A Textron Company 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181 TECHNICAL PUBLICATION REVISION PUBLICATION REVISION NO. *- PUBLICATION NO. PUBLICATION DATE Direct Drive December 1974 60294-7 Overhaul Manual 60294-7-9 The page(s) furnished herewith are intended to replace the corresponding page(s) of the pub ication indicated above.
Lycoming TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION PUBLICATION NO. PUBLICATION DATE Direct Drive Overhaul 60294-7-8 Manual 60294-7 December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) on the publication indicated above.
Lycoming 652 OliverStreet Williamsport,PA 17701 U.S.A. 717/323-6181 TECHNICAL PUBLICATIONREVISION REVISION NO. 60294-7-7 PUBLICATION Direct Drive Overhaul Manual PUBLICATION NO. PUBLICATION DATE 60294-7 December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above.
TECHNICAL PUBLICATION REVISION REVISION NO. PUBLICATION 60294-7-7 Direct Drive Overhaul Manual PUBLICATION NO. 60294-7 PUBLICATION DATE December 1974 The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above. Previous revisions to this publication May, 1972 (Cont.
Overhaul Manual Direct Drive Engine A Approved by F.A.A. Sixth Printing December 1974 Part No.
OVERHAUL MANUAL - TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TO THE OWNER OF THIS MANUAL IN ADDITION TO THIS MANUAL AND SUBSEQUENT REVISIONS, ADDITIONAL OVERHAUL AND REPAIR INFORMATIONIS PUBLISHED IN THE FORM OF SERVICE BULLETINS AND SERVICE INSTRUCTIONS. THE INFORMATION CONTAINED IN THESE SERVICE BULLETINS AND SERVICE INSTRUCTIONS IS AN INTEGRAL PART OF, AND IS TO BE USED IN CONJUNCTION WITH, THE INFORMATION CONTAINED IN THIS OVERHAUL MANUAL.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TABLE OF CONTENTS SECTION 1 INTRODUCTION 2 GENERAL DESCRIPTION Cylinders Valve Operating Mechanism Hydraulic Tappets Crankcase Crankshaft Crankshaft Counterweights Accessory Housing Connecting Rods Pistons Lubrication System Cooling System Induction System Carbureted Fuel Injected Turbocharger Controls Ignition System 3 1-1 4 5 2-6 2-6 2-6 2-6 3-1 3-1 6 3-3 3-3 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-5 3-5 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 IGNITION SYS
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TABLE OF CONTENTS SECTION 7 PAGE CRANKCASE, CRANKSHAFT AND RECIPROCATING PARTS Removal of Accessories Disassembly Starter Ring Gear Support Prop.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION Section 1 Introduction 1. INTRODUCTION 1-1. This manual contains the necessary information for the major overhaul of the Avco Lycoming horizontally installed direct drive engines. Unless otherwise noted, all information and data in the manual will apply equally to all models; those portions of the text applying to any one particular model or series will be so identified. 1-5.
OVERHAUL MANUAL- LYCOMING Figure 1-2. Typical Figure l-3.
OVERHAUL MANUAL. LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION GENERAL Section 2 General Description 2. DESCRIPTION 2-1. The engines covered in this manual are direct drive, four, six and eight cylinder, horizontally opposed, air cooled models. 2-2. CYLINDERS. The cylinders are of air cooledconstruction with the major parts, head andbarrel, screwed and shrunk together. The heads are made from an aluminum alloy casting with a fully machined combustion chamber.
Section2 OVERHAUL MANUALGeneralDescription LYCOMING DIRECT DRIVE AIRCRAFT ENGINES valvesthrough pushrods andvalve rockers. Thevalve rockers are supported on full floating steel shafts. The valve springs bear against hardened steel seats and are retained on the valve stems by means of split keys. A rotator cap is employed on sodium cooled exhaust valves.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES draulic lifter cylinder outward. This action forces the ball check valve onto its seat; thus, the body of oil trapped in the pressure chamber acts as a cushion. During the interval when the engine valve is off its seat, a predetermined leakage occurs between plunger and cylinder bore which compensates for any expansion or contraction occurringin the valve train.
Section2 OVERHAUL MANUALGeneralDescription LYCOMING DIRECT DRIVE AIRCRAFT ENGINES OilReturn Figure 2-5. Schematic Oil System - AIO-320 and AIO-360 pressure wet sump lubrication system. See figures 2-3 and 2-4 for diagrams of typical four and six cylinder lubrication systems. See figure 2-5 for schematic of the oil system of the AIO series. 2-15. COOLINGSYSTEM.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section2 GeneralDescription Magneto Gear Ratio1:1 FuelPump IdlerGear - FuelPump DriveGear Ratio1:1 An Type FuelPumpDrive Diaphragm Type Ratio.50:1 Figure 2-7. Gear Train Diagram - Typical 4 Cylinder Engine 6 Cylinder Engine Timing marksareshown when of No.lcrankpin isat TC. Figure 2-8.
Section 2 OVERHAUL MANUAL General Description LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 2-16. INDUCTION SYSTEM (Engines Employing Carburetors). Subject engines maybe equippedwith either a float type or pressure type carburetor. Particularly good distribution of the fuel-air mixture to each cylinder is obtained through the center zone induction system, which isintegralwith the oil sump and is submerged in oil, insuring a more uniform vaporization of fuel and aidingin cooling the oilin the sump.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES FuelPump Drive Shft Gear-(ANType) No.of Teeth.13 Ratio 1:1 Figure 2-10. Gear Train Diagram Section2 GeneralDescription Hydrulic PumpDrivenGear No.of Teeth 10 Ratio 1.30:1 - Typical 4 Cylinder (Dual Magneto Housing) -Hydraulic PumpDrivenGear No.of Teeth/0 Ratio 1.30:/ Figure 2-11.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 3 General Overhaul Procedures SECTION 3. GENERAL OVERHAUL PROCEDURES 3-1. This manual will describe in separate sections the complete major overhaul procedures for each individual portion of the engine, thus dividing the manual for all practical purposes, into a series of individual handbooks dealing in turn with each component part.
Section 3 OVERHAUL MANUALGeneral Overhaul Procedures LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 3-12. When grit-blasting parts donot use sand or any metallic abrasives. It is recommended instead that mildly abrasive organic substances such as rice, baked wheat, plastic pellets, or crushed walnut shells be used. All machined surfaces must, of course, be adequately masked and all openings tightly plugged before blasting.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 3 General OverhaulProcedures age the part by overheating and burning thin areas adjacent to the electrodes. Again, skill and experience on the part of the operator are of the utmost importance. Consult the latest edition of Service Instruction No. 1285 for proper amperage. 3-26. CORROSION-PREVENTION. Uponcompletion of inspection, coat all steel parts with preservative oil. rinse.
OVERHAUL -3 MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES ated example of this sort is show” in figure 3-l. Note that the edges of the gear are not even; the one gear is too far forward on its longitudinal axis. 3-42. During manufacture of bevelgears, the relationship between the edges of the gear (or tooth length) is carefully controlled.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 3 General Overhaul General Overhaul Procedures Procedures c. Visually, and by feel, determine if the edges of the mating gears are even. If the edge of one gear protrudes beyond the edge of the other, remove shims from the protruding gear and add shims of equal thickness to the other gear to achieve pitch alignment of the gears.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION IGNITION 4-1. GENERAL. All subject four, six and eight cylinder engines are equipped with high tension ignition systems which deliver high tension current directly tothe spark plug outlets. Some eight cylinder engines are equipped with a low tension ignition system. This system carries the low tension current, produced by the magneto, through alead to a transformer mounted on the magneto.
