Continental Refrigerator C75 Overhaul Manual Download

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Publication X30010

2011 CONTINENTAL MOTORS, INC.

AUG 2011

C75
C85
C90

O-200

CONTINENTAL

AIRCRAFT ENGINE

OVERHAUL

MANUAL

FAA APPROVED

Summary of Contents for C75

Page 1: ...Publication X30010 2011 CONTINENTAL MOTORS INC AUG 2011 C75 C85 C90 O 200 CONTINENTAL AIRCRAFT ENGINE OVERHAUL MANUAL FAA APPROVED ...

Page 2: ...Change Page Change Cover 1 A 1 1 blank added 1 2 thru 124 0 Published and printed in the U S A by Continental Motors Inc Available exclusively from the publisher P O Box 90 Mobile AL 36601 Copyright 2011 Continental Motors Inc All rights reserved This material may not be reprinted republished broadcast or otherwise altered without the publisher s written permission This manual is provided without ...

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

Page 4: ...ledyne Continental C Series in current production The parts catalog section is not included in this edition since it is subject to frequeht change in details A manual of this scope cannot be revised often enough to be kept up to date at all times since it is our policy to improve details of engine design in the interest of maximum safety and utility of our products whenever the results of our cont...

Page 5: ...rates 29 Method of Packing and Preservation 29 Removal of Engine from Crate 30 Preparation for Installation 30 Storage of Engines 31 General 31 Flyable Storage 31 Temporary Storage 31 Section Para 5 4 5 5 5 6 VI 6 1 6 2 6 3 6 4 6 5 VII 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 7 12 7 13 7 14 VIII IX 9 1 9 2 9 3 X 10 1 10 7 10 18 10 24 10 30 10 38 10 47 XI 11 1 11 10 Tide Page Indefinite Storag...

Page 6: ...93 15 1 General Procedure 93 15 4 Detailed Procedure 93 LIST OF TABLES Table Table No Title Page No Title Page Features Common to all Models 11 XIV Accessory Drive Speed Ratios II Type Certificate Numbers 11 and Rotation 14 III Features Peculiar to Each XV Line and Instrument Connections 14 Model Group 11 XVI Weights of Standard Engine IV Dimensions Peculiar to Each Model Equipment 15 or Model Das...

Page 7: ...with Taped Pliers 71 Installing Helical Coil Inserts 82 Dimensions of Rocker Shaft Boss Bushings 84 Drill Fixture 87 Drilling Hole in Bearing 88 Drilling Adapter Assembly 88 Plug Detail 89 Drill Fixture 89 Drill Fixture Installed 89 Name Plate Change 89 Tightening No 1 Connecting Rod Bolts 95 Installing Crankshaft Bearing and Old Type Thrust Washer 97 Installing Crankshaft and Connecting Rods 98 I...

Page 8: ...Figure 1 Left Side View Model C85 12F Figure 2 Three Quarter Right Rear View Model C85 12 ...

Page 9: ...Figure 3 Three Quarter Left Front View Model C90 16F Figure 4 Three Quarter Right Rear View Model C90 16F 7 ...

Page 10: ...Figure 5 Right Front View Model C90 Figure 6 Left Rear View Model 0 200 8 ...

Page 11: ...the exact model designation and serial number 1 2 DEFINITIONS ABBREVIATIONS A B e Approx A T e Bar B B C B H P B T e F A A After Bottom Center Approximately After Top Center Barometric Before Bottom Center Brake Horsepower Before Top Center Federal Aviation Administration e F M e G Dia o o F Fig Front Ft G P M H20 Hg I D In Hex Hr Left Side Lbs Lockwire Man Max Min 30 N P T N C N F O D Press P S 1...

Page 12: ... and screws The importance of accuracy in these operations cannot be over emphasized All necessary data will be found in the Table of Limits A chart provides a visual reference to locations of the points where measurements are to be made 1 4 CLEANLINESS Every effort should be made to keep engines free from external accumulations of foreign matter and to prevent the entrance of abrasive particles ...

Page 13: ... III FEATURES PECULIAR TO EACH MODEL GROUP Model C75 C85 C90 0 200 Piston Stroke inches 3 5 8 3 5 8 3 7 8 3 7 8 Total Piston Displacement cubic in 188 188 201 201 Compression Ratio 6 3 1 6 3 1 7 0 1 7 0 1 TABLE IV DIMENSIONS PECULIAR TO EACH MODEL OR MODEL DASH NUMBER Model or Model Dash Number C75 C85 C90 8 8F 12 12F 14F 16F 0 200 Overall Height 27 55 64 27 55 64 28 3 4 28 3 4 28 3 4 28 3 4 28 3 ...

Page 14: ...vity Fuel Press at Carbo psi Pump Feed Fuel Press at Carbo psi Min Carbo Air Entrance Press in HO Max Carbo Air Entrance Press in HO For setting float level For Marvel carburetors With Hot Oil C75 30 60 10 1 2 2 4 6 12 C85 30 60 10 1 2 2 4 6 12 C90 2475 2625 90 95 C90 525 275 170 225 75 C90 30 60 10 6 Max 3 5 4 75 TABLE VIII MODEL OR MODEL DASH NUMBER EQUIPMENT Model or Dash Number C75 C85 C90 8 8...

Page 15: ...ABLE XI VALVE MECHANISM SPECIFICATIONS Model C75 C85 Type of Valve Mechanism Overhead Overhead Hydraulic Valve Lifters Installed X X Valve To Rocker Clearance Operating 0 0 Valve To Rocker Clearance Lifters Deflated inches 030 110 030 110 Valve Lift inches 0 382 0 382 Intake Valve Opens OB T e 8 8 Intake Valve Closes 0 A B e 57 57 Exhaust Valve Opens OB B e 49 49 Exhaust Valve Closes CA T e 16 16 ...

