TELEDYNE CONTINENTAL AIRCRAFT ENGINE MANDATORY service bulletin

Transcription

1 TELEDYNE CONTINENTAL AIRCRAFT ENGINE MANDATORY service bulletin Supersedes M89-11 Technical Portions Are FAA Approved 29 June 1989 TO: SUBJECT: All Malibu Owners THRU BOLT TORQUE CHECK AND VISUAL INSPECTION #2 MAIN BEARINGS MODELS AFFECTED: TSIO520BE, S/N thru COMPLIANCE: Within Next 10 Hours of Operation It has come to our attention that some engines may not have achieved the optimum compression load in the crankcase bearing boss during compliance with Service Bulletin M It is, therefore, required that the above affected engines be inspected as follows: Section A. Crankshaft end play checked within 10 hours and repeated every 25 hours of operation. Section B. Section C. Thru bolt torque check within 10 hours (one time inspection only). Visual inspection of #2 crankcase main bearing within 10 hours and repeated every 200 hours of operation. The repetition of Section A crankshaft end play and Section C visual inspection will not be required once engine has been overhauled or crankcase has been split, inspected for fretting and bearings replaced. The inspection requirements should be accomplished in accordance with the following procedures: Section A. Crankshaft End Play 1. Allow the engine temperature to stabilize to ambient room temperature. Insure that the magnetos are properly grounded. Check crankshaft end play at eight positions starting at the 12 o'clock position and rotating propeller counter clockwise at 45 degree increments. NOTE...If there is no crankshaft end play at any position, contact Teledyne Continental Motors for disposition. WARNING...USE EXTREME CAUTION IN THE AREA OF THE PROPELLER WHILE PERFORMING THIS CHECK. TELEDYNE INDUSTRIES, INC Member of GAMA General Aviation Manufacturer s Association TELEDYNE CONTINENTAL MOTORS Aircraft Products PO Box 90 Mobile Alabama 36601

2 29 June 1989 Page 2 Section B. Thru bolt Torque Check 1. Allow the engine temperature to stabilize to ambient room temperature. Remove one spark plug (the most accessible) from each cylinder. Insure that the magnetos are properly grounded. Turn the engine with starter approximately 15 seconds to obtain positive lubrication to main bearings. Attach a spring scale to the propeller blade at the 36 inch station (4 inches in from prop tip). Rotate the propeller in normal direction of rotation via the attached scale and record the pounds required to rotate with the propeller in motion. Normal range is approximately 0 to 20 pounds. NOTE...If the recorded pounds are not within the normal range, contact Teledyne Continental Motors for disposition. WARNING...USE EXTREME CAUTION IN THE AREA OF THE PROPELLER WHILE PERFORMING THIS CHECK. 2. Remove the intercooler, peripheral baffle, cylinder drain tube and intercylinder baffles as required from the 1,3,5 cylinder side of the engine to gain access to the thru bolt nuts of the number 3 and 5 cylinders. The intercylinder baffle between number 3 and 5 cylinders must be disassembled in two pieces for ease of removal. The intercylinder baffle between number 1 and 3 cylinders is removed as a completed assembly. With a 5/8 inch cylinder base wrench, loosen the four (4) thru bolt nuts and back them away from the cylinder flange approximately 1/2 inch. Caution should be used so as not to remove the nuts from the thru bolts as accessibility to re-install the nuts is very restrictive without extensive engine disassembly. Assure the thru bolt threads are cleaned and liberally lubricate the exposed threads and the nuts with clean 50 weight engine oil. Torque the nuts to a preliminary torque to 350 inch pounds then repeat final torque to 700 inch pounds each. Make sure cylinder base wrench shank does not contact cylinder barrel and create false torque reading. It may be necessary to retain the opposite nuts to prevent thru bolt rotation. NOTE... Torque should be with a calibrated torque wrench. 3. Repeat paragraph B1 above and record the pounds required to rotate the propeller. If after torquing the thru bolts per paragraph B2, the effort (pounds) to rotate the propeller has changed from the previously recorded value by more than three pounds or the crankshaft has no end play, contact your local Teledyne Continental Motors representative (listed below) for disposition. If no special disposition is required, proceed to Section C.

