is subject to the following limits Pits No morethan two pits in any 114 inch Dia circle diameter Not morethan 25 pits of any size in entire cylinder boreis acceptable intakevalve seat inserts incylinder head dia Intakevalve guide incylinder head dia Exhaustvalve g...

Page 190: ... 015 length Exhaustvalve Max tip regrind 015 length lntakeand exhaust valve Full indicator reading warpage Valve rocker toe to valve stem dry lifter PISTONS RINGS PINS Piston Bottom of skirt with cast ring inserts in cylinder dia Piston Bottomof skirt without casting ringinserts in cylinder dia Top piston ring ingroove rectangular side clearance Top and second pistonring Semi Keystone in grove sid...

Page 191: ... Connecting rodbearingon crank pin tri metal bearing dia Connectingrod pistonborewith counterpin boretwist or convergenceper inchof length Bolt inconnecting rod dia Connectingrod pin bore dia Hydrauliclifter incrankcase dia lnnervalve springNo 631521 Compressedto 1 230in length load lnnerValve spring No 631521 Compressedto 1 746in length dia Outervalve springNo 631837 Compressedto 1 275 in length ...

Page 192: ...cm rn1 WI V c c m rm 0 0 zo mn z CD FIGURE 72 30 08 TABLE OF LIMITS CHART 3 72 30 16 ...

Page 193: ... incounterweight dia Crankshaftgear on crankshaft dia Crankshaft infront bearing diameter Crankshaft inthrust bearing end clearance Oiltransfer sleeve in crankcase dia Oiltransfer collar on crankshaft dia Sleeve inoil transfer collar dia Damper pin bushingboreincounterweight and crankshaft extension diameter CAMSHAFT 18 Camshaftjournals in crankcase diameter 0 005 L 0 001 L 0 003 L 19 Camshaft inc...

Page 194: ...r 27 Oil pump housing pilot in crankcase dia 28 Crankcasemain bearingjournals dia 29 Camshaft bearingjournals in crankcase dia 30 Crankshaftwidth at deck ACCESSORY DRIVE IDLER ASSEMBLY 31 Bushing in idler gear diameter 0 001 T 0 003 T 32 Idler gear support in bushing diameter 0 005 L 0 0015 L 0 0035 L 33 Idlergear end clearance 0 043 L 0 004 L 0 037 L O I L PRESSURE PUMPASSEMBLY 34 Oil pumpdriven ...

Page 195: ...ERNOR DRIVE SECTlOh 3 J SECTION 1 1 OIL SECTON 1 1 OIL PUMP AND FILTER OIL UNDER PRESSURE PUMP AND FILTER INVISIBLE PATH v A OIL DRAINAGE OIL SUCTION SECTION THROUGH OIL PRESSURE RELIEF VALVE FOR EARLY 0 470 A ENGINES FIGURE 72 30 08 TABLE OF LIMITS CHART 4 ...

Page 196: ...mpdriver gear shaft inoil pumpcover diameter 0 0045L 0 0015L 0 003L Oil pumpdriver gear shaft intachometerdrive bevelgear diameter 0 004L 0 0005L 0 0025L Oil pumpdriven gear in housing diameter 0 006L 0 0015L 0 004L TACHOMETER DRIVEASSEMBLY 10 Washertachometerthrust thickness 0 140 0 150 0 170 11 Tachometerdrive shaft in oil pump cover diameter 0 0045L 0 0015L 0 003L 12 Oil seal intachometerdrive ...

Page 197: ...vel at temperature Oiltemperaturecontrolvalve 0 16 inches minimumtravel at temperature Oil temperaturecontrolvalve 0 090 inches minimumtravel at temperature Oil temperaturecontrol valve must close between oiltemperature Oil temperaturecontrolvalve mustclose between oiltemperature Oil filter by passvalve spring No 631478 in pumpcomp to 1 09 in length load 40 5 Ibs 29 Ibs 32 Ibs 1Oo F 135OF 120 F 14...

Page 198: ...n magnetodrive gear slot side clearance Magneto coupling rubberbushingon magneto drive lugs side clearance Magnetopilot incrankcase diameter STARTER DRIVE Starter shaft gear in bushing diameter 0 0055 L Starter shaft gear in bearing diameter 0 0031 L Starter shaft gear front bushing journal diameter Starter shaft gear front Bearing journal diameter 0 748 Starter clutchdrum on starter shaft gear di...

Page 199: ...earing diameter Starterworm gear on shaft diameter Starter pilot to starter driie adapter diameter Starter drive tongue to worm shaft drive slot side clearance Needlebearingto shaft worm gear diameter FUELPUMPASSEMBLY 3 1 Pilotfuel pumpadapter in crankcase diameter 0 001 L 0 006L 32 Fuelpumpgear inadapterdiameter 0 004L 0 0005L 0 0025L 33 Fuet pumpdrivegear incrankcaseend clearance 0 054L 0 002L 0...

Page 200: ... fi1 SECTION N N MAGNETO COUPLJNG 27 SECTION P P SECTION 0 0 FIGURE 72 30 08 TABLE OF LIMITS CHART 5 72 30 24 ...

Page 201: ... is indoubt CRITICAL NEW PARTS DIMENSIONS Part Name Feature NewDimension Inches Cylinder Head Valve RockerShaft Valve Rocker Bushings IntakeValve ExhaustValve Piston Standard PistonPinAssembly ConnectingRod CrankshaftAssembly Crankcase HydraulicValve Liers RockerShaft Boss Bore IntakeValve Guide Bore ExhaustValve Guide Bore OutsideDiameter InsideDiameter Stem Diameter Stem Diameter Diameterat Bott...

Page 202: ...ssory DriveAdapter BushingInsideDiameter Idler Gear Assembly BushingI D Sandcast Crankcase ldler Gear Support Pin Gear Support Dia SandcastCrankcase 72 30 10 PROTECTIVECOATING The manufacturer protects all aluminum alloy castings sheet metal and tubing from corrosion by treating all surfaces of the parts with wAccelagold Turco Products 3300 MontrealIndustryWay Tucker Georgia 30084 72 30 11 APPLICA...

Page 203: ... until color of the newfilm isapproximatelysameas original D Flush part with clear water and dry with warm air current Do not air blast or rub with cloth to dry new film area If color is too light repeat step C until desired color is obtained NOTE If Accelagold does not adhere to metal a more severe cleaning method must be used 12 to 16 ounces of Oakite No 61 or equivalent solution per gallon of w...

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Page 205: ... Counterweight Pins and Bushings 72 40 04 Camshaft 72 40 05 Connecting Rods 72 40 06 Gears 72 40 07 Pistons and Rings 72 40 08 Cylinders 72 40 09 Hydraulic Valve Utters 72 40 10 Intake Tubes 72 40 11 Lubrication System 72 40 12 Fuel System 72 40 13 Ignition System 72 40 14 Exhaust System 72 40 15 Inspection Chart 72 40 01 ...

