Sharp R-520F Betriebsanleitung

Publication X30039©2011 CONTINENTAL MOTORS, INC. AUG 2011IO-520CONTINENTAL® AIRCRAFT ENGINE OVERHAULMANUALTECHNICAL CONTENT ACCEPTED BY THE FAA

1-2Term . Explanation N.C. National Coarse (thread)N.F. National Fine (thread)O.D. Outside Diame

6-28FIGURE 6-2. TABLE OF LIMITS CHART (3 OF4).

6-29/6-30FIGURE 6-2. TABLE OF LIMITS CHART (1 OF4).

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7-1SECTION VIIASSEMBLY OF SUBASSEMBLIES7-1. NEW PARTS. Parts which require protectionfrom atmospheric dust and moisture are wrapped orboxed individu

7-2f. Place cover and tachometer drive assembly onpump housing, turning drive gear to mesh bevel gears,and attach it temporarily with two sets of att

7-3b. Install clutch spring (18) on worm wheel (19).Turn spring so it tends to unwind until offset enddrops into gear hub groove. Position spring on

7-4 JANUARY 19857-13. CRANKSHAFT AND CONNECTINGRODS -TYPICAL OF SANDCAST CRANKCASE(See Figure 4-24).a. Lay crankshaft on a bench with a notched

MAY 1980 7-57-15. CAMSHAFT (See Figure 4-23).a. Tap a Woodruff key (3) on front end of camshaft(9) and install bevel gear (2).b. Install gears

7-6FIGURE 7-3. FUEL PUMP AND VAPOR SEPARATOR FITTING LOCATIONS

7-7FIGURE 7-4. FUEL CONTROL VALVE FITTING LOCATIONS

1-31-8. OIL SUPPLY AND MEASUREMENT.1-9. The capacity of the oil sump is 12 U.S. quarts.The oil filler cap is attached over the oil filler neckon top

7-8FIGURE 7-5. FUEL MANIFOLD VALVE FITTING LOCATIONS

8-1SECTION VIIIFINAL ASSEMBLY AND TEST8-1. GENERAL INSTRUCTIONS.8-2. LUBRICATION. Apply clean enginelubricating oil liberally to all bare steel sur

8-2c. Insert governor driven gear (1, Figure 4-23) into itsbearing.d. Lay camshaft assembly in its bearings in leftcrankcase, meshing spur gear teet

8-3q. Attach right crankcase mount brackets to theassembly stand and rotate stand until engine is uprightas shown in Figure 8-4.r. Install generator

8-4j. Insert, from above, through bolts (58, 59,60, 61).Tap all of these through to centered positions withnon-marring hammer. These bolts align cran

8-5FIGURE 8-7 TORQUING SEQUENCEa. Nuts on both ends of thru bolts must torqued. b. All stud and thru bolt threads to be lubricated withcastor oil.A

8-6FIGURE 8-8 TORQUING SEQUENCEa. Nuts on both ends of thru bolts must torqued. b. All stud and thru bolt threads to be lubricated withcastor oil.A

8-7FIGURE 8-9. CYLINDER FLANGE TORQUE SEQUENCEFIGURE 8-10. FUEL PUMP, OIL PUMP AND STARTERADAPTER INSTALLED. SANDCAST CRANKCASE.g. As soon as each

8-8FIGURE 8-11. INSTALLING PUSHROD HOUSING. FIGURE 8-12. BOTTOM VIEW WITH VALVE MECHANISM AND OIL SUCTION TUBE INSTALLED. SANDCAST CRANKCASE.1.

