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Continental O-200-C75-C85-C90 - X30010 Overhaul Manual

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2K views124 pages

Continental O-200-C75-C85-C90 - X30010 Overhaul Manual

Uploaded by

Dale Berger
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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OVERHAUL MANUAL FOR AIRCRAFT ENGINE MODELS C75,C85,C90 & 0-200 FAA APPROVED FORM X-30010 JANUARY 1984 FOREWORD This manual is published for the guidance of all facilities engaged in operation, maintenance and overhaul of four cylinder engines of the Teledyne Continental C and 0-200. Series. A description is included in this manual of the various models and special equipments of the series and photographs selected to illustrate the major differences between models. ‘The Table of Specifications provides more detailed information in regard to features and performance of the models. tt should be noticed that such descriptive material is neither intended nor adequate to enable conversion of any model to another in instances in which such conversion is permissible. For detailed information regarding application of parts and their interchangeability, refer to the Spare Parts Catalog, For model and series number conversion instructions, refer to the Teledyne Continental Service Bulletin on that subject. Service maintenance instructions relative to accessories installed on Teledyne Continental aircraft engines in our factory are reprinted herein by permission of the accessory manufacturers. Instructions for overhaul of these acces sories may be obtained direct from the manufacturers or through their authorized service facilities. All descriptive and dimensional information and all instructions contained in this edition have been revised and extended to cover all four eylinder models of the Teledyne Continental C Series in current production. The parts catalog section is not included in this edition, since it is subject to frequent 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 co improve details of engine design in the interest of maximum safety and utility of our products whenever the results of our continuous experimental and development program indicate the desirability of replacing the old with something even better. For this reason we issue Service Bulletins to our Approved Distributors to advise of important changes in parts, desirable inspections and precautions found necessary in operation and maintenance. These bulletins are available for reading at all Teledyne Continental Approved Service Stations. Those who need permanent copies of Service Bulletins may obtain them by direct mail, as issued, from the factory Publications Department on an annual subscription basis. A nominal charge is made to cover the cost of mailing. It is suggested that a careful study of the text of this manual will provide the reader with knowledge of engine construction and of techniques for both ‘operation and repair work which, if applied in practice, will promote safety in flight and long engine life. If, in spite of the high quality of materials and the careful inspection and testing of these engines, any defect is suspected, the question should be brought immediately to the attention of the nearest Teledyne Continental Approved Service Station so that a diagnosis and any necessary correction may be made. Section & Pars, 327 328 $29 440 B30 a7 138 at) 340 Mi v 44 42 4a 44 v SH 52 83 TABLE OF CONTENTS Page Introduction, ° Model Designation : 9 Definitions and Abbreviations... ° Measurement 10 Cleanliness : io Table of Specifications... . n General Description... as Difference Between Model Groups «1. 16 Significance of € Series Dash Numbers and Letters cee 16 Model Conversions, 16 Optional Equipment : W Superseding Pacts 0... 7 rankease Construction uv Crankshats 1B 18 5 : 9 Connecting Rods, 19 Canvshatts 19 Camshaft Gears an Hydraulic Valve Lifters. -- 20 Pushrods and Housings... [a Piston Assemblies 2 Cylinder Assemblies a Crankease Gover Assembly for 12,-14, -16 8 0-200 Models... 22 Gnunkease Cover Assembly for “8 Models, =. 