Teledyne Continental Motors GTSIO-520 Series, GTSIO-520-H, GTSIO-520-L, GTSIO-520-M, GTSIO-520-K Overhaul Manual

OVERHAUL

MANUAL

FOR

GTSIO-520

AIRCRAFT

SERIES

ENGINES

FORM

X-30045A

FAA

MARCH

APPROVED

1981

CURRENT

STATUS

OF

PAGES

AS

OF

PAGE

ithru

iv

V

vi

thru

viii

ix

thru

x

A-1-1

A-1

-2

A-2-1/A-2-2

A-3-1 A-3-2 A-3-3

thru

A-3-6

A-4-1

thru

A-4-13 A-4-14 A-4-15 A-4-18 A-4-19 A-4-21 A-4-26 A-4-27 A-4--30 A-5-1 A-6-1 A-6-2 A-7-1 A-8-1 A-9-1 A-9-4

A-10-1

A-10-2

A-10-3 A-10-5/A-10-6 A-11-1 A-1 1 -3 A-1 1 -4 A-1 A-12-2 A-12-4 A-12-5

A-1

A-13-1 A-13-3 A-1 A-13-5/A-13-6 A-14-1

2-1

2-7

3-4

thru thru

thru

thru thru

thru

thru thru

/A-1

thru

A-5-4

A-7-6

A-8-2

A-9-3 A-9-6

2-8

INSERT

THE

MODELS

A-4-17 A-4-20

A-4-25 A-4-29

A-10-4 A-11-2

A-12-3 A-12-6

A-13-2

A-14-4

LATEST

PAGES

MARCH

PAGES

IN

THIS

PUBLICATION

GTSIO-520-C,

ISSUE

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1980

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1981

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1981

DESTROY

CONSIST

D,

PAGE

B-1

B-2

B-3 B-4 B-5

B-6

B-7

thru

B-1l

thru

B-14

thru

B-22

B-23

thru

B-26

B-27/B-28

C-1-1

thru

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-8

C-1-9

thru

C-2-1

C-2-2

C-2-3

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thru

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thru

C-2-9

thru C-2-13 C-3-1

thru

C-3-3

thru

C-3-5

thru

C-3-7

thru

C-3-9

thru

C-3-15 C-4-1

thru

C-4-3 C-4-4

thru

C-5-1

thru

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thru

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thru

C-5-9 C-5-10 C-5-13 C-6-1

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H,

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OF

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B-25

C-1-7

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C-2-8 C-2-12

C-2-16 C-3-2 C-3-4

C-3-6

C-3-8 C-3-14

C-3-18 C-4-2

C-4-20

C-5-2 C-5-4

C-5-8

C-5-12

C-5-16

C-6-2 C-6-4 C-6-1

C-6-16

C-7-18

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FOLLOWING:

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and

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N

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i-1.

COMPOSITION.

i-2.

This adequate operations

these

three

The

basic

a

hypothetical

the

most involved. basic)

and covered Chapter Table manual. covered cerned indexed

model, of manual Page

1

3

i-3.

i-4.

instructions

chapter through duction, Illustrations, Unpacking Shipment, Repair assemblies.

Accessories

model

Chapter GTSIO-520.

i-5.

i-6. for The Chart referred

of

only

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Limits.

A-

13

of

Chapter

This

and

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Chapter

This

all

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index

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Specification

publication

information

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(3)

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engine

GTSIO-520

common

Any

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letter

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Limits

Personnel

this

with

by

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A

All

pages,

numbered

-7

refers

A.

chapter

for

the

consists

XIV.

These

Special

and

Preparation

Disassembly,

Replacement,

Final

and

Testing

Hereafter,

A

will

B.

chapter

covered

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of

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Overhaul,

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FOREWORD

i-7.

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in

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i-8.

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sections, model. for

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coverage

Difference those

i-9.

AVAILABILITY.

i-10.

Further

Contintal

be

purchased Approved craft

engine

such

publications

i-11.

SERVICE

i-12.

Important changeability

datory mation and

duration which of

aircraft study to

aircraft personnel annual

service

i-13.

SERVICE

i-14.

It Motors and

requests Distributors. touch them maintenance

experience

maintenance aircraft

at

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Service

operators

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REPORTS

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Parts

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modernization

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service

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all

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. . . . .A-6-1

. .. . .A-6-1

. .. .

. .. . .A-7-1

. .. .

......

.A-6-1

.A-7-1

.A-7-2

A-7-2

A-7-3

A-74

A-7-5

Section

Forew i-1. i-9. i11. i-13.

I

II.

III

ord

. . . .

. . . . . .

COMPOSITION AVAILABILITY SERVICE SERVICE

BULLETINS.......

REPORTS

INTRODUCTION

1-1.

1-3.

1-5. 1-6 1-7

1-9 1-8

Scope Difference Related

Definition Cylinder Aircraft

Definitions

SPECIFICATIONS,

GENERAL

3-1.

3-2.

DESCRIPTION

Construction

Functional

. . . . . .

...........

........

. . . . .

Data

Sections...

Manuals

of

Terms.....

.......

Arrangement

Engine

Nameplates

and

Abbreviations

LIMITS

..

Systems

. . . . .

....

AND

.

.........

CHAPTER

TABLE

OF

. .

CHARTS

. . . .

A

(BASIC)

CONTENTS

Page

A-1-1 A-1-1 A-1-1 A-1-1 A-1-1 A-1-1 A-1-1 A-1-2

A-2-

A-3-1 A-3-1 A-3-2

i.

1

IV

V

VI

VII

ILLUSTRATION

SPECIAL

UNPACKING

6-1. 6-2. 6-3.

TOOLS

AND

Unpacking Preparation Preparation

DISASSEMBLY

7-1

7-2

7-3

74

7-5

7-6

7-7

7-8 7-9 7-10 7-11

7 7-13

7-14 7-15 7-16 7-17 7-18

Aircraft Extent Parts Disassembly Preliminary Ignition Fuel

Induction Magneto Oil

Oil

12

Alternator Starter Oil Cylinders and Crankcase Camshaft Crankshaft

Parts

of

to

be

System

Injection

Sump Cooler

and

Pump

S

AND

EQUIPMENT

PREPARATION

...................

for

Service

for

Storage

and

Accessories

Disassembly

Discarded

Stand

...........

Cleaning

............

System

and

Accessory

................

.

. . . . .

Assembly

Starter

Drive

Assembly

Pistons.........

.. . .

Assembly

.............

............

.........

..........

.........

...........

Drives.

. .. . . .

..........

Adapter..

..........

. .. . ..

..........

FOR

.. .

. .. ..

SERVICE,

.

STORAGE

.

OR

SHIPMENT

A-4-1

A-5-1

A-6-1

... ... ...

A-7-1

... ... ... ... ... ... ... ... ... ... . . .

. . . .

.

ii

CHAPTER A TABLE OF

CONTENTS

(continued)

Section VIII

IX

CLEANING 8

1

8-2 8-3 8-4

8-5 8-6 8-7 8-8

PARTS

Materials Specific Valves. Cylinders.

and

Parts.

Processes.

....................................

...............................

.......................................

......................................

Pistons. .......................................

Crankshaft. Crankcase.

Ball

Bearings.

.....................................

...................................

INSPECTION

9-1 9-2

9-3 9-4 9-5

9-6 9-7 9-8 9-9

9-10 9-11

9-12 9-13 9-14 9-15

9-16

9-17 9-18

Definition of Protection Visual

Magnetic

Fluorescent

Terms

from

Corrosion. .............................

Inspection. ..................................

Particle

Inspection.

Particle

Inspection. Dimensional Inspcction. Protective Coating. Application Repair Enamel

Specific Crankcase. Crankshaft Crankshaft Camshaft. Connecting

Gears.

Pistons

of "Alodine

of

"Alodized"

Coatings.

..................................

Inspections.

.....................................

and

Propeller

and

Counterweight

......................................

Rods.

..................................

........................................

and

Rings.

.. .. ... ..... .. .. .. .. .... . ... . .. ..

...........................

.................................

1200".............................A-9-2

Surfaces

. . . .