Section 4 Ignition System OVERHAUL LYCOMING MANUAL- DIRECT DRIVE AIRCRAFT ENGINES CONVENTIONAL AND. RETARD BREAKER IMPULSE COUPLING SERIES AND SLlCK MAGNETO DRIVE ASSEMBLIES S4-20-200-1200 9 IO 3 2 II 9 I2 I 7 6 S6- 20- 1200 SERIES IMPULSE COWLING MAGNETO DRlVE ASSEMBLIES S6-20-200-1200 SERIES CONVENTIONAL AND RETARD BREAKER MAGNETODRIVE ASSEBLIES I 7 6 0 S8-700 1. 2. 3. 4. 5. SERlES MAGNETO DRIVE ASSEMBLIES 6. 7. a. 9. 10. 11.
LYCOMING DIRECT DRIVE AIRCRAFT ENGINES OVERHAUL MANUAL- NOTE Section 4 IgnitionSystem Slick) are given in detailin the latest editions of Service Instructions 1119 or 1153. The gears mentioned in the preceding paragraphs are associated with and form a part of the accessory drives and should not be considered part of the ignition system. Their removal and reassembly is discussed in this section because they should be removed and reassembled at the times the magnetos are removed or reassembled. 4-15.
Section4 IgnitionSystem OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 4-19. SPARK PLUG END. Install hex ferrule (8) over leadwithflange endtoward endof wire. After assembly of this ferrule, bend and rotate the silicone insulation to flare out the copper shielding. Install drive ferrule (9) over insulation and under shielding to within 1/16 inch of flange of hex ferrule. Slide hex ferrule over drive ferrule until tight. Mount drive plate (figure 4-6) in a bench vise.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 4 IgnitionSystem 4-1. Assemble a gasket (1), adapter (7) and gasket (6) on the magneto mounting pads. Assemble the ball bearing (12) onthe magneto gear and retainer (5) and install the assemblies engaging the marked tooth of the magneto gear (See figure 4-3) between the two marked teethon the crankshaft idler gear (See figure 4-4). Install the drive cushions (11) in the retainer.
OVERHAUL MANUALSection 4 IgnitionSystem LYCOMING DIRECT DRIVE AIRCRAFT ENGINES ling will not move beyond the point where it trips and the spark occurs. Reverse the rotation approximately 25° until the timing pin hole appears in the center of the vent plug hole. 4-35. Hold the rotor by inserting the timing pin, and linethe timingpin withthe centerof thevent plughole, and install the magneto on the engine. 4-36.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 4 IgnitionSystem ALIGN TIMING MARKON DRIVE PLATE Figure 4-12. Timing Mark on Drive Plate Aligned With Indent on Magneto Housing 4-45. (FinalTimingS8-700Series). Remove the screw lockwasher and dust shield from the opening marked "T" onthe side of the magneto. Thenwithabox wrench, remove the breather. See figure 4-13. 4-46. Connect atiminglighttothe switchwire ed capacitor wire) and to a good ground. Figure 4-11.
OVERHAUL MANUALSection 4 IgnitionSystem LYCOMING DIRECT DRIVE AIRCRAFT ENGINES c. Remove the switch, coil and retard leads from their terminals in the distributor block. b. Tighten the two setscrews block in the magneto. d. Loosen the two setscrews mounted radially in the rear flange of the magneto and carefully remove the distributor block from the magneto. e. Reach into the magneto and grasp the rotor.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION ACCESSORY 5-1. It is assumed, at this time, that the magnetos and all accessories have been removed from the accessory housing. 5-2. Unless specifically called out tothe contrary, all references to component parts will apply to all engines except those with a housing incorporating dual magnetos in a single housing. These housings willbe identified as Dual Magneto Housings. DISASSEMBLY 5-3. Fuel Pump (Diaphragm type) - See figure 5-3.
0 \ \ \ OVERHAUL Section 5 Accessory Housing 5-2 \ \ \ \ \ MANUAL- \ \ I I
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 2 Hyd. Pump Drive Adapter Oil Seal Fuel Pump Gasket Dual Magneto Driving Impeller Driven Impeller Magneto Gear Accy. Driven Gear Gasket Valve Thermostatic Washer 0 Spring 19 22 10. Retaining Ring 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Crankcase Oil Pump Drive Gear Fuel Pump Plunger Oil Pump Body Idler Shaft Vac. Pump Pad Spring Seat Sleeve Retaining Ring Oil Filter Assy. I 12 14 Figure 5-2.
m zZ 12 2 3 4 2 7 0 m r 8 m 1. 2. 3. 4. Vacuum Pump Gasket Oil Seal Adapter 5. 6. 7. 8. Washer Vacuum Pump Driven Gear Fuel Pump Cover Figure 5-3. Vacuum Pump and Propeller Governor Drive Assemblies 9. Retaining Ring 10. Propeller Governor Drive Adapter 11. Propeller Governor Driven Gear 12.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 5-19. Turbo Scavenge Pump (Where applicable) See figure 5-10 or 5-11. Disassemble as shown in the illustration. 5-20. 5-12. Oil Scavenge Pump (AIO-360, -320) See figure Disassemble as shown in the illustration. C LEANING 5-21. Drilled Oil Passages. Remove all plugs from oil passages. Particular care must be given to see that oil passages are thoroughly cleaned.
OVERHAUL MANUALSection5 AccessoryHousing 3 1 LYCOMING DIRECT DRIVE AIRCRAFT ENGINES l 2 4 6 12 8 7 9 11 7 10 2 0 - 13 4 1. 2. 3. 4. 5. 6. Gasket Brace Cover Oil Seal Vacuum Pump and Prop. Spacer Figure 7. Washer 8. Dual Drive Adapter 9. Accessory Drive Gear 10. Dual Accessory Drive Gear Gov. Dual Drive Adapter 11. Idler Gear 12. Vacuum Pump Driven Gear 13. Vacuum Pump and Hydraulic Pump Dual Drive Assembly 5-5.
OVERHAUL MANUAL- 2 3 5 6 1. 2. 3. 4. Drive Shaft Plug Body Driving Impeller Figure Section5 Accessory Housing four 1/4-20plainnuts, plain washers and lockwashers. If the engine is equipped with vacuum pump drive only, place a cover over the exposed end of the drive toprevent entrance of dirt and/or other foreign matter. If the engine is equipped with vacuum pump install the vacuum pump on the adapter instead of the cover. 5-31. Propeller Governor Drive. See figure 5-3.
OVERHAUL Section5 Accessory Housing 5-8 MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Revised z I May, 1972
OVERHAUL MANUAL LYCOMING 5-33. “AN” Fuel Pump Drive. See figure 5-4. If the engine is equipped with an “AN” fuel pump drive, assemble the unit as follows: Insert a new oil seal (1) into the recess in the pump side of the fuel pump adapter assembly (3). Make sure that the seal is inserted with the grooved side toward the adapter. Insert the fuel pump drivengear (5) into the adapterbeing careful not to damage the seal.
OVERHAUL MANUAL. Section 5 Accessory Housing LYCOMING DIRECT DRIVE AIRCRAFT ENGINES CAUTION Brace must be seated properly so there is no stress at either end of bracket when nuts are tightened. 5-36. Fuel Pump (Diaphragm Type) See figure 5-3. Before installing the diaphragm type fuel pump make sure that the pump drive plunger is all the way up and the cam of gear is on the low side.