MARCH 1982 8-9FIGURE 8-13. BOTTOM VIEW WITH VALVE MECHANISM AND OIL SUCTION TUBE INSTALLED PERMOLD CRANKCASE.1

1-4FIGURE 1-3. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-B. (PERMOLD CRANKCASE)FIGURE 1-4. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-B. (PER

8-10 MARCH 19828-17. OIL COOLER -TYPICAL OF SANDCASTCRANKCASE (See Figure 4-11).a. Install new gasket (11) on crankcase studs. Installoil cooler

MAY 1980 8-11b. Place a hose clamp on each end of cylinder intaketube so it faces center tube. Push end tubes into hosepreviously installed on ce

8-12 MAY 1980Position hoses (2) over beads and secure withclamps(1).8-24. INDUCTION SYSTEM, IO-520-E (SeeFigure 4-8).a. Push a new hose (2) on ei

8-138-27. PLACING CRANKSHAFT IN TIMINGPOSITION TYPICAL OF SANDCASTCRANKCASE.a. Cover the lower spark plug hole with the thumband turn crankshaft clo

8-14Position bracket so that its centerline is 21-1/4 inchesfrom edge of No. 2R ferrule and 7-1/2 inches fromedge of No.6 ferrule.f. Install all spar

8-158-32. FINAL PARTS.a. Install gaskets and covers on mount pads behindmagneto drive gears and attach with four sets of plainwashers, lockwashers a

8-168-41. ELECTRICAL WIRING. A 24-volt storagebattery must be connected by a No. 0 stranded coppercable from its positive terminal to the power term

JANUARY 1985 8-17b. Turn magneto switch to "BOTH" position.c. Press boost pump button and hold it until 2.5-3.0psi nozzle pressure is o

8-18TABLE XVII. STANDARD ACCEPTANCE TEST FOR IO-520, 285 H.P. ENGINEPROPELLER STANDNote: Engine oil pressure must be supplied to propeller transfer

8-19/8-20TABLE XVII. STANDARD ACCEPTANCE TEST FOR IO-520, 300 H.P. ENGINEPROPELLER STANDNote: Engine oil pressure must be supplied to propeller tran

1-5FIGURE 1-5. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-C. (PERMOLD CASE)FIGURE 1-6. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-C. (PERMOLD

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9-1SECTION IXIO-520-MThe IO-520-M is similar to the other Permold enginescovered in Sections I thru VIII except that the airthrottle body is air frame

9-2b. Remove attaching parts (17,18) Clamp (16) andremove balance tube (16) and bracket (14).c. Remove attaching parts (21 thru 24) and re movebrack

9-3FIGURE 9-2. FUEL INJECTION SYSTEM.1. Gasket, Fuel Pump to Crankcase 19. Spring2. Coupling 20. Control Assembly3. Fuel Pump 21. Washer Tab4. Was

9-4FIGURE 9-3. FUEL PUMP AND VAPOR SEPARATOR FITTING LOCATIONSABC D EINLET ANDANGLE°OUTLETANDANGLE°MIXTURERETURNANDANGLE°VAPORRETURNAND ANGLE°DRAINAN

9-5FIGURE 9-4. FUEL CONTROL VALVE FITTING LOCATIONSABC D ETOMANIFOLDVALVEFUEL RETURNTO TANKPRESSURETAPFUEL INLETTOMANIFOLDVALVEIO-520-M PLUG

9-6FIGURE 9-5. FUEL MANIFOLD VALVE FITTING LOCATIONSENGINEMODELFITTING“A” NUMBERFITTING“B” NUMBERFITTING“C” NUMBERIO-520-M90° ELBOW 90° NIPPLE 0° 45°

9-7TABLE XIX. TEST OPERATING LIMITSFEATURE IO-520-MMaximum takeoff powerMaximum continuous powerFull throttle speed (RPM)Idling speed (RPM)Fuel grade

9-8TABLE XX. STANDARD ACCEPTANCE TESTPROPELLER STANDNote: Engine oil pressure must be supplied to propeller transfer collar during all testing.Perio

MARCH 1982 10-1SECTION XIO-520-BB,CB,MB10-1 INTRODUCTIONA. Information contained herein applies to the modifiedcrankshaft version of the Permold I

1-6FIGURE 1-7. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-D. (SANDCAST CRANKCASE)FIGURE 1-8. THREE-QUARTER LEFT REAR VIEW OF THE IO-520-D. (SA

10-2 MAY 1980TABLE XXI(SEE FIGURE 10-1)* Full Indicator reading

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1-7FIGURE 1-9. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-J. (SANDCAST CRANKCASE)FIGURE 1-10. THREE-QUARTER RIGHT FRONT VIEW OF THE IO-520-L.

