standard practices del motor tsio-550-g (importante)

7/29/2019 Standard Practices Del Motor TSIO-550-G (IMPORTANTE)

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Teledyne Continental Motors, Inc.

TM

Standard Practices

TSIO-550 Permold Series Engine Installation and Operation Manual C-129 November 2006

Appendix C. STANDARD PRACTICES

CONTENTS

Appendix C. Standard Practices.... ......................................................................................... C-1

C-1. Handling Parts.... ................................................................................................................. C-2 C-2. Replacement Parts.... ........................................................................................................... C-3

C-2.1. Background.... ........................................................................................................................................... C-3 C-2.2. Acceptable Replacement Parts.... .............................................................................................................. C-3 C-2.3. Know Y our Supplier.... ............................................................................................................................. C-4 C-2.4. 100% Parts Replacement Requirements.... ............................................................................................... C-4 C-2.5. Mandatory Overhaul Replacement Parts.... ............................................................................................... C-5 C-2.6. Authorized Oversize/Undersize Parts.... ................................................................................................... C-5

C-3. Torque.... ............................................................................................................................. C-5 C-4. Safety Wiring Hardware.... ................................................................................................. C-6 C-5. Tab Washer Installation.... .................................................................................................. C-8

C-6. Cotter Pin Installation.... ..................................................................................................... C-9 C-7. Applying Gasket Maker ..... ............................................................................................. C-10 C-8. Gasket Installation..... ....................................................................................................... C-11 C-9. Hose and Tubing Installation..... ....................................................................................... C-12

LIST OF FIGURES

Figure C-1. Right-hand-thread safety wire installation.... .......................................................... C-6 Figure C-2. Safety wire Patterns for Right-Hand Threads.... ..................................................... C-7 Figure C-3. Tab Washer Installation.... ....................................................................................... C-8 Figure C-4. Cotter Pin Installation.... .......................................................................................... C-9

Figure C-5. Installing Hoses and Fittings..... ............................................................................ C-12


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Standard Practices Teledyne Continental Motors, Inc.TM

C-2 TSIO-550 Permold Series Engine Installation and Operation Manual29 November 2006

PRECAUTIONS, WARNINGS, AND TIPS

C-1. Handling Parts

When removing, replacing, or re-installing parts, heed the following precautions,warnings, and tips:

WARNING

If the power is not turned OFF, a loose or broken wire couldallow the engine to start and the propeller to rotate. Do notstand or place equipment within the rotational arc of thepropeller.

If the engine is installed, disconnect electrical power to the engine and verify theIgnition Switch is turned OFF to prevent accidental starting of the engine whileworking on the engine.

Inspect replacement parts for deterioration or wear. Do not install parts that appearworn or deteriorated.

Prevent safety wire, nuts, washers, dirt, etc. from entering the engine. If anything accidentally falls into the engine, stop working on the engine immediately

and retrieve the dropped object(s). Tag unserviceable parts or units for investigation and possible repair. To promote proper re-installation of usable parts, tag or mark all parts and hardware

as they are removed or disassembled. Use protective caps, plugs, and covers to ensure openings are unexposed. Install dust

caps over the tube ends of open lines and NOT I N the tube ends. Be sure to removethe dust caps and covers after the maintenance or repair work is complete.

Cover engine sub-assemblies. Inspect new parts for transit damage. Do not install damaged or non-conforming

parts . Re-seal or rewrap the new part until the part is ready to be cleaned, prepared,and installed.

Check the shelf life of new parts to be installed. Do not install parts with an expiredshelf life.

Ensure all parts are thoroughly clean; refer to the Cleaning section in theMaintenance and Overhaul Manual (M-18) for cleaning information.

Use only a plastic or rawhide mallet to tap engine parts during assembly; never use ahammer.

Always install new gaskets, o-rings, rubber components, seals, packing, cotter pins,

tab washers, safety wire, and lock washers when servicing components. Use only new, shakeproof or split lock washers, tab washers, elastic stop nuts, cotter

pins, and corrosion-resistant safety wire. Do not replate cadmium-plated fasteners or washers. If the cadmium plating has been

removed, discard the item and replace it with a new part. Do not re-install any worn, deformed, or single use fasteners. Torque hardware according to torque specifications in Appendix B of this manual. Before installing nuts and bolts, verify the fastening hardware is lubricated as

specified in Appendix B of this manual. Inspect all fasteners for proper plating andthread form. Failure to verify a fasteners serviceability or to correctly lubricate the


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fastener as directed in Appendix B prior to installation will result in the fastener notbeing properly pre-loaded and subsequent failure of the fastener.