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Page 207: ...f Limits 72 30 09for limitsof run out at the centerjournal NOTE In case of prop strike sudden stoppage refer to TCM Service Bulletin M84 16 or current revisionas applicable 72 40 03 CRANKSHAFT COUNTERWEIGHTPINS AND BUSHINGS A Excessive localized galling of the crankshaft dampener pin bushings can affect propeller blade tip stresses It is recommended that at each normal major overhaul the pin bushi...

Page 208: ...ion 72 30 08 Table of Limits To measure bushing and bearing convergence mount a dial indicator on a surface gage and swing the rod around the big end arbor to the vertical position against a f i n stop Pass the indicator over the bushing arbor at points an exact number of inches apart The difference in readings at the two ends divided by the distance between points of measurements again gives the ...

Page 209: ... its proper depth as mentioned above At this point measure the ring gap with a feeler gage If gap is too tight according to Table of Limits file ring to within limits and polish end with an Arkansas stone If gap is too large go to a 0 005 inchoversize ringto reachTable of Limits B MEASURINGRlNG SlDE CLEARANCE After piston rings have been checked for ring gap install rings on piston do not allow th...

Page 210: ...lves at engine overhaul regardless of condition and all intake valves should be measured in length if the stem tips were ground Inspect the spark plug hole and intake flange screw hole helical coil inserts for looseness deformation and position The outer ends should lie in the first full thread of the tappet holes in which they are installed The spark plug hole helical coil has teeth at the outer ...

Page 211: ...ect all parts of the system in accordance with the instrucitonsin Sections72 30 03 07 09 72 40 12 CARBURETOR The Carburetor either Marvel Schebler or Bendix Stromberg should be overhauled according to the applicable Manufacturers instructions prior to re installaion on the overhauled engine For adjustments and minor maintenance procedures refer to Chapter 73 fuel system 72 40 13 IGNITION SYSTEM A ...

Page 212: ...the ignition system can Worn Out Severe Excessive eroded center and ground electrodes and extensive necking of fine wire ground electrodes indicate abnormal engine power operation Check fuel metering and magneto timing Discard the plugs and before installing new spark plugs a careful check should be made to determine if proper heat range plugsare being used FIGURE 72 40 13A SPARK PLUGS FIGURE 72 4...

Page 213: ...indersas a quality check Stem Holes in Valve Guides Valve Seats Cooling Fins Head Barrel oversize bore Dimensional honingshould removeringstep of more than0 002 inchdiameter Taper limit Table of Limits must not be exceeded by honing Referto Table of Limits Scoring diameter Rareat ends Roughnesscaused by honing Cracksand brokenareas Penetrateinspection100 Magna Flux Diameters of stem holesin new gu...

Page 214: ...d rounded edge on intakevalve head Use height gageto detect stretchand check for re ductiondueto tip grinding Scoring diameter Obstruction Side clearance between cylinder head supports Diameter scoring rough ends Measureusingair gaugewith correct size air plug and master setting ring Special Considerations Allow not over 0 001 inch out of flaton machined surface Polishingmust not reduce diameter b...

Page 215: ... fit Burring scoring wear enough to alter profile Damaged or dirty threads Diameter and fit incrankcase bearings Scoring pitting and corrosion PittIng along toe line loss of slope along toe line width across heel and toe at center of length Distortion of threads Nicks peening other irregularities Scoring burring pitting wear enough to alter profile Special Considerations Must be polished before ma...

Page 216: ...ar bearing between camshaft flanges lnspectvisually galleries mainand camshaft bearing supply holes using inspec tor s flashlight to illumi nate Probe other oil holes with brass rod Deformed or dirtythreads Distortion Check for backingouts Usetoolmaker ssquareto check studs suspectedof bending Insidediameter scoring Warpage cracks Observe that old seal has been removedwithout damage to retainer At...

Page 217: ...s Tapped Holes Mounting Surfaces All Areas Threads Wrench Flats Threads Tube Filter Machined Surfaces All Areas Gearshaft Plugs Damagedthreads cracks around holes Scratches warpage cracks Cracks Lookfor distortion Lookfor damagedcorners Damagedthreads dented tube cracks intube distortedor plugged filter Scratches cracks Cracks scratcheson machinedsurfaces restric tions inoil holes Lookfor scoring ...

Page 218: ...age and Referto Table of Limits micrometer caliper Outside Surface Measurediameter Look for scoring nicks etc Must seat perfectlyin Spread Prussianblue oil base pigment on face of plunger and turn on seat all around plungerface must be lappedto seat Measurediameters Referto Table of Limits Seethat old oil sealwas screen out of round pilot ASSEMBLY Cracks scratches on machinedsurfaces damaged Rough...

Page 219: ...nd looseness Cracks scratches on machinedsurfaces damaged mountingholes Lookfor scoring Measurediameter Seethat oil sealwas removed without damageto casting HubAssembly Hub INDUCTION SYSTEM IntakeManifold Scoredor under bearing surfaces Damagedor broken Lookfor chipped cracked and brokenteeth scoring burning and wear Measure borediameter Thickness excessivewear Checkfor warping by placing flanges ...

Page 220: ...Make surethat new plugwas installedafter magnetic particle inspectionof gear and visual inspectionfor cleanlinessof center bore Checkfor looseness Fuel Pumpand Vapor Separator Fuel Injection ControlAssy Fuel Manifold Valve Assy ShroudAssy Air Throttle Assembly Referto Table of Limits Inspectionis limited strictly to visual for evidenceof damage or leakage Inspectionis limitedstrictly to visual for...

Page 221: ... Flats Gear Bushing Oil Seal Studs Teeth Shaft Lookfor cracks flat spots out of roundends Distortionor stripping Lookfor damaged corners Measure borediameters Observethat old seal has beenremovedwithout damageto castingbore Lookfor strippedand deformedthreads Scoring burringor wear enoughto altertooth profile Measurediameters and comparewith bushing diameter Referto Table of Limits Referto Table o...

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Page 223: ...S 72 50 01 General 72 50 02 Oil Pump Assembly 72 50 03 Starter and Drive Assembly 72 50 04 Cylinder Assembly 72 50 05 Piston arnd Ring Assemblies 72 50 6 Pushrod Housing 72 50 07 Crankshaft and Connecting Rods 72 50 08 Camshaft 72 50 09 Crankcase 72 50 10 Carburetor 72 50 01 ...

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Page 225: ...rrosion resistantlockwire TIGHTENING TORQUES The accuracy of any torque indicating wrench depends on a smooth application of force Do not back up a nut or bott and leave it in that condition If part is accidentally tightened too much loosen it and retighten it to a value within the specified limits If nut slot cannot be aligned with a cotter pin hole within the specified limits substitute another ...