1-8FIGURE 1-11. INSTALLATION DRAWING FOR THE IO-520-A,D,E,J,K & L.FIGURE 1-12. INSTALLATION DRAWING FOR THE IO-520-B.

1-9/1-10FIGURE 1-13. INSTALLATION DRAWING FOR THE IO-520-C.

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2-1SECTION IIGENERAL DESCRIPTION2-1. SIGNIFICANT DIFFERENCES. Specificdetail parts differences in the IO-520 Series will benoted in the Parts Catalog

A IO-520 Series Engine Overhaul Manual31 August 2011Supersedure NoticeThis manual revision replaces the front cover and list of effective pages for Pu

2-2 JANUARY 1985base flanges. The governor mount pad is located atthe lower front corner. On the right permoldcrankcase an alternator pad is locat

2-3sockets and rocker faces and pressed-in bronzebearings. They are drilled -for lubrication.Pushrods are constructed of steel tubes and pressed-in,

2-4FIGURE 2-2. GEAR TRAIN DIAGRAM (TYPICAL WITH SANDCAST CRANKCASE).1. Crankshaft gear... 1:12.

2-5FIGURE 2-3. GEAR TRAIN DIAGRAM (TYPICAL WITH PERMOLD CRANKCASE).1. Crankshaft gear... 1:12.

2-6FIGURE 2-4. LUBRICATION SYSTEM (TYPICAL WITH SANDCAST CRANKCASE).

2-7FIGURE 2-5. LUBRICATION SYSTEM (TYPICAL WITH PERMOLD CRANKCASE).

2-8 MAY 1980d. Passageways from the left crankcase gallerydirect oil to the front, intermediate and rear mainbearings.e. Four drilled passages radi

2-9/2-102-16. The barrel type hydraulic lifter (See Figure 2-6) consists of a steel body (1), an expanding spring(2), and a check valve assembly (3,

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3-1SECTION IIISPECIAL TOOLS AND EQUIPMENT3-1. It is advisable to have an enginetransportation stand (Figure 3-4) on which theengine can be inverted s

i

3-2FIGURE 3-4. ENGINE TRANSPORTATION STANDFIGURE 3-5. VALVE SPRING COMPRESSOR, BORROUGHS NO. 5202BORROUGHS NO. 5204 RIGHT HAND BORROUGHS NO. 5203 LE

4-1SECTION IVDISASSEMBLY4-1. GENERAL. .4-2. AIRCRAFT PARTS AND ACCESSORIES.4-3. Instructions in this section are based on theassumption that all part

4-2FIGURE 4-1. FUEL INJECTION SYSTEM (IO-520-A,E,F,J,K & L)1. Clamp, Fuel Discharge Tube 21. Spring, Compression 41. Nut, Plain, Hex2. Tube Ass

4-3FIGURE 4-2. FUEL INJECTION SYSTEM (IO-520-B)1. Clamp 20. Washer, Plain 39. Screw, Idle Adjusting2. Tube Assembly 21. Washer, Wave 40. Spring3.

4-4FIGURE 4-3. FUEL INJECTION SYSTEM (IO-520-C)1. Tube Assembly 20. Washer, Wave 39. Washer, Wave2. Clamp 21. Washer, Wave 40. Washer, Plain3. No

4-5FIGURE 4-4. FUEL INJECTION SYSTEM (IO-520-D)1. Tube Assembly 20. Washer, Lock 39. Pin2. Clamp 21. Washer, Plain 40. Screw3. Nozzle Assembly 2

4-64-11. FUEL INJECTION SYSTEM (See Figures4-1, 4-2 and 4-3).a. Use the following basic procedure to disassemble thefuel injection system on the IO-52