23 Gear Pain... 2 arburetor Induction System, 4 i Sumps cH lynition System 4 DelewrRemy Searee 2s Prestolite Starter 6 Generator and Drive, 26 Site Mounted Fuel Pump - - - 6 Duel Fuel Pump Equipment... 6 Lubrication Systems... cceeeeeee 27 Unpacking the Hagine . : 2» Shipping Crates... sD Method of Packing and Preservation 2» Removal of Engine from Crate 0 Preparation for Installation...0..-..- 30 Storage of Engines... 3 General a1 Fable Storage 31 ‘Temporary Storage . 31 Section 1 Para sa Indefinite Storage ...... ss Procedure For Return of A/C to Service 56 Indefinite Storage Inspection vw Installation in Airplane & Removal 61 Mounting the Engine 62 Fuel Systems 63 Oil System os Propeller Installation 6s Engine Removal vo Operating Instruction 7A Procedure Preliminary to Starting. 72 Starting Procedure 7 Warm-Up 74 Ground Test rs. Take-Off 76 Climbing Level Flight LetDown and Landing. ‘Stopping the Engine Lubricating Oi! Viscosity Oil Change Periods i Change Procedure Engine Fuel Vi Engine Troubles and Service Repairs x Periodic tnspection and Maintenance, 94 Daily Inspection 92 First Fifty Hour Inspection 93 100-Hlour Periodic Inspection x Adjustment and Minor Repair 10-1 Carburetors 10-7 Magnetos 10-18 Replacement of Ignition Cables 1024 Deleo-Remy Starter 1030 Prestolice Starcer 1038 Generator and Drive. 1047 Hydeaulie Valve Lifters, xi Disassembly - : 111 Preliminary Operations 1110 Disassembly Page 2 3B 48 46 48 9 31 si 3 37 9 @ 0 o Section & Para, Mt Ra Ls xu ra Le Bs et sw Ma lar ga leat Table No, uw m1 u vu vit XI xu xin TABLE OF CONTENTS (Con't) Tite Cleaning Materials and Processes. Specific Pars Inspection Definitions. Inspection Tools Inspection Methods Inspection of Critical Pars Repair and Replacement General Repait : Repair and Replacement of Specific Pares Grankease Modification Protective Coatings . Assembly of Subassemblies General Procedure Detailed Procedure Title Features Common to all Models type Cerificate Numbers Features Peculiar 10 Eaeh Model Group, Dimensions Peculiar to Each Made! ‘or Model Dash Number Speed and Power Ratings Operating Temperature Limits Operating Pressure Limits Model or Model Dash Number Equipment, Goneral Ignition Systems Specitications Lenition Timing. Valve Mechanism Specifications Lubrication System Specifications uel Mecering System Specifications. Page n n n u oy 1% 8 n at 81 2 0 9 3 3 Section Para, xvi tet 164 XVII i 72 03 74 15 176 7 178 19 xvint Title Final Assembly General Procedure Derailed Procedure Testing after Overhaul ‘Testing Equipment Test Stand Instruments. Test Club nore Test After Overhaul so... Preservation Fuel and Lut eating O1 ‘Testing Engines Instaled in Aircraft Inspection .....+. Table of Limits.» LIST OF TABLES Page 2 R R R B B 1B B 4 xv xv XVI XVII xvitt XIX xx XXI Xxit Xxtt xxv XxVv Title Accessory Drive Speed Ratios and Rotation . Line and Weights of Standard ¥ngine Equipment. Additional Weights of Optional Equipment . Recommended Oil Viscosity Grades Magnflux Inspection Duta. Stud Identification Chart Test Operating Limits. . est Schedule il Sump Capacity General Use - Tightening Torques. Pipe Plugs Instrument Connections Page 7 ” 106 106 106 106 106 106 um un um un us Page “ “ Is a 7 a 109 Ho Hs Hs LIST OF ILLUSTRATIONS igure No. Page 1 Left Side View, Model C85-12F... 6 2 theee-Quarter Right Rear View, Model C85-12 6 3 “Vhree Quarter Left Front View, Model €90-16F | 7 4 ‘Vhrce-Quarter Right Rear View, Model C90-16F 7 5 ight Front View, Model C90... .cceeceecseeeceeeres 8 6 Left Front View, Model 0-200, .. : : coltiteneeeeee os 8 7 ylinder Arrangement Diagram (Top View) oon w 8 Section Through Hydraulic Valve Lifter. . s . : 2 9%, ‘Crankcase Cover and Accessories of -12, 14, 16 and 0-200 Models . 2 10, Gear Train of -12, 14, 16 and 0-200 Models... : Aeee "1 ojsting Engine by Crankshaft Lifting Eye. Bape 2» 2 ‘Typical Installation Diagram for 12, -14 & -16 Models, Side View 35 Be Installation Drawing for -12, -14 & -16 Models, Front View. oo 8 14 Installation Deawing for -12, 14 &-16 Models, Rear View ...- 36 15 Installation Drawing for-12, -14 & -16 Models, Side and Top Views Bape eeee seca 6. ine Mounting Equipment of Models C90-14 & 16 and 0-200, 38 17 Ignicion Wiring Diagram... 