A -- N Revised May, OVERHAUL 1972 MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT 2- ENGINES 5-11
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION Section 6 Cylinders, Pistons, andValveTrain 6. CYLINDERS, PISTONS VALVE TRAIN AND 6-1. The piston, being a reciprocating part, is normally grouped with the crankshaft in a theoretical breakdown of the engine into basic components. However, from a practical standpoint, it is felt that the piston should be considered with the cylinder insofar as overhaul procedures are concerned.
Section6 OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 6-17. HYDRAULIC TAPPET PLUNGERS. (Where applicable) Using hydraulic tappet tool (64941), remove the push rodsocket by placing heavy grease on ball end of ‘T”, inserting the ball end in socket and withdrawing, the socket will adhere to the grease. Using the hollow end of the tool pushingit over theplunger and withdrawing the hydraulic tappet plunger.
26. 27. 28. 29. 30. 6 7 8 9 10 2 31. 32. 33. 34. 35. 36. 37. Drain tube Hose clamp Hose Nipple 3/8 inch cylinder base nut (0-235-C) Nut, lockwasher, washer Exhaust flange Exhaust flange gasket Valve key Valve spring seat Outer valve spring Inner valve spring 36 13 15 32 16 19 31 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Section 6 OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 6 Cylinders, Pistons, and Valve Train
OVERHAUL Section 6 Cylinders, Pistons, and Valve Train MANUAL - LYCOMING DIRECT DRIVE AIRCRAFT ENGINES
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section6 Cylinders,Pistons, and Valve Train DISASSEMBLY 6-18. CYLINDER. Place cylinder over the cylinder holdingblock (64526-1, or -2), assemble valve spring compressor (ST-25) on cylinder, and compress valve springs far enough to remove the valve retaining keys. NOTE If keys are stuck tight in spring seat, a light blow with a leather mallet on top of compressor will release keys. 6-19.
Section 6 OVERHAUL MANUAL Cylinders, Pistons, andValveTrain LYCOMINGDIRECTDRIVEAIRCRAFTENGINES dd. Minimum fillet at the root of the removed portion of the fin is one quarter inch radius. Minimum corner at top of fin adjacent to the removed portion is one half inch radius.
OVERHAUL MANUAL AIRCRAFTENGINES LYCOMING DIRECT DRIVE AIRCRAFT 6-28. CYLINDER BARREL (VISUAL INSPECTION). In additionto a thorough inspection of the cylinder barrel to ascertain its general condition, make the following specific checks: a. Cooling Fins. It is recommended that notches or nicks be profiled with a hand grinder or file. A cracked cylinder barrel is cause for rejection of the cylinder. b. Cylinder Skirt. Replace any cylinder having a bent, cracked or broken skirt. c.
LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section6 OVERHAUL MANUALCylinders, Pistons, and Valve Train FACEOF VALVEMUSTRUN TRUEWITHSTEMWITHIN .0015 6-40. Using an optical magnifier, examing the valve in the stem area and the tip for evidence of cracks, nicks, tool marks, or other indications of damage. Damage of this nature seriously weakens the valve, making it liable to failure. Any valve having a nick, with ragged edges more than 1/16 inch inlength should not be reused.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section6 Cylinders,Pistons, and Valve Train Figure 6-17. Appearance of Spalling Marks on Face of Hydraulic Tappet Bodies Any indication of distress, surface irregularity or featheringat the edge of the lobe is cause for rejection of the camshaft. NOTE Each tappet face will have one or two Rockwell marks (figure 6-18) which is not cause for rejection, and this is notto be confusedwith a spalled or pitted condition as shown in figure 6-17.
Section6 OVERHAUL MANUAL Cylinders,Pistons, and Valve Train LYCOMING DIRECT DRIVE AIRCRAFT ENGINES ROCKWELLMARKS I Figure 6-18. c. Tighten fixture. IF THIS SURFACEAPPEARSWAVY THE PARTMUSTBE REJECTED Rockwell Marks to hold the assembly securely Figure 6-19. Circular Face of Hydraulic Wear Pattern Tappet Body on in the d. Pass a current of 500 amps through the tappet body for 1/2 to 3/4 of a second while the solution is running over tappet body.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES REQ. Section 6 Cylinders, Pistons, and Valve Train FIBER COPPER MCHSCR. 4 3 C.R.S. ' COPPER 2 REQD.COPPER IREQD. COPPER DET. NO NO. REQ. FIBER COPPER STOCKSIZE MATERIAL Figure 6-21. Dimensions for Making Holding Fixture d. When the plunger does not bounce back but remains collapsed, it is an indicationthat the ballcheck valve is not seating properly.
OVERHAUL MANUAL Section6 Cylinders,Pistons, and ValveTrain LYCOMING DIRECT DRIVE AIRCRAFT ENGINES REMOVEFERROXCOATINGFROM THIS SURFACEBEFORE MAGNAFLUXING MACHINE S Figure 6-24. Checking Plunger Assembly NOTE When inspection reveals the necessity of replacing a spark plug heli-coil insert, it must be replaced with a . 010 inch oversize insert. A .010 inch bottoming tap (64596-1) is available. Figure 6-22. Surface to be Cleaned of Ferrox Coating 6-61. SPARK PLUG THREAD INSERT.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 6 Cylinders, Pistons, and Valve Train using the expanding tool (64593), secure the insert firmly in the spark plug holes. The limit of expansion can be kept within the thread gage limits by fixing the stop nut on the expanding tool at the correct position. After expanding the insert, it may be staked by assembling the staking sleeve over the mandrel until the sleeve meets the boss.
Section6 OVERHAUL MANUAL Cylinders,Pistons, and ValveTrain LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TABLE VI-II VALVE SEAT REPLACEMENT TOOLS VALVE SEAT RECESS CUTTER ID Valve Seat Hole in Cylinder 2.280-2.281 1.733-1. 735 2.073-2.075 1.926-1.928 1.918-1.920 2.087-2.089 1.994-1.996 -1 Indicates -2 Indicates -3 Indicates Head Part No. ST-51-1,-2,-3 ST-52-1, -2, ST-53-1, -2, ST-54-1, -2, ST-56-1, -2, ST-57-1, -2, ST-58-1, -2, -3 -3 -3 -3 -3 -3 . 010 inch oversize . 020 inch oversize .
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section6 Cylinders, Pistons, andValveTrain guide. From cylinder barrel end insert the bolt (3/8-24) into the end of the 3/4 inch bolt. Tighten the 3/8 bolt until snug against the valve guide. Turn the nut in rocker box in a clockwise direction until valve guide is out of cylinder head. 6-83. VALVE GUIDE SELECTION. Check each valve guide hole in the cylinder headwiththe applicable valve guide hole plug gage. (See Table VI-III).
Section 6 OVERHAUL MANUALCylinders,Pistons, andValveTrain TABLE VI-III VALVE GUIDE REPLACEMENT GAGE LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TOOLS SIZE REAMER Valve Guide Hole in Cylinder Head (. 5913/. 5923 hole) 64571 64507 64509 64511 64639 Standard .005 oversize .010 oversize .020 oversize .030 oversize 64678-2 64678-3 64678-4 64678-5 (. 6247/. 6257 hole) ST-89 ST-89-5 ST-89-1 ST-89-2 ST-89-3 Standard .005 oversize .010 oversize .020 oversize .030 oversize 6-88.
OVERHAUL MANUAL- LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 6-91. Check each rocker shaft bushing hole in cylinder head with a standard plug gage (64810). If plug gage enters hole more than 1/8 inch an oversize rocker shaft bushing will be required. If the fit of plug gage in the hole is quite loose, it is evident that the bushing that was removed was an oversize bushing. Use the 0. 005 oversize plug gage to determine what oversize bushing should be used for replacement.