4-74-13. INDUCTION SYSTEM.a. IO-520-A, B, C, F,J, K, L (See Figure 4-6).(1.) Loosen hose clamps (1) or clamp assemblies (2)on hoses (3) or (4) and r

4-8FIGURE 4-6. INDUCTION SYSTEM. (A,B,C,F,J,K & L)1. Clamp, Hose 20. Tube Assembly 39. Bushing2. Clamp Assembly 21. Gasket 40. Sleeve3. Hose,

MAY 1980 4-9FIGURE 4-7 INDUCTION SYSTEM. (IO-520-D)1. Clamp 12. Screw2. Hose 13. Washer, Lock3. Tube 14. Washer, Plain4. Tube 15. Tube Assemb

4-10FIGURE 4-8 INDUCTION SYSTEM. (IO-520-E)1. Clamp 14. Washer, Plain 27. Sleeve2. Hose 15. Tube Assembly 28. Throttle Assembly3. Tube Assembly

4-11FIGURE 4-9 OIL SUMP (STAMPED ALUMINUM SHEET METAL IO-520-A,C,D,E,F & K)1. Plug, Oil Drain 7. Gasket, Oil sump 13. Bolt.2. Gasket, Annular 8

4-12FIGURE 4-10 OIL SUMP (CAST ALUMINUM IO-520-B)1. Plug, Oil Drain 7. Screw 13. Screw2. Gasket 8. Washer, Lock 14. Nut3. Nut, Plain, Hex 9. Wash

4-13FIGURE 4-11 OIL COOLER (TYPICAL ON SANDCAST CRANKCASE).FIGURE 4-12 OIL COOLER (TYPICAL ON PERMOLD CRANKCASE).1. Screw2. Washer, Lock3. Washer, P

4-14d. Remove nut (13) and washer (14), and bolts (15,16); Idler kiss bracket (17) will come off at this time.Generator (18) should pull free. Remove

4-15FIGURE 4-14. GENERATOR ASSEMBLY(IO-520-E) FIGURE 4-15. ALTERNATOR ASSEMBLY ON PERMOLD ENGINES(IO-520-B & C)1. Belt2. Spacer3. Sheave4.

4-164-21. STARTER AND STARTER DRIVE ADAPTER(See Figure 4-16).a. Remove two sets of attaching parts (1, 2, 3) andpull starter from starter adapter stu

4-17FIGURE 4-16. STARTER ADAPTER WITH GENERATOR DRIVE SHEAVE.(SANDCAST CRANKCASE)1. Nut 22. Cover2. Lockwasher 23. Gasket3. Washer, Plain 24. Sle

4-18FIGURE 4-16. STARTER ADAPTER WITH GENERATOR DRIVE SHEAVE.(SANDCAST CRANKCASE)1. Nut, Plain, Hex 11. Washer, Plain 23. Bearing, Ball2. Washer, P

4-194-23. OIL PUMP ASSEMBLY (See Figure 4-18).a. Loosen oil screen (6) and tachometer drive housing(12) to facilitate later removal. (Tachometer dri

4-20i. Remove hydraulic valve lifter assemblies (43). It isrecommended that all hydraulic lifters be replaced ateach major overhaul regardless of co

May 1980 4-21NOTEDo not attempt to remove bolt andwasher adjacent to right magnetoupper stud. These two parts areinstalled be- fore the stud and ca

4-22FIGURE 4-18. OIL PUMP (INTEGRAL TYPE OIL SCREEN).1. Nut 18. Washer, Plain 36. Gear2. Washer, Lock 19. Cover 37. Bushing3. Washer, Plain 20.

4-23FIGURE 4-19. OIL PUMP (PERMOLD ENGINE FULL FLOW TYPE FILTER).1. Filter 18. Washer, Plain 34. Gasket 50. Screw, Adjusting2. Nut 19. Cover 35.