Page 16: ...0 200 Rotation as viewed from rear of engine t Rotation when facing driving pad C Shaft Drive Speed Ratio 1 0 5 1 0 5 1 1 1 1 1 0 5 1 35 7 1 2 035 1 0 5 1 1 TABLE XV LINE AND INSTRUMENT CONNECTIONS Connection Location Primer Jet Hole Int Man Cyl Hd Fuel Inlet Stromberg Carbo Fuel Inlet Marvel Schebler Carburetor Mixture Control Lever Hole Carburetor Throttle Lever Cable Hole Carbo Man Carbo Heat C...

Page 17: ...t 20 Amp Propeller Hub Assembly 8 and 12 Carburetor Air Intake and Filter Assembly used with Stromberg Carburetors Carburetor Air Intake and Filter Assembly used with Marvel Schebler Carburetors Propeller Attaching Parts 8F 12F 14F 16F 0 200 Eight Rubber Mount Bushings Four Steel Washers Domestic Shipping Crate Export Shipping Crate TABLE XVII ADDITIONAL WEIGHTS OF OPTIONAL EQUIPMENT Description R...

Page 18: ...Pump Adapter Otherwise like 12 models F Flange type crankshaft installed replaces tapered shaft H Crankcase and crankshaft adapted to feed oil to hydraulic controllable pitch propeller Various combinations of the foregoing dash numbers and suffix letters are used to describe equipment of the different models In the following discussions and instructions the term 12 models will indicate all models ...

Page 19: ...engine lifting eye to the upper flanges Each casting has two cylinder mount pads machined in its vertical side Cylinder openings in pads on the two sides of the case are not quite opposite Each casting has a heavy lateral web at the rear another near the center and a third near the front These webs are cut out for ventilation and oil drainage and have enlarged bosses at the case parting surface fo...

Page 20: ...Each crankshaft has three main journals the front one being immediately ahead of No 4 front crankcheek The cheek is ground flat around the journal and contacts the rear crankcase thrust washer to 18 transfer propeller thrust A small anti thrust flange at the front end of the front journal acts as an oil slinger ICAUTION I This design should not be used in pusher installations Older types of shaft ...

Page 21: ...rance Standard camshafts for C series carburetor engines have an eccentric machined at the front fuel pump lever A special camshaft with two eccentrics is available for installations which require a second fuel pump Camshafts installed with vacuum pump equipment in 16 and 0 200 engines have no pump drive eccentric The front end of this type has six tapped holes for screws which attach the vacuum p...

Page 22: ...osed the cam follower a is in contact with the heel of the cam lobe as shown in Figure 8 Since there is no inward force on the pushrod the plunger spring K holds the plunger C and the socket outward against the pushrod end and the hydraulic unit cylinder and 20 lifter body inward keeping the cam follower against the cam lobe This expanding action takes up any increase in effective length of the va...

Page 23: ...ed with two studs Bronze guides for intake and exhaust valves are pressed into holes bored from the bottom of the rocker box into the valve chambers in line with the valve seats Alloy steel exhaust valve seat inserts and aluminum bronze intake valve seat inserts are shrunk into counterbores i nth e combustion chamber surface Early production cylinders had threaded spark plug inserts screwed and pi...

Page 24: ...METER DRIVE CONN GENERATOR the combustion chambers Later improvement in smoothness of the head castings made the hand polishing operation unnecessary and current production cylinder and head assemblies are identical in all models Any cylinder and head assembly with a smooth air intake passage may be installed on C90 models Older assemblies with any roughness in the passage must be used only on C75...

Page 25: ...een opening The screen cap is screwed into the screen housing over a copper asbestos gasket The oil screen is permanently attached to the cap and is reinforced by a ferrule at its open front end The ferrule fits closely in a hole bored in the front wall of the oil passage From the screen outlet another passage in the cover leads to a hole drilled in the cover parting flange in register with the cr...

Page 26: ... thick mounting flange ring four brackets an oil fill neck and a drain plug boss are welded to the body to complete the assembly The location and length of the oil fill neck vary to suit the aircraft installation A bracket is welded to the neck for support by attachment to a stud in the lower crankcase mount ing arm The tubular steel neck has a bayonet lock ing device at the outer end for quick at...

Page 27: ...hex nut Shielded magnetos have spring terminals within the breaker housing and switch wires must be equipped with terminal assemblies consisting of contact insulators ferrules and union nut Wire terminal assemblies are furnished with LA 4 magnetos Bendix terminal kits are sold separately and are slightly different 3 34 MAGNETO DRIVE GEARS Eisemann AM 4 magnetos installed on the left side of C85 8 ...

Page 28: ... a slot in the front side of the hub Two lugs on the drive gear fit into a front slot in the rubber disc Gear torque is transmitted through 26 the lugs to the disc The flat sides of the disc and steel retainer transmit the torque to the slotted hub which drives the generator shaft through the woodruff key A steel sleeve passes through the gear rubber disc and retainer and presses the hub against t...

Page 29: ...re supplied with oil as described in paragraph 3 16 and shown in figure 8 From the lifter sockets oil flows through the hollow pushrods to the rocker arm passages described in paragraph 3 23 to lubricate the rocker bushings and the valve stems Oil sprayed into the rocker boxes drains back to the crankcase through the pushrod housings All the oil returned to the crankcase and the portion which is s...

Page 30: ... pump delivery pressure caused by the restriction opens the by pass valve allowing the oil to by pass the cooler 28 and return to the crankcase inlet The by pass valve also permits cold viscous oil to by pass until its pressure is reduced by increased temperature This equipment can be installed only on 12 14 16 and 0 200 models ...

Page 31: ... packing operation the same mixture is sprayed into spark plug holes All openings are closed to exclude moisture Engines are supported in shipping crates in the inverted position Carburetor air intake assemblies air filters and other installation equipment parts are fastened securely to the engine Propeller hubs if used are fastened to the crate base A moisture proof shroud is placed over the engi...

Page 32: ...ch the eye to opposite propeller bolt bushings 30 4 4 PREPARATION FOR INSTALLATION Fasten the engine mounting arms securely to a suitable assembly stand or support which will hold the engine in the vertical position Detach and remove all loose parts fastened to the engine and remove closures from the breather elbow cylinder exhaust ports carburetor bottom flange and any other sealed openings If it...

