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TSIO-520-BE
Continental Motors TSIO-520-BE User Manual
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Publication X30570
CHANGE 2
©
2011-2013 CONTINE
NT
AL MOT
ORS, INC.
OCT 2013
TSIO
-520-BE
CONTINENT
AL
®
AIRCRAFT ENGINE
PERMOLD SERIES
MAINTENANCE
AND
OPERA
T
OR’S MANU
AL
TECHNICAL CONTENT ACCEPTED B
Y THE FAA
2
Table of Contents
List of Effective Pages
2
Supersedure Notice
2
Table of Contents
4
Chapter Index
4
Figure Index
5
Introduction
7
Scope
8
Related Publications
9
Definitions and Abbreviations
10
Tools and Equipment
17
General Information
18
Special Tools
18
Identification Code for Tools
20
Oil Filter Sludge Inspection
25
Strap Wrench
25
Cylinder Base Nut Wrench
26
Cylinder Base Nut Wrenches 3882 Series
26
Crankshaft Blade and Dampener
27
Cylinder Hone
27
Piston Pin Removers
27
Holding Fixture Adapters
28
Universal Cylinder Holding Fixture 5221 B
28
Seal Seat Cutter 8066
29
Spring Checker 7521 a
29
Valve Guide Cleaner 122
29
Valve Guide Removers
29
Piston Ring Compressors
30
Rocker Arm Bushing
30
Valve Guide Replacers
30
3170 - Floating Holder
31
Flaring Tool for Push
31
Push Rod Spring
31
Valve Spring
31
Installer
32
Remover and Replacer 8086
32
Valve Seat Insert
32
Valve Seat Inserts
32
8116 Common Parts Kit
33
Alignment System
33
Valve Guide to Valve Seat
33
Boring Bars
34
Expanding Guide Bodies
34
Reamers
34
Valve Stem Hole Reamers
34
Rosan® Stud Remover
35
Valve Seat Insert Cutters
35
Adapter Kits
36
Connecting Rod Reaming and Alignment Checking Fixture
36
Reamers, Connecting Rod Bushing
36
Common Drive Handle 8122A
37
Pilots
37
Universal Connecting Rod Bushing Remover and Installer Set 8098
37
Counterweight Bushing Remover / Installer 8077C
38
Hydraulic Crankshaft Dampener Bushing Remover / Replacer Sets 8077 a and 8077B
38
Needle Bearing Installers
38
All Position Engine Stand
39
Tork Band Tension Adjuster 7726
39
Blind Needle Bearing 8093C
40
Cylinder Heating Stand 8156
40
Puller
40
Starter Clutch Shaft
40
Belt Tension Gauge BT-33-73F (TSI0-520-BE Uses BT-33-89P)
41
Cylinder Checker
41
Differential Pressure 7251
41
Differential Pressure Gauge 5210
41
Engine Timing Disc 3608A
42
In-Aircraft Alternator/Generator Tester 8091
42
Pulley Alignment Gage Bar 8082
42
Pulley Holder 4974
42
Removal
42
Crankcase Drill Fixture 8094A
43
For Starter Clutch Adapter
43
Per Continental Bulletin 79-10
43
Vacuum Pump 8334
43
Per Continental Bulletin M77-9
44
Spark Plug Insert Replacer 4918
44
Spark Plug Insert Tap 504-1
44
Thru-Bolt Bore Step Cutters
44
Crankcase Splitter Set L423
45
Drill Fixture 4978
45
Rosan® Lock Ring Installer 8074
45
Stud Drivers
45
Oil Pressure Relief Spot Facers
46
Polishing Tools for Crankshafts Bearings
46
Propeller Shaft Oil Seal Installer 5209
46
Runout Block Set 8177 a
46
Crankcase Thru-Bolt Removers
47
Hex Drive for Hex Tube Nut 7912A
47
Injector Nozzle
47
Remover and Installer 8165
47
Pullers
48
Dial Bore Gages
49
Inspection Instruments
49
Outside Micrometers
49
Blade Micrometers
50
Depth Micrometers
50
Screw Thread
50
Reamer, Rocker Arm & Shaft Bushing
51
Reamer, Rocker Arm Bushing
51
Reamer, Rocker Shaft Bushing
51
Reamers, Rocker Shaft Support Boss
51
Adapt Square Shank Reamers to No. 2 or 3 Morse Taper
52
Engine Application Chart for Valve Guide Stem Hole Reamers
52
Plug Gauges, Valve Guide Stem Hole
52
Suggestions for Reaming Valve Guide Stem Holes
52
Dial Thickneыы Gage
53
Precision Vernier Calipers
53
Шnside Measuring Instruments
53
Alternator Analyzer
54
Alternator/Regulator/Battery Tester Model E100
54
Voltage Regulator Testeк
54