4-24FIGURE 4-20. CYLINDER.1. Screw, Fillister Head 16. Washer 31. Spring, Valve, Inner2. Washer, Lock 17. Packing 32. Retainer, Inner3. Washer, P

4-25FIGURE 4-21. SANDCAST CRANKCASE ASSEMBLY COMPLETE.1. Rod Assembly, 20. Bolt 43. Washer, Plain 65. Bracket, Oil Gauge 21. Eye, Engine Lifti

4-26FIGURE 4-22. PERMOLD CRANKCASE ASSEMBLY COMPLETE.1. Gauge and Cap Assy., Oil 27. Bushing, Flanged 53. Washer, Lock2. Screw 28. Gasket 54. Was

4-27FIGURE 4-23. CAMSHAFT ASSEMBLY1. Gear, Bevel, Driven2. Gear, Bevel, Drive3. Woodruff Key4. Screw5. Cam Gear6. Gear, Camshaft7. Plug, Pipe8. Plug,

4-28FIGURE 4-24. CRANKSHAFT GROUP (TYPICAL OF SANDCAST MODELS1. Washer, Thrust 19. Nut, Marsden2. Bearing, Crankshaft, Main 20. Collar, 1-3-5 Side3

4-29/4-30FIGURE 4-25. CRANKSHAFT GROUP (TYPICAL OF PERMOLD CRANKCASE).1. Washer, Thrust 19. Collar, 1-3-5 Side2. Bearing, Crankshaft, Main 20. Coll

iv October 1978

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5-1SECTION VCLEANING, REPAIR AND REPLACEMENT5-1. MATERIALS AND PROCESSES.5-2. Equipment, materials and processes in generaluse in aircraft engine ov

5-2 MARCH 1982since the corner radii at the bottoms of the groovesmust not be altered, nor any metal removed from thesides. Discoloration and ligh

5-3torn, install the next larger oversize stud. If the oldstud was of the maximum oversize, of if the thread isdamaged, the hole may be tapped and a

5-4oil with two parts kerosene to prevent over heating ofthe metal and tearing of the thread.5-21. To remove a damaged helical coil insert use thepro

MAY 1980 5-5FIGURE 5-1. STANDARD CYLINDER ASSEMBLY DIMENSIONS

5-6FIGURE 5-2. INSTALLING TYPICAL HELICAL INSERTFIGURE 5-4. INSTALLING SPARK PLUG HOLE HELICAL INSERT.FIGURE 5-5. EXPANDING SPARK PLUG HOLE HELICAL

5-7FIGURE 5-7. HYDRAULIC LIFTER.5-26. VALVE ROCKERS. Worn bushings may bedriven out with a suitable drift, and if properlydesigned the same tool ma

5-85-31. Hardened steel bushings in the crankshaftblades may be removed and replaced if excessivelyworn. It may be necessary to chill the old bushin

5-9clean engine lubricating oil. The rear pad of theadapter, rather than the studs, should be supported ona parallel block and a flat block should be

October 1978 v

5-105-36. STARTER DRIVE ADAPTER. The clutchspring sleeve is shrunk and doweled in the housing. Ifit is necessary to remove the needle bearing in th

5-11/5-12FIGURE 5-11. EXPLODED VIEW OF IGNITION SYSTEM.1. High Tension Cable Outlet Plate 27. Magneto2. Outlet Plate Grommet 28. Magneto Holding Wa

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MARCH 1982 6-1SECTION VIINSPECTION6-1. DEFINITIONS OF TERMS.6-2. The following definitions apply to terms used todescribe kinds of damage for whi

6-2 MARCH 1982areas. Inspect all studs for possible bending,looseness or partial removal. Inspect all threadedparts for nicks and other damage to

MARCH 1982 6-3PART NAME FEATURE NEW DIMENSION(INCHES)Camshaft Journal Diameter (4) Permold CrankcaseJournal Diameter (4) Sandcast Crankcase0.9980 -