................................

Driveshaft.

Bushings.

..............

9-19 Cylinders. ......................................

9-20 9-21 9-22 9-2 3 Fuel

9-24

Hydraulic

Intake

Tubes.

Lubrication

Injection

Ignition

System.

Valve

Lifters.

....................................

System.

.................................

..............................

................................

...............................

............................

..........................

........................

......................

.................

Page

A-8-1

A-8-1 A-8-1 A-8-1 A-8-1 A-8-2

A-8-2 A-8-2 A-8-2

A-9-1 A 9-

A-9-1 A-9-1

A-9-2

A-9-2 A-9-2 A-9-2

A-9-3 A-9-3 A-9-3

A-9-3 A-94 A-94 A-9-5 A-9-5 A-9-5

A-9-5

A-9-5 A-9-6 A-9-6 A-9-6 A-9-6 A-9-6

X

REPAIR

10-1

10-2

10-3

104

10-5

10-6 10-7 10-8

10-9

10-10 10-11 10-12

AND REPLACEMENT

Castings. Stud Replacement. Helical

......................................

Coil

Insert

Installation.

.................................

Cylinders. ......................................

Crankshaft Idler Magneto Tachometer Starter

Oil

Pump Assembly.

Ignition

100%

Assembly.

Gear.

.....................................

and

Accessory

Drive

Adapter.

Cables.

Replacement

................................

Drive

Adapter

Housing.

.............................

...............................

................................

...................................

Parts

At

Normal

...........................

Assembly.

Major

Overhaul.

.................

................

A-10-1

A-1b-1

A-10-1

A-10-1 A-10-2 A-10-3 A-104

A-

10-4

A-

10-4

A-1

0-4 A-1O0-4 A-10-4 A-10-5

iii

CHAPTER A TABLE

OF

CONTENTS

(continued)

Section

XI

XII

ASSEMBLY 11-1

11-2

11-3

11-4

11-5

11-6

11-7 11-8

11-9 11-10 11-11 11-12

11-13

11-14

FINAL

12-1 12-2 12-3 12-4 12-5 12-6 12-7 12-8 Oil 12 1 12-11 12-12 12-13 12-14

12-15

12-16 12-17

12-18

12-19 12-20 12-21

New Tightening Final Lubrication

Oil

Pump Assembly Starter Cylinders Piston Pushrod Crankshaft Camshaft Alternator

Crankcase . . . . . . . . . . . . . . . . . . . . . . .

Fuel O

il

Cooler

ASSEMBLY

General Crankcase Crankshaft

Camshaft

Propeller Crankcase Cylinders

Pump

9

Starter

2-1 0 Alternator

Oil

Cooler.........

Magneto Oil

Sump Induction Fuel

Injection Magneto Placing

Magnetos ..........

Ignition Fuel

Lines

Final

OF

SUBASSEMBLIES

Parts

..

Torques

Cleaning

.....................

. . ... . . . . . . . . . . . . . . .. .

Adapter

Assembly

........................

and

Ring

Assemblies

Housings

and

Connecting

........................

Assembly

Injection

Control

. . . . . . . . . . . . . . . . . . . . . . .

Instructions....

.........

Assembly....

Assembly

Shaft

.......

Reassembly...

..........

Adapter

Assembly....

and

Accessory

.

System .....

System

Drive

Gears....

Crankshaft

Harness

......

.........

Parts .........

. . . .

..................

..............

...................

Rods...........

..................

and

Air

....

......

Drive

...

in

Timing

..............

Throttle

Adapters

Position

. . . .

Body

Assembly

. .

Page

A-11-1

A-1

1-1 A-11-1 A-1

A-1

1-1 A-11-1 A-1

12

A-1

1-2 A-1

1-3

A1

13

A-11-3

A-1

1-4 A-1

1 A-1

1-4 A-

1 1-4

A-

114

A-

12-1

A-12-1 A-12-1 A-12-1 A-12-1 A-12-1

A-12-2

A-12-3

A-12-4

A-12-4 A-12-4

A-12-5 A-12-5 A

12-5 A-12-5 A-12-6 A-12-6

A-12-6 A-12-6 A-12-7 A-12-7 A-12-7

-

XIII

iv

REPAIR AND

13-1

13-2 13-3 13-4 13-5 13-6 13-7 13-8

13-9

Hydraulic Disassembly Cleaning Testing

Reassembly ..............

Oil

Cooler

Testing

Lubrication

Accessories

TESTING

Valve

..

and

Inspection........

................

...............

................

..............

OF

ACCESSORIES

Tappets

. . . . .

.. ..

A-13-1

.

A13-1

A-13-1 A-13-1 A-13-2 A

A-13-3 A-13-4 A-134 A-134

13-2

CHAPTER

A

TABLE

CONTENTS

OF

(continued)

Section

XIV

Figure

A-4-1

A-4-2

A4-3

A4-4 A-4-5 A4-6 A4-7 A-4-8 A-4-9 A4-10 A4-1 A-4-12 A-4-13 A4-14 A.4-15 A4-16 A4-17 A4-18 A4-19 A-4-20 A-4-2

A-4-22 A-4-2 A-4-24 A-4-2 A-4-26 A-4-27 A4-28 A-4-29 A4-30

A4-31 A-4-32

A4-33

A-4-34

A-4-

A-4-36

A-4-

TESTING 14-2 14-3

14-4

14-5

14-6

No.

1

3

5

35

37

AFTER

Equipment

Test Engine Starting

Test

Procedure Preservation. Engine

Cylinder

Run-In

Numbering

Three-Quarter Three-Quarter Three-Quarter Three-Quarter Three-Quarter Three-Quarter

Diagram

Train

Gear

Lubrication

Sump.

Cooler.

Adapter

Pump

Location.

Rocker

View

and

Assembly.

and

Assembly.

Ring

Machining

Typical

Spark

Rod

Cutaway Magneto Oil Alternator

Oil

Starter Oil Cylinder Crankcase Camshaft Crankshaft

Stud

Inspecting Cylinder

Installing Installing

Expanding

Removing Valve Connecting Counterweight

Installing

Exploded

Alternator Valve

Alignment Checking

Installing

New

View

Drive

Spring

of

Rocker

Cylinder

OVERHAUL

....................

Overhaul.

After

......

.....................................

Overhaul

Top

After

LIST

Diagram

GTSIO-5

View

CTSIO-520D

View

CTSIO-5

View

GTSIO-5

View

GTSIO-520-L........................

View

GTSIO-520-M.

View

................................

System

Diagram.

of

Hydraulic

Accessory

Valve

Drives

....................................

..............................

....................................

..................................

...............................

Assembly.

Piston

...............................

..............................

..................................

Clearance.

Side

Dimensions.

Helical

Plug

Bearing

and

with

Starter

of Ignition

Gear

Coil

Helical

Hole

Helical

Hole

Helical

Hole

Dimensions.

Bushing

Oversize

Adapter

System.

Installed.

Installation.

Arm

Marks.

Clearance.

Timing

Baffles.

...........................

One

Of

Or

CHAPTER A

ILLUSTRATIONS

OF

Title

...........................

20-C.

.......................

20-H 20-K.

........................

.......................

..........................

Lifter.

..........................

........................

.........................

Insert.

.......................

Insert.

Coil

Insert.

Coil

Insert.

........................

Dimensions

Bushings.

Needle

and

.....................

Bearing.

.......................

.........................

............................

...........................

........................

............................

............

More

....................

..................

.................

..................

Installation.

.................

Cylinders.

...........

..

Page

A-

14-1

A-14-1 A-14-2 A-14-2 A-14-2 A-14

Page

A4-1

A4-2 A-4-2 A4-3 A-4-3 A4-4

A44

A-4-5

A4-6 A4-7 A4-8 A-4-9

A-4-1

A4-12

A-4-13

A-4-14 A-4-15 A-4-17

A-4-18 A-4-19 A-4-19 A-4-20 A-4-2

A-4-21 A-4-2 A-4-2

A-4-2 A-4-2 A-4-2

A-4-23

A-4-24

A-4-26

A-4-26 A-4-26

A-4-26

3

0

1

1 1 1

2

3

June

1980

v

CHAPTER

Figure

No.

