Continental Aircraft Engines Io-550 Bcgnpr Overhaul Manual
File Details:
Continental Aircraft Engines Io-550 Bcgnpr Overhaul Manual
- File Format:PDF
- Downloadable:Yes
- Pages:371
- Language:English
Description:
Continental Aircraft Engines Io-550 Bcgnpr Overhaul Manual
- This manual does not contain overhaul information for supplemental type certificated components or systems. This manual contains information on engines, components and systems designed, tested and certified byi TCM in accordance with the pertinent type design data.
- The following publication contains overhaul information only. All personnel involved with these functions must thoroughly read and understand the information provided; these instructions inform of the procedures necessary to overhaul an engine and they must be followed carefully.
- This manual contains no warranties, either expressed or implied.The owner/operator is responsible for the continued airworthiness of the aircraft. In accordance with FAR, certification of materials, parts and appliances for return to service for use on aircraft is the responsibility of the person/agency who signs the approval.
- To insure the continued safe operation of your aircraft, you must exercise great care when inspecting, testing, and determining the acceptability of all parts and materials. A very important part of this is verifying the origin of all materials, parts, and accessories that are used on your aircraft .
Table OF Contents:
Continental Aircraft Engines Io-550 Bcgnpr Overhaul Manual
Cover.................................................... 1 Introduction............................................. 9 Introduction......................................... 11 Scope................................................ 11 Definition of Terms.................................. 11 Manual Revisions..................................... 11 Related Publications................................. 12 Service Documents.................................... 13 Service Reports & Inquiries.......................... 13 Engine Design Features............................... 13 Tools and Equipment...................................... 15 General Information.................................. 16 Possible Special Tool Procurement Sources............ 17 Special Tools........................................ 18 Seallants and Lubricants................................. 21 Ashless Dispersant Oils.............................. 21 Preservative Oil..................................... 22 Lubricants........................................... 22 Sealants............................................. 24 Adhesives............................................ 25 Miscellaneous........................................ 26 Airworthiness Limitations................................ 27 Standard Practices....................................... 29 General.............................................. 30 Lockwire Procedure................................... 31 Lockwire Patterns.................................... 32 Tab Washer Procedure................................. 33 Cotter Pin Procedure................................. 33 Application of Adhesives............................. 34 Installation of Gaskets.............................. 34 Hose & Tubine Installation........................... 34 Engine Overhaul.......................................... 37 General.............................................. 38 Engine Removal Instructions.......................... 39 Preliminary Cleaning................................. 40 Extent of Disassembly................................ 40 100 % Replacement Parts.............................. 40 General Cleaning..................................... 42 Visual Inspection.................................... 43 Magnetic Particle Inspection......................... 43 Ultrasonic Inspections............................... 44 Fluorescent Penetrant Inspection..................... 44 Dimensional Inspection............................... 44 Dimensional Limits................................... 44 Original Dimensions.................................. 44 Parts Limits......................................... 45 Coatings............................................. 45 Helical Coil Insert Replacement...................... 46 Stud Replacement..................................... 47 Rosan Stud Replacement............................... 48 New Parts............................................ 50 Torque Applications.................................. 50 General Use Torques.................................. 51 Hose Fitting Torques................................. 52 Specific Torques..................................... 53 Exhaust System........................................... 57 Ignition System and Magneto Accessory Drives............. 59 Removal & Disassembly................................ 60 Accessory Drive Pad Removal.......................... 72 Magneto Accessory Drive Disassembly.................. 74 Cleaning............................................. 74 Magneto Drive Gear Inspection........................ 74 Inspections.......................................... 74 Dimensions........................................... 77 Magneto & Accessory Drive Adapter Assembly Repair.... 78 Bushing Installation................................. 78 Oil Seal Installation................................ 79 Studs, Helical Coils and Protective Coating.......... 79 Sub-Assembly......................................... 79 Fuel Injection System.................................... 81 Removal & Disassembly................................ 82 IO550A............................................... 82 IO550B............................................... 84 IO550C............................................... 86 IO550G,N,P,R......................................... 88 Component Disassembly................................ 90 Manifold Valve....................................... 90 Fuel Pumps........................................... 93 Fuel Control IO550A,B,C.............................. 97 Fuel Metering IO550G,N,P,R........................... 98 Fuel Nozzles......................................... 