Aircraft Magneto Timing Lighе
55
Aircraft Timing Indicator Model E25
55
Cold Cylinder Test Model E10
55
High Tension Lead Tester Kit
56
Master Orifice Toolp/N 646953
56
Alcor Portable Digital CHT Unit
57
Alcor Portable Digital EGT Unit
57
Cylinder Head Temperature Exhaust Gas Temperature Test Units
57
Detailed Engine Decription
59
Basic Design Feature
60
Description of Engine Model Code
60
Lubrication System
60
Lubrication System Schematic
61
Exhaust System
62
Induction System
62
Induction and Exhaust System Schematic
63
Turbocharger Sectionsl
63
Fuel System
64
Ignition System
64
Turbocharger System
64
Fuel Injection System Schematic
65
Cylinders
66
Valve Train
66
Engine Specifications and Operating Limits
67
Engine Specifications
68
General
68
Operating Limits
69
Accessories
70
Unpacking, Installation, Testing and Removal
71
Preparation for Service
72
Unpacking
72
Engine Installation Instructions
73
Installation Drawing TSIO-520-BE
74
Flight Testing
76
Preflight and Run-Up
76
Engine Removal Instructions
77
Crating and Shipping
78
Ground Handling
78
Normal Operating Procedures
79
Prestarting
80
Starting
80
Cold Starts
81
Flooded Engine
81
Ground Warm-Up
81
Hot Starts
81
Pre-Takeoff Check
82
Power Control
83
Takeoff
83
Climb
84
Cruise
85
Descent
85
Landing
85
Engine Shutdown
86
Priming Time Requirement
86
Emergency Procedures
87
Engine Fire During Start
88
Engine Roughness
88
General In-Flight Information
88
Troubleshooting Failure
89
High Cylinder Head Temperature
90
High Oil Temperature
90
In-Flight Restarting
90
Low Oil Pressure
90
Engine Fire In-Flight
91
Abnormal Environmental Conditions
93
Cold Weather Operation
94
Preheating
94
Hot Weather Operation
96
Ground Operation at High Altitude Airports
97
Servicing and Unscheduled Maintenance
99
Servicing
100
Approved Products
101
50 Hour Inspection
102
Preflight Inspection
102
100 Hour Inspection
103
Cylinder Compression (Leakage) Check
104
Leakage Checks
104
Static Seal
104
Unscheduled Maintenance
104
Dynamic Seal
105
Master Orifice Assembly Tool Borroughs P/N 646953
105
Equipment
106
Master Orifice Tool
106
Performing the Check
106
Differential Pressure Tester
107
Static Seal Check
107
Dynamic Seal Check
108
Troubleshooting
111
Engine Troubleshooting Chart
112
Ignition Troubleshooting
118
Oil System Troubleshooting Chart
119
Fuel Injection System Troubleshooting Chart
120
Exhaust System Troubleshooting
122
Engine Preservation and Storage
123
Engine Preservation after Overhaul
124
Flyable Storage
124
Indefinite Storage
125
Temporary Storage
125
Indefinite Storage Inspection Procedures
126
Returning Engine to Service
126
Airworthiness Limitations
127
Engine Performance and Cruise Control
129
Cruise Control by Performance Curve
130
Cruise Control by T.I.T.
130
Table of Performance Charts
131
Sea Level Performance
132
Constant Speed Sea Level Performance Full Rich Mixture
133
Constant Speed Sea Level Performance Best Power Mixture
134
Altitude Performance
135
Mixture Ratio Curve - 80% 2500 RPM and 32.8" Hg. ADMP
136
Mixture Ratio Curve - 75% 2400 RPM and 32.5" Hg. ADMP
137
Mixture Ratio Curve - 65% 2300 RPM and 30.0" Hg. ADMP
138
Mixture Ratio Curve - 50% 2200 RPM and 35.8" Hg. ADMP
139
Fuel Flow Vs. Brake Horsepower
140
Metered Fuel Pressure Vs. Fuel Flow
141
Fuel Injection Fuel Pump Pressure PSIA Vs. % Rated Horsepower - 100 F AVGAS
142
Fuel Flow Vs. Pressure Drop
143
5
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Continental Motors TSIO-520-BE Specifications
General
Brand
Continental Motors
Model
TSIO-520-BE
Category
Engine
Language
English
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