A-4-38

A-4-39 A-4-40 A-4-41

A442

A-4-43

A-5-1 A-5-2

A-5-3

A-5-4 A-5-5

A-5-6 A-5-7

A-5-8

A

LIST

Torquing

Installing Timing Installing Prop with

Wiring

Borrough's Starter

Piston Push Valve Schematic Engine Valve

OF

ILLUSTRATIONS

(continued)

Title

Sequence

.........................

Cylinder..........................

Marks

...........................

Oil

Seal

on

Prop

Drive

Shaft

Gear

................

Drive

Shaft

Retaining

Gear and

Ring

and

Oil

Spring

Seal

in

Installed

Cavity

.

. .. .

Diagram....................................................

Cylinder

Adapter

Ring

Compressor

Rod

Spring

Lifter

Bleed

Diagram

Transportation

Spring

Compressor.......................

Base

Nut

Bearing

Installer....................

.......................

Compressor.

Down

Tester

of

a

Differential

Stand

Wrenches.................

...................

....................

Pressure

Tester

.....................

. . .

............

. . .

... .

.

Page

A-4-2

A-4-27 A-4-28

A-4-

29

A-4-29

A-4-3

A-5-2

A-5

-2

A-5-2

A-

5-2 A-5-3 A-5-3 A-5-3

7

0

Table

1

2

3

4 5 6

7

8 9

10 11 12

Figure

B-1

B-2 B-3 B-4

B-

No.

5

Table

of

Limits......................

Tightening General Pipe Magnetic Critical

Inspection Standard Stud Helical Crankshafts Table

LIMITS

LIMITS LIMITS

Torques....................

Use

Plugs

.......................

Particle

New

Chart

and

Setting

Coil

and

of

Lubricants

CHART CHART CHART CHART

CRANKCASE

CHAPTER

-Tightening

Torques...............

Inspection...............

Parts Dimensions

.....................

Oversize

Stud

Identification

Heights....................

Special

Tool

Data

Crankcases.................

....................

LIST

(Chart (Chart (Chart (Chart

STUD

1) ............

2)

............

3)

............

4)

............

HEIGHTS

B

(TABLE

LIST

OF

TABLES

...............

...........

..............

CHAPTER

OF

ILLUSTRATIONS

TITLE

..........

OF

B

LIMITS)

....................

. . . . . . . . . .

Page

B-1

B-9

B- 10 B-11

B-

B-14 B-24 B-2 B-26 B-26

B-2

Page B-5 B-6

B-7

B-8 B-24

12

5

7

vi

CHAPTER

TABLE

C

(DIFFERENCE

OF

CONTENTS

DATA)

Section

II.

1.

DIFFERENCE

General Detail Operating Major

Start

Oil

Fuel

Injection

Cleaning,

Reassembly................................C-1-6

Induction Cleaning,Inspection

Reassembly...............................

Crankcase

Magneto Cleaning,Inspection

Reassembly

Turbocharger

Improved

DIFFERENCE

General Detail Operating Major Overhaul Start

Oil

Fuel

Injection

Disassembly...............................C-2-6

Cleaning,

Reassembly...............................C-2-6

Induction

Disassembly...............................C-2-7

Cleaning,Inspection

Reassembly...............................C-2-7

Turbocharger

Improved

DATA

Information

Engine

Test

Overhaul

SECTION

Specifications

Limits

Test

Run..........................C-i-5

Consumption

System

Inspection

System.............................C-1-6

................................

and

Accessory

...............................

Valve Stem

DATA

Information

Engine

Test

Consumption

Inspection

System

Oil

Valve

and

Oil

Inlet

SECTION

..............................

Specifications

Limits...........................C-2-4

Test

Run

System...........................C-2-6

and

............................

and

Inlet

Stem

FOR

THE

MODEL

...............-.............

........................

...........................

Determination

...........................

Repair

Drives........................C-i-7

Repair........................C-1-7

Adapter

and Guide

.........................

Determination.....................C-2-6

Repair

Repair........................C-2-7

Adapter .......................

and

.......................

........................

.......................

Q

FOR

THE

MODEL

........................

.......................

Guide

Lubrication..................C-2-7

GTSIO-520-C

GTSIO-520-D

Page

C-1-1

C-1-2 C-1-2 C-1-4

C-1-5

C-1-6

C-1-7 C-1-7 C-1-7

Cx1-7 C-1C-1-

C-2-1

C-2-2 C-2-2

C-2-5

C-2-6

C-2-7

III.

DIFFERENCE

General Detail Operating Major Start

Oil

Fuel

Injection

Disassembly...............................C-3-6

Cleaning,

Reassembly...............................C-3-7

Induction

Disassembly...............................C-3-7

Cleaning,Inspection

DATA

Information

Engine

Overhaul

Specifications

Test

Consumption

System...........................C-3-6

Inspection

System

SECTION

...........................

Limits...........................C-3-4

Test

Run..........................C-3-5

Determination.....................C-3-5

and

Repair

............................

and

Repair

FOR

THE

........................

.......................

MODEL

GTSIO-5

20-H

C-3-1

C-3-2 C-3-2

C-3

C-3-7

-6

vii

CHAPTER C TABLE

OF

CONTENTS

(continued)

Section

III

IV.

CONTINUED

Reassem Improved

bly...............................C

Valve

Turbocharger

DIFFERENCE

General

Detail Operating

Major

Start

Oil Exhaust Removal Assembly

Hot

Prime

Removal

Assembly

Induction Removal Assembly

Oil

Sump...............................

Removal

Assembly Oil

Cooler Removal Assembly

Oil

Pump Removal Assembly

DATA

Information...........................CA4-2

Engine

Test

Overhaul

Consumption

Assembly............................

and

Equipment...........................C-4-6

and

System

and

................................-

and

Assembly

and

Stem

and

Guide.......................C-3-7

Oil

Inlet

Adapter

SECTION

Specifications

.......................

FOR

THE MODEL

........................

Limits...........................C-4-4

Test

Run

.........................

Determination.....................C-4-5

Disassembly.........................

Installation

.........................

Disassembly.........................

Installation

.........................

.............................-

Disassembly

Installation

Disassembly

Installation

..........................

.........................

..........................-

.........................

Disassembly.........................CA4-7

Installation

.........................

............................

Disassembly

Installation

..........................-

.........................

GTSIO-5

20-K

Page

3-7

C-3-8

C-4-1

C-4-2

C-4-5

C4-6 C4-6 C-4-6

C4-6 C4-6

4-6

4-6 C-4-7 C4-47

4-7

C4-7

4-7

C-4-7

-4-7 4-7

C-4-7

Viii

V.

VI.

DIFFERENCE

General Detail

Operating

Major

Start

Oil

Induction

Cleaning,

DATA

Information

Engine

Specifications

Test

Overhaul

Consumption

System

Repair

SECTION

............................-

Limits

...........................

Test

Run

.........................

Determination.....................C-5-5

............................

and

Replacement

FOR

.........................-

Reassembly...............................C-5-6

Fuel

Injection

Cleaning,

Reassembly

DIFFERENCE

System...........................C-5-6

Inspection

and

Repair

...............................

DATA

SECTION

FOR

......................

General Information............................C-6-2

Detail

Engine Operating Top

or Minor

Start

Oil

Induction

Specifications

Test Limits

and

Major

Consumption

System

............................

........................

...........................

Overhaul

Determination

THE MODEL

......................

THE

MODEL

Test

Run

...................-

.....................

GTSIO

520-L

GTSIO-520-M

C-5-1

5-2 5-2

2-5-4

C-5-5

C-5-6

-5-6

C-6

-5-6

C-6-1

C-6-2

-6-4 6-5

C-6-5

C-6-6

CHAPTER

C

TABLE

OF

CONTENTS

(continued)

Section

VI

VII.

CONTINUED

Cleaning,

Repair

and

Replacement......................C-6-6

Reassembly...............................C-6-6

Fuel

Injection

Cleaning,

System...........................C-6-6

Inspection

and

Repair.......................C-6-6

Reassembly...............................C-6-6

DIFFERENCE

General Detail

Engine Operating Special

Major Start

Overhaul

Oil

Inducation Cleaning,

DATA

Information

SECTION

.............................