WARNING

The improper use of sealants and lubricants may cause enginemalfunction or failure. The use of any form of silicone RTV orother non-TCM approved sealant on engine parts may cause aloss of through-bolt torque. Subsequent loss of main bearingcrush and fretting of the crankcase parting surfaces promotesmain bearing movement that can cause oil starvation to theconnecting rod journals and crankshaft journals leading tosubsequent engine failure.

C-2. Replacement Parts

C-2.1. Background

An increasing amount of replacement parts (including standard parts), materials,appliances, and instruments are represented as being of aircraft quality when actually thequality and origin of these units is unknown. Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use oncertified aircraft. Frequently, such units are deceptively advertised or presented asunused, like new, or remanufactured, implying the quality of such units is equal toan original or appropriately repaired or overhauled unit.

The performance rules for replacement of parts and materials used in the maintenanceand alteration of U.S.-certified aircraft are specified in Federal Aviation Regulations(FAR) 43.13 and FAR 145.57. The responsibility for the continued airworthiness of theaircraft, which includes the replacement of parts, is the responsibility of theowner/operator as outlined in FAR 91.163, FAR 121.363, FAR 123.45, FAR 127.131,and FAR 135.143.

C-2.2. Acceptable Replacement Parts

Teledyne Continental Motors, Inc. (TCM) provides Instructions for ContinuedAirworthiness (ICAs) based on the design, testing, and certification of engines and partsfor which TCM is the holder of the Type Certificate (TC) or Parts ManufacturingApproval (PMA) issued by the Federal Aviation Administration (FAA). Theseinstructions, which include maintenance, repair limits, overhaul, and installation areapplicable only to engines and parts supplied by TCM. TCM does not provideinstructions relating to the installation or use of parts not manufactured or supplied by

TCM. Instructions provided by other engine parts manufacturers or resellers should beused for their parts. TCM has not participated in design, test, or certification in regards toaftermarket parts manufacturers and has no experience with respect to such parts.

FAA regulations require only FAA-approved parts be used on a type certified product.FAA-approved parts may be identified in accordance with the information given below.

TCM does not play any role in the FAA approval of such parts; does not have anyresponsibility for the design, certification, service life, repair, overhaul, or quality of such


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parts; and has made no determination regarding the effect, if any, that using such partsmay have on TCM supplied engines or parts.

C-2.3. Know Your Supplier

Some reproduced parts and components, particularly instruments, have beenmanufactured by entities other than the original equipment manufacturer and areavailable for purchase and installation on U.S.-certified aircraft. Often, an original part isused as a sample to produce duplicates. The reproduced parts appear to be as good as theoriginal part. However, there are many unknown factors to be considered that may not bereadily apparent to the purchaser, such as heat-treating, plating, inspections, tests, andcalibrations. All too often, the faulty part is not discovered until a malfunction or anaccident occurs.

Therefore, in accordance with FARs, certification of materials, parts, and appliances foraircraft return to service is the responsibility of the person or agency who signs theapproval. The owner/operator is responsible for the continued airworthiness of theaircraft. To assure continued safety in aircraft operation, it is essential that great care beused when inspecting, testing, and determining the acceptability of all parts andmaterials. Particular caution should be exercised when the identity of materials, parts, andappliances cannot be established or when their origin is in doubt.

C-2.4. 100% Parts Replacement Requirements

NOTE: Service documents published or revised subsequent to theissuance of this publication may mandate the replacement of components and parts not included in these instructions. At engineoverhaul, the technician must review all service bulletins to ensurecompliance with the manufacturers requirements for continuedairworthiness.

Replace all gaskets, seals, packing, hoses, O-rings, cotter pins, retaining rings (snaprings), safety wire, self locking fasteners (including exhaust nuts), and lock washers withnew parts during assembly, regardless of the type of maintenance.

Do not re-use worn, damaged or deformed fasteners. Do not replate cadmium platedfasteners or washers. If the cadmium plating has been removed, discard the item andreplace it with a new part.

Engine mounted accessories must be maintained in accordance with the manufacturers

instructions. Additionally, accessories must be overhauled during engine overhaul, ormore frequently, in accordance with the manufacturers instructions.

At engine overhaul the starter, alternator, magnetos and engine fuel system must beoverhauled. On turbocharged engines, the turbocharger, waste gate, controller andexhaust system must be overhauled. All engine baffles must be repaired or replaced andall flexible baffle seals replaced.

Replace items such as spark plugs, alternator drive belts and air-conditioning drive beltson condition.


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C-2.5. Mandatory Overhaul Replacement Parts

In addition to the previously listed items, the following parts must be discarded andreplaced with new parts during engine overhaul.