Page 226: ...irotallic ExhaustGasketAssy Attaching ManifddFlangeNuts Starterto Adapter Nut Alternator HubAssembly Nut Alternator Nut Oil PressureRelief Valve New Gasket Housing Oil TemperatureContrdValve Spark Plug Oil BypassPlug q o r ueto low limit if cotter pin ill not enter i crea torque r du II u t hi h limit gl cqtter pin will not enter in th s rage replacenut and repeat no case shall nuts torqu88beifoXI...

Page 227: ...40 on driie gearshaft C If electric tachometer is used follow procedure described in paragraphs D E F If mechanical tachometer is used skip to paragraph G and proceed as described See Figure 72 10 138 Oil PumpCover and Tachometer Drive D lnstall new oil seal 11 in tachometer drive housing 10 lnstall new gasket 9 on housing 10 Carefully work lip of oil seal over shaftgear 5 6 or 7 and push shaft th...

Page 228: ...lve heads Clamp cylinder base flange to prevent it from rising Again apply Molyshield to valve stems B Place valve spring retainers 17 over valve guides 8 9 cupped side up lnstall valve guide seal on intake valve guides lnstall inner and outer valve springs 15 16 per instructions in Fig 72 50 04 rotocoil 14 Compress springs and install keys 13 On Models 0 470 U spec 11 18 install rotocoils on exha...

Page 229: ...derfront and rearjournals B Lay out connecting rod assembly parts 20 thru 24 opposite crankpins according to position number stamped on bolt bosses install new bearing inserts 25 in each rod and cap sotheir edges projectthe same distance C Lubricate and install each rod and cap with their position numbers on top when odd number rods are extended to the right and even numbers to the left Attach the...

Page 230: ... Section72 30 08 A Replace any pipe plugs which were removed during previous operations lnstall machine thread plugs B lnstallgasket 64 and oil fillertube 63 Securewith attachingparts 62 C lnstallgasket 56 governor padcover 55 and securewith attaching parts 51thru54 D lnstall gasket 50 cover 49 and securewith attaching hardware 46 47 48 E lnstall mountinglegs 45 Securewith attaching hardware F Lay...

Page 231: ... Drive Adapter 720 0O7 Alternator Assembly 72 60 08 Magneto and Accessory Drive Adapters 72 60 09 Oil Cooler 72 60 10 Valve Mechanism 72 60 11 Oil Sump 72 60 12 Induction System 72 60 13 Carburetor 72 60 14 Magneto Drive Gears 72460 15 Placing Crankshaft in riming Position 72 60 16 Magnetos 72 60 17 Ignition Harness 72 6018 Fuel Lines Hoses 72 60 19 Exhaust System 72 60 01 ...

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Page 233: ...wer the assembly into position in the left crankcase bearings with the oil seal positioned so as to enter its case recess The connecting rod position numbers should automatically be toward the upper case flange if properly installed Laythe odd numberedconnectingrodsonthe upper flange D Insertthe governordrivengear 1 Figure 72 10 16 intoits bearing E Slide the governor driier gear on the front end ...

Page 234: ...inder mount pad the seven 10 3 4 in through bolts 35 through the cylinder mount pads and the four 10 112 in through bolts 37 below the camshaft level Tap all of these through to centered positions with a non marring hammer These bolts align the crankcase castings and thrust bearings L Install a spacer and a flanged nut on each end of the two front through bolts a spacer and a flanged nut on the to...

Page 235: ... 36 37 and thru bolts 19 22 27 28 29 to 300 400 inchIbs in sequence shown 6 Install cylinder No 1 Tighten stud nuts 31 32 34 35 36 37 and thru bolts 30 33 38 to 300 400 inchibs in sequence shown 7 Torque thru bolts and stud nuts 1 thru 38 to the correct torque values in sequence shown 8 Tighten bolts No 39 thru 57 in sequence shown to torque specified on the chart listed below NOTE Repeat torquing...

Page 236: ... Then turn the shaft for Nos 1 and 6 and installthe last two assemblies E Place the piston over the connecting rod with the position number on its head forward Pushthe pinthrough until it is centered FIGURE 72 60 03A INSTALLING NO 6 FIGURE72 60 03B TIGHTENING CYLINDER CYLINDER BASE NUT F Hang a piston ring compressor on the piston skirt Holding the cylinder in left arm center the compressor over t...

Page 237: ...s enough that most of the brush marks disappear if not use a new can of Permatex Allow to air dry to a tacky condition beforethreading 3 Apply Permatexto all areas on non threadedpart usingthe sametechniquesas above 4 Apply silk thread part no 641543 position as shown by dotted lines in Figure 72 60 04 above 5 To assemble use bolts for alignment to prevent movement of the thread and torque all bol...

Page 238: ...ATORASSEMBLY See Figure72 10 11A NOTE Overhaul generator per Manufacturersinstructions priorto re installation A lnstallsheave 3 on generator Securewith retainingnut B lnstall generator on generator mounting bracket 14 Install gear bracket to generator lower attaching hardware Attach generator drive belt and adjusting arm to generator attaching hardware tension drive beltand tighten generator bolt...

Page 239: ...seflange D To install each pushrod housing 38 compress spring 37 and place packing 36 between two steel washers 35 on that end of housing Insert this end of housing into crankcase guide until other end and its seal ring can be aligned with cylinder head opening Move assembly outward until packing 36 sandwiched between two steel washers 35 as applicable has entered cylinder hole Releasespring slowl...

Page 240: ...etaining screw 19 washers 20 21 torque screws according to Table of Tightening Torques Figure 72 50 018 and secure with safety wire NOTE Besureto lubricateall movingpartsliberallywith engine oil NOTE Check valve to rockerclearance See Figure72 30 08Chart 2 item23 G Install all pushrods and rockers in other cylinders in same manner lnstall valve rocker covers 28 gaskets 32 and securewith attachingp...

Page 241: ...tube Push tube ends into connecting hoses installed on front intake tubes Position clamp and secure bracket to sump with two sets of attaching parts Position clamp assemblies between tube and elbow over beads and tighten Turn engine upright INDUCTIONSYSTEM FOR 0 470 A J K L R S U See Figure72 10 08A A Push hoses and clamps on No 1 and No 2 intake tubes until clear of ends Position manifoldriser be...

Page 242: ...ructions contained in Chapter 73 EngineFuel Systemand run inschedule 72 60 14 MAGNETO DRIVEGEARS See Figures 72 10 08 72 60 14 NOTE Overhaul magneto s per Manufacturers instructions prior to re installation A With engine in upright position insert one pressed steel retainer 18 into each gear hub slot B Cover each of four new rubber coupling bushings with a film of Molyshield grease and inserttwo b...