3 29 June 1989 Page 3 Section C. Visual Inspection of #2 Crankcase Main Bearing 1. Gain visual access to the #2 crankcase main bearing by removal of number three (3) cylinder. NOTE...DO NOT REMOVE THE PISTON FROM THE CYLINDER. REMOVE ONLY TO A POINT TO GAIN ACCESS TO THE PISTON PIN. REMOVE THE PISTON PIN, THEN THE PISTON AND CYLINDER AS ONE UNIT. 2. With cylinder and piston pin removed, visually inspect the number 2 crankcase main bearings for any signs of: a. Bearing shift forward and aft within the crankcase. The back of the bearing shell will be shiny if there has been movement. b. Bearing contact with crankshaft fillet. c. Mismatch of bearing halves at case split line. The pattern has been for right bearing shell to move forward and the left bearing shell to move aft. The crankshaft should be moved fore and aft while performing this inspection. The crankshaft will also require rotation to allow for unobstructed view of the bearings. NOTE...The crankcase main bearings are numbered from number 1 in the rear of the engine and progressing forward (toward the propeller flange). Figure A depicts how bearing should generally appear. Figure B depicts a bearing that has shifted. NOTE...Contact you local Teledyne Continental Motors representatives (see listing below) for disposition of any bearing appearing as in Figure B (Press F7 to see Figure B) or with any signs of distress as noted in paragraph C2. 3. If no problems are detected during the inspection outline in paragraph C2, proceed with the installation of the #3 cylinder assembly and the reassembly of the engine. Assure that the cylinder thru bolts and deck studs are cleaned and oiled. Use clean 50 weight engine oil. Replace thru bolt nuts (P/N ) and cylinder base nuts (P/N ) if there are any signs of deterioration to threads or nut retention wrench flats.

4 29 June 1989 Page 4 4. The cylinder should be installed and torqued with a calibrated torque wrench per the instructions in Figure C. New cylinder gasket sets should be used, P/N A1. 5. After cylinder installation, check for crankshaft end play and assure prop rotation is still within limits of Section B1. 6. Finalize reassembly of the engine. Perform appropriate testing, make appropriate logbook entry stating compliance to this service bulletin with results of crankshaft end play and pounds required to rotate prop. Return the engine to service. WARRANTY...The action to comply with this service bulletin is covered by the TCM Gold Medallion Warranty subject to its terms and conditions. Warranty claims may be filed through any TCM distributor. When submitting the warranty claim for compliance with this service bulletin, you must enter the pounds required to rotate the propeller as recorded in paragraph B1 and B3. It should be recorded in the CONDITIONS REPORTED SECTION of the warranty claim. EXAMPLE: Compliance with Service Bulletin Paragraph B1-12 pounds Paragraph B3-12 pounds Man hours required to comply with this Service Bulletin: 10 man hours. Parts Required: 1 ea. P/N A1 gasket set. Address: Teledyne Continental Motors David Blanchard Edgardo Martedi Attn:J.Black/C.McClellan/D.Conrad P.O. Box 427 R Charles S Chaplin 85 P.O. Box 90 Scarborough, ME Apartment #23 Mobile, AL (207) Sao Paulo (205) BRAZIL J.A. Buskirk R.A. Deets Venetian Way Chalet Lane Dallas, TX Huntingdon Beach, CA (214) (714) Tom Thys/Tony Evanson R. M. Robbins Room 4, 19 The Square Wolftooth Pass Sand Bach, CW11 OAT Litteton, CO Chesire, ENGLAND (303)

5 29 June 1989 Page 5 Figure B

6 29 June 1989 Page #3 Cylinder Deck CAUTION...Before proceeding note that the nuts (P/N ) utilized with the seventh stud (positions 9 and 10) have a conical seat and can only be used in these positions. Assembly and preliminary torque: 1. Install cylinder and tighten nuts (1 thru 10) to inch pounds in sequence shown above. 2. Finish torquing thru bolts and stud nuts to final torque in sequence shown above. Final torque values Thru bolts 1 & inch pounds Stud nuts 2,3,5 thru inch pounds NOTE...Repeat final torque sequence Figure C Cylinder Base Torque Sequence