Specifications..........................C-7-2

Test

Limits

Items

............................

Required

Test Run...........................C-7-6

Consumption

Determination

System..............................C-7-7

Repair

and

Replacement.......................C-7-7

Reassembly.................................C-7-7

Fuel

Injection Cleaning, Reassembly Fuel

Injection

System ............................

Inspection

and

Repair........................C-7-7

.................................

Adjustment

LIST

FOR

THE

MODEL

or

Equivalent

...................

.....................

Procedures....................C-7-18

CHAPTER

OF

ILLUSTRATIONS

C

GTSIO-520N

Page

C-7-1

C-7-2

C-7-4 C-7-5

C-7-6

C-7-7

Figure

C CCC-1-4

C-1-5 C-1-6 C-1-7

C-1-8 C-2-1

C-2-2 C-2-3

C-2-4

C-2-5

C-3-1

C-3-2 C-3-3 C-3-4

C-3-5 C4-1 C4-2 C4-3 C-4-4 C-4-5

No.

11 12 1-3

Fuel

Injections Induction Crankcase

Magneto

Fuel

Control

Fuel

Cran

Fuel

and

Manifold

Valve

Pump

kcase

Injections Induction Fuel

Manifold

Control

Fuel Fuel

Valve

Pump

Injection Induction

Control Manifold

Fuel

Exhaust [lot

Fuel

Valve

Pump

Assembly

Prime

Injection Induction Oil

Sump(GTSIO-5

System

(GTSIO-520-C)

Assembly

Accessory

Valve

Fitting

Stud

Setting

System

(GISIO-520-D) Valve Fitting

Fitting

System

(GTSIO-520-H)

Fitting

Equipment

System

(GTSIO-520-K)

Title

(GTSIO-520

C)

....................

......................

(GTSIO-5

Fitting

Locations

Heights (GTSIO-520

20-C)

.....................

Drives

(GTSIO-520-C)

Location

(GTSIO-520-C)

(GTSIO-520-C).................C-1-14

(GTSIO-520-C)..................C-1-15

.......................

D)

....................

......................

Fitting

Locations

(GTSIO-520-D)..................C-2-13

(GTSIO-5

(GTSIO-520-D)

(GTSIO-5

20-H)

....................

......................

Locations

Locations Locations (GTSIO-520-K).

(GTSIO-5

(GTSIO-520

(GTSIO-520-H)

(GTSIO-5

20-H)..................C-3-14

.~....................C4-8

20-K)....................

(GTSIO-520-K)....................

......................

20-K).........................

.................

..............

20-D).................C-2-12

H).................C-3-12

................

Page

C-1-9

C-1-10

C-1-11 C-1-12 C-1-13

C-1-16 C-2-9 C-2

-10

C-2-11

C-3-9 C-3-11

C-3-13

C4-9 C4-10 C4-11 C4-13

MARCH

1981

ix

CHAPTER

C

LIST

OF

ILLUSTRATIONS

(continued)

Figure

C-4-6

C-4-7 C-4-8 C-4-9 C-4-10 C-4-11

C-5-1

C-5-2 C-5-3 C-5-4

C-5-5 C-5

C-6-1 C-6-2 C-6-3 C-6-4 C-6-5 C-6-6

C-7-1

C-7-2

C-7-3 C-7-4 C-7-5 C-7-6

No.

-6

Oil

Cooler

Oil

Pump

Crankcase

Fuel

Pump

Fuel

Manifold

Air

Throttle Induction Fuel

Injection Manifold Control

Fuel

Pump

Crankcase

Induction

Fuel

Injection Manifold

Control Fuel

Pump

Crankcasc

Induction Fuel

Injection

Manifold Fuel

Control

Fuel

Pump

Crankcase

(G'TSIO-5

20-K)...........

Assembly(GTSIO-520-K)

Stud

Fitting

System

Valve

Fitting

Stud

System

Setting

Fitting

&

Controller

System

Fitting

Setting

Heights

Locations(GTSIO-5

Locations

Fitting

(GTSIO-520

(GTSIO-520L)

Locations

Heights

(GTSIO-520-M)........

System (GTSIO-520-M)

Valve

Fitting

Stud

System

Valve

Fitting

Stud

Fitting

Setting

System

Fitting

Locations

Hcights(GTSIO-520-M)

(GTSIO-520-N)......................C-7-9

(GTSIO-520-N)

Fitting

Locations

Setting

Heights

Tide

.......

(G'TSIO-520-K)

..

20-K)....

(GTSIO-5

Locations

L)

........

20-K)..

(K)

...

......

(GTSIO-5

20-L)

..

(GTSIO-520-L)...

(GTSIO-520-L)....

(GTSIO-5

20

M).

......

(GTSIO-520-M)

(GTSIO-5

20-M)....

...

...................

(GTSIO-520-N)...............C-7-11

(GTSIO-520-N)

(GTSIO

520-N)

................

(GTSIO-520-N)...............C-7-14

.. .. .. .. . .. .. ..

.. . .

.. .

..............

.. . .

.............

.. . .

.. . .. .

..

...............

. . .

. . . . .

. . . .

. . . . . . . .

. . .

. . ..

.

. .

. . .

. .

. . . . . .

. .

. . .

. . . . . .

. ..

. .

. .. . . .. .. .. .

. .

. . .

. . . . .

. .

. . .

. . . .

. .

. . .

. . . .

. . .

. ... . . . .

.. .

. .

.

. ...

.

.C-6-1

.

.C-6-11 .C -6-12

.

.C-6-13

C-7-10

C-7-12

C-7-13

Page

.C

-4-14

.C

-4-15

.C-4-16 .C-4-17 .C-4-18

C4

-19

.C-5-8 .C-5-9 .C-5

C-5-1

.C-5-12

C-513 .C-6-8 .C-6-9

10

1

0

Graph

C-7-1

C-7-2

C-7-3

No.

Fuel

Flow

100%

Meterer

Limits

Power

Fuel

(GTSIO-520-N)......................C-7-15

Fuel

Pump

Pressure

vs.

Fuel

Limits

Flow

(GTSIO-520-N).............C-7-17

(GTSIO-520-N)...........C-7-16

x

MARCH

1981

SECTION

I

INTRODUCTION

1-1.

1-2. structions

hereafter

is a 6 charged, manufacturered Aircraft

1-3.

1-4.

overhaul and vided Data

1-5.

numbers

contained instructions as

X-30079,

30129,

30533,

a. Starter Prestolite

51

b. Magnetos Components

C. Starter Delco-Remy Anderson,

SCOPE.

This

cylinder

fuel

Products

DIFFERENCE

Sections

instructions

test

instructions

in

the

Sections.

follows:

GTSIO-520-F,

GTSIO

and

Service

and

Company,

1

Hamilton

Service

may

Service

and

for

referred

in

GTSIO-520-C,

GTSIO-520-N,

Indiana.

Chapter

a

hypothetical

to

horizontally

injected,

by

I

thru

latter

sections

PUBLICATIONS.

service

Parts

Catalog

are

contained

520-L,

instructions

Alternator

Street,

instructions

be

obtained

Division,

instructions

Alternator

Division,

comprises

as

the

opposed,

air

cooled,

Teledyne

Division,

DATA

XIV

for

the

for

specific

by

assemblies

in

X-30047;

X-30128,

X

30532,

X-30551.

may

Division

Toledo,

from

Sidney,

may

General

the

GTSIO-520

"basic"

geared,

4

Continental

Mobile,

SECTIONS.

of

this

manual

basic

engine.

models

the

use

for

this

X-30046A.

Operator's

GTSIO-520-D,

GTSIO-520-H,

GTSIO-520-M,

for

the

be

obtained

of

Eltra

Ohio

43601.

for

Bendix

New

York

for

the

be

obtained

Motors

overhaul

engine,

engine.

cycle

of

Detail

Handbooks

Corporation,

the

Delco-Remy

Corporation,

This

turbo-

engine

Motors,

Alabama.

contain

Overhaul

are

pro-

Difference

part

engine

Operating

Prestolite

from

Bcndix

Electrical

13838.

from

in-

are

X-

the

1-6.

and engine position,

1-7.

are

numbers

1-8.

