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 9l2sl20L7

WELCOME TO THE
LYCOMING SERVICE SCHOOL
Fronr Lycomilrg EnEines arrd
Workforce *evelopment & Continuing tduc*tiot:
 e/2sl2oL7

LYCOMING AUTHORIZED
TRAINING CENTER
Traiming Progrmrn $yilabus

Program Description
The Lycoming Engine Service School includes the construction, theory of operation and
servicing of Lycoming reciprocating engines. It also covers the inspection, servicing and
troubleshooting of the related components.

RATIONALE

This Service School is solely authorized to the Pennsylvania College of Technology by

Lycoming, a division of Avco corporation, Williamsport, PA. Upon completion of this
program, it can be used for qualification for the Inspection Authorization Renewal
Program FAR 65.93 (a) (4).

ATTENDANCE
Strict attendance is mandatory to receive credit for all training hours for the Lycoming
Service School program. The program consists of four (4) seven hour days. Training is
conducted 8 a.m. to 4 p.m. with one hour For lunch at a restaurant of your choice.
 elzsl2oL7

Program Outline
l. Brief History of the Lycoming Engine
2. Discussion on Availability and Impoftance of Publications
A. Service letters, bulletins, instructions (SL 114)
B. Operator's handbook
C. Overhaul manual
D. Special service publications
E. Vendor publications
3. Engine Model Coding
A. Engine model designator
B. Engine color codes (SI 1181)

Program Outline Continued..,

Crankshaft
A. Hardness (SB 222)
B. Propeller strikes (SB 533)
C. Crankshaft gear inspection (SB 475) and AD 2004-10-14
D. Counterweights (SB 245) (SI 1012)
E. Crankshaft seal replacement (SI 1324) (SI 1111)
F. Crankshaft flange bushings (SI 1098)
Starter Ring Gear Support
Camshaft
A. Failure, internal timing
Crankcase
A. Engine mount (Type I, Type II)
B. Alternator (Si 1154)
C. Starter (SI 1154), shim LU 16152
D, Alternator shimming (SI 1270)
Connecting Rod
A. Connecting rod bolts (SI 1458)
B. Description and inspection of rods (SB 439)
 9l2sl2OL7

Program Outline Continued...

Cylinder, Piston AssemblY
A. Cylinder assemblY
B. Piston, rings (SI 1037) and plugs (SI 1267)
C. Installing and torquing cylinder assemblies (SI 1029)
Valve Train
A. Proper setting of the dry tappet clearance .028" to .080"
B. Failed valve (SI 1193)
C. Push rod length (SI 1060)
D. Valve inspection (SB 301)
E. Guide clearance inspection (SB 388)
Lubrication System
A. Understanding the oil system
B. Setting oil pressure
C. Troubleshooting the lubrication system
D. Understanding and troubleshooting the propeller governor system (SI
r462)
E. Inverted oil system
Ignition System
A. Magnetos (SI 1443)
B. Spark plugs (SI 1042)
C. Magneto to engine timing (SI 1437)

Program Outline Contillued..'

Exhaust System
A. Exhaust port inspection (SL 228)
B. Exhaust gaskets (SI 1204)
C. Effects of exhaust leaks
Induction System
A. Air inlet filter (SI 1002)
B. Troubleshooting
C. Induction systems
Fuel System
A. Carburetor
B. Fuel injection
C. Flow divider and nozzles (SI 1414)
D. Operation and troubleshooting
Turbo-charging Systems
A. Understandingoperation
B. Inspection (SB 313) (SB 452)
C. Repair (SI 1122)
D. Operation specifications (SI 1257)
E. Rissins adjustment (SI 1211) (SI 1187) (SI 1341)
F. Over boost and over speed (SB 392)

4
 el25l2ot7

SLl 14: Ordering Publications

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Your Instructor
D. Michael *Mike' Damiani
 el2sl2oL7

A BRIEF HISTORY OF LYCOMING ENGINES

6
el2sl2ot7
el2s/2017
e/2sl2oL7
9lzsl2O77

1_0
sl2s/2oL7

7L
 9/2512017

Publications
. Overhaul Manuals:
- Direct Drive,
. Standard Manual for all Direct drive engines prior to amendment 9
of FAR 33
- Geared,
. Covers all engines with planetary gear boxes and also
supercharging.
- 76 Series,
. Hybrid engines - automotive style valve train components.
- Integral Accessory drives,
. Accessory drives incorporated into the crankcase. No separate
accessory section. TIOITIGO-541 series
. Limited use - used only on Beech Duke and Piper P-Navajo

L2
 e/2s/2ot7

Publications
. Overhaul Manuals Continued:
- Vertical drives,
. Vertical Drive engines used exclusively in older piston
helicopters
. "MASH" Helicopter (Bell 47) most common usage.
- Engines after Amendment 9 of FAR 33
. 3 Manuals
- Overhaul Manual.
> Standard overhaul Procedures
- Maintenance Manual
>> Maintenance and recommended inspection
information formerly found in operator's manual
- Operations and Installation manual
> Deals with correct engine operation and break in.