Section6 OVERHAUL MANUAL Cylinders,Pistons, and ValveTrain a. Friable Bond Material b. Grain Size - 54 LYCOMING DIRECT DRIVE AIRCRAFT ENGINES - 2A c. Grade-K d. Structure - 5 porous e. Vitrify Bond Treatment - V92 f. Diameter - 3-1/2 to 4 inches 2. Wheel Speed a. 3-1/2 inchwheel - 5600 to 6000 surface feet per minute. b. 4 inchwheel - 5350 to 5730 surface feet per minute. 3. Work Speed - 250 RPM b. Nitrided Barrels 1. Wheel a. b. c. d.
OVERHAUL MANUAL LYCOMINGDIRECTDRIVEAIRCRAFTENGINES Section6 Cylinders,Pistons, and Valve Train 6-118. (All Pistons. ) Upon completion of assembly of the piston rings, check the side clearance of the rings in the grooves. Use feeler gage and straight edge as shown in figure 6-11. NOTE Under no circumstances should oversize piston rings beused inchrome platedbarrels. 6-119. AssemblyofCylinder. See figure 6-5. Coatthe valve guides and valves with a pre-lubricant as described in paragraph 3-39.
Section 6 OVERHAUL MANUALCylinders, Pistons, andValveTrain LYCOMING DIRECT DRIVE AIRCRAFT ENGINES loosen nuts and repeat steps b and c. 6-127. After all cylinder base nuts have been tightened, remove any nicks in the cylinder fins by filing orburring. 3 2 3/8 INCH 1/2 INCH Figure 6-32. Sequence of Tightening Cylinder Base Nuts 6-126.
OVERHAUL MANUAL LYCOMINGDIRECTDRIVEAIRCRAFTENGINES Section 6 Cylinders,Pistons, and ValveTrain 6-135. Angle Valve Cylinder. Slide rocker shaft back and install rocker (22, figure 6-6) and thrust washer (23, figure 6-6). Before installing exhaust valve rocker place special cap (32, figure 6-6) over the exhaust valve stem. Slide rocker shaft back into position. Repeat with the other rocker arm and thrust washer.
Section 6 OVERHAUL MANUAL Cylinders, Pistons, andValveTrain LYCOMING DIRECT DRIVE AIRCRAFT ENGINES d. Mask off the flange area as shown in figure 6-35. Proceed to paint the cylinder with a Phthalate resin type enamel (AMS3125C or equivalent MIL-E-7729) properly thinned with Toluene or equivalent (AMS3180 or equivalent Federal Spec. TT-T-548). e. Use a cloth dipped in thinner to clean paint from all surfaces where paint may have accidentally accumulated. f.
OVERHAULMANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section7 Crankcase, Crankshaft, andReciprocating Parts SECTION VII CRANKCASE, CRANKSHAFT AND RECIPROCATING PARTS 7-1. At this time it is assumed that all accessories, cylinders, accessory housing and sump have been removed from the engine. DISASSEMBLY 7-2. Starter Ring Gear Support - Remove the starter ring gear support assembly (32, figure 7-5) from the crankshaft propeller flange by tapping lightly on the rear face of the assembly.
Section 7 OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Crankcase, Crankshaft, and Reciprocating Parts 15 23 13 10 24 22 21 20 19 18 1. Front Main Bearing Insert 2. Lifting Strap 3. Oil Relief Valve Plug (Field Conversion) 4. Ball 5. Spring 6. Washer 7. Spacer 8. Gasket 9. 10. 11. 12. 13. 14. 15. 16. 17.
OVERHAUL MANUAL Figure 7-2. Camshaft Wired to Crankcase LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7 Crankcase, Crankshaft, andReciprocating Parts CAUTION All crankpin journal sludge tubes must be removed from the crankshaft; otherwise accumulated sludge loosened during cleaning will clog the crankshaft oil passages and cause subsequent bearing failures. The oil transfer tubes, however, which conduct oil from the main bearings to the crankpin journals must not be removed under any circumstances.
SECTION 7 OVERHAUL MANUAL - TEXTRON LYCOMING AIRCRAFT ENGINES CRANKCASE, CRANKSHAFT, AND RECIPROCATING PARTS DIRECT DRIVE 1. Gasket 2. Thrust Washer 3. Cover 4. Idler Gear Shaft 5. Gasket 6. Hex head Plug 7. Woodruff Key 8. Prop. Governor Drive Gears 9. Prop. Governor Idler Gear Figure 7-4. Propeller Governor Drive (6 and 8 Cylinder Engines) INSPECTION 7-22. Inspect all crankcase, crankshaft and reciprocating parts in accordance with the general instructions contained in Section 3.
OVERHAUL A MANUAL LYCOMING clearances in the same manner, see Table of Limits, Reference 502. If clearances do not fall within prescribed limits, the shaft must be brought undersize. See Repair and Replacement section for instructions for regrinding. 7-31. Camshaft (Visual Inspection). Carefully inspect all surfaces of the camshaft for cracks, scoring, galling, corrosion, pitting or other damage; be particularly careful when inspecting bearing surfaces.
LYCOMING 7 5 1. 2. 3. 4. 5. 6. I. 8. Hex Head Bolt Lockplate Breather Slinger spacer Tachometer Shaft Camshaft Gear Dowel Camshaft 9. 10. 11. 12. 13. 14. 15. 8 Pin Camshaft Integral Gear Pi” Tachometer Shaft spacer Retaining Ring Camshaft (Prop. Governor Drive on Crankcase) Figure 7-6. Camshafts - Integral and Separate Gears (4 Cylinder Engines) 7-37. When inspecting O-540 models, the above inspection procedure must he performed on both intermediate bearing saddles. ‘l-36.
OVERHAUL MANUAL LYCOMING IING DIRECT DRIVE AIRCRAFT ENGINES Section7 Crankcase, Crankshaft, andReciprocating Parts REPAIR AND REPLACEMENT 7-44. Repair all crankcase, crankshaft and reciprocating parts in accordance with the general instructions contained in Section III. Specific instructions follow. 7-45. Crankshaft (Bearing Surfaces). Duringoverhaul of the crankshaft, the operator must determine if it has standard or undersize bearing journals, then proceed with its overhaul accordingly.
'.YCOMING DIRECT DRIVE AIRCRAFT ENGINES Section7 0VVERHAUL MANUAI Crankcase,Crankshaft, and ReciprocatingParts 2 -2 Crankshaft Oil Seal Surface. 7-49. ReconditioningWorn If inspection personnel have found that the crankshaft oil seal surface on the shaft itself is damaged to the extent that the oil seal might leak, the following procedures are submitted to recondition this area of the crankshaft. flange bushings from crank1.
OVERHAUL MANUAL LYCOMING DIRECTDRIVE AIRCRAFT ENGINES Section 7 Crnkcase, Crankshaft, and Reciprocating Parts 7-50. Crankshaft, Counterweight Bushing Replacement (Where applicable). Wear or damage to the crankshaft counterweight bushings located in the crankshaft counterweight lugs, is almost impossible to detect by normal inspection procedures.
Section7 Crankcase, Crankshaft, and Reciprocating Parts OVERHAUL MANUAL TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES -PILOTDIAMETER TABLE 7-2 Hole Size Reamer No. .9369/.9377 .9420/.9425 .9445/.9450 .9470/.9475 .9495/.9500 .9520/.9525 None 64874 ST-210 64875 ST-211 64876 3. Determine the oversize reamer needed and assemble the reaming fixture over the crankshaft lug.