BEFORE anyone first approval 45,

In will to that serial approval.

The submitted approval, current

handling, permanently-stamped

Because in

wll

the

All should shipment:

DEFINITION

right,

as

facing

CYLINDER

numbered

on

AIRCRAFT

a

contact

from

Section

addition,

be

necessary

effect,

number

old

and

price

we

the

past,

not

be

remittance

request,

be

as

used

viewed

the

starting

the

right

Teledyne

new

nameplate,

his

them

45.13

if

the

giving

along

nameplate

to

TCM

a

remittance

list

stamping

did

not,

we

wish

supplied

is

received

along

sent

to

Teledyne Attn:

P.

0.

Mobile,

(b).

the

Box

OF

TERMS.

in

this

manual,

by

the

mechanic

accessory

ARRANGEMENT.

and

Continental

local

in

old

to

supply

with

along

to

cover and

nameplate.

in

to

at

the request

with

following

Continental

Service

90

Alabama

end.

from

the

even

ENGINE

the

person

FAA

accordance

nameplate

a

the

engine

the

(when

with

in

the

costs

mailing

all

cases,

emphasize

with

the

Department

36601

numbers

office

notarized

evidence

available)

evidence

make

the request.

correct

address

Front,

rear,

refer

to

in

a

normal

Cylinders

rear,

with

on

the

NAMEPLATES.

Motors

has

amount

involved

that

of anyone

Motors

involved

and

with

been

model

of

it

mandatory

a

remittance,

to

can

issue

must

obtain

FAR

Part

lost,

statement

and

of

FAA

must

of

FAA

listed

in

a

new,

nameplate

unless

expedite

left

the

odd

left.

it

full

be

in

the

OCTOBER

1980

A-1-1

If,

for

any

the

status

and

ask inquiry specifying

1-

9.

DEFINITIONS

Term

A.B.C.: Approx.: A.T.C.:

Bar.:

B.B.C.:

B.T.C.:

F.A.A..:

c.f.m.:

Dia.:

0

F:

Fig.:

Front: ft.:

G.P.M.: 1120:

Hg.:

reason,

of

for

to

"Attn:

your

"Service

the

it

becomes

nameplate,

Department,"

Mobile

Service

Department."

AND

Explanation

After

Bottom Approximately After

Top

Center Barometric Before Brake

Before Federal

Cubic Center

Bottom

Horsepower

Top

Aviation

feet

per

of Gravity Diameter Degrees Degrees Figure Propeller

Foot Gallons

of

Angle

Fahrenheit

(Illustration)

End

or feet

per Water Mercury

Inside

Diameter

necessary

to

call (205)

or

address

given

ABBREVIATIONS

Center

Administration

minute

check

438-34

your

above

on

11

Term

in.("); Hex.; hr.: Left

Side:

Lbs.: Lock

Man.: Max.: Min.:

3

0':

N.P.T.: N.C.: N.

F.:

O.D.: Press.:

pS.i.: Rear: Right

R.

P.M.: Std.: T.

D.

C.: Temp.: Torque:

Wire:

Side:

Explanation

Inches Hexagon Hour Side

on

cylinders

Pounds Soft

steel nections, Manifold Maximum

Minimum

Thirty one

National National National outside

minutes

degree)

pipe Coarse Fine

Diameter Pressure Pounds

per Accessory Side

on

which

cylinders

are Revolutions Standard

Top

dead

Temperature

Force torque ft.

applied

from

x

=

125

bolt

2

which

are

located

wire etc. or

manometer

thread

(thread)

square

end

of

No.'s

located

per

center

lever

lbs.

center

ft.

from

No's

used

of

angle

(thread)

inch

engine

minute

arm

force

center)

2,

to

safety

(60'

(tapered)

1,3

and

(125

applied

or

62-1/2

4

ft.

5

and

con-

equal

-

6

lbs.

one

lbs.

A-1-2

MARCH

1981

PURCHASED

ACCESSORIES

TEMPERATURE

TMEAUELMT

LIMITS

Accessory

Controller...................

Regulator

Magneto.

Assembly,

...................

Starter.....................

Alternator...................

Turbocharger.................

Oil

Cooler

...................

Intercooler..................

Fuel

Pump

.1..........

Spark

Plugs.

.................

IGNITION

Feature

Left

upper

Right

and

Firing

magneto

No.

magneto

lower

2,

No.

order

fires

4,

6

plugs.

fires

2,

4,

(cylinder

lower

6

5-2-3-6

Fuel

Pressure......

SYSTEM

No.

upper

plugs

numbers)

DETAILS

1,

3,

No.

1,

5

and

3, 5

1-4-

.

Qty.

12

Value

1 1

2 1 1 1 1

1

Indicated

Oil

temperature

Oil

temperature Cylinder (bayonet

Magneto

(at

coil

*

Installed

with

downdraft

Indication

Oil

pressure

Oil

pressure

Oil

pressure

Airport

Condition

at

head

temperature

thermocouple)*

temperature

hold-down

in

tapped

holc

cooling

PRESSURE

(idling) (in

flight)

(

with

OIL

VISCOSITY

Ambient

Air

take-off

screw)

in

bottom

system.

of

LIMITS

cold

oil)

Temperature

Minimum

75F

-

cylinder

hcad.

Minimum

10

psi

30

psi

-

GRADES

S.A.E.

Maximum

-

0

240

F

0

460

F

170F

Applicable

Maximum

-

60

psi

100

psi

Grade

only

CHARACTERISTICS

Dimension

Piston Number Cylinder Piston

strokes

stroke

of

cylinders

bore

per

(in.)..........

(in.)

cycle........

.........

.

AND

DIMENSIONS

.

All

Va

due

4 6

Temperatures

Or

if

Temperatuers

Below

400

Above

400

Are:

F.

15W

20W

30

50

or

-

50,

-

50

10W

-

30

5.25

.

4

Ambient

Air

Temperature

June

(Sea

1980

Level)

A-2-1/A-2-2

SECTION

III

3-1.

a.

appearance illustrated information Lubrication

b. ings form ings the throughout

1.

line bearings

cision, main

the propeller through governor into main starter

2.

case pads necting pad attaching mount crankcase pad

CONSTRUCTION.

GENERAL.

CRANKCASE.

are

joined

the

(with

"left

Bosses

bored

steel-backed,

bearing

crankcase

lateral

the

bearing,

shaftgear.

Cylinder

are

on

rod

has

pad

is

located

of

engine

in

Section

will

Charts.

along

complete

studs

crankcase"

this

publication.

molded

in

the

for

the

inserts.

halves

driveshaft.

bosses

drive

shaft.

right

crankcase,

to

mounting further the

right

to

work

six

studs

cylinder

is

located

at

the

lower

on

The

parts

IV,

be

found

Two

the

crankcase.

and

inserts)

and

in

assembled

camshaft

lead-alloy

Provision

at

the

Precision

for

A

support

forward

crankcase

on

and

base

front

the

right

and

Chapter

aluminum

vertical

will

the

crankcase

and

top

the

needle

to

the

pads

than

a

separate

two

flanges.

on

the

corner.

crankcase

GENERAL

arrangement

components

A.