Page 243: ...dertop spark plug hole 2 Installtimingdisc of indicatorbeingused on crankshaft 3 Turn crankshaftslowly indirectionof rotationuntil pistonlightlytouches TDC locator 4 Rotatedisc of timing indicatoruntiltop center mark is underthe pointer 5 Slowly turn crankshaft in opposite direction until piston lightly touches TDC locator Observe the reading on the disc under the pointer and move the disc to exac...

Page 244: ... then clockwise until the timing indicators pointer is pointing to the correct degree for modd engine Both timing lights should go out at the same time The timing mark on the crankshaft Range should also align with crankcase parting flange or the timing mark on the alternator drive gear appears in the center of the crankcase inspectionhole G Install gaskets and covers on mount pads behind magneto ...

Page 245: ...rew on the elbow coupling nuts only enough to keep the elbows from turning Keep the lower spark plug cables above the intakemanifoldand insidethe intake elbows H Check service bulletins occasionally issued by ignition harness manufacturers regarding tips for increasedservice life I UPPER SPARK PLUGS I RIGHT LEFT MAG MAG SWITCH SWITCH 0 J LOWER SPARK PLUGS FIGURE 72 60 17 IGNITION WIRING DIAGRAM 72...

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Page 247: ...Club 72 70 03 Cooling Air Scoop 72 70 04 Induction Air Intake 72 70 05 Exhaust Stacks 72 70 06 Controls 72 70 07 Electrical Wiring 72 70 08 Instruments 72 70 09 Breather 72 70 10 Fuel System 72 70 11 Governor Pad Cover 72 70 12 Engine Test 72 70 13 Starting Procedure 72 70 14 Overhaul Test Run 72 70 15 Test Flight 72 70 01 ...

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Page 249: ... be used contingent on careful observation of cylinder temperatures Headthe aircraft intothe windfor this test 4 Calibrationof the aircraft engine instrumentsmust be performed For further information see TCM Service Bulletin M88 7 or current revisions as applicable C TEST STAND After each major overhaul engine performance should be tested and new parts run in while the engine is mounted on a rigid...

Page 250: ... the alternatorvent tube 72 70 04 INDUCTION AIR INTAKE An air filter and housing should be attached to the turbocharger inlet flange The filter area must be sufficient to avoid restriction of air flow Always clean filter before each test Calculations of filter area should be based on approximately 389 c f m of air required by the engine at full throttle and on the filter capacity per unit of area ...

Page 251: ... common ground 72 70 08 INSTRUMENTS The control panel should be equipped with the following calibrated engine instruments A A mechanically driven counterclockwise 1 2 engine RPM tachometer and flexible shaft assembty is required B An oil pressuregageand tube connection C An oiltemperaturegageand capillaryassembly D A cylinder head temperature gage and wiring to each cylinder See test operating lim...

Page 252: ...nd the time required to trip with a known fuel overbalanceat the switchover time may betimed by a stopwatch FIGURE72 70 10 THREE QUARTER RIGHTFRONTVIEW OF STROMBERG PSD BC CARBURETOR 1 Manualmixturecontrol lever 2 ldle cutoff lever 3 ldlecutoffplunger 4 Air section drain hole 5 Fuel inlet portshipping plug 6 Fuel strainer plug 7 Drain hole 8 Regulatorneedlevalve plug 9 Fuel pressuregage connection...

Page 253: ...sary to shieldthe crankcasefromthe coolingair stream since ittakes some heatfrom the oil 72 70 13 STARTING PROCEDURE A FuelSelector On appropriatetank B Propeller Control HighRPM C Mixture Control FullRich D Battery Switch On E Throttle Full Open F BoostPumpsor Primer On2to 3 seconds G Throttle 1 2 inch Open H Magneto Start Switch Start Position Releasethe MagnetolStartSwitchto BothPositionas soon...

Page 254: ...MINUTES Check Fuel System Oil Pressure Oil Temperature M A P C H T and Alternator Magneto Dropand Spread To Be Taken Engine Must Be ThrottledTo Specified RPMand Temperature Allowed To Settle Out Before Taking Magneto Drop And Spread Cooling Period 300 Max C H T Before Shut Down Recheck IdleAdjustments Runs8 And 9 Must Be Made With Stops For Leak Checks At The End Of Each Run See Operating Limits S...

Page 255: ...d See Operating Limits Section77 10 W Adjust engine fuel flow and pressure Reduce RPMfor adjustments Checkfuel injection oil pressure oil temperature MAP C H T and alternator Magnetodrop and spreadto be taken Enginemust bethrottledto specified RPMandtemperature allowedto settle out beforetaking magneto drop and spread Refillsumpwith clean oil Readingsmustbe recordedafter completionof each 10minute...

Page 256: ...peratures 15W50 20W50 Oil consumptionat Max Continuous Power Lbs BHP Hr Maxat Rated Powerat RPM MODELS 0 470 A C E J Notto exceed 018 Lbs per BHP Hr at Rated Powerand RPM 0470 B G P Notto exceed 015 Lbs per BHP Hr at Rated Powerand RPM 0 470 H K M N Notto exceed 012 Lbs per BHP Hr at RatedPowerand RPM 0 470 R S U 006 X Power Lb BHP Hr Maxat RatedPower 100 and RPM Oiltemperature desired range Oil t...

Page 257: ...r s operatinginstructions Level flight cruise should be at 75 power with best power or richer mixture for the first hour of operation The second hour power settings should alternate between 65 and 75 power with the appropriate best power mixture settings Engine contrds or aircraft attitude should beadjusted as requiredto maintainengine instrumentationwithin specifications The descent should be mad...

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Page 259: ...SECTION 72 80 ENGINE PRESERVATION 72 80 00 ENGINE PRESERVATION 72 80 01 General 72 80 02 FlyableStorage 72 80 03 Temporary Storage 72 80 04 IndefiniteStorage ...

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Page 261: ...ures which will vaporize moisture and other by products of com bustion In consideration of the circumstances mentioned TCM has listed three reasonable minimum preservation procedures that if implemented will minimize the detriments of rust and corrosion It is the owner s responsibility to choose a program that is viable to the particularaircraft s mission Aircraft engine storage recommendationsare...

Page 262: ...TEMPORARY STORAGE Up to 90 Days 1 Preparationfor Storage a Remove the top spark plug and spray preservative oil Lubrication Oil Contact and Volatile Corrosion Inhibited MIL L 46002 Grade 1 at room temperature through upper spark plug hole of each cylinder with the piston in approximately the bottom dead center position Rotate crankshaft as each pair of opposite cylinders is sprayed Stop crankshaft...

Page 263: ...res Allow engine to cool to ambient temperature Accomplish steps 1 a and 1 b of TemporaryStorage NOTE MIL C6529 Type I f may be formulated by thoroughly mixing one part compound MIL C 6529 Type I Essor Rust Ban 628 Cosmoline No 1223 or equiva lent with three parts new lubricating oil of the grade recommended for service all at roomtemperature Singlegrade oil is recommended b Apply preservative to ...