Page 33: ...rcraft per normal airframe manu facturer s instructions b Each seven days during flyable storage the propeller should be rotated by hand without running the engine Rotate the engine six revolutions stop the propeller 45 to 90 from the original position For maximum safety accomplish engine rotation as follows 1 Verify magneto switches are 0FF 2 Throttle position CLOSED 3 Mixture control IDLE CUT OF...

Page 34: ...NDEFINITE STORAGE a Preparation for Storage 1 Drain the engine oil and refill with MIL C 6529 Type II Start engine and run until normal oil and cylinder head temperatures are reached The preferred method would be to fly the aircraft for thirty 30 minutes Allow engine to cool to ambient temperature Accomplish steps 5 2 a and 5 3 a of temporary storage NOTE MIL C 6529 Type II may be formulated by th...

Page 35: ...e oil from cylinders d Re install the spark plugs and rotate the propeller by hand through the compression strokes of all the cylinders to check for possible liquid lock Start the engine in the normal manner e Give the aircraft a thorough cleaning visual inspection and test flight per airframe manufacturer s instructions 5 6 AIRCRAFT STORED IN ACCORDANCE WITH THE INDEFINITE STORAGE PRO CEDURES SHO...

Page 36: ...rubber bushing holes without tearing them f place a steel washer supplied with engine on each bolt end g Install a slotted nut on each mount bolt and tighten all nuts to 60 80 inch pounds torque This is very important since insufficient 34 tightness will allow excessive vibration whereas too much tightening will deform the rubber bushings h Install cotter pins i If the engine is a C90 14 16 or 0 2...

Page 37: ...O VOLTAfJEl EGULATOR r HEWALL TO 16NITION SWITCH TO PRIMER OUTLET TO NIXTtlHE CONTROL TO THROTTLE CONTROL TO CARB IIEATCONTROL TO PRIMER INLET T06ASTANK Figure 12 Typical Installation Diagram for 12 14 16 Models Side View Figure 13 Installation Drawing for 12 14 16 Models Front View 35 ...

Page 38: ...IA HOLE I L 3 1 I ___ 15 _ _ _ 8 3It Name plate K Tachometer drive S A E standard 1 2 engine Oil filler optional location speed C W rotation S A E No 1 flanged crankshaft optional L Oil drain 5 8 18 N F tap and plug Fuel pump special equipment M Oil temp capillary 5 8 18 N F tap Breather connection 5 8 I D hose N Oil screen Exhaust mounting P Oil pressure relief valve Throttle control lever R Air ...

Page 39: ...PORTS REOD TO REMOVE EISEMANN MAGNETO LA 4 16 OVERALL LGTH ALL CRANKCASES R d E1 tR 16 TO MACHINED PAD f ____ 5 ll i t h I l It 7 16 I IA EXHAUST 12 R PORTS 16 5 15 6iS 732 OPPOSITE SIDE c I PE ITAP ___Jj T 5 1Ir IOii REOUIRED TO REMOVE DELCO REMY GENERATOR Figure 15 Installation Drawing for 12 14 16 Models Side and Top Views 37 ...

Page 40: ...ing nozzle is installed in a 1 8 inch N P T hole in the left side of the intake manifold 6 3 OIL SYSTEM The lubrication system is contained with the engine except that an oil cooler and adapter may be installed on the engine if required When the vacuum pump is installed on the 16 and 0 200 engines an oil return line between the pump and crankcase cover must be installed Connect the oil 38 WASHER S...

Page 41: ...h removal of the engine c Drain the oil sump d Disconnect throttle control cable from carburetor e Disconnect mixture control from carburetor f Disconnect fuel supply line from carburetor or pump g Disconnect carburetor hot air tube h Disconnect carburetor air heat control cable from intake housing 1 Disconnect oil pressure gauge line j Unscrew and remove oil temperature capillary from oil screen ...

Page 42: ...rime only enough to keep the engine running until it will run smoothly on the normal mixture If the engine cannot be started after several attempts refer to Section VIn for possible causes 7 3 WARM UP As soon as the engine starts adjust throttle to obtain approximately 800 R P M and observe the following precautions a Watch oil pressure gauge closely If no pressure is indicated within 30 seconds s...

Page 43: ... control then reduce R P M with the throttle During flight observe the following procedures and precautions a If a Stromberg carburetor is installed leave mixture control in the FULL RICH position at altitudes less than 5000 ft above sea level If a Marvel Schebler carburetor is installed the mixture control may be adjusted to obtain best rich power at any cruising altitude b To obtain best rich po...

Page 44: ...r is a Marvel Schebler MA 2SSPA stop the engine by moving the mixture control to the full lean position where it acts as an idle cut off Do not open the throttle because it actuates the accelerator pump and rapid opening will flood the engine 7 10 LUBRICATING OIL Teledyne Continental Aircraft Engines are certificated on straight mineral oil Detergent oils are not a requirement It is recognized tha...

Page 45: ...t and safety with lockwire Remove and inspect the oil screen If the screen contains heavy sludge deposits or if the drained oil is highly diluted more frequent oil changes will be advisable If many or large metallic particles are found on the screen or in the drained oil except machinings in new engines the engine is in need of overhaul Clean the screen in unleaded gasoline Replace it with a servi...

Page 46: ...ded REMEDY Fill tank Clean tank vents blowout supply line replace shut off valve repair pump clean Hlter Remove carburetor and repair Remove and clean Repeat starting procedure with more priming Clear cylinders by turning propeller several revolutions with ignition switch OFF throttle wide open Disconnect fuel line at car buretor and purge system Recharge battery Turn propeller by hand sev eral re...

Page 47: ...s Warped valves Detonation REMEDY Correct carburetor adjustment Disassemble as required and clean Remove and clean Tighten loose joints Replace damaged parts Remove and inspect Tighten Refer to Section XVIII Remove and clean Inspect gaps Replace worn valve guides or piston rings Test for break down at high voltage Overhaul magneto Check for very fine cracks in block Overhaul engine Remove and test...