Publications

Pafts Catalog
- Grouped by engine series
- Changing to be grouped by similar models. i.E. 0-320-
D2GlD3G
www.lycoming.com
Special Manuals
- SSP manuals or special Service Publications
- Includes SSP-110 troubleshooting guide,
- SSP-885-2 Oil filter installation and approval,
- SSP-1776 Service Table of Limits

13
 el2sl2oL7

Publications
. Service Letters, Bulletins and Instructions
- Index
. arranged in Alphabetical order and by SB, SL, and SI number
. Numeric listing and a list of applicable SB's, SI's, SUs for each
series.

- Service Letters -
. General information
- Number stafts with letter L
- Service Bulletins * Airworthiness Directives
" Safety of flight issues - Considered Mandatory
- Numbering starts at 100

- Service Instructions -
. Instructions on how to perform a task
- Numbering stafts at 1000 (1002 is first SI)

Publ ications Ava i labil ity

. prort r-r.o..nins pr#.?tli, ur" no* uu.itrnt" ut

Lycomino's weboaqe

14
 9lzsl2OL7

Publications
. Service publications revision information

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s

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Original issue'date i
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. Revision letter

Service Bulletin, Considered Mandatory = Safety of flight RHD

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15
 e/2sl2oL7

O-32O-H2AD Engine for Cessna L72

. How Bulletins and Instructions work together
. 1\T"
Mod-
- Reflected in the Suffix of S/N L-xxxxx-76"T"
. Larger lobes on camshaft
- Parts list SI t4A6
. Larger diameter cam followers
Part number listing SI 1402
. Oil additive -
- 1W16702 (TCP or TPP)
- sr 1409
_ sB 446 +AD B0_04_03R2

Publication Exercise
. SLLL _
- Publication availability and ordering
. sI 1009 -
- Time Before overhaul requirements
. sB24A-
- Mandatory parts replacement
. sI 7304 -
- Nameplate replacement
. sI 1059 -
- Pre-lubrication of parts during assembly
. sL L195 -
- Seal removal and installation tools

16
 el25l2OL7

Publication Exercise
. sL223-
- New part numbering sYstem
. 13519 649 - Crankshaft Gear
-f = PowerSection
nart
' ':rtf2[snart
. L9649 = Sequential Number

Model Designation

Prefix -
_ AEIO
Cubic Inch Displacement all cylinders
- 540
Suffix
- L1B5D

. Cciunterweight APP|ication

t7
 s/2s/2017

Prefixes
Aeiobatic (DRY $UMp)
, ,",=.
Aerobatic Engine
Diesel (drone use only)
Electronic
Geared
Horizontal Helicopter
Fuel Injected
Left Hand Rotation Crankshaft

Drone
Opposed Cylinders
Supercharged

Cylinder Cubic Inch Displacement

18
 elzsl2ot7

Suffixes
Not available as a published list

Counterweight Applications

On VO-540 models - The #3 as the 4th suffix character

indicates six 3rd order counterweights.

On O & IO-540 models - The #5 as the 4th character

indicates one-fifth and one-sixth order counterweights.

On 4 cylinder models - The #6 as the 4th suffix character

indicates one-sixth and one-eighth order counterweights.

On 6 cylinder models - The #6 as the 4th suffix character

indicates one-sixth and five-third order counterweights.

19
 el2s/2oL7

Engine Mounts

Conical -
- Straight mounts
- bolts aligned parallel to per
crankshaft centerline
- Use 2 Conical bushings mount point
Dynafocal -
- Mounts set at a specified angle to the engine C.G. both from
the side and top.

4 cylinder Type 1 (30o) and Type 2 (18o)

6 cylinder they are Type 1 (31o) and Type 2 (20o)

- Lord or Barry controls, engine mount isolators.
- Remember... GOLD Washer takes the Load

Engine Serial Numbers

L = Lycoming
L-12345-48
- No suffix letter
. Std. Cylinder flange
. "Narrow Deck"
L-12345-4BA
- oA" Suffix
. Wide Cylinder Flange
. "Wide Deck"
RL-12345-4BA
- R.prefix
Factory zero time rebuilt
L-12345-48E
- \rE" Suffix
. Roller tappets

20
 sl2sl2oL7

Engines
.New-
- Zero
.
Time
parts
All new
. Rebuilt - (remanufactured)
- Zero Time -
-OTSN
. Used parts that meet new specification.
. Overhaul-
- Time Continues -
_ O SMOH
. Used parts that meet overhaul limits
Note:
All Lycoming Engines leaving the factory receive
new cylinder kits.