OVERHAULMANUAL TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES the threads are undamaged. The threads can be cleaned by running a tap through them. Use a standard .3125-24NF3 (P.D. .2854/.2878) tap for 5/16inch threads. Use a standard .500-20NF3 (P.D. .4675/.4701)tap for 1/2 inch threads. Check the depth of the thread by threading a gear retaining bolt to the bottom of the hole and comparing the exposed length of the bolt with the thickness of the gear and lockplate.
OVERHAUL MANUAL - LYCOMING AIRCRAFT ENGINES SECTION 7 DIRECT DRIVE CRANKCASE, CRANKSHAFT, AND RECIPROCATING PARTS If the dowel has been removed, check the condition of the dowel hole in the crankshaft. If out-of-round or oversize, ream as required for installation of an o//ersize dowel. Available oversize dowels and the ~~corresponding reamed holes are shown in Table 7-3. 4. ,,~ 0/Y////y///,~~~~~ Size DRIVEN TO LOCATE END OF DOWEL .160 IN.ABOVE COUNTERBORE SURFACE OF CRANKSHAFT.
OVERHAUL MANUAL TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES CAUTION Some old crankshaft gears are carborized all over. If carborized, they willnot nick when a file is used on scallop. If carborized all over, gear should not be reworked. Section7 Crankcase, Crankshaft, and Reciprocating Parts 7-54. Starter Ring Gear. The latest edition of Service Instruction No. 1141contains all the information necessary to accomplish the replacement of the starter ring gear. 7-55.
Section 7 Crankcase, Crankshaft, and ReciprocatingParts OVERHAUL MANUAL TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 5/16" Bolt Head Must Be Identified As Shown. NOTE Refer ToTable 7-4 For Ap plicable Bolt Part No. No. Assemble With Threads Clean And Dry Of All Foreign Substances, Prior To Adding Lubricant. Note: In Some Engines A Tang Will Be Found Instead Of A Slot At This Location. It Should Be Free From Nicks And Dents. Add Small Amount Of Fel-Pro Food Grade AA, P/N 51168.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7 Crankcase, Crankshaft, andReciprocating Parts 6. Assemble reamer to universal and proceed to finish ream the holes, once again paying attention to the preceding "caution" note. -REMOVEPROPELLERFLANGE BUSHINGBEFORE \GRINDING. MASK HOLESBEFOREPLATING.REPLACE \WITH NEW BUSHINGAFTER PLATING. 7. Disassemble crankcase halves and hand tap the anchor threads 0. 007 inch oversize using tap (P/N 64907). 8.
Section 7 Crankcase, Crankshaft, and ReciprocatingParts OVERHAUL MANUAL TEXTRON LYCOMINGDIRECT DRIVE AIRCRAFT ENGINES 2. Draw the tap and sleeve straight out of the bore with a sharp quick pull. LEVER 3. Clean the relief valve bore thoroughly with petroleum solvent and a suitable bristle brush, taking care to see that all metal particles are removed. The sleeve seat in particular must be entirely free from foreign matter, or new sleeve will not seat properly. 4.
OVERHAUL MANUAL TEXTRON LYCOMING DIRECT DRIVE AIRCRAFT ENGINES faces at any location. (.001 feeler gage is used as an indicator, however there must be no clearance between crankshaft and gear.) Retighten the gear attaching bolt to the proper torque. Tighten the 5/16 inch bolt to 204 inch-pound torque or the 1/2 inch bolt to 660 inch-pound torque. Measure the clearance between the O.D. of the gear flange and the pilot I.D. of the crankshaft. There should not be more than .0005 inch clearance at any point.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7 Crankcase, Crankshaft and Reciprocating Parts TO SEPARATE DOWELED CRANKCASES TO ASSEMBLE DOWELED CRANKCASES Step 1. Right Side of Crankcase Showing Installation of Bolts on Half-Inch Cylinder Studs Step 1. Right Side of Crankcase Showing Bolts Installed on Thru-Studs Step 2. Right Side of Crankcase Showing Installation of Plate Step 2. Right Side of Crankcase Showing Plate Assembled Over Bolts Step 3.
Section7 OVERHAUL MANUAL Crankcase, Crankshaft, andReciprocating Parts LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SLUDGE TUBESTO THESEDIMENSIONS REMOVE EXPANSION PLUGFORCONSTANT SPEED OPERATION MODEL DIMENSION "A" DIMENSION "B" 0-235, 0-290 0-320,0-340 0-360 0. 20 inch 0.20 inch 0.25 inch 0. 20 inch 0.20 inch 0.31 inch Figure 7-17. Dimensions to Drive Sludge Tubes (Four Cylinder Engines) side of the counterweight.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7 Crankcase,Crankshaft, and ReciprocatingParts 7-73. Crankcase. Place both crankcase halves on a suitable support with the interior of each half facing upward. Place new main bearing inserts in the center and rear main bearings of both crankcase halves, making certain thatthe tang of each insert is fitted into the recess provided in the crankcase.
OVERHAUL MANUAL 7 Section LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Crankcase, Crankshaft, and Reciprocating Parts (Point A) regrind the front face of the crankshaft slinger (Point "B") to remove the clearance. Grind only that amount, from the face of the slinger, necessary to remove clearance. Push the crankshaft as far as possible to the rear of crankcase. Check the clearance betweenthethrust surface of crankshaft and crankcase. 7-83. Pre-lubricate the main bearing inserts of the right crankcase half.
OVERHAUL MANUAL- 7-88. Installtorque hold downplates alent) at cylinder pads. LYCOMINGDIRECTDRIVEAIRCRAFTENGINES Section7 Crankcase,Crankshaft, and Reciprocating Parts (ST-222 or equiv- 7-89. Install nuts on free ends of 1/2 inch thru-studs and using the sequence specified in figure 7-21, 7-22 or 7-23, whichever is applicable, tighten to 300 inch pounds.
Section 7 OVERHAUL MANUAL Crankcase, Crankshaft, andReciprocating Parts LYCOMING DIRECT DRIVE AIRCRAFT ENGINES TH TIGHTEN ONRIGHTSIDE 4TH TIGHTENONLEFTSIDE ND TIGHTEN ONLEFTSIDE -3RD TIGHTEN ON LEFTSIDE TIGHTEN ONRIGHT SIDE 7 THTIGHTEN CRANKCASE FASTENINGS (7)THRU INSEQUENCE INDICATED Figure 7-23. Crankshaft Tightening Sequence (Eight Cylinder Engines) bled over the flange bushing also identified with "O" etched on crankshaft flange next to bushing.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES Section 7 Crankcase,Crankshaft, and ReciprocatingParts is marked. The smaller diameter gear is marked at one location with the etched circles on two adjacent teeth. The camshaft is marked with smalletched circles on two adjacent teeth and the crankshaft gear is marked at one location with one circle.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES SECTION OIL SUMP AND Section 8 Oil Sumpand FuelInduction 8. FUEL INDUCTION 8-1. General. To accomodate the number of engine models, covered inthis manual, a number of oilsump configurations are employed. Basically all oil sumps are similar and overhaul procedures will apply to all models unless specifically called out to the contrary. Remove the studs and clamps that secure the intake pipe extensions and remove the extensions. 8-2.
Section8 Oil Sumpand FuelInduction OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 3 2 11 4 12 11I 10 6 7 7 8 1. 2. 3. 4. 5. 6. Intake Pipe Gasket Flange Gasket Flange Oil Suction Screen Gasket 7. 8. 9. 10. 11. 12. Figure 8-1. Oil Sump and Related Parts must Inspection of carburetors 8-19. Carburetors. determine parts serviceablility and repair and replacement requirements. Check applicable manufacturer's publications for limits to be used when conducting inspection. 8-20.