Page 264: ... propeiler tagged in a conspicuous place with the following notation on the tag DO NOT TURN PROPELLER ENGINE PRESERVED PRESERVA TION DATE PROCEDURESNECESSARYFOR RETURNINGAN AIRCRAFTTO SERVICEARE AS FOLLOWS 1 Remove the cylinder dehydrator plugs and all paper tape desiccant bags and streamers usedto preservethe engine 2 Drainthe corrosionpreventivemixtureand re servicewith recommendedlubricatingoil...

Page 265: ...months or more frequently if bore inspection indicates corrosion has started earlier than six months Replace all desiccant and dehydrator plugs Before spraying the engine should be inspected for corrosion as follows Inspect the interior of at least one cylinder on each engine through the spark plug hole If cylinder shows start of rust spray cylinder corrosion preventive oil and turn prop over six ...

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Page 267: ...SYSTEM 73 00 00 ENGINE FUELSYSTEM 73 10 01 MeteredFuelPressureAdjustment 73 10 02 Flushing RegulatorNeedleValve 73 10 03 IdleAdjustment Bendix Stromberg Carburetor 73 10 04 Fuel Pump 73 10 05 FuelSystem Troubleshooting Chart ...

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Page 269: ...rce 1 Roughor surgingengine operation at cruising power or possiblehigher power 2 Highcylinder headtemperaturesduring extendedengineoperationat cruisingpower Before readjusting the discharge diaphragm adjusting screw to change the metered fuel pressure observe the barrel of the screw If the original factory adjustment has not been disturbed a punch mark on the screw will align with another on the ...

Page 270: ... idle stop If idling speed is appreciable above or below 600 RPM turn the idle speed adjusting screw a notch at a time inward to increase or outward to decrease speed If idling speed changes during the following steps readjust in the same manner D Move the manual mixture control slowly and smoothly into the IDLE CUTOFF position watching the tachometer closely for any change in RPM As soon as the f...

Page 271: ...al gage can be made locally to rest on the body stud and space the lever wide open stop at 35 degrees while the enrichment screw is readjusted and its lock nut tightened After such adjustment be sure to install lock wire inthe enrichment screw and lever NOTE Before flushing the needle valve investigate all other possible causes of trouble symptomsas describedinthe TROUBLESHOOTINGCHART To flushthe ...

Page 272: ...ns to stop the engine since leaning the mixture with the cutoff momentarily corrects a slightly over rich condition If a greater increase in RPM was observed the idling mixture setting is too rich and if no increase occurs it is too lean Always return the manual mixture control to the full RICH position before the engine stops if further running is desired To avoid false results due to spark plug ...

Page 273: ...ugged Cleanthroughly Remove moisture Carburetor flooded Disassembledand clean Check float needle and seat Cylinders overprimed Place mixture control in IDLE CUT OFF position Switch ignitionoff Open throttle wide Turn propeller several revolutions Insufficient priming puffs Prime more In cold weather draw of white smoke and weak plunger slowly back push hard Check pump output at priming jet No fuel...

Page 274: ...l 1 8 in and taper seat plugsfor tightness Engineruns too rich Manualmixture control in Check control linkage at cruising power Restrictionin air scoop Carburetorair heat valve open Enginerunstoo lean Improperfuel pressure Check gauge and clean strainer if or too rich at take pressurewill not risewhen boost off or rated power but satisfactorily at Incorrectjet installed Check by removingjet plug i...

Page 275: ...cover and inspect Punctured pump diaphragm Removepump cover and inspect Overhaul carburetor off with manualmix poppet valve to close ture control in IDLE CUTOFFnposition Fuel leakagethrough primer Leakageat fuel pump seal Linkagedoes not permit idle cutoff leverto reach OFF Clean strainer carburetor screen carburetor mainjet Measureflow through supply line Engine requires 113G P M at full throttle...

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Page 277: ...00 GENERAL 74 00 01 Magnetolnstallation 74 00 02 HarnessAssembly Installation 74 20 00 IGNITIONTROUBLESHOOTING SLICK IGNITIONSYSTEM 74 30 00 GENERAL 74 30 01 Magneto lnstallation 74 30 02 HarnessAssembly lnstallation 74 50 00 IGNITIONTROUBLESHOOTING ...

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Page 279: ...tery voltage to the magneto primary circuit during starting and 2 automatically retardthe spark duringenginecranking The following detailed explanation gives the meaning of the various letters and numbers appearinginthe type designations A S indicatessingletype ignitionunit B 4 6 or 8 indicatesnumberof cylindersfired C R or L indicates direction of rotation of rotating magnet viewed from drive end...

Page 280: ...72 50 01 6 for proper torque Disconnect timing light from magneto Make connections between magneto and ignition switch using 18gage wire following airframe manufacture swiring instructions WARNING The magneto is in a SWITCH ON condition when the switch wire is disconnected Therefore the usual precaution must be observed 74 00 02 HARNESSASSEMBLY INSTALLATION Before installing harness on magneto che...

Page 281: ...04A Fasten coupling nuts to the proper spark plugsand torque as specified inTable II Tightenelbowassembly nutsto outer ferrule FlurocarbonSpray MS S 122 Miller StephensonChemicalCo Inc 16Sugar HollowRoad Danbury Connecticut06810 GoJoNo Lok Gojer Inc Akron Ohio 44309or MolykoteType G The Alpha Molykote Corp Stamford Connecticut06904 NOTE Hold ferrules while tightening or loosening spark plug coupli...

Page 282: ...gnetointernaltiming in Installcorrectlytimed magneto correct or timed for opposite Weak condenser Replacecondenser Loose or improperlygapped Tightento specifiedtorque Adjust to proper gap Hightensionleak in ignition Check for faulty inspection Weak or burned out condenser Replacepointsand condenser as evidenced by burned or pittedbreaker points SluggishOperation Fouledor dead spark plugs Clean spa...

Page 283: ... drive coupling for the magneto The following detailed explanation gives the meaning of the various numbers appearing in the serial number E G 2 03 1 3 2 The mbnthof Manufacture 03 March The year of Manufacture 2 1982 74 30 01 MAGNETO INSTALLATIONAND TIMING TO ENGINE The number of a particular model manufactured inthe monthspecified Before magnetos are installed on the engine the rotation and inte...

Page 284: ...timing light will indicate both magneto contacts are opening simultaneously at engine full advance firing position See Section 72 00 00 for correct firing position If contacts do not open within limits adjust magneto to engine timing as necessary Secure magnetosand removetiming lights CAUTION When installing the magneto on the engine using the available nuts and clamps please take the following pr...