27
 el2sl2oL7

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dEdj,
r.-,- J{.1
HAtr5
c---{

) /7L
Ll--=+--.t
fL--JnL--J \r.+{j:7
\ru-
-ft
To Determine Reverse Rotation firing order

4 cylinder
. Standard Rotation = L324

To find left rotation Firingorder

. Move the 1 to the back L324
1-
. readbackward 3 2 4 1 --\
. So... Left rotation for a 4cylinder = L 4 2 3
Same process for 5 cylinder engines

Crankshaft

22
 el2sl2oL7

Crankshaft
. Crankshaft Construction
. Forged Steel
. Provides a vey tight strong grain structure to the metal
. Forging is aged (Rust ls an aging process)

. Machining Processes
. 1, flange and front bearing machined
. 2. Counterweight ears machined in
. 3. iournals and crankPins cut
. 4. ProPeller bushing bores cut in

. Straightening during manufacturing

. Crank is heated to 12000 F 24 hours
. Runout is checked on V-blocks while heated
. Crankshaft is straightened using a press while at temperature.
. Straightening tolerance must corrected w/in 2 minutes after
removal from heat treat.

Crankshaft
. Crankshaft Construction (cont.)
. Nitrided (case hardened) .
. 022" to .025" deep hardened surface'
. Hard as glass surface
. Strong, tough ductile forged steel underneath
. 0riginal process
. gas (ammonia) nitriding process.
. EnvironmentallYdamaging
. Copper plating was applied to the areas to be protected
from the nitriding Process.
. Current process
. Ion (plasma) Nitriding
. Electrical ionization charges force the nitrogen into the
metal causing the hardened surface.
. Protection provided for the crankshaft flange by a cup or
cap over the flange.

23
 9l2s/2OL7

Crankshaft
. Repair process
. .003-.006" undersize of journals
. Can be Polished to size.
. .010" undersize
. Requires grinding
. Also requires re-nitriding of the journal surfaces
. See SB 222 Crankshaft Re-nitriding Recommendations
. Undersize Journals require undersize bearings
''
i'Eii,;l#"'-",,.ffi ir',,,,,tS : ; JJff l.J:;,tXt
main bearings
Used with .006" undersize crankshaft

Crankshaft
Crankshaft Service bulletins'
. sB 552,553,
. Core sample tested for proper grain structure
. sB 566,
. Mandatory crankshaft replacement
. Metallurgical structure flaws found
. sB 569
. Crankshaft retirement program written into an AD
. SB 569 issued in 2005.
. Affected Crankshafts forged from Jan. 1997 - early
2003
. Affected crankshafts were to be taken out of Service
bY Feb. 28 of 2009
. Discounted replacement kits no longer available
after Feb 28 2009.
. Currently all Cranks are tested for proper grain structure!

24
 el2sl2or7

Crankshaft Plugs
. Types of plugs

. Seals crank in fixed pitch applications

Also used as shipping plug for constant speed

. Moves oil supply to center

of crank.
. Not replaceable in the field.

Crankshaft Plugs
. Troubleshooting relating to the crankshaft plug
. Sluggish proPeller oPs...
. Possible loose rear Plug
. Possible excessive leakage past bearings
IFM AG EDIIACEq

25
 sl2sl2o77

Crankshaft Plugs
. Oil Flow in crankshaft
. Sluggish propeller ops
. Possible sludge buildup in the crankshaft bore
EXPNS 4UG ffi

6r1O2 ffi [S

qtNl.R{l@tuhe+kM

. Oil Sludge buildup and recommended de-sludging interval

. Remove propeller and clean sludge approx. 500 hours

Crankshaft Corrosion Inspection

. Crankshaft Bore inspection
. sB 505
. Inspection for corrosion

Erqlnql@tuhPq&Cd finnals"n{kMbhd
FinnaL8"n{khCbh&

Crankshaft Bore corrective action

. SB 5_3-S- P.I.D. coating - no corrosion
. Urethabond 104
. NOTE: Crankshaft must be removed from engine
. Machine to Max bore of 1.910" to remove corrosion
. Add Urethabond 104 after machining

26
 9/2sl2Ot7

. Proper propeller indexing

. Reduces vibration
. Reduces loads and stresses on the crankshaft and bearings
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*eAr*p,lt

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Propeller Strike
Other Crankshaft issues
. Propeller Strike

. Lycoming SE-533
. Defines a prop strike
. Provides recommendations for
repair after a prop strike and a
repair checklist
. Best recommendation?

Disassemble and inspect an

engine that was prop struck FYI - Lycoming replaces the mags
pelttre checklist in ia sssa on a propeller strike
ir:?Sf,::''lv
. NOTEI
Lycoming SB 475C, provides the correct procedure to install the
crankshaft gear bolt.