Page 48: ...ged Fuel flow restricted Worn cylinders pistons and or piston rings REMEDY Continue warm up Check for binding kinks slipping worn parts Remove and clean filter Readjust Clean carburetor Drain sediment trap Check all joints and throttle shaft bearings Test for high voltage leaks Replace parts Replace valves and guides Replace valves Grind seats Overhaul magneto Readjust linkage Remove f tlter inspe...

Page 49: ...il supply Dirty or diluted oil Winter baffles installed Prolonged ground operation at high speed Excessive rate of climb Lean fuel air mixture REMEDY Replenish Drain sump Reml with correct grade Remove and clean Clean plunger and seat Replace dirty oil Overhaul engine Refmish valve seat Remove cap and plunger Clean parts Remove sump Clean screen Overhaul engine Test gauge and replace or repair Ove...

Page 50: ...OTE The air ftlter should be cleaned as it becomes dirty every day under severe conditions Whenever the intake ftlter is found to be restricted by dust it must be removed and cleaned To remove the ftlter turn each of the four locking studs to the left and draw the ftlter forward Remove the gasket if it adheres to the ftlter dean the ftlter element with mineral spirits solvent used for cleaning par...

Page 51: ...nt repair or replacement of parts accessories and or instruments a Start and warm up the engine to obtain an oil temperature of 100 0 F During this period check all engine instruments to detect fluctuations or other abnormal indications Test operation of all engine controls and observe engine response Restrict running to the minimum time necessary for warm up and instrument checks In warm weather ...

Page 52: ... paragraph 9 1 1 m Test operation of all engine controls and inspect control connections for wear and looseness and conduits for firm support 50 n Remove fuel filter bowl Empty and clean bowl and screen and reassemble parts Remove carburetor screen clean and replace Turn on fuel supply and check for leaks o Remove cotter pins from engine mount bolts and test torque on nuts Tighten all nuts 60 80 i...

Page 53: ...TALLATION Coat the carburetor upper flange gasket with a film of non hardening gasket paste and place the gasket on the manifold studs Install the carburetor on the manifold with the throttle lever on the right side Install four slotted hex nuts and plain washers if the manifold studs are drilled or plain washers lockwashers and plain hex nuts if manifold studs are undrilled Secure slotted hex nut...

Page 54: ...fuel metering at high speed 52 10 5 MARVEL SCHEBLER CARBURETOR ADJUSTMENT If after checking all other possibilities it is found necessary to readjust this type of carburetor proceed as follows a Start and warm up the engine in the normal manner b Set throttle stop screw to obtain an idle speed of 500 R P M c Turn idle adjusting needle out slowly until engine rolls from richness then turn in slowly...

Page 55: ...ts normal rotation Magneto timing marks are located and may be inspected as follows a Eisemann AM 4 There are no timing marks for installation Locate No 1 firing position roughly by inserting a cable in the marked outlet socket holding the bare cable end near the bare mount flange and spinning the shaft through the frring positions When spark occurs the rotor has just passed No 1 position b Eisema...

Page 56: ...hined front surface of the crankcase with the index mark at the split line the apex will indicate No 1 crankpin angles Figure 32 illustrates the use of a special tool to locate No 1 crankpin 54 positions when a tapered crankshaft is installed A timing disc and a piston position indicator or a Time Rite indicator for Time Rite information and prices address Gabb Mfg Co 16 Orchard St East Hartford 8...

Page 57: ...minal clips into the magneto dis tributor housing sockets Start by inserting No 1 plug cable in the marked socket and continue in the clockwise direction around the cap inserting Nos 3 2 and 4 cables in that order To connect spark plug cables to an LA 4 magneto start by inserting No 1 plug wire through the left end spigot of the distributor cable plate on top leading it around the left side of the...

Page 58: ... screws which attach the cable plate on top to the end plate These are the two front 56 screws in the group of four Remove the three screws which attach the adapter to the end plate then carefully remove the adapter and cable plate assembly bending the spark plug cables and allow it to hang to one side Clean the inside of the distributor block with a clean lint free cloth and inspect the carbon br...

Page 59: ... terminal parts will depend on the type of magneto installed This information will be found in the parts catalog Since cables for Eisemann magnetos are individual complete assemblies they are supplied separately by part number for the various locations with proper terminals and ready for installation Since unshielded cables for Bendix magnetos are assembled into the cable and plate assemblies they...

Page 60: ...ped with Bendix magnetos the radio shielded ignition system consists of the two magnetos and a cable and plate 58 assembly for each plus two ground terminal kits with which to make up the switch wire terminal assemblies If the dielectric qualities of any cable have been reduced so that a break down under high voltage occurs both cable and plate assemblies should be replaced They are obtainable und...

Page 61: ...ed from the front side of the upper extensions of the crankcase rear flange When these five attachments have been removed die starter will be free except for possible adhesion of the gasket Tap the motor housing with a non marring hammer or bump the motor housing with a non marring hammer or bump it with the hand if necessary to break loose the gasket The starter clutch is piloted on the pivot hea...

Page 62: ...lastic hammer or bump it with the hand to break loose the gasket 60 adhesion Be careful when removing the starter that the clutch assembly does not drop 10 32 INSTALLATION Lubricate the starter pinion and intermediate gear and install on starter adapter Hold the starter assembly in position to align the clutch bore with the crankcase pivot and push the clutch over the pivot holding the assembly in...

Page 63: ...er 2 from end of inner race 3 Discard snap ring 2 Remove inner race 3 from outer race assembly 4 by a slight rotation of inner race in the over running direction clockwise Remove needle bearing a Remove inner snap ring 5 and washer 6 Discard snap ring b Examine inner race sprag and bearing diameters 3 Insert mandrel 7 figure 17 3 from needle bearing end a Push sprags out of outer race assembly 4 f...

Page 64: ... 3 h EJ II Figure 17 4 4 10 Figure 17 5 Figure 17 6 10 38 GENERATOR ALTERNATOR AND DRIVE 10 39 REMOVAL Before removing the generator and drive assembly disconnect the tachometer drive conduit and pull the cable end from the engine drive shaft Inspect for oil leakage into the tachometer drive conduit If leakage is observed a new oil seal should be ...