Hydraulic valve lifters (tappets) Bearings: connecting rod, crankshaft main

and thrust, needle, ball, and roller Bushings: rocker arm, connecting rod,

counter weight and crankshaftcounterweight blade

Counterweight pins, retaining plates andsnap rings

Connecting rod bolts and nuts Connecting rod with beam width less than

.625 inches (TCM CSB96-13) Camshaft gear bolts Crankshaft gear bolts Crankshaft alternator face gear bolts andlock plates

Woodruff keys Magneto drive rubber bushings Exhaust valves Exhaust valve rotocoils

Intake valve rotocoils with solid valve retainerspart # 35971

Intake and exhaust valve keepers Inner and outer valve springs Piston pins Piston rings Pistons Rocker shafts Rockers shaft thrust washers Crankcase Through Bolts Cylinder deck stud nuts and through bolt nuts Exhaust clamps (Turbocharged engines) Cold Start primer diverter valves Fuel pump drive coupling P/N 631263 with P/N

653359 (TCM MSB 95-6 or latest revision ) Turbocharger oil supply and return check

valves Ignition system harness

C-2.6. Authorized Oversize/Undersize Parts

Replacement authorized oversize (AO) or authorized undersize (AU) parts must be usedwith the proper AO and AU mating parts. Example: Use 0.015 oversize piston and pistonrings with 0.015 oversize cylinder assembly.

C-3. Torque

Torque hardware with calibrated torque wrenches according to the specifications inAppendix B in this manual.


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C-4. Safety Wiring Hardware

Safety wiring secures two or more parts together so any tendency of the parts to loosenwill be counteracted by increasing the tension on the safety wire attached to the otherpart(s). The only way to loosen the parts is to remove the safety wire. Always use newsafety wire to secure hardware. Safety wire must conform to MS20995 Condition A.

1. Verify the hardware (bolts or nuts) to be safety wired has been correctly torqued inaccordance with Appendix B of this manual.

CAUTION: Do not apply torque above or below specified limits toalign holes.

2. Insert half of the required length of new safety wire through the first piece of hardware and do the following:

a. For right-hand threaded hardware, install the safety wire so the strand will pulland lock clockwise .

b. For left -hand threaded hardware, install the safety wire so the strand will pull andlock counter-clockwise .

Figure C-1. Right-hand-thread safety wire installation

(Reverse application for left hand threads)

3. As shown in Figure C-1 , bend the safety wire to tightly loop around the head of thehardware so force is exerted in the tightening direction. Ensure there is no slack in theloop and the loop is under the protruding strand that will wrap around the opposing


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piece of hardware to ensure that the loop is held in place on the first device. Pull theprotruding strand of safety wire with pliers until it is taut (but not overstressed).

4. While keeping the protruding strand of safety wire taut, twist the strands (based onthe wire gauge specified below) until the twisted part is just short of a hole in the nextunit. The twisted portion should be within one-eighth (1/8) inch from the hole in

either unit:a. Twist 0.032 diameter safety wire at a rate of 7 to 10 twists per inch.

b. Twist smaller diameter safety wire at a rate of 9 to 12 twists per inch.

5. Pull the braided safety wire strand with pliers until it is taut (but not overstressed).

6. Insert the uppermost strand through the hole in the second piece of hardware.

7. Bend and wrap the twisted wire braid around the second piece of hardware, pullingthe wire taut as described in the previous steps, which will counter-lock the hardware

joined by the safety wire. Repeat the previous steps for any subsequent hardware tobe safety wired by this strand. Refer to Figure C-2 for various safety wire patterns.

All safety wire must fit snugly.8. After safety wiring the last piece of hardware, continue twisting the safety wire to

form a pigtail, providing sufficient twists (four minimum) to assure that the pigtailwill not unravel.

9. Trim the excess safety wire and bend the pigtail toward the hardware and against thebolt head flats.

CAUTION: Do not allow the pigtail to extend above the bolt head.

Figure C-2. Safety wire Patterns for Right-Hand Threads

(Reverse the wire orientation for left-hand threads)


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C-5. Tab Washer Installation

Tab washers are used in various locations in TCM engines. Do not re-use tab washers.Always install new tab washers.

Procedure

1. Insert the locator tab (bent part of the tab washer) in the predrilled hole.2. Lubricate and torque hardware in accordance with Appendix B in this manual.

3. Using a soft drift, bend the lock tab on the other side of the tab washer firmly againstthe bolt or nut flats as shown in Figure C-3 . Ensure the lock tabs are bent flat upagainst the hardware without protrusion as shown in top and side views to properlylock the hardware and prevent the lock tabs from breaking off.

Top View Side View

Locator Tab

Lock TabLock Tabs

Top View Side View

Locator Tab

Lock TabLock Tabs

Figure C-3. Tab Washer Installation


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C-6. Cotter Pin Installation

Cotter pins are not reusable. Replace used cotter pins with the specified new cotter pinsmade of corrosion-resistant steel.