27
 elzsl2oL7

Nose Seal
Make sure to follow Instructions
Current Sealant is Dow-Corning 737 RTV
NOTE: If using Pliobond all old RTV residual
oils must be cleaned out of the pores of the
metal!

'=*-- -i""tlil-oisrrctctrsJatFi$re4 G€nkshaftl'ropelter{lleq-Sltguns

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ffi%*ffi#S$"'fr[?

Nose Seal Leaks

Causes
. Age - Rubber hardens
. Wear - of the rubber or the crankshaft itself
. Intermittent use
. Engine sits idle for long Periods

. Improperinstallation
. No grease used on installation
. Improper tooling
. Excessive crankshaft end PlaY

Remedy
. Replace the seal

28
 9l2sl2OL7

Counterweights
Dynamic Counterweight (Harmonic Dampener or Balancer)
. Function
. Dampens Torsional and Harmonic vibrations between a specific
propeller and engine combination

Counterweight De-Tuning
. Definition:
. Damage to the counterweight rollers and bushings caused
by various factors, which reduces or negates the
effectiveness of the Torsional and Harmonic Vibration
reduction.
. Force on detuned countenrueight can exceed 90 tons
between the rollers and the bushings
. Causes
. Rapid Throttle Movement
. Propeller strike or sudden stoppage
. Driving an engine with the propeller (diving with power off)
. Feather an engine from high power

. Prevention
. Smooth slow throttle
. idle to full throttle 2

29
 9l25l2OL7 -

S i(sr
Proper installation of
counterweight Rollers
and Washers
Rollers

. Washer installed "numbers" out

. Circlip installed "sharp side" out

Gap must be centered toward

bottom of the counterweight
(toward the crankshaft)
. Gap must be the correct width

Crankshaft Gear dowel replacement

. Inspect Dowel for damage per SB 475C

Dowel removal
- Select proper Dowel size for the bore
. Drill through the center of the old dowel with a U8"
drill bit untit it is all the way through
. Fill the hole into the dowel with oil,
. Drive a !fB" pin punch into the hole onto the oil
column
. Hydraulic action will drive the old dowel out'

Follow sB 475 instructions for proper installation of the

new dowel

30
T€

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 9lzsl2OL7

Causes of Camshaft Failure

. Inactive Engines
- Rust
- Corrosion
. Short Engine runs on the ground
-Heats engine just enough to create
moisture internally.
-Creates Corrosive environment inside
the engine
. Turning engine by hand
-Scrapes all protective oil off of the
cam, tappets and cylinder walls.

Causes of Camshaft Failure

. High RPM Starts
. Cold Starts without Preheat
.Referencee f
. Valve Action
- Too loose
* Too tight
. Sticking Valves
. Overspeed

. Nole! Since 2006 All factory Rebuilt

engmes and overhauls that dse Roller
tappets.come back from the factory
equipped with roller tappets

35
 9l2sl20L7

Camshaft to Crankshaft Timing

A simple check of internal timing
Internal timing check
- Remove #lrocker cover
- Set engine on #! cylinder TDC Compression stroke.
. Move propeller approx. 5-10" either direction off of TDC #1
. #2 cylinder cam lobes are at valve overlap
. #2 rockers should move opposite of each other.
. Lycoming Knowledge Base
. http:/ll
timing

Camshaft Publications
. SL 206 Field Recondition of Tappet Bodies
. SI 1505 Cold Weather Operating Procedures
. SB 44615.11409 LW-16702 additive
. SI 1514 RollerTappet and Camshaft pafts

36
 e/2s/2077

Crankcases
Material = Sand Cast Aluminum
- Cases are cast as seParate halves
. 2 halves put together and line bored
thru Crankshaft and Cam areas
- Once line bored case halves are
matched.
* Matching number stamPed on each
half.
- Engine S/N is stamped on flats on
left case half parting surface
- Flats are left over after large
aluminum shafts used for machining
purposes are cut off.
) IMPORTANT!
> Case must be replaced as a
complete unit.
> Individual case halves cannot
be replaced.

Crankcases Paint
- Any color you want as long as it's
Lycoming Gray
- High temp Gray Enamel over a Zinc
Chromate primer base
. Previous paint - High Temp GraY
Enamel over bare metal.
. Environmental concerns dictated a
change to a less environmentally
harmful paint,
. Tried Acetone based paint
- Adhesion issues
. Tried Water based over Primer

. -
New Paint = adhesion issues
Return to original and primer with
the help of Randolph engineering
Experimented with
. Anodizing
. Considered powder coating.
Thunderbolt
. Custom Paint available
. Titanium Gray color is standard.