Page 65: ... This arrangement prevents any possibility of shearing the rubber member If the drive gear is serviceable and single piece discs still available the second type of drive may be continued in service though the latest type is preferable The original drive without disc retainers should not be reinstalled 10 42 REASSEMBLY OF DRIVE If groove is machined in the generator shaft adjacent to the bearing li...

Page 66: ...nd The unit is designed for operation in a battery charging circuit 64 in which the battery negative terminal is grounded For proper performance the air blast directed through the vent tube must provide a minimum air pressure differential across the generator of 1 1 2 inches of water column by manometer test Brush spring tension should be 24 ounces For early 12 volts 12 amperes generators the fiel...

Page 67: ...safety the suction tube at assembly may allow it to loosen progressively A crack caused by dropping or other shock can develop in the crankcase cover oil suction passage wall allowing a constant air leakage Warp in the oil pump cover can have the same effect 4 Solid particles in the oil after long use may be fine enough to pass the oil screen and plug or restrict passages to the lifters Under some...

Page 68: ... to remove possible dirt and repeat the frrst test If the plunger still does not kick back discard the 66 unit In handling hydraulic lifters remember that cleanliness is essential Also no grinding lapping or interchanging of parts is permissible No shellac paste or gum may be allowed to reach the units The plunger must be free in the cylinder and the check valve must not leak appreciably For more ...

Page 69: ...5 IGNITION SYSTEM Remove spark plug cable terminals from the plugs Detach cable brackets of shielded systems from case studs If Eisemann AM 4 magnetos are installed the unshielded cables may be pulled from the magneto sockets and threaded through the brackets to remove them individually If Eisemann LA 4 magnetos are installed the cables should be removed with the magnetos and disassembled later Be...

Page 70: ...s Careful handling is necessary to avoid distortion and subsequent oil leakage Prying is not advisable 68 because of the possibility of scratching the rocker box flange 11 15 CYLINDERS It is not necessary to remove rockers and pushrods before the cylinders are removed however this may be done after pushing out the rocker shaft Usually the valve lifters make it difficult to remove the rocker shaft ...

Page 71: ... d Turn the work stand bed to place the crankcase cover upward Loosen and remove the oil screen from its housing in the cover e Loosen the bronze acorn cap of the oil pressure relief valve at the right rear side of the 8 rear cover or at the right side of the 12 14 16 or 0 200 crankcase cover Hold against spring force as the cap is unscrewed and comes free Lift out the spring and the plunger f If ...

Page 72: ...he 2 4 side casting then remove the casting from the work stand and store it on a wood surface NOTE Current production crankcases have a gallery drilled to lubricate the starter clutch adap ter Old style cases can be adapted per instructions in para 14 13A 11 19 CONNECTING RODS For greatest ease of disassembly it is suggested that the crankshaft be held in a fixture similar to that illustrated in ...

Page 73: ...alves need not be marked for position since they will be refaced Remove the cylinder base packing ring from the barrel skirt 11 23 HYDRAULIC VALVE LIFTERS A Rack should be contructed to hold the disassembled lifter parts i e lifter bodies hydraulic units and sockets so that their original assembly relation will be obvious The groups of rack holes or compartments should be labeled No 1 IN No 1 EX e...

Page 74: ...ng oil after reassembly 12 4 No polishing compound or abrasive paste or powder should be needed or employed for cleaning engine parts Scraping abrasion with wire brushes sand paper or abrasive cloth and buffing wheels are dangerous methods to use on soft metals such as aluminum Scratches resulting from such methods allow a concentration of stress at the scratch and may cause fatigue failure 12 5 V...

Page 75: ...e removed to permit reliable magnetic indications 12 13 CONNECTING RODS If a mineral spirit solvent does not clean these parts thoroughly they may be immersed in a chemical carbon solvent They should be immersed only long enough to loosen and soften the deposits without adversely affecting the metal The parts should be pre soaked in mineral spirit fortified with organic solvents to soften the hard...

Page 76: ...necessary due to wear in order that readings will be of value Nearly all micrometer calipers have means of taking up wear in the thread to overcome looseness after long service Such adjustments must be made carefully when necessary Various types of dial gauges are sold for measurement of larger bores These provide a rapid metho of measurement when many pieces are handled Cylinder bore gauges of th...

Page 77: ... in water at room temperature in the proportions of 2 lbs of caustic soda per gallon of water Expose the aluminum surface to the cleaning action of the solution for no more than 60 seconds b Immediately rinse the part in running water then neutralize the action with a solution of I part nitric acid in 4 parts water Allow the diluted acid to act only long enough to remove the black deposit left by ...

Page 78: ...be completely demagnetized after inspection and between successive magnetizations Demagnetization is performed by inserting the part in an alternating current demagnetizer from which it is withdrawn slowly Irregular shaped parts must not be withdrawn at a rate of more than 12 feet per minute The magnetic substance must be removed completely from all parts after inspection All plugs must be removed...

Page 79: ...n Center 1500 keyways Conductor Shaft Circular 1000 to Teeth splines Teeth Between 1500 Heads Two Times 90 Circular and 1000 to Splines keyways Longitudinal 1500 change of section Circular and 500 threads under head Longitudinal Possible Defects Fatigue cracks heat cracks flange cracks from prop strike Fatigue cracks Heat cracks fatigue cracks Fatigue cracks Fatigue cracks Fatigue cracks Fatigue c...

Page 80: ...and front end and propeller flange 13 17 CONNECTING RODS Inspect alignment in plane convergence and twist of the crankpin bearing seat without inserts and the piston pin bushing If the bushing was replaced its bore should be compared with limits in The Table of Limits Section XVIII if not the bore should be compared with the piston pin diameter Look for peening on all surfaces and bends in the bea...

Page 81: ...Inspect valve port studs for burrs stripping bending elongation and backing out Examine spark plug inserts for thread condition and tight installation Inspect cylinder base flanges for cracks bending nicks corrosion and smoothness of nut seats Inspect rocker shaft support bosses for cracks worn bores and side wear If bores are worn excessively the bosses may be repaired by installation of repair b...