Page 285: ...ly nutsto outer ferrule Flurocarbon Spray MS S 122 Miller StephensonChemical Co Inc 16 Sugar Hollow Road Danbury Connecticut 06810 Go40 No Lok Gojer Inc Akron Ohio 44309 or MolykoteType G The Alpha Molykote Corp Stamford Connecticut06904 NOTE Hold ferrules while tightening or loosening spark plug coupling nuts to protect againsttwisting conduit or cable D Clampharnessleads as required FIGURE 74 38...

Page 286: ...etos and IgnitionTimingfor timing Shorted condenser Replacecondenser Magnetointernaltiming Installcorrectly timed magneto Weak condenser Replacecondenser RoughAt Speeds Looseor improperly gapped Tightento specifiedtorque Adjust to proper gap Checkfor faulty inspection Weak or burnedout condenser Replacepointsand condenser as evidenced by burned or pitted breaker points SluggishOperation Fouledor d...

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Page 289: ...turi is mixed with fuel and carried into the induction manifold to the cylinder intake portswhere the combustiblemixture enters the cylinderwhenthe intakevalve opens The induction manifold is an air distribution system mounted in several different configura tions according to engine model It serves to carry induction air to the individual cylinder intakeports The cylinder intake ports are cast int...

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Page 291: ...CHAPTER 76 ENGINECONTROLS 76 00 00 GENERAL 76 10 00 CRUISE CONTROL BY PERFORMANCE CURVE 76 20 00 CRUISE CONTROL BY E G T 76 30 00 PERFORMANCECHARTS ...

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Page 293: ...ust throttle in that order Whenreducingpower retard throttle then adjust RPM and mixture NOTE It may be necessary to make minor readjustments to fuel flow mixture after changing RPM 76 20 00 CRUISE CONTROLBY E G T If an exhaust gas temperature indicatoris usedas anaidto leaning proceedasfollows 1 Adjust manifold pressureand RPMfor desired cruisesetting 2 Slowly move mixture control toward lean whi...

Page 294: ... Level Performancefor 0470 M Sea Level Performancefor 0470 R S Sea Level Performancefor 0470 U Altitude Performancefor 0470 A Altitude Performancefor 0 470 8 Altitude Performancefor 0 470 E Altitude Performancefor 0470 G Altitude Performancefor 0 470J Altitude Performancefor 0470 K I R S Altitude Performancefor 0 470 M Altitude Performancefor 0 470 U FuelFlowLimitsfor 0 47043 FuelFlow Limitsfor 0 ...

Page 295: ...0 A COMPRESSION RATIO 7 0 1 FULL METERING CARB M A 4 4 FUEL GRADE 80187 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM I 29 28 27 26 25 24 23 60 55 50 2000 2200 2400 2600 2800 ENGINE R P M SEA LEVEL PERFORMANCE FOR 0 470 A ...

Page 296: ... ENGINE MODEL 0 470 0 COMPRESSION RATIO 8 0 l FUEL METERING PSD 5C FUEL GRADE 91 96 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM I ENGINE RPM SEA LEVELPERFORMANCE FOR 0 470 B ...

Page 297: ...ENGINE MODEL 0 470 E COMPRESSION RATIO 7 0 l FUEL METERING CARB PSD 5C FUEL GRADE 80187 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM ENGINE RPIW SEA LEVEL PERFORMANCE FOR 0 470 E ...

Page 298: ... IENGINE MODEL 0 470 G COMPRESSION RATIO 8 0 l I FUEL METERING CARB PSH 5BD FUEL GRADE 91 96 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM I ENGINE RPM SEA LEVEL PERFORMANCEFOR 0 470 G ...

Page 299: ...ENGINE MODEL 0 470 5 COMPRESSION RATIO 7 0 1 FUEL METERING CARB M A 4 5 FUEL GRADE 80187 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM ENGINE RPM SEA LEVELPERFORMANCE FOR 0 470 J ...

Page 300: ...INE MODEL 0 470 K L COMPRESSION RATIO 7 0 l FUEL METERING GARB MA 4 5 FUEL GRADE 80187 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM 1 8 0 0 2000 2200 2400 2600 ENGINE RPM SEA LEVEL PERFORMANCE FOR 0 470 K L ...

Page 301: ... ENGINE MODEL 0 470 M COMPRESSION RATIO 8 0 l FUEL METERING CARB PSD 5C FUEL GRADE 91 96 OCTANE INLET AIR STD ATMOSPHERE WITHOUT RAM 1800 2000 2200 2400 2600 ENGINE RPM SEA LEVEL PERFORMANCEFOR 0 470 M ...

Page 302: ...ENGINE MODEL 0 4704 DATE 7110174 MIN FUEL GRADE 80187 COtAP RATIO 7 l INLET AIR STD ATMOSPHERE WITHOUT RAM 1800 2000 2200 2400 2600 ENGINE RPM SEA LEVEL PERFORMANCE FOR 0 470 R S ...

Page 303: ...ENGINE MODEL 0 470LU DATE 9 2 75 MIN FUEL GRADE 100 lOOLLr COMP RATIO 8 6 1 INLET AIR STD ATMOSPHERE WITHOL T RAM 1600 1800 2000 2200 2400 ENGINE RPM SEA LEVEL PERFORMANCEFOR 0 4704 ...

Page 304: ...RFORMANCE FOR 0 470 A 76 00 14 4 s Ie t I CI a z Z4 Jo 4 A 7L hi U 2 0 Ut a a I 9 hi U z U 0 C J C hi U 000000C ID N C w v 4 1 J dV43J 7v ols 0 01 1 2 4 0 cr MILO war V w J cr N Jo 1 1 cll 3 3A I W3S 4 Z 4 a 4 0 0 U N N m N N C N N F4 0 V E m 7 I 1 I U Z 2 z 1 7 I lz i z Zl d q z t 7 I U 4 cl z adim I Ed M 3 I i I I 1 I I s s m mm 7 ss mmm mcm s1 m r K MRmm Nt I lK 0000000 WV NVO N IC CY c 0 CY co...

Page 305: ...CY II f1 I 9 I I N 0 0 I Lu 0 0 0 0 0 0 l q 1 0 N LI I k I XAl I1 9 LA Y C C LAUC ALTITUDE PERFORMANCE FOR 0 470 B 76 00 15 z c 0 I hi a hi a PI j 4x 2 41 a if II I I 0I I 0 Q a 0 N co N V C N 0 0 N N II a 2 I eQ O 4 z I trip I I I xi I N I rq q I E l I 37rim M M v Er 40 w mgm bm b 2 M Mlb mbubloAArAm bm Ems 11 cI Ill Xlklm L w u v x p I II 7x t i at i 1 4 1 w 5 ...

Page 306: ...ALTITUDE PERFORMANCE FOR 0 470 E ...