37
 el2sl2o77

Crankcases
. Thru-Bolts or Thru- Studs
- Anchor tyPe
. Threaded into one or the other crankcase half
. Used on Narrow Deck cases
. Used on very earlY wide deck cases
- Case bearing saddles sealed with dowels or O-rings'
- Body fit or free tYPe
. Replaced anchored studs.
. Center of stud seals crankcase with a tight press fit.
- Leaks can be repaired by installing an oversize stud.
- Or case can be machined for dowels OR O-rings
- ReferenceW
- Wide Deck
. Yz" diameter studs increased in veftical separation by
almost 1 full hole diameten

Crankcases
Bearings
- Low Crush
. Thick Wall
. Located with Dowels

- High Crush
. Thin wall
. Retained by "crush between case
halves.
. Extends .003" from case on either
side
. .005" total crush

38
 el2sl2o77

Crankcase Oil Flow

M&Bffi vi{ \ \
ru,rytry€
_ l-.
S#Jf* \ )
}6r--.-9=-$563.

Crankcase Sealing
. P.O.B. #4 Gasket Sealer
. Silk Thread - Size 00

Note: No nylon, Dacron, fishing line, etc.

Alternate Means of Sealing

. RTV 102
. Loctite 515

Note: Do not use silk thread with either of the

alternates.

39
 e/2sl2ot7

Crankcase Oil Leaks

40
 el2sl2ot7

Crankcase Publications

. SI 1290 Repair of Leakage at Thru-Studs

. SI 1125 Alternate Crankcase Parting Sudace Sealant
. SI 1059 Pre-lubrication for assembly
. SI 1029 Tightening Procedures of Crankcase Thru-Studs
and Bolts

Connecting Rod

4L
 sl25l2OL7

Connecting Rod Publications

. Srlconnecuno
l4|@IalS
lMdMs,re.,
Rod Bolt and Nuts
r}*relMdriEdl!{d!rt,
[email protected]*
,,M . SBIRework of
ffilEt,3rsw@il*sdffi3qdB
Connecting Rods
&!dF'&6t*td#@k
eg*@
when fretted
Ei*''Ml!ffi'MM@d@W
-#Mi&[email protected]@dL@
d*rws(tuhesnk,4r4
.@*6.*tur}*r@
@
AcrlJr* l]MiNrsBrxM+kr&tBsn

r,wl4tumar
',kDd&Lhsku&Si&
.@@ilrdJrdtat*a

lffi *t*
rryEI nsnl
trd Ctnre&tdNrilBtuktu

Piston Pin & Plug

42
 e/2sl2ol7

Piston Pin & Plug

. Piston Pin
. Thin Wall/lightweight LW-13445
. Used in lower horsepower applications
. Example
. O-540-J3A5D or l3C5D 235 HP

. Thick wall or heavY LW-14078

. Used in all other normal applications can be used in all
engines. But must be matched
. SB 527 Mid 90's inspect for correct markings

. Pin Plugs
. 3 types

: fl,:uxxT,mnum sll;H:l ril;ix8Hi.*""

. Aluminum Bronze

43
 el2s/20L7

Ring Grooves
Ring lands

Back-Side of Piston
Piston Pin Boss

for Turbo Charged engines

Number indicating cylinder position

44
 elzs/20L7

Piston Rings
. Compression rings
. Semi-wedge type (half wedge)
. Combustion pressure forces the ring tightly against the
cylinder wall in operation.
. Oil Control Ring
. Rectangular in cross section
. Uses a Ring Stabilizer to reinforce the oil control ring
. ord distribute oil evenly
. All rings installed with the part number or "dot" facing the dome
of the piston.

45
 el2sl2077

Cylinders

Sand Cast Head

Chrome Molybdenum Barrel
Interference fit between head and barrel creates.O10" choke

Cylinder Compression Test

. Differential

- All cylinders must be within 5 PSI of each other

. Size of Orifice between Gauges - .040 inch
diameter x .25" long with entrance angle of
5gol60o.

. Direct Reading

46
 el2sl20L7

Genuine Lycoming Cylinder Identification

Fin Markings
. No Color: Plain Steel Barrel
. Blue: Nitrided Steel Barrel
. Orange: Chrome Barrel
. Yellow (in spark pluo area): Long Reach Spark Plug Required
. Black Oxide Inside Cvlinder Barrels: Corrosion Protection for
Storage.
Note: CylinderEegc markings: Green +.010 Yellow + .020 O.S, Reference: SI 1181

Cylinder Colors

Gray or Blue (76 Series)

Nitriding (blue or gray)
Yellow between Spark plug hole and rocker box
Indicates Long Reach Spark Plugs
- Long reach = L3/L6
- Shott reach = 7z
Green at Base = .010 Oversize
Yellow at Base = .020 Oversize
Black Oxide on Inside of Cylinder Barrels = Corrosion
Protection While in Storage

