Continental Aircraft Engines Io-550 Bcgnpr Overhaul Manual – PDF Download

Description

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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CONTINENTAL AIRCRAFT ENGINES IO-550 BCGNPR OVERHAUL MANUAL – PDF DOWNLOAD:

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