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES to the nozzles. Check for clogged nozzles. edsecurely Remove nozzles, if clogged, and conduct a priming operation to make certain fuel flows from the nozzle. NOTE Nozzles for this system are a matched set and are stamped "A", "B" or "C". Fuel flows for these nozzles are: a. "A" - 280to284cc psi supply pressure. Section8 Oil Sumpand Fuel Induction REPAIR AND REPLACEMENT 8-25. Intake Pipe Connection Removal.
Section8 Oil Sumpand FuelInduction OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 6 2 6 4 6 7-9 5 13 1 12 13 1 12 16 15 14 12 13 1. 2. 3. 4. 5. 6. 7. 8. Annular Gaskets Oil Sump Baffle Plug, 7/8 - 14 x .62 Hose Hose Clamps Flange Gaskets Intake Pipe Flanges Intake Pipes 9. "O" Ring 10. Gaskets 11. 12. 13. 14. 15. 16. Intake Pipe Connection Oil Suction Screen Plug 1.00 - 20 x. 62 Intake Pipe Extension Studs Intake Pipe Extension Clamps Intake Pipe Extensions Figure 8-3.
OVERHAUL 1. 2. 3. 4. 5. 6. MANUAL LYCOMING DIRECT DRIVE AIRCRAFT I. 8. 9. 10. 11. 12. Gaskets Intake Pipe Flange Intake Pipes 1 Inch Plug Gasket Oil Suction Screen ENGINES Section 8 Oil Sump and Fuel lnduction Helicoil Induction Housing Oil Seal l/2 Inch Plug 3/4 Inch Plug Oil Sump Figure 8-4. Gil Sump and Induction System (IO-720) 8-32. Induction Housing (10-720-A, -C). See figure 8-4. Assemble the induction housing (8) to the bottom of the sump.
Section 8 OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES OilSumpand FuelInduction bly and throttle body of the Simmons #530 fuel injeccure the flange to the cylinder. Slide hose (4) over tor mustbe the same. These units are notinterchangconnection (11) and tighten clamps. eable. 8-37. Air Bleed Nozzles. Air bleed nozzles are installed in the cylinder head. In upper side of head on 8-35. Flow Dividers.
LYCOMING DIRECT DRIVE AIRCRAFT ENGINES OVERHAUL MANUAL Section9 Test Procedure SECTION TEST 9. PROCEDURE 9-1. At the completion of assembly of the engine after overhaul, it is recommended that theengine be mounted upon a test stand for its initial or run-in operation.
TABLE 9-1 ENGINE RUN-IN TEST LIMITS Fuel Pressure psi - at inlet to carb. or injector Fuel - Minimum Octane Rating Aviation Grade Lbs. /Hr. 2-5 2-5 2-5 2-5 2-5 2-5 18-28 18-28 18-28 18-28 18-28 18-28 2-5 80/87 100/130 80/87 80/87 80/87 91/96 80/87 91/96 91/96 100/130 100/130 91/96 91/96 0.9 0. 9 0.9 1.0 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.3 .50 .50 50 .
OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 9-4. Test stand oil supply pressure to engines which can be run simulated wet sump shall be held to 1.5 2. 0 psi throughout the run. Test stand oil supply pressure to engines run simulated dry sump shall be held to 0. 5 - 3. 0 psi at rated conditions. Personnel should consult Service Bulletin No. 113 when desiring to use dry sump test stand installation for wet sump engines. 9-13. PRESSURE CARBURETORS.
Section9 Test Procedure OVERHAUL MANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 9-23. Non-adjustable Oil Pressure Relief Valve - Although the valve is not adjustable, the oil pressure can be controlled by the addition of STD-425 washers under the cap as required (maximum of three) to increase pressure or the use of a spacer (P/N 73629 or 73630) to decrease pressure. A later modification to the relief valve eliminates the need of the spacer and uses STD-425 washers as required (maximum of nine).
OVERHAUL LYCOMING MANUAL DIRECT DRIVE AIRCRAFT Left Side View Right Side View Figure 9-3. Simmonds Type 530 Fuel Injector a. Move the mixture A control lever toward the idle cut-off position with a smooth, steady pull and note tachometer. An increase of more than 10 RPM indicates an excessively rich mixture while an immediate decrease (if not preceded by a momentary increase) indicates the mixture is too lean.
Section9 Test Procedure OVERHAULMANUAL LYCOMING DIRECT DRIVE AIRCRAFT ENGINES 9-37. Engines shall have spark plugs installed in the bottom cylinder location and dehydrator plugs, P/N 40238 installed in the upper cylinder location. The ignition harness shall be attached to the spark plugs in the bottom locations and have ignition cable protectors (AN-4060) on the top locations. TABLE 9-3 RECOMMENDED RPM REPRESERVATION LOAD SCHEDULE TIME (MINUTES) 9-38.
SECTION 10 TABLE OF LIMITS This section of the manual has been reserved for the Special Service Publication No. SSP-1776 Part I, Table of Limits and Tightening Torque Recommendations. Upon receipt of the owner's registration card, attached in the front of this manual, at Textron Lycoming,a copy of the Special Service Publication SSP-1776Part I will be forwarded to the registered owner. The SSP-1776PartI shouldthen be insertedin the manual at this location.
Lycoming SERVICE TABLE OF LIMITS AND TORQUE VALUE RECOMMENDATIONS NOTICE The basic Table of Limits, SSP2070 (including SSP2070-1, SSP2070-2, SSP2070-3 and SSP2070-3A) has been completely revised and reissued herewith as SSP1776. It is now made up of the following four parts, each part contains five sections.
INTRODUCTION SERVICE TABLE OF LIMITS This Table of Limits is provided to serve as a guide to all service and maintenance personnel engaged in the repair and overhaul of Textron Lycoming Aircraft Engines. Much of the material herein contained is subject to revision; therefore, if any doubt exists regarding a specific limit or the incorporation of limits shown, an inquiry should be addressed to the Textron Lycoming factory for clarification. DEFINITIONS: Ref.