6-46-6. FLUORESCENT PARTICLE INSPECTION.This process, commonly known under the trade nameof "Zyglo", is recommended for inspecting aluminum

JANUARY 1985 6-5NOTE... If "Alodine" does not adhere tometal a more severe cleaning method must beused. A solution of 12 to 16 ounces of

6-6 FEBRUARY 1989c. Replacement bushings are available in standard,.0015", .003" and .005" oversize on the outsidediameter.d. A sp

6-7FIGURE 6-1. INSPECTING RING SIDE CLEARANCE.cam-ground contour should not be altered. If thepiston is dimensionally serviceable in other respectsa

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6-8fully, either it is excessively worn or check valve isleaking. To check for leaking valve, repeatcompression test while plugging end of oil inlett

6-9SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSValve Seats Roughness caused by honing. If seats cannot be madeserviceable by g

6-10SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSCONNECTING RODASSEMBLYBushing Inside Diameter Measure with telescopinggauge an

6-11SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSGear Teeth Scoring, burning, pitting, wearenough to alter profile.CRANKCASEASS

6-12SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSPlugs Threads Look for distortion.Wrench Flats Look for damaged corners.Oil Te

6-13SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSGears Shafts Measure diameters andcompare with bushingdiameters.Refer to Table

6-14SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSGears Shafts Measure diameters andcompare with bushingdiametersRefer to Table

6-15SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSFuel PumpDrive GearTeeth Look for chipped, cracked andbroken teeth, scoring, b

6-16SUBASSEMBLYAND PARTINSPECT NATURE OF INSPECTIONSPECIALCONSIDERATIONSMAGNETO ANDACCESSORY DRIVEASSEMBLYAdapter Gear Bushing Measure bore diameter.

6-17TABLE XCRANKCASE STUD SETTING HEIGHTSMODEL IO-520LOCATION THREAD SIZE SETTINGHEIGHTABCDEFJ KLCylinder Mount PadsEngine Mount PadsOil Cooler Mount

MAY 1980 1-1SECTION IINTRODUCTION1-1. SCOPE. This publication comprisesOverhaul Instructions for the IO-520 Series AircraftEngines.1-2. RELATED P

6-18 MAY 1980TABLE XIMAGNETIC PARTICLE INSPECTIONFLUORESCENT METHOD PREFFERED,WET CONTINUOUS PROCEDURE REQUIREDPart*Method ofMagnetizationAC or DCA

MARCH 1982 6-19TABLE XIITABLE OF LIMITSNew PartsRef.No.ChartNo.Model Description ServiceableLimitMin. Max.1234456789101112131415161718192021222324

6-20 JANUARY 1992New PartsRef.No.ChartNo.Model Description ServiceableLimitMin. Max.394041424344454647484950515253545556575859606162636465666768111

6-21New PartsRef.No.ChartNo.Model Description ServiceableLimitMin. Max.7070717273747576777879808182838485868787888990909192939495969798323234222233234

6-22New PartsRef.No.ChartNo.Model DescriptionServiceableLimitMin. Max.99100101102103104105106107108109110111112113114115116117118119120121122123124125

6-23New PartsRef.No.ChartNo.Model DescriptionServiceableLimitMin. Max.1371381391401411421431441451461471483442332322323221111CAllAllSPPSPSSPSPAllSAllA

6-24 MAY 1980TABLE XIIITABLE OF TIGHTENING TORQUESTorqueRef.No.ChartNo.Model Special ApplicationsThreadSizeQty.In. Lbs. Ft. Lbs.T1T2T3T4T5T6T7T8T9T

6-25TABLE XIVGENERAL USE – TIGHTENING TORQUESBOLTS, NUTS & SCREWS DRIVING STUDSSIZE IN. LBS. FT. LBS. IN. LBS. FT. LBS.8-3210-32¼-20¼-285/16-185/1

6-26 MAY 1980FIGURE 6-2. TABLE OF LIMITS CHART (1 OF4).

6-27FIGURE 6-2. TABLE OF LIMITS CHART (2 OF4).