Page 307: ...MANCE FOR 0 470 G 76 00 17 0000004 WV0 044 444 I CL 2 F 9 C M 0 4 O N 0I k0 0c C 0 0 I I i 0 I Z II 0 QI Uk I3 V1 4 I cC a hi IL aW I i hI 0 IE cc A i hi hi i la I 0l II 0 I I I 00 000I0II a 90 0 44 4 II 0 4 c 4 44 WM I 2k0 n a x O4 Q 01 M24 EV r 7 4 I I V 6 t t 7 Z Mt UT 0 O i I I 1 0 4 0 0 SAW 4 0 r4 CY CY N N O N U Cy CY 0 NN N 1 710 A CY 0 N I ...

Page 308: ...ALTITUDE PERFORMANCE FOR 0 470 5 ...

Page 309: ...7 0 0 0 a 0C 7 Ir IIJ 1 7 IN 1 I 1 V Y 0 0 0 0 I I N 1 0 0 T ALTITUDE PERFORMANCE FOR 0 470 K LR S 76 00 19 L 1 u 0 Iii ia I 4 4 I c hi hi 0 01I I I Z In I C N CY 0w i L mm 0 y Z 2 roe 2c Z Z 7 7 Z mtm Z Z WE cd CD I T mm al M C n 71 m I M L t 3 7 1 1 ctm I ltm I s I VW 4 I L 7 II II cI cI kN 9 k I I 1 I I 8 I It I I I x I I cl 311 I 9 u ...

Page 310: ...m m 0 Ct c 0J A 1I IUCDU 0 co P 0 CY I D r I I cm N I CY II I I I 0 I1 LN I I a I I I I CD 0 C0 ci 0 CC C II Z11 4 t z Q ALTITUDE PERFORMANCE FOR 0 470 M 76 00 20 OIL cu z 49 0 a I j 4 u w It CY CY ci C 0 z 0 I hi w I 21 lam I 6 I 31 V r 7 7 r 1 r 4 4 p 4 1 A f Z 7 z I 0 2 I I Z V I I 0 I I I I I c I m I I r I q c I tI I I I I d3moogdotf lmwmv 0 0 0 0 0 0 0 0 2 2 mCDr omI I ID Nl ...

Page 311: ...ALTITUDE PERFORMANCE FOR 0 470 U ...

Page 312: ...btract 1 3 Ib of fuel from curve For every 10 F decrease in carburetor inlet air temperature add 1 3 Ibs of fuel to curve I I I I I I CHART INSTRUCTIONS I I I I 1 Obtain actual Full Throttle RPM 2 Determine Fuel Flow for 100 maximum power by reading directly above actual maximum RPM point FUEL FLOW LIMITSFOR 0 470 G ...

Page 313: ...FUELFLOW LIMfTS FOR 0 4704 ...

Page 314: ... FUEL FLOW LIMITS FOR 0 470 K L R S ...

Page 315: ...etor alr temperature For every 10 F increase In carburetor nlettemperature subtract 1 0 Ib of fuel from curve l l l l l l l CHART INSTRUCTIONS 1 Obtatn actual Full Throttle RPM Actual Full Throttle RPM 2700 Fuel Flow 128 0 138 8 FUEL FLOW LIMITS FOR 0 470 M ...

Page 316: ... FUEL FLOW LIMITS FOR 0 470 U ...

Page 317: ...CHAPTER 77 ENGINE INDICATING 77 00 00 GENERAL 77 10 00 OPERATING LIMITS 77 20 00 ENGINETROUBLESHOOTINGCHART ...

Page 318: ...INTENTIONALLY LEFT BLANK ...

Page 319: ...362 539433 539432 625351 625350 635862 627449 628450 631277 635610 635611 649909 649913 649914 649915 632503 632504 632507 632508 530203 530574 626296 627341 627342 635863 530892 531132 626418 626026 626761 627643 627978 630378 635156 635151 635012 632572 635013 646629 646630 642097 642098 646091 646092 534411 627892 632460 632461 632462 632463 632467 MODELS Auburn HSR 86 HSRaP HSR 93 SR86 S86R SR...

Page 320: ...SL360 P1 250 Champion RHB32M RHB36W RHB32P RHB32W RHB32E RHB33E RHB36P RHB36S RHB332S Smith RSH33 8R 1 RSH35 8R RSE35 8R 1 TOM 630532 630533 635859 632738 632740 635860 635613 649910 628036 635152 635153 635154 634675 630436 632673 642831 646632 646090 641977 646089 632465 635148 77 00 04 ...

Page 321: ...tinuousOperation all except 0 470J U 2600 RatedMaximumContinuousOperation 04704 2550 Rated MaximumContinuous Operation 0 470 U 2400 RecommendedContinuousMaximumfor Cruising All Except 0 4704 U 0 470 S 2450 0 470 T U 2400 RecommendedCruiseManifoldPressure All0470 23 0 Fuel Pressure PSI 0 470 A K L 1 5 9 0470 B E G M 9 11 0470J R S U 0 5 6 Fuel Min Grade 0 470 A C E J K L R S Aviation Grade 80187 Oc...

Page 322: ...E J Not to exceed 018 Lbs per BHP Hr at Rated Powerand RPM 0470 B G P Notto exceed 015 Lbs per BHP Hr at Rated Powerand RPM 0470 H K L M N Not to exceed 012 Lbs per BHP Hr at Rated Powerand RPM 0470 R S U 006 X Power Lb BHP Hr Maxat Rated Power 100 and RPM OilTemperature Limits Minimumfor Take Off 75OF MaximumAllowable 0470 A B C E G H J K L M N P R 225OF MaximumAllowable 0470 S U 240 F Magneto Sp...

Page 323: ...y adjusted Mixtureleversset for im properlymixture Fouledspark plugs Referto Pilot s Checklistfor starting proceduresand check for performanceof each item Place mixtureleversin IDLE CUT OFFposition Openthrottle wide Turn engine over several revolutionsto clear cylinders Tightenor replacelooseor damaged hoseconnection Replacestarter adapter Isolatecauseand correct See Troubleshooting FuelSystem Pag...

Page 324: ...gine Runs RoughAt f iigh Speed ContinuousMissingAt High Speed Fuelsystem malfunction Restrictioninair intake passages Fuelsystem malfunction Pistonrings excessivelyworn or broken Pistonringsare not seated Clean screen SeeTroubleshooting Fuel SystemPage 73 00 07 Check passagesand remove restrictions SeeTroubleshootingthe Fuel System Page73 00 07 Replacerings Replacecylinder if damaged Hone cylinder...

Page 325: ...Dirtbetweencylinder fins Excessivecarbondeposits in cylinder headand on pistons Magnetosout of time No appreciabledropdetected check compression Draintanks and replacewith correct grade of fuei Referto Chapter 76 for properfuel flow settings Checkand correct Cleanthoroughly Check ignitionandfuel system Re time internallyand externally during pre flightcheck Magnetodistributor block contamination E...