Introduction The illustrations shown are typical of the referenced limit or fit described in the Table and in no instance are these illustrations intended to represent a specific part or engine model unless specified. Also, the terms used to designate cylinder, piston and ring materials such as "nitride, chrome, half-wedge" are more fully explained in the latest edition of Service Instruction No. 1037.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION I CRANKCASE,CRANKSHAFT, CAMSHAFT Ref. Ref. New Old 500 Chart 501 A Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. erv. & Max. Max. Max. All Main Bearings and Crankshaft .0025L .0055L .0060L .0060L Main Bearings and Crankshaft (Thin Wall Bearing - .09 Wall Approx.) .0015L .0045L .0060L B-G-J-S-T-Y-AF Main Bearings and Crankshaft (Thick Wall Bearing .16 Wall Approx.) .0011L .0041L .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION I CRANKCASE,CRANKSHAFT,CAMSHAFT Ref. Ref. New Old 501 502 Chart S-T-AF 954 A-B-D-G-J-S-T-Y-BD-BE S-T-AF 502 564 ALL 503 566 ALL 504 567 505 ALL 556 Dimensions Mfr. Min. Serv. & Max. Max. Diameter of Connecting Rod Journal on Crankshaft (2-1/4 in.) 2.2485 2.250 Connecting Rod Bearing Bore Diameter (2-1/8 in.) (MeasuredAt Axis 30° on Each Side) 2.2870 2.2875 Connecting Rod Bearing Bore Diameter (2-1/4 in.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION I CRANKCASE,CRANKSHAFT,CAMSHAFT Ref. Ref. New Old 508 607 509 941 Chart ALL ALL Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Crankshaft Prop. Flange Run-Out .002 Starter Ring Gear and Support .014T .022T (A) .005 510 504 A-B-D-G-J-S-T-Y-AF 504 A-B-D-J-S-T-Y-AF-BD-BE Crankshaft Timing Gear and Crankshaft .0005T .010L (A) 511 536 A-B-D-G-J-S-T-Y-AF Tappet Body and Crankcase .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION I CRANKCASE,CRANKSHAFT,CAMSHAFT Ref. Ref. New Old 522 774 ALL (AS APPLICABLE) 523 524 Chart D 509 D Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. O.D. of Counterweight Roller (See latest edition of Service Instruction No. 1012) Thrust Bearing and Propeller Shaft .0000 .0012L Thrust Bearing and Thrust Bearing Cap Clamp Fit (Shim to this Fit) .003T .005T .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION I CRANKCASE,CRANKSHAFT, CAMSHAFT Crankcase, Crankshaft, Camshaft and Related Parts SSP1776 1-5
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Ref. Ref. New Old 600 510 ALL 601 510 6 602 Chart Connecting Rod and Connecting Rod Bushing ALL Finished I.D. of Connecting Rod Bushing A-B-D-G-J-BD J-B Length Between Connecting RodBearing Centers 6.4985 6.501 S-T-Y-AF-BE Length Between Connecting RodBearing Centers 6.7485 6.7515 Connecting Rod Bushing and Piston Pin Piston Pin and Piston ALL Diameter of Piston Pin Hole1249 in Piston 1.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Ref. Ref. New Old 606 Chart Nomenclature 517 A 607 615 Dimensionsns Mfr. Min. Serv. Max. Max. Max. Piston Ring and Piston - Side Clearance (Bottom) Clearance Mfr. Min. & Max. .003L .0055L Serv. Max. .007L(B) ALL Piston Ring Gap (Compression) .020 Plain and Chrome Cylinders .030 .047 (Straight Barrels) ALL Piston Ring Gap (Compression) .045 Nitrided and Chrome Cylinders .055 .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Ref. Ref. New Old 611 523 Chart Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. A Exhaust Valve Seat and Cylinder Head .0065T .010T (A) B-D-G-J-S-T-Y-BD-BE Exhaust Valve Seat and Cylinder Head .0045T .008T (A) S1-S2-S3-S5-S6-S7S9-S10-T2-T3-AF Exhaust Valve Seat and Cylinder Head .0075T A O.D. Exhaust Seat 2.0025 2.004 B-D-G-J-S-T-Y-BDBE O.D. Exhaust Seat 1.7395 1.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Ref. Ref. New Old 613 527 Chart Nomenclature Dimen sions Mfr. Min. Serv. & Max. Max. Y O.D. Exhaust Valve Guide .6267 .6272 G-J-S-T-AF-BD-BE O.D. Exhaust Valve Guide .6633 .6638 S1 O.D. Exhaust Valve Guide .6953 .6958 A-B-D-J I.D. Exhaust Valve Guide Hole in Cylinder Head .5913 .5923 I.D. Exhaust Valve Guide Hole in Cylinder Head .6247 .6257 I.D. Exhaust ValveGuide Hole in Cylinder Head .6613 .6623 I.D.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Ref. Ref. New Old 615 527 Chart Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. A-B-D Finished I.D. Exhaust Valve Guide .4040 .4050 A-G-J Finished I.D. Exhaust Valve Guide .4370 .4380 Finished I.D. Exhaust Valve Guide .4375 .4385 Finished I.D. Exhaust Valve Guide (Parallel Valve Heads) .4985 .4995 Finished I.D. Exhaust Valve Guide (Angle Valve Heads) .4995 .5005 Finished I.D.
SERVICE TABLE PART 1 DIRECT OF DRIVE LIMITS ENGINES SECTION II CYLINDERS Ref. Ref. New Old Chart Nomenclature Dimensions ions Mfr. Min. & Serv. Max. Max. 619 611 620 531 S1-S2-S3-S5-S6S7-S9-S10-T2T3-AF Finished I.D. of Valve Rocker Shaft (Bushing)in Cylinder Head (Angle Valve Heads) ALL Valve Rocker Shaft and Valve Rocker Bushing ALL ALL .6252 .6263 .6270 O.D. Valve Rocker Shaft .6241 .6245 .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS Cylinder, Piston and Valve Components SSP1776 1-12
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION II CYLINDERS 0-235 TYPE PARALLELVALVE HEAD 619- ANGLE VALVE HEAD Cylinder, Piston and Valve Components SSP1776 1-13
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTIONIII GEAR TRAIN SECTION - OIL PUMP Ref. Ref. New Old 700 554:: ALL Chart 701 601 A-B-D-G-J-S-T-AF Y BD-BE (DUAL MAGNETO) BD-BE 703 :::542::A-B-D-G-J-S-T-YAF 542BD-BE 704 543 ALL (Except BD-BE) BD-BE AS APPLICABLE AS APPLICABLE AS APPLICABLE BD-BE 705 544 706 558 707 602 Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Oil Pump Drive Shaft and Oil Pump Body or Cover .0010L .0025L .
SERVI CE TABLE OF LIMITS PAR RT1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN SECTION - SCAVENGEPUMP Ref. Ref. New Old 708 545 G2-S2 Chart Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Scavenge Pump Drive Shaft and Adapter .0010L .0025L .004L Scavenge Pump - End Clearance .000 .045L .060L Scavenge Pump Impellers Diameter Clearance .007L .O11L .014L Scavenge Pump Impellers Side Clearance .003L .005L .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN SECTION - FUEL PUMP (CONT.) Ref. Ref. New Old 724 620 Chart A-B Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Crankshaft Idler Gear- End Clearance .003L .043L .058L Crankshaft Idler Gear - End Clearance .005L .040L .055L Crankshaft Idler Gear - End Clearance .007L .037L .052L S (DUAL MAGNETO) Crankshaft Idler Gear - End Clearance .020L .030L .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN SECTION - GOVERNOR & HYDRAULICPUMP (CONT.) Ref. Ref. New Old 733 Chart 675 G-J-S 734 674 735 772 Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Rear Governor Gear and Adapter .0010L .0025L .005L G-S (DUAL MAGNETO) Rear Governor Gear and Accessory Housing .0010L .OO1OL .0025L .005L G-J-S Rear Governor Gear - End Clearance .002L .024L .
SERVICE TABLE OF LIMITS PART I DIRECT DRIVE ENGINES SECTION III GEAR TRAIN SECTION - VACUUM& TACHOMETER(CONT.) Ref. Ref. New Old 742 743 744 Chart G-J-S (DUAL DRIVE) Idler Gear and Shaft G-J-S (DUAL DRIVE) Idler Gear - End Clearance 764 G-J-S (DUAL DRIVE) G-J-S (DUAL DRIVE) 745 Nomenclature 794 G-J-S (DUAL DRIVE) Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. .0010L .0030L .005L .021L .041L .060L Propeller Governor Gear and Adapter .0013L .0028L .