Additional

in

the

Limits

alloy

The

be

"right

castings

seats

lined

has

front

guides

tappets

bearing

right

front

on

the

to

permit

through

side

center

crankpin.

plane

individual

referred

crankcase"

castings

to

for

the

crankshaft

been

made

to

support

are

and

for

is

pressed

of

the

end

the

left

corresponding

each

bolts

The

governor

of

the

The

alternator

at

the

DESCRIPTION

and to

and

are

and

cast-

to

are

form

pre-

the

bored

the

rear

of

the

crank-

con-

Each

for

left

front.

to

as

in

specific thread spark special solid spring semi-circular grooves. steel machined, are bosses. pressed-in sockets of

steel ball The bead

ring. spring,

d.

draulic crankcase overhead reservoirs the

pushrod the bushings.

oil,

valve cates

the

crankcase

are rubber the

returning

barrel

inserts

plug

heat

valve

retainers

Valve

cadmium

held

in

Valve

and

tubes

ends

pushrod

at

the

The

washer,

VALVE

valve

system,

drilled

Each

through

stem.

the

valve

sealed

seals.

assembly.

diameters.

are

holes.

and

stem

tips

are

keys

rocker

plated.

chrome

place

rockers

bronze

rocker

and

which

bead

inside

housings

cylinder

at

seal

lifters,

main

ends

rockers

valve

a

The

stems

through

to

cylinder

Drain

oil

are

galleries,

the

oil

to the

Valve

guides

Special

installed

Exhaust

corrosion-resistant

are

hardened.

locked

which

covers

plated

by

screws

are

bushings,

faces.

pressed

center

are

end

the

crankcase

ring

and

MECHANISM.

under

the

lifter

lifters.

is

forced

and

the

rocker

nozzle,

spray

and

the

heads

holes

in

sump.

in

valves

to

the

engage

are

Rocker

steel.

in

the

steel

hardened

Pushrods

in,

hardened,

drilled

beaded

retains

end

a

second

pressure

is

divided

guide

The

through

groove

directs

towards

from

springs.

pushrod

and

valve

18mm

upper

stems

The

a

oil

the

lifter

are

then

helical

are

faced

material.

The

by

in

stamped

shafts

rocker

cylinder

forgings

are

forged

for

oil

steel

washer

retains

washer.

Oil

fed

between

surfaces

which

the

pushrods

between

a

portion

the

rockers

Oil

is

returned

housings

crankcase

guides

reamed

coil

and

lower

with

The

outer

valve

tapered,

the

stem

sheet

are

fully

shafts

rocker

with

pushrod

composed

steel

passages.

tubes.

The

and

seal

a

heavy

to

from

and

reaches

their

of

respective

lubri-

which direct

a

hythe the the

to

its

to

by

3.

breather

with

breather crankcase.

C.

are prior the

The

a

CYLINDERS.

heated

to

steel

crankcase

consisting

side

extension

assembly

and

the

head

alloy

barrel

of

is

valve

being

interior

a

tube

for

pressed

The

seats

screwed

to

make

is

ventilated

and

baffle

hose

attachment.

into

aluminum

and

guides

and

the

permanent

the

alloy

are

shrunk

by

assembly

upper

heads

installed

onto head

The

left

a

e.

forging

faces

journals

The spline reduction the on crankshaft

CRANKSHAFT.

is

of

front

which

propeller

the

front

machined

the

and

crankpins

end

mates

gear.

driveshaft

for

has

The

all

over

crankcheeks.

are

of

the

crankshaft

with

a

The

reduction

which

attachment

side

blades

six-throw

except

The

nitrided

quill

shaft

gear

has

of

the

projecting

steel

for

some

main

after

grinding.

has

an

to

drive

in

turn

a

flange

propeller.

from

alloy

sur-

bearing

internal

the

drives

formed

The

the

A-3-1

crankcheeks of

third

order counterweights torsional onto

A

snythetic the castings crankshaft

f.

connecting

bushings same

end. limited

g.

ings lindrical

shaft

built

and

ring manufactured

cast machined. piston Piston permanently variation

h. machined

gear

journals

the crankcase passage. unequally relation with

gear.

vibration.

the

crankshaft

in

the by

CONNECTING

and

type

Weight

to

1/2

PISTONS.

or

forgings.

relief

counterweights.

since

ring

assembly

model.

steel

insert

Because

configurations

pins

is

CAMSHAFT.

on

mount

are

front

journal

cross

The

spaced

to

the

camshaft

and

are counterweights. on

rubber

is

seated

front

a

helical

rods

have

two

identical

as

the

main

variation

ounce.

Pistons

The

cuts

1975

incorporate

Some

engines

with

into

are

full

floating

forged-in

limited

flange

hardened

the

four

journals,

at

passes

passage

camshaft

bolts

camlobes.

gear

to

machined

their

pins

The

crankshaft

and

is

located

oil

seal

shaft

exit,

spring

RODS.

split

bearings)

of

two

are

skirts

at

the

All

GTSIO-520

replacing

in

a

piston

which

of

the

weight

are

aluminum

1/2

ounce

A

steel

the

rear

and

ground.

engine

gear

to

locate

A

and

for

Oscillation

dampen

which

between

and

inside

The

bronze

precision

rods

in

aluminum

are

solid

bottom

a

four

the

current

which

the

top

difference,

not

to

ground

in

alloy

nine

camlobes

end.

A

oil

to

the

is

attached

its

cluster

drives

the

installation

crankshaft

gear

is

by

a

dowel.

is

stretched the

crankcase

is

sealed

the

seal

"I"

beam-type

piston

inserts

at

the

crankpin

any

one

alloy

and

have

to

clear

series

(4)

ring

original

production

incorporates

ring

groove

be

intermixed.

steel

tubes

plugs.

opposite

forging

The

lobes

groove

from

the

left

crankcase

by

timing

gear

is

the

fuel

of

shrunk

over

to

cavity.

(of

bay

cast-

crank-

engines

piston

five

are

these

with

Weight

bays.

and

the

and

around

right

four

mark

bolted

pump

the

pin the

cy-

(5)

in

a

is

tappets from newer shoulders the 1/16"

3-2.

a.

the

(16),

the turned, wormwheel shaftgear (20) disengaging used (1)

1. mitted idler

2. drive on splines

3.

the the with transmits tachometer bevel drives

4.

crankshaft shaft quill propeller

is

the

design,

O.D.

for

FUNCTIONAL

GEAR

engine

through

crankshaft

the

is

to

transmit

to

the generator

Torque by

gear

The

gears

the

crankcase

of

The camshaft oil

pump

internal

gear the

The

drive

shaft

that

center

which

roughly

The

socket

the

old

TRAIN.

torque

adapter

gear

clutch

hub

(21).

returned

the

(12)

and

idler

(14,

magneto

fuel

cluster and splines

torque

drive

(6)

governor

internal

(2)

gear

(23).

shaft

gear

the

ball

nearly

must

half

way

hole

and

1/8"

SYSTEMS.

Figure

is

transmitted

components

(1).

spring

and

grips

After

the

to

its

starter.

torque

drive

from

the

crankshaft

camshaft

gear

15).

Optional

upper

drive

pump

drive

gear

tachometer

of

to

the

oil

gear

on

the

front

driven

splined

transmits

(24)

through

The

drive

(25).

socket

to

use between

diameter

for

As

the

(20)

the

engine

normal

The

shaftgear from pulley.

crankshaft gear

gear

(12)

rear

are

gears.

gear

(3).

the

camshaft

pump

(1

1).

bevel

torque

an

gear

of

the

O.D.,

the

new

the

differences

the

new.

A-4-8.

When

from

(17

wormwheel

is

tightened

knurled

the

(1)

drives accessories

The

drive

The

of

gear

front

(24)

drum

is

started,

position,

(21)

crankshaft

(2)

directly

(3)

the

driven

(22)

is splined gear

gear

drive

gear

governor

the

camshaft

(7).

end

to

the

externally

then

old

tapered while snap

center

starting

the

thru

onto

is trans-

magneto

mounted

by

internal

driven

(8)

(3)

(9)

of

propeller

splined

drives

ring,

starter

21)

(19)

of spring

thus

is

now gear

to

the

end

mates

and

drive

the

and

are

to

is

the

by

of

(4)

i.

TAPPETS.

tappets

complete

Section the figure snap discernible

A-3-2

XIII.

tappets

A-4-10. ring,

may

be

disassembly

The

are

described

Current

which

difference

MARCH

The

removed

of

the

construction

in

tappets

is

red

between

1981

barrel-type

and

replaced

engine,

paragraph

in

as

and

incorporate

color. the

hydraulic

without

described

operation

A-3-1d

The

new

and

a

most

of

and

new

old

b.

in

1 . sump. oil being pump directed

LUBRICATION

The

engine

The

oil

suction

tube,

continually

gears.