47
 e/2s/2oL7

Cylinder Publications

. SI 1037 Approved Pistons, Rings and Cylinders

. SI 1047 Measurements, honing and also oversizing of gg1.teh
cylinder barrels
. SI 1181 Cylinder Colors
. SI 1191 Cylinder Compression Checks
. SI7267 Piston Pin Plug Usage
. SI 1340 Piston Pin Plug Identification
. SI 1526 New Piston Part Numbers
. SI 1558 New Piston Ring Part Numbers
. SFN-880-4 Cylinder kit reference

Valves

Intake
Exhaust

48
 el25l20L7

Powdered Sodium Melts

and travels away from
heat, reducing valve
temperature

Guide Runs 5000 F

Sodium Cooled Va
(cavity filled with

Exhaust Valve Runs 11500 F on Head

Sticking Valves
. Exhaust Valve Run 1150o F on Head
. Guide Run 5000 F
. Oil Cokes at 4000 F

Coking of oil in the guide is a distinct possibility.

49
 el2s/20L7

Symptoms of Valve Sticking

Morning Sickness
- Engine runs rough at 1st start up of the day
- Can occur multiple times (after engine cools back to "room
temperature")
Roughness on Climbout or In Cruise
- Engine runs rough and loses RPM on Climbout
- Intermittently runs rough in cruise.
High Magneto Drop
- Mag check is rough or high.
Intermittent Rough Idle
- Possible carb ice

Causes of Valve Sticking

Dirty Oil
High Cylinder Temp
Improper Leaning
- Too lean
- Too rich
Air Filter
- Silicon in Oil analysis - 8-10 ppm MAX!
Overhaul Procedures
- SI 1200 30 micro finish
Wrong Fuel or Oil Used
- Lead content in 80/87 .6ml/l
- Lead Content in 10011 4.6m1/l

50
 9lzsl2OL7

. To Avoid Stuck Valve

. To Correct a Stuck Valve

-I(ropetrick)

AtlEt tHt s LU{*IGATOR i{r$

BEg$ isEtdrAsEe ils6 i $c*Er{i^
&}rvFfi TS M*l4 !atr& stEi,
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f

$a*r$iE1&$€ $r8tisli'
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APFFoI iS&{"S$N Uii pt&Cg
wYHYlta s6r$*R*uI'r*Jug?
Dr*Lti{sK&?&ft T*0,

Figure 9. Dial Indicator in Position to Figwe 10. Pushing Valve Stern and Adapler
Cheek Valve Guide Clearacce Post Toward Dial Indicator to Establish
Valve Guide Condition

51
 9l25l2OL7

Valve Publications

. SL 197 Recommendation to Avoid Valve Sticking

. SI 1425 Procedure to Reduce Valve Sticking

'tRope Trick"

. SB 3BB Procedure to Determine Exhaust Valve

and Guide Condition

. SI 1485 High Chrome Content Valve Guide

Valve Spring Seats

52
 el2s/2a77

Valve Spring

Dampened End
Dampened End
Down in Cylinder

Troubleshooting
Spring issues

Valve Keepers (Keys)

Parallel Valve
Intake:
Wedge type
Exhaust:
Half Moon type
for Rotating valve
Anqle Valve
Intake:
Half Moon Type for Rotating Valve
Exhaust:
Half Moon type for Rotating Valve

53
 el2sl2oL7

i
1

I
I

Hydraulic Plunger AssemblY

54
 e/2sl2ot7

Dry Tappet Clearance

Table of limits SSP-1776

. All Engines with Hydraulic Lifters = .028" - .080"

Note 1: Exception 541 Engine = .040" - .105"

Note 2: All hydraulic tappets must be free of all oil;

that is why they call it dry tappet clearance.

55
 9l2sl2OL7

Valve Publications

. SB 238 Magnetized Condition of Hydraulic Plunger

Assembly
. SI 1060 Push Rod Identification
. SI 1240 Valve SPring RePlacement
. SB 388 Valve and Guide Condition
. SI 1485 High Chrome Content Valve Guide
. SI 1514 Roller TaPPet Pafts

56
 el2sl2ot7

Lubrication

- Straight mineral oil (MIL-L-6082 or SAE-J-1966)

- Ashless dispersant oil (MIL-L-22851 or SAE-I-1899)

Oil Grades

15w50
20w50

57
 slzs/2077

Oil Additive

. LW 16742
- TCP (original) Tricrystalphosphate
- TPP (current) Triphenylphosphate
- FAA Special Airworthiness Information Bulletin (SAIB) NE-05-
31 Information on Additized oils which comply with SB 446
- sB4461sI 1409

58
 9l2s/2017

Filtration Systems

Oil Pressure Screens

Oil Filters
Oil Suction Screen

Oil Filtration System Content Inspection

. Carbon
. Aluminum
. Steel
. Bronze
. Copper

Note: These engines will whisper before they scream.