Page 82: ... for deformation and burring of the teeth excessive tooth prome wear or scoring The starter driven 80 gear wheel of the crankshaft gear in 12 14 16 and 0 200 models must be discarded if any chipping or serious gouging of the entering edges is found ...

Page 83: ... it is not damaged install the next larger oversize stud If the old stud was maximum oversize or if the thread is damaged the hole may be tapped and a helical coil insert installed for a standard size stud Coat the new studs coarse thread with Alcoa Thread Lube if the hole is blind or with National Oil Seal Compound if it is a through hole that is subject to oil spray It is advisable to drive the ...

Page 84: ...d end of the barrel may be removed by grinding and the bore glaze may be roughened by honing to restore the original finish The proper surface roughness of refinished cylinder walls is specified in limit No 44 Section XVIII A close approximation of the correct bore surface may be maintained by visual inspection of refinished cylinder walls with a magnifying glass and by comparison with the appeara...

Page 85: ...Make sure that the lips of the drill are of equal length and angle to avoid enlarging the hole Drill to a depth of only 7 16 inch from the bushing surface Mark the cylinder head to locate the old pin hole Inspect the cylinder head hole for thread condition and clean it with solvent Obtain the next oversize insert and clean it thoroughly The cylinder assembly must be heated to not more than 575 F b...

Page 86: ...ylinder to 5750 F throughout and install the new insert with a tool which will grip it lightly and will be piloted in the valve guide A ball or lever detent on the insert holding shoulder is sufficient When the tool is piloted in the valve guide a quick thrust must be used 0 240 VIEW AA ASSEMBLE BUSHINGS FLUSH WITH BOSSES AS SHOWN to seat the insert before it has time to heat It is best to have th...

Page 87: ...a sleeve to bear on the crankshaft propeller flange The screw is inserted from the front through the bushing hole Dip the bushing in engine oil and screw it on the puller screw behind the flange Pull the bushing into the hole with its rounded flange corner toward the crankshaft b If main journals and crankpins are worn beyond limits of serviceability for standard size crankshafts they may be regro...

Page 88: ...ming or boring the rebushed rod must be inspected for bushing diameter taper out of round bearing center distance twist and convergence Twist out of plane and convergence of bearing seat and bushing bore must not exceed 001 inch per inch of length 86 NOTE Connecting rod assemblies are balanced in sets with a maximum difference in weight in any engine of 1 2 oz per pair in opposite bays If new or r...

Page 89: ...r to a flat rear surface If camshaft bearings are worn beyond serviceable limits they may be line bored or reamed to 020 inch oversize and an oversize camshaft installed It is most important that reboring of camshaft bearings be done without shifting the camshaft centerline in any direction The crankcase must be firmly clamped together during this operation and the finished bores must be 1 3945 1 ...

Page 90: ...irst and index hole lined up with lock pin hole Lock adapter m place with lock pm 3 Drill 1 8 inch hole until stop on drill bottoms on drill bushing Drill speed to be 2500 4500 RPM Drill length from tip to stop to be 0 625 inch 4 Use drill press for following operation Drill remaining distance with a No 60 drill 0 040 dia This operation forms the orifice to restrict oil flow Minimum length of 0 04...

Page 91: ... Fixture Installed 3 Place spacer tube on stud and lock down with cylinder base nut 4 Check drill to sleeve stop distance Ex posed drill should measure 2 625 inches to tip 5 Drill hole into crankcase web until drill stop bottoms on fixture bushing Pull drill back frequently to clear flutes Use 2500 4000 RPM drill speed Repeat drill process in other bushing Use cutting oil to prolong drill and fixt...

Page 92: ...d in minor 90 ways by brazing and straightening however any serious damage makes replacement with a new part necessary Lap mounting flanges flat if necessary and adjust plate valves to assure free operation and full closing 14 20 VACUUM PUMP ADAPTER Replace any loose bent stripped or broken stud Clamp the adapter pump mounting pad up between soft shielded vise jaws Engage jaws of an oil seal pulle...

Page 93: ...vary from light gold to dark brown When a part is treated with Alodine 1200 the thickness of the film or buildup on the mating or bearing surfaces is so fine that the effect on dimensional tolerances is negligible 14 25 APPLICATION OF ALODINE 1200 In the event the original finish of an aluminum part has deteriorated or been removed the part maybe Alodized as described in Alodine manufacturers Tech...

Page 94: ...s Div Bendix 92 Aviation Corp South Bend Indiana 14 32 MAR VEL SCHEBLER MA 3SPA CARBURETOR For overhaul instructions relative to these carbu retors address Service Department Marvel Schebler Tillotson Division Borg Warner Corp 2195 South Elwin Road Decatur IL 62525 C90 carburetors are identified by manufacturers part no 10 4252 and the 0 200 carburetors by part no 10 4115 14 33 MAGNETOS For Bendix...

Page 95: ...impellers in their chambers with the tachometer drive shaft end to the rear Install the pump cover and make sure that it fits perfectly on the chamber surface No gasket paste may be used in this joint place plain washers and bolts or slotted nuts on the pump studs and tighten to specified torque Install lockwire to connect the studs or bolts in pairs The lockwire must lie flat against the sides of...

Page 96: ... are used only on the 0 200 Make sure that the 94 set of inserts installed is the correct type for the crankcase being assembled and of correct size for the standard or reground crankshaft to be installed If there s an oil gallery for the starter clutch adapter make sure the bearing shell has a hole and is properly installed 15 7 CRANKSHAFT AND CONNECTING RODS For maximum ease of working the crank...

Page 97: ...to paragraphs 10 33 thru 10 36 for procedure and precautions to be observed in assembly of either type of generator drive 15 11 OIL COOLER ADAPTER If an oil cooler is used with the engine spread a film of Led Plate No 250 on the three socket head pipe plugs Install the 1 4 inch plugs tightly in the front and lower rear holes of the adapter and install the 1 8 inch socket head plug in the bottom ad...