99 Cleaning.............................................100 Inspection...........................................100 Dimensions...........................................101 Sub-Assembly.........................................102 Sealant Application..................................103 Induction System.........................................105 Removal & Disassembly................................106 IO550A...............................................106 IO550B...............................................107 IO550C...............................................108 IO550G,N,P,R.........................................109 Component Disassembly................................110 Cleaning ............................................113 Inspection...........................................113 Dimensions...........................................114 Repair & Replacement.................................115 Sub-Assembly.........................................115 Air Conditioning.........................................123 Disassembly..........................................124 Cleaning ............................................125 Inspection...........................................125 Repair & Replacement.................................125 Sub-Assembly.........................................125 Electrical Charging System...............................127 Alternator Removal...................................128 Disassembly..........................................129 Cleaning.............................................129 Inspection...........................................129 Repair & Replacement.................................130 Sub-Assembly.........................................131 Starting System..........................................133 Removal..............................................134 Disassembly..........................................138 Starter Motor Overhaul...............................139 Starter Adapter Cleaning.............................139 Inspection...........................................140 Dimensions...........................................144 Repair & Replacement.................................149 Starter Adapter Assembly.............................152 Lubrication System.......................................155 Oil Pump Removal.....................................156 Oil Cooler Removal...................................162 IO550A&C Oil Sump Removal............................165 IO550B&R Oil Sump Removal............................166 IO550G&N Oil Sump Removal............................167 IO550P Oil Sump Removal..............................168 Cleaning.............................................169 Inspections..........................................170 Dimensions...........................................173 Repair & Replacement.................................175 Sub-Assembly.........................................177 Cylinders and Pistons....................................181 Updraft Removal Procedures...........................182 Crossflow Removal Procedures.........................184 Cylinder Disassembly.................................186 Cleaning.............................................187 Inspection...........................................188 Dimensions...........................................193 New Parts Dimensions.................................203 Repair & Replacement.................................204 Subassembly..........................................223 Crankcase................................................230 Disassembly IO550A,B,C...............................231 Disassembly IO550G,N,P,R.............................233 Cleaning.............................................239 Inspection...........................................240 Stud Setting Heights.................................243 Dimensions...........................................252 Repair & Replacement.................................255 Subassembly..........................................257 Engine Drive Train.......................................260 Camshaft Disassembly.................................261 Crankshaft Disassembly...............................263 Cleaning.............................................265 Inspection...........................................266 Dimensions...........................................270 Repair & Replacement.................................274 Subassembly..........................................284 Final Assembly...........................................288 General..............................................290 Crankcase............................................290 Crankcase Sealant & Threading........................292 Through Bolt Installation............................292 Cylinder Installation................................296 Oil Sump.............................................302 Oil Pump.............................................303 Starter & Starter Adapter............................305 Optional Compressor Bracket..........................306 Alternator...........................................308 Magneto & Accessory Drives...........................308 Valve Mechanism......................................310 Cylinder Baffling....................................313 Cylinder Drain Assembly..............................313 Exhaust..............................................314 Induction............................................314 Fuel Injection.......................................316 Mag to Engine Timing.................................319 Ignition Harness.....................................325 Post Overhaul Adjustment and Test........................328 Testing After Overhaul...............................329 Engine Test..........................................332 Oil Pressure Adjustment..............................332 Fuel System Adjustment...............................333 Test Operating Specifications........................340 IO550A Performance Charts............................342 IO550B Performance Charts............................346 IO550C Performance Charts............................350 IO550G Performance Charts............................354 IO550N,P,R Performance Charts........................357 Operational Test Form................................360 Test Run Standard Acceptance Test....................361 Oil Consumption Determination........................362 Preservation ........................................363 Test Flight..........................................363 Auto Leaning Adjustment..............................366 Continued Airworthiness Instructions.................367 Special Instructions for IO-550-B39B and IO-550-C31B.....368 IO550B39 & C31.......................................368 Intake Valve Seat Grinding...........................369 Crankcase Assembly Additions.........................370
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