59
 s/2sl2oL7

Oil Pressure

. 55 - 115 PSI Cruise

. 15-25 PSI Idle
. depending on Engine Model

Oil Temperature
. 1600 F - 2100 F
. 1800 F
. Max Temp 2450 F

60
 9l2sl2Ot7

Externally Adjustable
Tall Tower

Oil Pressure Relief Valve

And Adjustment.
. Short Tower -
- Max adjustment 3 Washers (must have cage in
crankcase)
. Tall Tower
- Max 9 Washers
. Externally Adjustable
- Externally Adjustable - Use Wrench or Screw
Driver

- NOte! Washers are AN 960-10.

6L
 e/2s12017

Oil Pressure Relief Valve Springs

. 61084 6-8 psi compressed - Standard Spring

. LW-18085 14 psi compressed - Heaviest Spring
. See Parts Catalog
. See Table of Limits

Inverted Oil System

,'..*.-,
':

62
 el2sl2oL7

Lubrication Publications
. SI 1014 Lubricating Oils
. SI 1059 Pre-Lubrication of Parts Prior to
Assembly
. SI L492 Piston Pin Plug Wear
. SB 480 Oil Change Interval
. SI 1409/SB 446 Ot Additive LWt6702
. SL 180 Preservation for Active and Stored Aircraft
. SB 524 Oil Pump Impellers
. SI 1505 Cold Weather Starting
. SL 171 Spectrometric Oil Analysis
. SI 1462 Propeller Oil Control Leak Test

53
 el2sl2oL7

Ignition SYstem
. Spark Plugs

. Ignition Leads

' Magneto

Spark Plug

64
 9lzs/2017

Spark Plug

. Spark Plug Numbering Systems and Approved Spark plugs

reyffi
. Spark plug paft number

- REM4OE
- ft = Resistor
- f = Cap size (E = 5/B x24 threads)
- M - thread reach (M = Short Reach)
- Number 40 = Heat Range
- [ = Electrode type (E = Massive Electrode 2 prong)

Illustration From FAA A&P technician - Powerplant handbook

65
 el2sl2oL7

JTU\I
k\ lri /d
ll ffi
Ll=---|-\
..hot,: \
lNuLtit
M
tips

66
 el2sl2oL7

Spark Plug
. Incorrect Heat Range

- Too hot:
. Detonation
- Too Cold:
. Incomplete/inefficient fuel burn
. Power reduction

67
 9lzs/20t7

30. 3r TDC 30r go. I

Spark Plug

Spark plug reach

- Use the correct reach for the cylinder

Incorrect Reach

- Can cause hot spots and preignition

68
 9l2s/2OL7

Spark Plug
. Clean:

- Top plugs are.considered self cleaning as far as lead deposits

are concernecl.

- Massive Electrode Blast 3-5 seconds

- Fine Wire Blast 2-3 seconds

- Air blast to blow out media,

- Clean out lead dePosits

Note:
. Bottom plugs receive the lions share of lead deposits

69
 9/2s120L7

Spark Plug

-
-
V
Top to bottom
Bottom to top

- Rotating reverses polarity of the plug

- Promotes even wear of electrodes

- Plugs should be rotated every 50 hours

70
 e/2s120L7

Lead Fouling Reduction

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 e/2s120L7

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72
 sl2s/20L7

Engine Timing Marks

IDENTIHGANOT ffAM "O'

OilflE FBONI FACE S ru
S:AireN SUPPORf ASSEM.
AtY ls LNEO UP WTH IDEil.
fldca1ro,l MAnx -o" ff
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A8w L CaGi Alarl,Ml o{ Ad@ lilttirg f&*! iith S.tu Hodna

73
 el2s/2aL7

Magnetos

Magneto Dual Magneto

. Bendix = Continental Motors . Left Magneto = Master Mag
. Slick = Champion (t r{4j . Time Left Mag to Engine
. Bendix Dual Magneto = . Red Tooth in End Window
Continental (out of . Letter "K" Up in Top Window
production/overhaul only) . Both Magnetos Must Fire Within
Three Engine Crankshaft Degrees

Ignition Publications
High Altitude mag
- Bendix 1200 series
. Expands the air gap between distributor rotor posts
- Slick or Bendix 5-201200 series
. Pressurize magneto off of Turbo-charger discharge
SI 1308 Pressurized Magneto Pressure Test
Required on Turbo-Charged engines
recommended every 100 hours.