Procedure

1. Install the nut on the bolt.2. Torque the nut where the cotter pin is to be inserted to the lower torque limit specified

in Appendix B.

3. If the slots in the nut do not line up with one of the holes in the bolt, continuetorquing in small increments until the holes align; do not exceed the upper limit of thetorque specification. Change the nut if necessary.

4. Insert the cotter pin through a hole with the head seated firmly in the slot of the nut.

5. Spread the exposed ends of the cotter pin. Bend the ends over the flat on the nut andthe end of the bolt.

CAUTION: Do not use side-cutting type pliers to bend back thecotter pin ends. These pliers may cause nicks which can weaken thecotter pin to the extent that it can become detached.

6. Seat the ends firmly against the bolt and nut ( Figure C-4 ).

7. Trim the protruding ends as necessary.

8. All cotter pins must fit snugly in holes drilled in specific hardware. On castellatednuts, unless otherwise specified, the cotter pin head must fit into a recess of the nutwith the other end bent such that one leg is back over the stud and the other is downflat against the nut as shown in Figure C-4 .

Figure C-4. Cotter Pin Installation


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C-7. Applying Gasket Maker

Gasket Maker is an easily workable tacky gel which can be applied onto one side of aflange surface from a tube and evenly spread.

WARNING

Apply Gasket Maker only as directed. The improper use of sealants may cause engine malfunction or failure.

Procedure 1. Verify the surface where the sealant will be applied is clean and free of nicks, burrs,

oil, and grit.

2. For the engine nose seal, apply Teledyne Continental Motors General PurposePrimer (TCM part number 653692) to prepare the sealant surface before applyingGasket Maker at the engine nose seal area.

3. Apply and spread a thin, translucent coat of Gasket Maker (not to exceed .010 inchesin thickness) to the surface directly from the tube. For small parts, use a polyesterurethane sponge or a short nap roller saturated with Gasket Maker to apply the sealantto the part.

4. Once Gasket Maker has been applied, evenly torque the assembly into place.

5. Wipe away excess sealant with chlorinated solvent.

6. To remove Gasket Maker from your hands, apply waterless mechanics hand soapfollowed by soap and water.

WARNING

The use of any form of silicone RTV or other non-TCMapproved sealant during reassembly of the engine may cause aloss of through-bolt torque which will result in loss of mainbearing crush and fretting of the crankcase parting surfaces.Fretting of the crankcase parting surfaces promotes mainbearing movement which can cause oil starvation to theconnecting rod journals and crankshaft journals leading tosubsequent engine failure.


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C-8. Gasket Installation

WARNING

The use of any form of silicone RTV or other non-TCMapproved sealant during reassembly of the engine may cause aloss of through-bolt torque that will result in loss of mainbearing crush and fretting of the crankcase parting surfaces.Fretting of the crankcase parting surfaces promotes mainbearing movement that can cause oil starvation to theconnecting rod journals and crankshaft journals leading tosubsequent engine failure.

Install only new gaskets. Prior to installation, inspect each gasket for brittleness, cracks,wrinkles, damage, or deformities. Do not use a gasket with obvious defects, even if new;replace with a new manufacturer-specified gasket. Verify gasket surfaces are clean andfree of nicks, burrs, oil, and grit.

CAUTION: Do not install brittle, dirty, cracked, or wrinkledgaskets. Never reuse a gasket removed during disassembly.

Procedure 1. Apply a thin coat of TCM Gasket Sealant (TCM part number 642188) to both sides of

the gasket unless otherwise specified.

2. Install the gasket, following the contour of the mating surface.

3. Install the assembly and evenly torque the hardware to the specified value inAppendix B to prevent over-stressing the gasket.

4. Safety wire the hardware where indicated.

WARNING

Gaskets and components must be properly positioned with thehardware torqued and safety wired, as required, duringassembly to prevent oil loss.


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C-9. Hose and Tubing Installation

Hoses and tubing to fuel, induction, lubrication, and turbocharger system fittings must beproperly installed.

WARNING

Failure to properly support component fittings can result infitting and/or component damage and a resulting loss of systempressure or fluid.

Procedure Select the proper size open-end or crows foot wrenches for the connections1. Use a wrench on both mating connections to avoid applying excessive torque to the

fittings. Securely tighten fittings and torque to the specified value in Appendix B,Torque Values. Torque the hose or tubing end fitting while maintaining sufficientforce on adjacent fittings to prevent twisting and shear loads.

CAUTION: Do not exceed specified torque values

2. Support the last fitting in the assembly on components that contain multiple fittingscoupled in one location. DO NOT over torque fittings.

Figure C-5. Installing Hoses and Fittings

standard practices del motor tsio-550-g (importante)

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