Page 98: ...alve stem end for valve stem lubrication 96 j Invert the cylinder and place a new base packing ring on the cylinder skirt Push it against the flange and remove twists k place two clamps and a new pushrod housing rubber connector on each housing pushing connector back flush with the housing end 15 14 PISTONS Install C 90 and 0 200 piston oil control rings with the pistons inverted on the bench Inst...

Page 99: ...ring around the 3 8 inch stud spread a thin uniform film of Aviation Permatex Do not allow the liquid to run into the interior of the case Do not apply Permatex on the other camshaft bearing bo ses or on any main bearing bosses Use it only on the surrounding flange and around the 3 8 inch stud d When the Permatex has become tacky place a strand of No 50 Grade A silk thread along the upper lower an...

Page 100: ... crankshaft is to be installed spread the split oil seal ends by twisting and 98 Figure 33 Installing Dowel Type Thrust Washers and Split Oil Seal place the seal on the shaft behind the propeller flange with its recessed side toward the rear Pass the oil seal spring around the shaft behind the seal and hook its ends to make a loop place the spring joint opposite the seal split Lift the spring into...

Page 101: ...E On the 0 200 the front and rear thrust flanges are manufactured on the front main bearing Before torquing the through bolts or the backbone bolts pull the crankshaft up against the rear of the front main bearing to seat the front main bearing to seat the thrust flange of bearing against the bearing support boss Torque through bolts and backbone bolts Installing Starter Pinion Pivot Manual Starti...

Page 102: ...ighten the nuts moderately r Install protectors on all connecting rods to prevent the rods from touching the crankcase 100 s Test the crankshaft and camshaft for free rotation If they turn freely attach the 1 3 side mounting arms to the assembly stand t place plain washers and hex nuts on the two front through studs ahead of No 4 cylinder pad and on the through stud above the lower right mounting ...

Page 103: ... the treated gasket over the studs and on the crankcase rear surface The dowel holes in the gasket must fit over the crankcase dowels NOTE The cover gasket for 12 14 16 and 0 200 model crankcase does not have or need a hole for the left oil gallery g Lower the crankcase cover subassembly over the studs and seat it on the cover gasket as shown in Figure 36 for 12 14 16 or 0 200 models turning the c...

Page 104: ...rough the connecting rod bushing to the centered position d Remove the protector from No 1 connecting rod Hang the piston ring ompressor on the connecting rod Stagger the piston ring gaps 90 apart with no gap in line with the pin e Hold No 1 cylinder on the left arm Do not hold the pushrod housings Take the two pushrods for No 1 cylinder from the oil pan and insert them in the pushrod housings sea...

Page 105: ...ght Advance as required to install cotter pin Do not use wrench on castle nut See Figure 38 Make sure that inner hoses are in posItIOn within the outer hose connectors at both ends of all intake pipes and that all hose clamps are in position Push the projecting hose of each intake pipe over a manifold outlet and push the hose connectors at the opposite ends over the cylinder intake elbows Tighten ...

Page 106: ...I Firing Positions of No 1 Piston 104 Figure 40 Placing Flange Crankshaft III Firing Position of No 1 Piston one or two plain 5 16 inch washers as spacers Attach the sump and filler neck to crankcase plain studs with elastic stop nuts or to drilled studs with castle nuts and lockwire Install the oil gauge and cap assembly 16 14 IGNITION SYSTEM Install on the two magnetos the proper type or types o...

Page 107: ...s from turning Install igni tion cable terminals in the magnetos as described in paragraph 10 13 16 15 GENERATOR ALTERNATOR Spread a film of non hardening gasket paste on both sides of a generator and tach drive housing gasket place the gasket on the crankcase cover pad Install the generator with the wire terminals to the left meshing the drive gear with the camshaft gear internal teeth as the mou...

Page 108: ...g instruments will be needed to indicate engine operating conditions a Tachometer mechanically driven See Tables XIV and XV b Cylinder Head Temperature Gauge 106 c Oil Temperature Gauge d Oil Pressure Gauge e Fuel Flow Meter or accurate means of weighing the supply f Fuel Pressure Gauge carburetor engines pumps 17 4 TEST CLUB 10 p s i capacity for equipped with fuel Manufacturers of wood propeller...

Page 109: ...stem 4 Install the spark plugs and ignition harness g Engine starting and ground operation 1 Assure that all engine and cylinder baffling is properly installed and in good condition 2 Start the engine and assure that oil pressure rises to within the specified limits within 30 seconds 3 Operate the engine at 750 RPM for one minute gradually increasing toward 1000 RPM in three minutes Check the magn...

Page 110: ...ure for the first hour of operation The second hour power settings should alternate between 65 and 75 power with the appropriate 108 best power mixture settings Engine controls or aircraft attitude should be adjusted as required to maintain engine instrumentation within specifications 3 The descent should be made at low cruise power settings with careful monitoring of engine pressures and temperat...

Page 111: ...Hg 17 5 in Hg 17 0 18 5 in Hg Magneto Drop at Full Throttle RPM 75 75 tlOO tlOO Crankcase pressure maximum 1 0 in H2O 1 0 in H2O 1 0 in H2O 1 0 in H2O Cylinder Head Temp maximum 525 F 540 F 525 F 525 F oil Temperature desired 150 F 200 F 150 F 200 F 150 F 200 F 150 F 200 F Oil Temperature maximum 225 F 225 F 225 F 225 F oil Pressure at full throttle 30 45 psi 35 45 psi 30 60 psi 30 60 psi oil Pres...

Page 112: ...275 2325 Warm up to 2300 2300 2400 2500 2575 2625 Warm up to 2200 2200 2300 2400 2475 2525 Warm up to 2400 2400 2500 2600 2750 2800 Full Throttle Full Throttle 1800 1800 Check Magnetos Check Magnetos Check Magnetos Check Magnetos 5002 25 Idle Cooling Period 500 25 Idle Cooling Period 500 25 Idle Cooling Period Stop engine drain oil weigh and record engine oil consumption Magneto drop to be taken a...