SI 1132 Magneto Drop-Off

- Procedure to test mags during engine run up
- 775 RPM Max drop
- No more than 50 RPM differential
- Procedure if smooth but exceeds 175 RPM

74
 el2sl20L7

Ignition Publications
. SI 1042 Approved Spark Plugs
. SI 1043 Oversize Heli-coil for Spark Plug Hole
. SI L437 Engine Timing Marks
. SI 1308 Pressurized Magneto Pressure Test
. SI 1132 Magneto DroP-Off
. SL 192 Spark Plug Fouling

Exhaust System
Exhaust Gaskets

. Copper-Asbestos
. Copper or Stainless Blow-Proof
. Spiral Wound

75
 elzs/20L7

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SIip loints & Waste Gates

. Mouse Milk
. Loctite C5A copper based anti-seize during assembly

76
 9/2sl2OL7

V-Band Clamp Installation

Proper installation of exhaust V-band clamps

I V-band clamp assembly and torque procedures

Induction System

. Normally Aspirated
. Super Charged - Turbo or Mechanical
. Induction Leaks
- Symptoms of an induction leak
1. Miss at idle
2. Manifold pressure high at idle.
1. Flat tappet = florrflBl idle MAP L0-L2 in. hg
1. 13-15 in. hg or higher = Induction leak
2. RollerTappet -normal idle MAP 13-14 in. hg
1. 15"or higher = induction leak

77
 el2sl2oL7

Induction System continued

. Induction Leaks
- Symptoms of an induction leak Turbo
3. Turbo or Super Charged
1. System may not be able maintain correct MAP as
altitude increases

78
 elzsl2oL7

Induction System Maintenance

. Proper Installation of Induction tubes

. Proper Repair of induction leaks.
. Swaging of induction "Spigots" in sump
. Wear of ports on tuned induction sumps

79
 s/2s/2017

Carburetor Air Box

Induction Ice
- Impact
- Venturi
- Throttle
Carburetor Heat
- Usage

80
e/2s/2017

81
 9l25l2OL7

Fuel Metering Systems

. Carburetor
- How does it work?

82
 el2sl2017

Float Type Carburetor Maintenance

Fuel Pressure
* 3-5 PSi
Clean Screen
- Every 100 Hours
Drain Sump
- Every 100 Hours

Fuel Metering Systems Fuel Injection

Continuous flow type systems

. Fuel Injection
- How does it work

83
 elzsl2oL7

Fuel Metering Section

Regulator Section

Vaotlri rrctb&

lnl*.k p(rrrurc,

Frd iaht prerure,

Mdcrcd {ucl prcrrure.

84
 el2sl2aL7

Flow Divid-er

Nozzles

ir@: fr
P lffi, I;
., ffi+$*ffi*@1ffi?
'* , E=4
h1.,
l

85
 sl2s/2077

Fuel Injection Maintenance

Fuel Pressure 15-55 PSI

Clean Screen Every 100 Hours

Note: Clean from Inlet Side Only

Air Flow Section

Fuel Metering Section
Regulator Section

86
 9/2sl2OL7

Nozzle Flow Checks

Fuel Publications
SI 1002 Induction Air Filters
SI 1070 Specified Fuels
SL t72 Prist Fuel Additive
SL 190 TCP Fuel Additive
Sl L275 Cleaning Fuel Nozzles (Bendix/Precision)
SI 1301 Identification of Primer & Fuel Injector Lines
SB 342 Fuel Line Clamping & Installation

87
 9l2s/2OL7

Turbocharging

Supercharger
- Mechanically driven by the enginelcrankshaft

Turbocharger (turbo-super charger)

- Driven bY exhaust gasses

A * {/tPC)#c}

88
 9/2s/2017

Manually Controlled Turbo System

89
 elzsl2oL7

Manually Controlled Mechanical Inter-

Connect Turbo System

Pressure Relief Valve Control System

(Fixed Waste Gate)

90
 9l25l2lt7

Automatic Turbocharger System

91
 e/2s/2017

mflERClilTROLO{A(t S60iq"?5RPti
ocN,srY coNTRoL Fti-L fiinolYlE sEl1Fa
uin?s
El'tE,l€unoEl to,LTro.6{s J4. Jlto.N2c)
TT'HMHARG€N Tffi

Figue 13. LTIO/flO-540-JZB, -J2BD, -N2BD

Induction Air Temperature vs. Manifotd Pressure

VAR}ABLE ABSOLUTE TUBBO SYSTEEI

92
 s/2s/2aL7

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Turbocharging Publications

SI 1422 Exhaust System Inspection (TIT)

SI 1257 Horse Poweq Manifold Pressure, RPM Values
SI 1431 Adjustment of Fuel Metering and Turbocharging
Linkage
SI 1211 Setting Fuel Injector & Controller Adjustment
SI 1187 Turbocharger Density Controller Adjustment
SB 369 Engine Inspection After Overspeed
SB 592 Engine Inspection After Overboost

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