3 1% Removal of Hydraulic Unit from Valve Lifter Body... 6 vs. ‘Compressing Valve Spring to Remove Locks. ...0.0eccc ss seeeeeeeeee vol 20, Removing Plangce from Hydraulic Unit with Taped Pliers... ce fee 1" 21. Insalling Helieal Coil Inserts. 2 22 Dimensions of Rocker Shaft Boss Bushings, “ 23 Drill Wixeure. a 24. Drilling Hole in Bearing Aeancnae Bone 88 25, Drilling Adapter Assembly. - : ee 88 26, Plug Detail 89 21, Dall Fixtures oe 9 28, Dil Fixture installed » 29, Name Plate Change 89 30, Tightening No. 1 Connecting Rod Bolts. 9s 31 Installing Crankshafe Bearing and Old Type Thrust Washer 7 2 Installing Crankshaft and Connecting Rods. . a. : 98 33 Installing Dowel Type Thrust Washers and Split Oil Seal... 2s... cs sccceeeeeeeeesereres 98 4 Installing Starter Pinion Pivor ..... foo ae ; 9 35, Installing Crankease 1, 3 Side on 2, 4 Side oe co 9 36, Inscalling Crankcase Cover on 12, 14,16 and 0-200 Models...) veces sees 102 37 Insalling No.3 Cylinder. a : 103 3H Installing "O” Rings on Intake Manifold Studs |... . lsc cssecsseeseseseeee 108 39, Placing Crankshaft in Firing Position of No, 1 Piston Tos 40. Placing Flange Crankshaft in Firing Position of No. 1 Piston . . coe lO a uel Flow Limits vs, R.P.M, at Propeller Load, Model C90... ae 12 2 uel Flow Limits vs, RIP.M, at Propeller Load, Models C7 and C85... - 42 8, Fuel Flow Limits vs, K.P.M. at Propeller Load, Model 0-200 o M3 4 Limits and Lubrication Chart (Sheet 1 of 4)- Cross Section View... 60ecee cece eeeeeee 120 45, Limies and Lubrication Chart (Sheet 2 of 4)- Longitudinal Section View... . oo ial 39, Limits and Lubrication Char (Sheet 3 of 4)- Rear View & Horizontal Section -® Models... m2 40. Limits and Lubrication Chart (Sheet 4 of 4)- Rear View & Sections, 12,14 and 0-200 Models oe. cece ceeeeeseeeeeeeeeeeeeeee 4 123 Figure 1. Left Side View, Model C85-12F. Figure 2. ‘Three-Quarter Right Rear View, Model C85-12, Figure 4, ‘Three-Quarter Right Rear View, Model C90-16F Figure 6. Left Rear View, Model 0-200. SECTION | INTRODUCTION 1.1L MODEL DESIGNATIONS. This publication covers the maintenance and ‘overhaul instructions applicable to the four cylinder € Series and the 0-200 Aircraft Engines. C Series Engines covered by this publication fall into three model groups, namely, C75,C85 and C90, according to normal rated horsepower. Within each © model group, variations in equipment of the basic engine are denoted by suffix dash numbers, as explained in the Table of Specifications. Further explanation of the meaning of model dash numbers applicable to € models will be found in Section IIL Each engine bears an identification plate, on which is stamped the information peculiar to. that particular model, including the exact model and dash number designation and the engine serial number. NOTE Uf a new nameplate is required, refer to Service Bulletin M75-5. All correspondence with Teledyne Continental Distributors and with the factory Service De- partment in regard to specific engines should refer to the exact model designation and serial number, 12, DEFINITIONS & ABBREVIATIONS ABC After Bottom Center Apptos. Approximately ATC After Top Center Bar. Barometric BBC Before Bottom Center BHP, Brake Horsepower BL Before Top Center PAA, Federal Aviation Administration 1D. In.(") Hex. Hr. Left Side Lbs. Lockwire Right Side RPM. Std. T.D.G Temp. Torque Cubie Feet Per Minute Center of Gravity Diameter Degree of Angle Degrees Fahrenheit Figure (Illustration) Propeller End Foot or Feet Gallons Per Minute Water Mercury Inside Diameter Inches Hexagon Hour Side on Which No's 2 & 4 Cylinders Located Pounds Soft Steel Wire Used to Safety Connections, Ete. Manifold or Manometer Maximum Minimum Thirty Minutes of Angle (60° Equals One *) National Pipe Thread (Tapered) National Coarse (Thread) National Fine (Thread) Outside Diameter Pressure Pounds Per Square Inch Accessory End of Engine Side on Which No’s 1 & 3 Cylinders Located Revolution Per Minute Standard Top Dead Center Temperature Force X Lever Arm (125 fe. Ibs. torque = 125 Ibs. Force Applied One Ft. From Bolt Center or 62-1/2 Ibs. Applied 2 Fe. From Center} Figure 7. Cylinder Arrangement Diagram (Top View). 