From

to

the

is

sucked

to

oil

SYSTEM.

oil

supply

from

the

oil

displaced

the

pump

filter

is

the

pump

by

the

gear

chamber

Figure

contained

sump

through

to

fill

the

rotation

chamber,

and

A-4-9

the

in

the the

volume

of

the

oil

tacho-

is

meter clogged, permitting the passage any time, preset, to

2.

directed

filter. adapter From oil control or depends engine From to mechanisms.

through driven gears. oil bearings,

valve

Oil a

pad. through directed the propeller.

drive

oil

spring-loaded

the

inlet

From

A

the

cooler.

valve

directly

oil

the

to

the

mechanisms

is

introduced

drilled

From

center

the

filter leads

the

to

by-pass

in

filter

on

right

a

camshaft

passage

a

return

to

gear.

spring-loaded

oil

to

flow

outlet.

to

the

oil

pressure

side

of

the

outlet

the

full

valve

the

event

discharge

Oil

passing

is

directed

to

the

gallery

the

oil

temperature

crankcase

side

Oil

is

directed

passage,

Passages

main

crankshaft

and

to

and

the

governor,

port

the

oil

transfer

of

the

propeller

If

the

filter

by-pass

from

From

the

oil

pressure

exceeds

relief

valve,

pump.

side

flow

replaceable

is

incorporated

the

element port,

through

either in

the

temperature.

is

maintained

oil

valve

lifter

from

to

the

from

the left

bearings,

the

governor

the

propeller

port

in

oil

re-enters

in

the

mount

tube,

should

valve

the

gear

oil

filter

relief

the

oil

of

the pump,

becomes

oil

is

directed

the

oil

through

left

crankcase.

In

gallery,

guides

the

propeller

bearings,

valve

drive bearings.

governor

the

governor

which

shaft,

and

will

chamber

outlet,

valve.

limit

is

passed

element in

the

clogged.

temperature

the

this

manner,

at

oil

is

directed

and

right

driver

gallery

prop

lifter

through

the

crankcase

pad.

The

is

located

on

become

open

If,

of

the

back

oil

filter

to

the

cooler

This

1700

F.

valve

gallery,

and

direct

shaft

guides,

mount

oil

to

the

inner

dome.

Oil

in

the

crankcase

sump

through

to

a

6.

at

is

in

the

crankcase charger turbocharger

to

an

oil

to

the

scavenge

c. system fold

assembly,

air

throttle include, capable

pressure sure.

The

exhaust

a

higher

able

from

charger

body

which inducted injector

throttle the

manifold

intake

ports.

The

turbocharger-to-fuel provides discharge nozzles.

drain

The

turbocharger

left

oil

inlet

through

at

the

separator

pump

INDUCTION

consists

in

of

drop

velocity

ambient

discharge

in

system

body

pressurized

side

of

intake

assembly.

the

induction

40%

effectivity

across

gas

driven

and

side

controls

accordance

fuel

the

riser

to

conditions.

induction

and

holes.

is

gallery

oil

outlet

and

from

inlet.

SYSTEM.

a

turbocharger,

tubes,

In

the

cooler

turbocharger

greater

is

directed

the

with

control

intake

injection

air

from

the

fuel

is

returned

lubricated directed a

hose.

these

air

addition

system,

with a static

quantity

air

tubes

to

Oil

port

through through

The

manifold

most

an

of 6"

supplies

density than

Air

from

to

the

of

the

setting

unit.

From

is

directed

to

system

the

turbocharger

pump

and

to

by

oil

the

turbo-

leaves

a a

induction

intake

mani-

tubes

models

inter-cooler

cooling H20

attain-

the

turbo-

air

throttle

air

to

of

the

through

the

cylinder

manifold

injector

the

from

the hose hose

and

pres-

air

the

air

at

be

air

3. is adapter idler

4. conducted two shaftgear clutch lubricated crankcase of clutch

5 . by direct

From

directed

gear

Oil

radial

spring.

the

adapter

spring

Each

individual

a

groove

through

bearing,

bearing

from

through

holes

drum

Other

by

this

through

and

sleeve.

cylinder

oil

continuous

idler

to

the

from

and

spray.

a

squirt

in

the

drilled

gear

the two

starter

a

passage

which

bearing

parts

hole

in

a

slot

wall

stream

rear

passages

bearing

magneto

shaftgear

it

of

the

Oil

drains

the

in

and

piston

nozzles.

of

main

in

the

is

sprayed

surface

starter

bottom

the

bottom

These

oil

bearing,

to

the

and

from

bearings.

bearing

shaftgear

onto

under

drive

back

front

is

lubricated

at

the

starter

into

of

nozzles

piston

oil

the

to the the

are

the

side

the

In

most installations, scroll pressurization ments. sonic

is

mately

d. is plugs plugs mounted

accessory the supplies cylinder spark breaker.

feature

The

venturi

six

IGNITION

generated

of

the

of

pad.

front

high

spark

plugs,.

The

to

in

turbo-bleed

which

pounds

and right

the

left

on

the While

of

the

voltage

plugs

it

double

the

provide

addition

limits

of

air

SYSTEM.

distributed

side

front

the

left

current

and

is

also

breaker

turbocharger

turbo-bleed

to

the

air

is

provided

the

bleed

per

minute

High

to

cylinders

of

the

left

magneto,

crankcase

the

lower

equipped

magneto

has

air

engine

through

air

to

at

sonic

voltage

the

upper

and

lower

by

a

right

mounted

accessory

to

the

upper

right

with a double

serves a dual

a

dual

for

cabin

require-

approxi-

flow.

current

spark spark

magneto

crankcase

on

pad,

left

cylinder

A-3-3

a

purpose. breaker a

shower As disengaged,

are no running magnetos.

furnishes retarded

cranking

plugs

through

assemblies.

magnetos

by

e.

1.

simple,

the

multi-nozzle,

controls

change

combination of

correct

mixture

ed

any

The

vane

system

2. function engine pressure control for other

Main and the manifold the air-flow valve the fuel-air

blast pressure

When

and a starting

of

the

engine

the

longer

on

The

electrical

ignition

speed.

through

braided,

These

by

nuts.

FUEL

GENERAL.

low

intake

fuel

fuel; one

metering

fuel

valve

fuel

in

throttle

relation

control

pressure,

combination

continuous

pump.

fuel

except

FUEL -AIR

of

air

for

elements

for

fuel

enters

passes

to

valve

to

fuel-flow.

determines

pump.

control unit

air

cooled to switch,

high

pressure

the

intake

proper

cranking

vibrator

voltage

is

started

retard

breaker

transmitting

the

advance

battery

current

starting,

Spark

is

high

tension

flexible, shielded

assemblies

coupling

INJECTION

continuous

flow

both,

for

of

metering.

the metering

valve

and

valve

nuts

The

system

port

in

to

match

position,

causes changes

to

engine

and a flow

are

provided

of altitude

flow

system

There

the

engine -driven

fuel-air

and

fuel-air

in

this

which

the

control

controls

nozzles.

to

the

The

the

amount

The

fuel

is

enclosed

help

connected

the

engine,

are

sparks

to

and

cranking

and

spark

breakers

operated

to

the

regardless

transmitted

cables

are

and

to

SYSTEM.

fuel

injection

of

injecting

the

cylinder

type

flow

engine

airflow.

gage,

for

and

uses a typical

no

are

is

running

CONTROL

control unit

set

to

unit,

prevent

the

ratio.

one

for

fuel

unit

valve. the

fuel

A

linkage

air

throttle

position

of

control

in a shroud

vapor lock. A fuel

to

the

the retard

in

effect,

start

starting

and

starting

connected

the spark

indicating

precise leaning

power

There

for

mixture

through a strainer

The

of

fuel

portions

fuel

causing

the

engine.

motor

vibrator

the

engine

from

vibrator

magneto

of

engine

to

the

which

conduit

to

system

fuel

It

head.

system

airflow.

in

fuel

UNIT.

metered

passed

which

speed,

fuel

flow

A

manual

meter-

setting.

rotary

parts

in

pump.

is

to

control

are

air,

and

position

to

connecting

proportions

the

mixture

returned

of

control unit,

both

for

spark

pass

the

plugs

is a

into

is a

Any or

this

The

fuel

three

two

the

and

in

of

to

actuates

operate pressure pump

is

switch

is

3.

the the for cylinder bleed supplies pressurized arrangement

breaking fuel acceleration

with a letter

Replacement

4. unit, provides

a

individual cylinders.