SERVICE TABLE OF LIMITS PART I DIRECT DRIVE ENGINES. SECTION III GEAR TRAIN SECTION -MAGNETO, GENERATOR, STARTER (CONT.) Ref. Ref. New Old 758 7095 759 627 Magneto Gear and Bushing BD,IBE D 632D 762 633 763 634 764 637 Nomenclature T-AF (DUA ALMAGNETO) D 760 761 Chart D D D Dimensions Mfr. Min. Serv & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. .0015L .0035L .0055L Bushing - Magneto Drive and Crankcase .0025T .0045T (A) Generator Gear Bushing and Generator Gear .0020T .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN TURBOSCAVENGE PUMP& HYD PUMP(TIO-540-C) TURBO SCAVENGE PUMP& GOV.(TIO-360) DUAL MAG: TURBO SCAVENGEPUMP & HYD.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN AC FUELPUMP (4 CYL) AN FUELPUMP(DUALMAG) FUELPUMP(6CYL) AN FUELPUMP(6&8 CYL) AN FUEL PUMP(4CYL) Fuel Pumps SSP1776 1-21
TABLE SERVICE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTIONIII GEAR TRAIN 4 & 8 (WIDEDECK) 0-320-H 0,LO-360-E 6 CYL.(WIDEDECK)(2200 LB.) NARROWDECK(6 & 8 CYL.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN HYDRAULICPUMP-DUALMAG 732 REAR PROP GOV (4 CYL.) (STANDARD) REAR PROP GOV (4 CYL.) (DUAL MAG.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN TACHOMETERDRIVE VACUUMPUMP& TACHOMETER VACUUMPUMP DUAL DRIVE(VACUUMPUMP& PROPGOV.) OR (VACUUMPUMP& HYD.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN 0-435A HIO-360-D TYPE 8 CYLINDER 0-320-H, 0, LO-360-E 4 CYL.(S4LN-21 a S4LN-1227) 4 CYL. DUAL MAG. DUAL MAG.(6 8 8 CYL.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN VO, IVO-360 Accessory Drives: Magnetos SSP1776 1-26
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION III GEAR TRAIN 700 759 GENERATOR DRIVE 0-435-A Generator and Bendix Drive SSP1776 1-27
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION IV BACKLASH Ref. Ref. New Old Chart 800 623 A-B-G-J-S-T-Y-AF Nomenclature Dimensions Mfr. Min. Serv. & Max. Max. Clearances Mfr. Min. Serv. & Max. Max. Camshaft and Vacuum Pump Backlash .004 .015 .020 Camshaft and Vacuum and Oil Pump Drive - Backlash .006 .014 .020 Camshaft and Fuel Pump Backlash .004 .015 .020 Camshaft and Crankshaft Idler Backlash .004 .015 .020 Crankshaft and Crankshaft Idler - Backlash .004 .015 .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTIONIV BACKLASH Ref. Ref. New Old 819 973 Chart S-T-AF (DUAL MAGNETO) 820 974 T-AF 821 676 G-J-S Nomenclature .004 Pump Idler - Backlash .015 .020 Hydraulic Pump and Crankshaft Idler- Backlash .004 .015 .020 .004 .015 .020 Propeller Governor Drive and (Rear Governor) G1-G2-S2-S4-S6- Propeller Governor Idler and T-AF Camshaft - Backlash (Front Governor) 823 669 .020 .004 .008 .015 Gears) (Front Governor) .003 .011 .
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION IV BACKLASH CAMSHAFT TACHOMETER CRANKSHAFTIDLER, GOVERNOR ECCENTRIC -TACHOMETERMAGNETO VACUUMAC FUEL PUMP CRANKSHAFT PROP GOV -CAMSHAFT AT REAR CAMSHAFTAT 0-360 DUAL MAG.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION IV BACKLASH CAMSHAFT FUEL PUMP VACUUM PUMP 802 800 CRANKSHAFT IDLER 803 804 DRIVESHAFT OIL PUMPIMPELLERS MAGNETO DRIVEN VO, IVO-360 CAMSHAFT AT FRONT CAMSHAFT PROP GOVERNOR TACHOMETER CAMSHAFT VACUUM& OIL PUMP CRANKSHAFT OIL PUMP 0-320-H, 0, LO-360-E ALL VIEWS SHOWNFROM REAR OF ENGINE Backlash (Accessory Drives) SSP1776 1-31
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION IV BACKLASH PROP GOVERNORCAMSHAFT (FRONT) CAMSHAFT (REAR) 823- TACHOMETER IDLE VACUUM PUMP CRANKSHAFTIDLER ECCENTRIC--- IDLER AN FUEL HYDRAULICPUMP FUEL PUMP IDLER 0-540 & 10-720 DUAL MAG.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION IV BACKLASH STARTER DRIVE 0-435-A ACCESSORYHOUSING 0-435-A SECTIONTHRU REAR OF ENGINE Backlash (Accessory Drives) SSP1776 1-33
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS New Chart Old 900 829 A-B-D-G-Y-S-T-BD-BE Nomenclature Torque Limits 3/8-24 Connecting Rod Nuts 480 in. lbs. J 3/8-24 Connecting Rod Nuts 360 in. lbs. S1-S3-S5-S6-S7-S9T3-AF 3/8-24 Connecting Rod Bolts Tighten to Length BD-BE 9/16-18 Oil Pump Shaft Nut 660 in. lbs. 877 BD-BE 5/16-24 Rocker Stud Nut 150 in. lbs.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS(CONT.) Ref. Ref. New Old 919 871 Thread Thread ALL 920 875 ALL 921 S-T 1/4 Hex Head and Below Hose Clamps (Worm Type) 5/16 Hex Head and Above Hose Clamps (Worm Type) Cylinder Head Drain Back Hose Clamps 20 in. lbs. 45 in. lbs. 10 in. lbs. Exhaust V-Band Coupling Torque Data Coupling Size Tube OD 1.75 in. 2.00 in. 2.25 in. 2.25 in. 3.69 in. 3.69 in.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS (CONT.) Ref. Ref. New Old 930 849 Chart Thread Size Nomenclature 3/8 ALL 9/16 932 858 ALL 5/16-18 3/8-16 ALL Torque Limits Allen Head Screw (Diaphragm Fuel Pump) 225 - 250 in. lbs. Locking Nut (Valve Adjusting Screw) 450 in. lbs. Exhaust Transitions - Studs (Driving Torque) 100 in. lbs. Exhaust Transitions - Studs (Driving Torque) 200 in. lbs. SECTION V SPRINGS 950 800 951 COMP. LOAD Mfr.
SERVICE TABLE OF LIMITS STANDARD TORQUE UNLESS OTHERWISE LISTED Torque limits for propeller attaching bolts to be supplied by propeller or airframe manufacturer. TABLE I TABLE II BOLTS, SCREWS AND NUTS PIPE PLUGS Torcue In. Lb. Ft. Lb. Thread 10 1/4 5/16 3/8 7/16 49 96 204 360 600 Torque In. Lb. Ft. Lb. Thread 1/2 9/16 5/8 3/4 17 30 50 900 1320 1800 3240 75 110 150 270 THIN NUTS (1/2 DIA OF BOLT) - 1/2 LISTED TORQUE Torque In. Lbs.
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTIONV SPECIAL TORQUE REQUIREMENTS 918 ADJUSTABLE OIL RELIEF VALVE Engine Accessoriesand Hardware SSP1776 1-38
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS Engine Accessories and Hardware SSP1776 1-39
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS 915 904 912 915 I EngineAccessoriesand Hardware SSP1776 1-40
SERVICE TABLE OF LIMITS PART 1 DIRECT DRIVE ENGINES SECTION V SPECIAL TORQUE REQUIREMENTS Engine Springsand Hardware SSP1776 1-41