Page 326: ...3500 Feet smoothestat IDLE RPM Mixturetoo rich Adjust mixture perChapter 76 Acceleration At Airfields With A Ground ElevationOf 3500 Feet Or Higher EngineWill NotStop Fuel manifoldvalve not Repair or replacemanifoldvalve At Idle Cut Off Climbing to Altitudes Fuelvaporization Operatefuel boost pump Above 12 000 Feet accordingto aircraft Engine Quits When manufacturer sinstructions Power Reduced See...

Page 327: ...xiliary pump will clear system Operate auxiliary pump and Restrictionsinvapor Checkfor restrictionsinejector jet of vapor separator cover Clean jet with sdvent only Do Not Use Wire as Probe Replacemalfunctioningparts LowOil Pressure Insufficientoil inoil sump oil dilutionor usingimproper grade oilfor prevailing ambient temperature Highoiltemperature Malfunctioningoiltemperature controlvalve inoil ...

Page 328: ...alfunctioningignition Inspectspark plugsfor fouled electrodes heavy carbon deposits erosion of electrodes improperly adjusted electrode gaps and cracked porcelains Test plugs for regular firing under pressure Replacedamaged or misfiring plugs Spark plug gap to be0 015 to 0 019 inch EngineLacks Power Looseor damaged intake Inspectentire manifoldsystem for possibleleakageat Maximum Manifold connecti...

Page 329: ...CHAPTER 78 EXHAUST 78 00 00 GENERAL ...

Page 330: ...INTENTIONALLY LEFT BLANK ...

Page 331: ...00 00 GENERAL Exhaust systems for all 0 470 Model engines are supplied by the airframe manufacturer for overhaul maintenance and troubleshooting procedures refer to the airframe manufacturer s instructions ...

Page 332: ...INTENTIONALLY LEFT BLANK ...

Page 333: ...CHAPTER 79 OIL 79 00 00 GENERAL 79 10 00 APPROVED OIL PRODUCTS 79 20 00 OIL SYSTEM TROUBLESHOOTINGCHART ...

Page 334: ...INTENTIONALLY LEFT BLANK ...

Page 335: ...ralia Sinclair Oil Company Texaco Inc UnionOil Companyof California BPAero Oil CastrolaeroAD Oil ChevronAero Oil Conco Aero S DeltaAvoil Oil ExxonAviation Oil EE GulfprideAviationAD MobilAero oil MobilAero Super Oil SAE20W 50 PennzoilAircraft EngineOil Phillips66 Aviation Oil Type A X C Aviation MultiviscosityOil SAE20W 50 SAE20W 60 Quaker StateAD Aviation EngineOil Red Ram20W 50Aviation Motor Oil...

Page 336: ...ence of alkalinesolids insystem Malfunctioningpressure pump Malfunctioningpressuregage IWeak or broken oil pressure relief valve spring ICloggedfilter or strainer CORRECTION Replenish Cleanthoroughly Removecooler andflush thoroughly Remove cleanvalve and seat If still inoperative replace Drainand refillwith correctseasonal weight SeeChapt 77 Limit ground operationto a minimum Check wiring Check bu...

Page 337: ... 01 Prestarting 80 0 02 Starting 80 00 03 Ground Warm Up 80 00 04 Pro takeoff CheCk 80 00 05 Flooded Engine 80400 06 Cold Weather Operation 80 00 7 Preheatlng Woo 00 0 Hot Weather Operation 80 0 9 Ground Operation At High Altitude Airports 4 _f ...

Page 338: ...INTENTIONALLY LEFT BLANK ...

Page 339: ...ze himself with abnormal environmental conditions Whenever such abnormal conditions are encountered or anticipated the procedures and techniques for normal operation should be tailored accordingly For example if the aircraft is to be temporan operated in W e m e cold or hot weather consideration should be given to an early oil change and or routine inspectionseroici zg NOTE The following checklist...

Page 340: ... repaired before damaging starter adaper assembly 9 Throttle 1000to 1500RPM 10 Oil Pressure ABOVE 30 POUNDSWITHIN30SECONDS 11 Alternator Switch ON 12 Usethe same procedureto start other engine if operatinga twin engine installation 80 00 03 GROUNDWARM UP Teledyne Continental aircraft engines are aircoded and are dependent on the forward speed of the aircraft for cooling To prevent overheating it i...

Page 341: ...the maximum drop for each magneto is 150 RPM Observe enginefor excessive roughnessduringthis check If no drop in RPM is observed when operating on either magneto alone switch circuit should be inspected WARNING Absence of RPM drop when checking magnetos may indicate a malfunction in the ignition circuit This type of malfunctionshould be corrected prior to continued operation of the engine Should t...

Page 342: ...ler oil passages or air channels are blocked leadingto rapidwear of movingpartsinthe engine C Cylinder Head Temperature Any temperature in excess of the specified limit may cause cylinder or piston damage Proper cooling of cylinders depends on cylinder baffles being properly positioned on the cylinder heads and barrels and other joints in the pressure compartment being tight to force air between t...

Page 343: ...er Small electric heaters which are inserted into the cowlingopeningdo notappreciablywarm the oil and may result in superficial preheating WARNING Superficialapplication of preheatto a cold soaked engine can causedamageto the engine A minimum of preheat application may warm the engine enough to permit starting but will not de congeal oil in the sump lines cooler filter etc Congealed oil in such li...

Page 344: ... 1700 RPM If necessary approach this RPM in incrementsto prevent oil pressurefrom exceeding 100psi At 1700 RPM adjust the propeller control to Full Decrease RPM until minimum governing RPM is observed then return the control to Full Increase RPM Repeat this procedure three or four times to circulate warm oil into the propeller dome If the aircraft manufacturer recommends checking the propeller fea...

Page 345: ...re special attention on the part of the operator These are 1 Starting a hot engine 2 Ground operation under high ambient temperature conditions and 3 Takeoff and initial climbout 1 Starting a Hot Engine After an engine is shutdown the temperature of its various components will begin stabilize that is the hotter parts such as cylinders and oil will cool while other parts will begin to heat up due t...

Page 346: ...rature Conditions Oil and cylinder temperatures should be monitored closely during taxiing and engine run up Operate with cowl flaps full open Do not operate the engine at high RPM except for necessary operational checks If takeoff is not to be made immediately following engine run up the aircraft should be faced into the wind with engine idling at 900 1000 RPM It may be desirable to operate the f...

Page 347: ...CHAPTER 81 TURBINES 81 00 00 GENERAL ...

Page 348: ...81 00 00 GENERAL The 0470model enginesare naturallyaspiratedengines not utilizinga turbocharger ...

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