Page 113: ... an engine is installed in an aircraft it is recommended that no testing or running in of new parts be performed in this manner If it becomes necessary to run in an overhauled engine in the aircraft a wood test club should be used for ground operation The cowling should not be installed and the aircraft should be headed into the wind to provide the best possible cooling A cylinder head temperature...

Page 114: ...0 2200 2300 2400 2500 ENGINE R P M Figure 41 Fuel Flow Limits vs R P M at Propeller Load Model C90 8 J 7 CD J aD 6 II X II Q 5 J 4 o J J 3 2 I 1300 1400 1500 1600 1700 1800 1900 2 2100 2200 2300 2400 2500 ENGINE R P M Figure 42 Fuel Flow Limits vs R P M at Propeller Load Models C7Sand C8S ...

Page 115: ... 8 LBS GAL 40 POWER f 1 1 0 r i t 1 1 I 1 f t I _ L r 2 f I t t t t l f t t 1400 1600 1800 2000 2200 2400 2600 2800 1300 1500 1700 1900 2100 2300 2500 2700 Figure 43 Fuel Flow Limits vs R P M at Propeller Load Model 0 200 113 ...

Page 116: ...ap 3rd Ring in Cylinder C75 C85 C90 0 200 Gap 4th Ring in Cylinder C75 C85 Gap 4th Ring in Cylinder C90 0 200 Gap Compression Ring Tension closed to specified gap oil Control Ring Tension closed to specified gap PISTON PINS Piston Pin and Plugs No 530830 in Cylinder End Clear Piston Pin in Piston Pistons 40327 530348 Dia Piston Pin in Connecting Rod Bushing Rods A35160 A2 530184 A1 Dia Deleted CON...

Page 117: ...der Head Bosses VALVES AND GUIDES Exhaust Valve in Guide C75 C85 C90 Exhaust Valve in Guide 0 200 Intake Valve in Guide Valve Guide Int Exh in Cylinder Head Valve Face Exh to stem axis Valve Face Int to stem axis Exhaust Valve Stem PIN 3921 Exhaust Valve Stem PIN 629404 Intake Valve Stem Exhaust Valve Face Intake Valve Face Dia End Clear Dia Dia Dia Dia Dia Dia Dia Dia Dia Dia Angle Angle Dia Dia ...

Page 118: ...Stem to Rocker Clearance lifter deflated OIL PUMP Oil Pump Gear in Pump Housing Oil Pump Gear in Pump Housing End Clear Dia Oil Pump Gear Shafts in Accessory Case and Plate Gear on Crankshaft Pilot Dia Dia Camshaft Gear on Camshaft Pilot Oil Seal in Tachometer Drive Housing Magneto pilot in Accessory Case Starter pilot in Accessory Case Generator Pilot in Accessory Case oil Pump Gear Cavity Oil Pu...

Page 119: ... 001 T 001 L 68 4 Starter Pinion Pivot Shaft Dia 5595 5605 558 69 1 Hydraulic Tappet Bore in Crankcase Dia 7187 7197 70 2 Camshaft Bearings Dia 1 3745 1 3755 Main Bearing Bore Dia 2 0615 2 0625 GEAR TEETH BACKLASH 71 3 4 Crankshaft Gear to Camshaft Gear 006 009 013 72 3 Magneto Drive Gears to Crankshaft Gear 8 0140 017 020 73 4 Magneto Drive Gears to Camshaft Gear 12 14 16 0 200 012 014 016 74 4 S...

Page 120: ...t T 3 1 Nuts and Cap Screws General 1 4 28 90 110 7 5 9 2 T 4 1 Nut Cylinder Base 7 16 20 490 510 40 8 42 5 T 5 1 Nut Cylinder Base 3 8 24 410 430 34 2 35 8 T 6 1 Nut Crankcase Through Stud C75 C85 C90 7 16 20 400 450 33 3 37 5 T 6 1 Nut Crankcase Through Stud 0 200 7 16 20 490 510 40 8 42 5 T 7 1 Nut Crankcase Through Stud 3 8 24 275 325 22 9 27 1 T 8 4 Nut Generator Drive Shaft 5 16 24 175 200 1...

Page 121: ...ds Stud driving torques apply when the threads are coated with Alcoa thread lube if hole is blind or with National Oil Seal compound if hole is through to a cavity subject to oil Size If cotter pin holes must be aligned set torque wrench at low limit and tighten nut to first hole beyond this torque However on connecting rod nuts the torque limits must be maintained Replace nut and repeat as requir...

Page 122: ...ON THRU ROCKET SHAFT 36 37 50 49 CRoss e r T CROSS SECTION THRU 0 90 AND 0 200 CYLINDER VIEW 1011 1 12 11 17 _ 18 _ 21 PRESSURE OIL SCAVENGE OIL DRAIN Figure 44_ Limits and Lubrication Chart Sheet 1 of 4 Cross Section View ...

Page 123: ...57 _____ 60 56 __ 54 TlO T2 _ PRESSURE OIL SCAVANGE OIL SUCTION 65 1 Figure 45 Limits and Lubricatipn Chart Sheet 2 of 41 Lungitudinal Section View 121 ...

Page 124: ...L SCREEN INTO OIL GALLERY a PRESSURE RELIEF VALVE REAR VIEW SERIES 8 ENGINE 82 76 _ PRESSURE OIL SCAVANGE OIL SUCTION _ SCAVANGE OIL DRAIN Figure 46 Limits and Lubrication Chart Sheet 3 of 4 Rear View and Horizontal Section 8 Model 122 ...

Page 125: ...W Ie ENGINE SHOWING OIL PRESSURE RELIEF VALVE AND OIL COOLER MOUNTING PAD PRESSURE OIL SCAVENGE OIL SUCTION REAR PORTION OF LONGITUDINAL SECTION 12 ENGINE LUBRICATION CHART 12 ENGINE Figure 47 Limits and Lubrication Chart Sheet 4 of 4 Rear View and Sections 12 14 16 and 0 200 Models 123 ...

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