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Continental Motors C-125 - User Manual

Continental Motors C-125
68 pages
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Publication X30013
©
2011 CONTINENTAL MOTORS, INC. AUG 2011
C-125
C-145
O-300
CONTINENTAL
®
AIRCRAFT ENGINE
OVERHAUL
MANUAL
FAA APPROVED
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Summary

GENERAL DESCRIPTION

Engine Model Differences

Details differences between engine models like C-125, C-145, and O-300 variants.

Cylinder Construction Details

Describes the construction of cylinder heads and barrels, including fins and spark plug inserts.

Piston and Piston Pin Construction

Details the construction of pistons, ring grooves, and floating piston pins.

Connecting Rods

Describes the conventional split bearing design and materials of connecting rods.

Crankshaft Construction

Details the alloy steel, six-throw crankshaft design and its support bearings.

Crankcase and Oil Sump Construction

Explains the two-piece crankcase, oil sump construction, and mounting points.

Crankcase Cover Details

Covers the magnesium alloy rear crankcase cover housing oil pump and gears.

Valve Operating Mechanism

Details the zero lash hydraulic tappets and associated valve train components.

Lubricating System Overview

Explains the oil sump, pump, screens, and pressure relief valve system.

PACKING AND STORAGE PROCEDURES

Shipping Box Specifications

Provides general dimensions and weight of the engine shipping boxes.

Engine Packing Method

Describes the standard wooden shipping boxes and securing methods.

Engine Unpacking Steps

Outlines procedures for removing the lid and unfastening the engine.

Engine Storage Preparation

Details steps for preparing engines for storage to prevent corrosion and damage.

Post-Storage Engine Preparation

Explains checks needed before putting a stored engine back into service.

GENERAL OPERATING INSTRUCTIONS

Pre-Start Checks

Lists critical checks to perform before attempting to start the engine.

Engine Starting Procedure

Provides step-by-step instructions for starting the engine.

Engine Warm-up and Ground Testing

Details procedures for warming up the engine and performing ground tests.

Take-Off and Climb Procedures

Outlines procedures for take-off and initial climb phases.

Cruising Operation Guidelines

Provides guidance for cruising operation, including speed and temperature limits.

Landing Procedures

Details procedures for landing approach and execution.

Engine Shutdown Procedure

Explains the correct steps for shutting down the engine.

Carburetor Heat Control Usage

Advises on the use of carburetor heat control for optimal operation.

SERVICE INSPECTION AND MAINTENANCE

Daily Inspection Checklist

Lists essential daily checks for oil, fuel, controls, and general engine condition.

100-Hour Inspection Details

Outlines the detailed inspection and maintenance procedures for 100-hour intervals.

ADJUSTMENT, REPLACEMENT AND REPAIRS

Carburetor Adjustment and Repair

Describes the installation, removal, and adjustment of the carburetor.

Magneto Installation and Timing

Details the process for installing and timing magnetos correctly.

Ignition Wiring Diagrams

Refers to diagrams for the complete ignition wire system.

Starter Installation

Covers the mounting and installation of the starter motor.

OVERHAUL INSTRUCTIONS

Overhaul General Preparation

General guidelines for mounting the engine and preparing for disassembly.

Pre-Disassembly Operations

Steps before major disassembly, like detaching cables, plugs, and accessories.

Engine Disassembly Steps

Step-by-step instructions for disassembling major engine components.

REPAIR AND REPLACEMENT PROCEDURES

General Repair Techniques

Covers general principles for repairing machined surfaces.

Castings Repair Methods

Details methods for flattening cast surfaces using lapping.

Stud Replacement Procedures

Provides instructions for removing and installing studs, including oversize options.

Helical Coil Insert Installation

Explains how to install helical coil thread inserts for thread repair.

REASSEMBLY, TIMING AND TESTING

Major Sub-Assembly Reassembly

Instructions for reassembling major engine parts like cylinders and connecting rods.

Final Engine Assembly

Details the steps for the final assembly of the engine.

Engine Run-In and Test Procedure

Outlines the procedure for running in and testing the engine after overhaul.

TABLE OF LIMITS

Crankcase Limits

Lists dimensional limits and tolerances for crankcase parts.

Crankshaft Limits

Details dimensional limits and tolerances for the crankshaft and its components.

Connecting Rod Limits

Lists dimensional limits and tolerances for connecting rods and bushings.

Camshaft Limits

Provides dimensional limits for the camshaft and its bearings.

Pushrod Limits

Lists dimensional limits for pushrod length.

Piston, Ring, and Pin Limits

Details dimensional limits for pistons, ring grooves, and piston pins.

Cylinder and Valve Limits

Lists dimensional limits for valve guides, cylinder bores, and valve components.

CARBURETOR OPERATION AND MAINTENANCE

Carburetor Specifications

Provides essential data for the MA-3SPA carburetor, including engine models and part numbers.

Carburetor Installation

Details the correct mounting and installation of the carburetor on the engine.

Carburetor Construction

Describes the major units and materials used in the carburetor construction.

Carburetor Operation Modes

Explains the function of the idle system, metering, and accelerating pump.

BENDIX MAGNETOS OPERATION

Bendix Magneto Description

Describes the design and construction of the Bendix S4 and S6 series magnetos.

Bendix Magneto Installation

Details the steps for properly installing and timing the Bendix magnetos.

Bendix Magneto Maintenance

Covers routine inspection and maintenance of the magneto breaker points.

HYDRAULIC TAPPETS SERVICE

Hydraulic Tappet Handling Precautions

Lists critical points to consider when handling hydraulic tappets.

Hydraulic Tappet Operation Essentials

Details requirements for proper tappet function, including free fit and check-ball integrity.

Hydraulic Tappet Handling Steps

Provides instructions for handling and initial assembly of hydraulic tappets.

DELCO-REMY STARTER SERVICE

Delco-Remy Starter General

Describes the Delco-Remy Model 1109656 starter's design and features.

Delco-Remy Starter Installation

Details the installation steps for the starter motor and its components.

Starter Maintenance and Troubleshooting

Covers both normal maintenance and troubleshooting for the cranking motor.

DELCO-REMY GENERATOR SERVICE

Delco-Remy Generator General

Describes the Delco-Remy Model 1101876 aircraft generator.

Delco-Remy Generator Installation

Details the assembly and installation of the generator and its drive parts.

Generator Maintenance and Troubleshooting

Covers normal maintenance and troubleshooting for the generator.

DELCO-REMY GENERATOR REGULATOR SERVICE

Generator Regulator General

Describes the Delco-Remy voltage regulator unit and its functions.

Generator Regulator Servicing

Provides guidance on servicing the regulator, checking output, and diagnosing issues.

Regulator Contact Point Cleaning

Explains the importance and method for cleaning regulator contact points.

STARTER AND ADAPTER SERVICE

Starter and Adapter General

Describes the starter and its right angle drive adapter.

Starter and Adapter Removal

Details the procedure for removing the starter and adapter assembly.

Starter and Adapter Disassembly

Provides step-by-step instructions for disassembling the starter and adapter.

Starter and Adapter Cleaning

Outlines recommended cleaning methods for starter adapter parts.

Starter and Adapter Inspection

Details visual inspection methods and precautions for starter parts.

Continental Motors C-125 Specifications

General IconGeneral
Horsepower125 hp
Oil systemWet sump
Cooling systemAir-cooled
Type4-cylinder, horizontally opposed, air-cooled
Displacement125 cubic inches
Fuel TypeAvgas
Bore4.00 in (101.6 mm)
Power output125 hp
Fuel systemCarburetor
Weight (kg)77 kg

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