10 1.3, MEASUREMENT Throughout this manual are instructions regarding measurement of parts dimensions and proper tightening of nuts and screws. The importance of accuracy in these operations cannot__be overemphasized. 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. SECTION II TABLE OF SPECIFICATIONS TABLE I. FEATURES COMMON TO ALL MODELS pyre toa on Operating Cycle: lee .Ott0 [4 stroke) Number of Cylinders: ee, es Type of Cooling System cad Overall Wideh of Engine: D1 2 Sayainches Number of Mounting Bolts: 6 ooo Geo ses ett coe 4 Diameter of Mounting Bolts: SS tn Cylinder Bore: 2... Boao eS ipoinches Direction of Crankshaft Rotation: es Clockwise TABLE Il. TYPE CERTIFICATE NUMBERS Model 75, cas, 90 0-200 ‘Type Certificate Number 2. 233 233 252 252 TABLE Ill. FEATURES PECULIAR TO EACH MODEL GROUP Model 75 85, C90 0-200 Piston Stroke (inches)... ee 35/8 3-5/8 3118 37/8 ‘Total Piston Displacement (cubic in... 2... 188 188 201 201 Compression Ratio ee 68H 6.3:1 7.0:1 7.01 ‘TABLE IV. DIMENSIONS PECULIAR TO EACH MODEL OR MODEL DASH NUMBER Model or Model Dash Number (C75,€85,C90) 8 -8F “12 “12F “14F 16F = 0-200 27-55/64" 27-55/64" 28-3/4" —28-3/4" —28.3/4” —28.3/4" —-28.3/4"" 30-1/2” — 29-13/32" 32-23/64” 31.11/32” 31-11/32" 31-11/32" +27-17/32" Overall Height . Overall Length. cer of Gravity of Crankease Rear Surface... Below Crankshaft Centerline... 61a" 61/4" 4.19/32" 4.19/32" 4.19/32” 4.19/32" 4.19/32” ajay ayn 1-32” 1-1j32"—4-41/32" 111/32" 1.11/32" W TABLE V. SPEED AND POWER RATINGS Model oy cas 90 0.200 Normal Rated RPM . eee eee eee 2275 2575, 2475, 2750 Take-off RPM (Max. S minutes). 2). 1. 2. 2275 2575, 2625 2750 Normal Rated Brake Horsepower... 0... 1. 75 35 90 100 Take-off Brake Horsepower... 2 ee TB 85 95 100 TABLE VI. OPERATING TEMPERATURE LIMITS Model ons 85 c90 0-200 Maximum Cylinder Head Temperature (°F)... . «550 540 525 525 Maximum Cylinder Base Temperature (°F)... . . . 300 300 275 290 Maximum Magneto Temperature (°F)... . 1... 160 160 170 170 Maximum Oil Temperature at Screen (°F)... s,s 225 225 225 225 Minimum Oil'Temperature at Take-off ("F) . 2... 75 5 5 75 * To front of crankshaft flange TABLE VII. OPERATING PRESSURE LIMITS Model 15 css, 90 0.200 Oil Pressure for Cruising (psi). 2. 1. ss 3060 3060 © 30603060 Min, Oil Press. at Idling Speed (psi)... i io 10 10 10 + *Static Gravity Fuel Press. at Carb. (psi)... 2... 2 1/2 **6Max. **6 Max. *Pump Feed Fuel Press. at Carb. (psi) ©.) 1s. 24 24 *93,54.75 *93.5-4.75 Min. Carb, Air Entrance Press. (in.HO) 5... 0... 6 6 : Max. Carb. Air Entrance Press. (inHO) . 5... 2s. 12 2 : * For setting float level ** For Marvel carburetors + With Hot Oil TABLE VIII MODEL OR MODEL DASH NUMBER EQUIPMENT Model or Dash Number (C75, C85, C90) 8 -8F 12° -12F -14F -16F 0-200 S.A.E.No. Taper Crankshaft... 2... X x SAE. Type 1 Flange Crankshaft... 2. x oe x x Stromberg NA-S3A1 Carburetor. 6 5.2... XX XK XX *Marvel-Schebler MA-3SPA Carb... . . . . . Opt. Opt. Opt. Opt. Opt. X =X Lord Mount Bushings... 2 2 eee x xX Xx Delco-Remy Electric Starter... 5... ox mt x £ Delco-Remy Electric Generator... ss oe x xk x ‘Vacuum Pump Adapter x x TABLE IX GENERAL IGNITION SYSTEM SPECIFICATIONS Model or Mode! Dash Number (C75, C85, C90) 12 “4 16 0-200 Unfinished Eisemann Magneto Model... . AM4 *Radio Shielded Eisemann Magneto Model. Lad Radio Shielded Bendix Magneto Model... S4RN-21. SALN-21 S4LN-21 S4LN-21. S4LN-21 **Slick Magneto... 2... + + +» « 447/400 47/4000 447/400 447/4000 447/400 Number of Magnetos 2 2 2 2 2 Number of Spark Plugs... 0.2... 8 8 8 8 8 Firing Order C75, €85,C90,0-200 ..... 1324 13,24 13,24 13,24 13,24 “Approved for C75 and C85 only + *Approved for C90 and 0-200 only TABLE X IGNITION TIMING Model cms css 900.200 Right Magneto Fires Upper Plugs (°B:T.C.) — a 28 26 24 Left Magneto Fires Lower Plugs (°B.T.C.) wee 30 30 28 24 ‘TABLE XI VALVE MECHANISM SPECIFICATIONS Model crs cas, 90 0-200 ‘Type of Valve Mechanism 0. 1... Overhead Overhead Overhead Overhead Hydraulic Valve Lifters Installed a.

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