In valve

at

close simultaneously. A piston type insure before restrictions fine mesh additional against

5. is a positive-displacement, has a shaft section swirl well separated fuel the

jet

returned engine-driven, pump more fore,

is

constant provided

to

at a high

drops switch to

operate.

FUEL

fuel

manifold,

metered

each

cylinder.

heads

and

the

lines

FUEL

fuel

is

a

the

fuel

raises

the

that

fuel

screen is

dirt

FUEL

of

the

by a swirling

is

fed

top center

of

fuel and

to

flow

fuel

than

a

relief

fuel

so

cause

fuel

solidly

of

delivered

central

or

individual cylinder

the

flow

to

protection

or foreign

for

of

to

that

the

auxiliary fuel

speed

if

the

engine-driven

5

below

must

DISCHARGE

to

These

outside

nozzle

aids

in

high

vacuum

the

on

the

nozzles

MANIFOLD.

manifold, a diaphragm

lowers,

plunger fully

starts.

fuel

included

INJECTION

connection

engine.

the

vapor

the

pump. The

of

the

is

fed

the

fuel

changes

proportionally.

required

is

valve

pump

the

PSI.

be

ON

for

individual

the

fuel

nozzles

each

pressurization

air

to

the

vaporization

at

filled

and

engine.

hex

must

match.

From

to

the

point

for

fuel

by

Thus,

flow

in

of

the

matter.

PUMP. rotating

to

Fuel

enters

separator.

motion

swirl

well

into

the

tank.

in

engine

by

is

provided

pressure.

auxiliary

NOZZLES.

discharge

intake

nozzle.

Nozzles

of

fuel

dividing

pressure,

check

opens

there is

the

vapor is

vapor

Since

The

pump

The

auxiliary

the

fuel

pressure

fuel

lines

nozzles,

are

installed

valve.

arrangement

The

air bleed

of

fuel

idle,

maintains

ready

the

the accessory

so

by a small

the

A

pump

are

the

nozzle

the

manifold

and plunger

fuel

supply

valve

the

no

fuel

manifold.

fuel

injection

The

vane

the

Here,

that

return

the

speed

pump engines. to check

pressure

for

stamped

fuel

to

serves

outlet

unbalance

manifold

fuel

pump

vapor

only

drawn

pressure

pump

affect

maintain

to

pump

fuel

From

carry

one

in

the

An

air

and

by

the

instant

body.

control

which

to

the

open

port

ports

nozzles

pump

type.

drive

at

the

liquid

from

line

and

total

supplies

There-

valve

can

or

to

A

as

It

is

a

is

A-3-4

bypass starting. pump automatically is

failure,

ON.

Incorporated

the

In

engine-driven

case

of

engine-driven

the

auxiliary

when

the on

the

fuel

auxiliary

fuel

injection

fuel

pump

fuel

pump

injection

pump

injection

will

pump

for

operate

switch

is

a

variable pump. charger controls

altitude.

at

orifice

The

aneroid

discharge

the

pressure

controlled

is

pressure.

from

by

an

controlled

The

the

fuel

aneroid

by

the

variable

injection

on

the

super-

orifice

pump

A-3

-5

/A-3-6

6

SECTION

IV

ILLUSTRATIONS

5

4

2

FIGURE

A4-1.

CYLINDER

NUMBERING

3

1

DIAGRAM

A-4-1

FIGURE

A-4-2.

RIGHT

FRONT

VIEW

-

GTSIO-520-C

A4-2

FIGURE

A-4-3.

LEFT

REAR

VIEW

-

GTSIO-520-D

FIGURE

A-44.

RIGHT

FRONT

VIEW

-

GTSIO-520-H

FIGURE

A-4-5.

LEFT

FRONT

VIEW

-

GTSIO-520-K

A-4-3

FIGURE

A-4-6.

RIGHT

FRONT

VIEW -GTSIO-520-L

A4-4

FIGURE

A-4-7.

RIGHT

SIDE

VIEW

-

GTSIO -520-M

24

.25

2

18

4

5

1.

Crankshaft

2.

Crankshaft

3

.

Camshaft

4.

Camshaft

5.

Hydraulic

6.

Governor

7.

Governor

8.

Oil

Pump

Drive

Shaftgear

9.

Oil

Pump

10.

Scavenge Driven Gear

11.

Scavenge

12.

Idler

Gear

FIGURE

Gear

Cluster

Tappet Drive Driven and

Tach

Driven

Driver

Assembly

Gear

Bevel

Gear

A4-8.

Gear

22

GEAR TRAIN

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

DIAGRAM

Idler Gear Left

Magneto

Right

Magneto

Starter

Worm Drive

Starter

Starter Clutch Starter

Fuel Pump Quillshaft Prop Prop

Worm Gear Worm Spring

Shaftgear

Gear Shaft Shaft

Support

Drive

Shaft

Weel

Drive

11

Gear

A-4-5

A-4-6

FIGURE

A-4-9.

LUBRICATION

SYSTEM

DIAGRAM

FIGURE

A4-10.

CUT-AWAY

1.

Body

2.

Spring,

3.

Housing,

4.

Spring,

5.

Plate,

6.

Plunger

7.

Socket

8.

Ring,

9.

Oil

10.

Oil

11.

Oil

1

2.

Oil

13.

Oil

14.

Hole,

15.

Oil

16.

Hole,

VIEW

OF

Plunger

Check

Retaining

Groove,

Inlet,

Body

Groove,

Inlet,

Plunger

Reservoir,

Oil

Discharge

Reservoir,

Oil

Outlet

HYDRAULIC

Valve

Exterior

Interior

Plunger

Body

VALVE

LIFTER

A-4-7

A-4-8

FIGURE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Washer,

11.

Washer,

12.

Adapter,

A-4-11.

Nut,

Hex Washer, Washer, Cover Gasket Nut,

Hex Washer, Washer, Nut,

Hex

MAGNETO

Lock Plain

Lock

Plain

Lock Plain

Accessory

AND

ACCESSORY

1

14.

15.

16.

17.

18.

19.

20.

21.

22. 2 3.

3.

Gasket Bushing Seal,

Oil Gear Bushing, Retainer Sleeve Gear Bearing Gear Sleeve

DRIVES

Coupling

11

6

FIGURE

1.

Gasket,

2.

Plug

3.

Screw,

4.

Washer,

5.

Washer,

6.

Sump

7.

Gasket,

8.

Screw,

9.

Screw,

10.

Washer,

11.

Tube

12.

Gasket,

A4-12.

OIL

Annular

Ilex

Head

Lock

Plain

Assembly,Oil

Oil

Sump

Hex

Head

Hex

Head

Plain

Assembly,

Suction

SUMP

Suction

Tube

A4-9

CUT

Must

AND

Not

BEND

Touch

AS

SHOWN.

Thrust

Washer

AND

CUT

Not

Extend Beyond

AS

SHOWN.

End

Of

Shaft.

OTTER

PIN HEAD

IN

SLOT

8

5

12

11

10

7

4

A-4-10

2.

4.

5.

6.

7.

1 .

3

.

Nut,

Hex Washer, Washer, Alternator Gasket, Pin,

Cotter

Nut,

Slotted

FIGURE

Lock Plain

Assembly,

Alternator

Hex

A4-13.

Complete

ALTERNATOR

8.

9.

10.

11.

12.

13.

ASSEMBLY

Key,

Woodruff Washer, Gear Bushing Spring, Hub

Thrust

Assembly,

Clutch

Assembly,

Alternator

Gear

Driven

Teledyne Continental Motors GTSIO-520 Series, GTSIO-520-H, GTSIO-520-L, GTSIO-520-M, GTSIO-520-K Overhaul Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD