SSP 475 Trouble Shooting

LYCOMING

ReciprocatingEngine

TROUBLESHOOTINGGUIDE

Reprint2006SSP475

652OliverStreetWilliamsport,PA.17701U.S.A.

Telephone+1(800)2583279U.S.andCanada(TollFree)Telephone+1(570)3236181(Direct)Facsimile +1(570)3277101

www.lycoming.com

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INTRODUCTION

TROUBLESHOOTING

1. Troubleshootingisthestepbystepprocedureusedtodeterminethecauseforagivenproblemandthenselectingthebestand quickest way to solve that problem. While the use of turbochargers and automatic controllers has complicated thetroubleshootingprocedures,alwaysstartbydiscussing theproblemwiththepilotand the facilitymanagement.Theywillassistyouinnarrowingtheproblemtoasfewpossibilitiesaspossible.Inthecaseoftwinengineaircraft,makesureyouareworkingonthecorrectengine.Afterathoroughdiscussionandverbalanalysisoftheproblem,youarereadytogotowork.Ifyouareanexperiencedmechanic,youmaybeabletoautomaticallyeliminatesomeoftheprobablecauses.Ifyouarenewonthejob,youwillhavetogothroughalloftheprobablecauses.Theimportantthingtorememberistoalwaysstartwiththesimpleandinexpensivethingsfirst,andthenworktowardthemorecomplicated,timeconsuming,andexpensivethingslater.

2. After you have received all possible information from the pilot and the facilitymanagement, a quick observation of theexternalconditionoftheenginemaygiveyouanindicationoftheproblem.Someareastolookataretheintakeandexhaustpipes for leaks, the ignitionharness, breather, and the engine compartment for excessive oil stains, gas stains or exhauststains. More information may be gained rather quickly by doing a compression check to locate any low compressioncylinders.Doaboroscopeinspectiontodeterminetheconditionofthecombustionchamber.Someinformationthatmaybeobtainedis:thepresenceofexcessivecarbondepositsmayindicatehighoilconsumptionthelackofcarbondepositsmayindicatecontinuousleanengineoperationordetonationandscratchedorscoredcylinderwallsmayindicatebrokenrings.Moreinformationmaybecompiledbyremovingthesparkplugstoinspectthecombustionchamber.

NOTE

Besuretokeeptrackofwhichpistonpinplugscameoutofwhichcylinder.Duringreassemblythepistonpinplugsmustbematchedupwiththecylindertheycameoutof.

Anothergoodtroubleshootingtoolistheuseofspectrometricoilanalysis.Tobeeffectivetheenginemustbeintheanalysisprogram for an extended period of time to develop a useful history of periodic samples of oil that were analyzed. Theprogrammustbecarriedoutbyexperiencedandreputablepeopleintheoilanalysisfield.

3. Thefollowinglistofproblems,causes,andsolutionswasselectedbecausewebelieveitrepresentsthemorecommonandrecurring problems encountered bymechanicswhen doing troubleshooting. It should be noted that the list is general innature,anddoesapplytobothnormallyaspiratedandturbochargedengines.Thesequenceinwhichthelistsarearrangedisnotnecessarilytheexactstepbystepproceduretouse,butshouldbeusedasaguidetodetermineallofthepossiblecausesandsolutionstoaproblem.Alwayskeepinmindtodothesimpleandinexpensivethingsfirst,thenproceedwiththemorecomplicatedandexpensivethingslater.

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CONTENTS

PageNo.

1. HARDSTARTING.........................................................................................................................................................1 3

2. ROUGHIDLE ................................................................................................................................................................3 4

3. ENGINEWILLNOTIDLEUNLESSBOOSTPUMPISON..........................................................................................4 5

4. ENGINEWILLNOTIDLEUNLESSBOOSTPUMPISOFF .............................................................................................5

5. POORIDLECUTOFF...................................................................................................................................................5 6

6. HIGHFUEL FLOW.............................................................................................................................................................6

7. LOWFUELFLOW.........................................................................................................................................................6 7

8. ENGINEWILLNOTTURNSTATICRPM....................................................................................................................7 8

9. ENGINESURGES..........................................................................................................................................................8 9

10. FAILUREOFENGINETODEVELOPRATEDPOWER ............................................................................................9 11

11. LOSSOFPOWERGOINGTOALTITUDE ......................................................................................................................12

12. CANNOTREACHSPECIFIEDCRITICALALTITUDE............................................................................................ 13 15

13. LOWOILPRESSURE................................................................................................................................................ 15 16

14. HIGHOILCONSUMPTION ...................................................................................................................................... 16 17

15. HIGHCYLINDERHEADTEMPERATURE.............................................................................................................. 17 18

16. SPLITINMANIFOLDPRESSURE(TWINENGINE) ............................................................................................... 18 19

17. HIGHOILTEMPERATURE .............................................................................................................................................19

18. HIGHMANIFOLDPRESSUREATIDLE.........................................................................................................................19

19. HIGHOILPRESSURE......................................................................................................................................................20

20. MANIFOLDPRESSUREFLUCTUATES .........................................................................................................................20

APPENDIXI

TROUBLESHOOTINGTHEBENDIXRSAFUELINJECTOR ................................................................................21

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HARDSTARTING

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Technique. 1. RefertotheOperatorsManual

recommendedstartingprocedure.1. Solutionisselfexplanatory.

2. Flooded. 2. Cleanengine. 2. Crankenginewiththrottlefullopenandmixtureinidlecutoff.

3. Throttlevalveopentoofar. 3. Setforapproximately800RPM. 3. Solutionisselfexplanatory.4. Insufficientprime(maybe

accompaniedbybackfire).4. Increasesame. 4. NOTE: Makesure primerisnot

leaking.5. Magnetoimpulsecouplingnot

operatingproperly.5. Removeandcheckforbinding,or

brokenimpulsespring.5. Removemagnetoandcheckthatthe

springisnotbrokenandflyweightsmovefreely.Checktorqueoncouplingretainingnut.If unabletolocatetheproblem,removecouplingandcheckaccordingtolatestrevisionofServiceInstructionNo.1189.

6. Defectivesparkplugsorignitionwire.

6. Inspectandreplaceorrepairasnecessary.

6. Removeplugs,inspect,clean,and/orreplaceasnecessary.Visuallyinspectignitionharnessforbreaksandcracks.TestleadsbyremovingdistributorblockfrommagnetoandusingaBendixhightensionleadtestNo.118888or1188881orequivalenttypeequipment.

7. Lowvoltageatvibratorinput. 7. Checkwithvoltmeterandreplacebattery,ifnecessary.(Besurebatteryterminalsarecleanandtight,alsocheckleadsforcondition.)

7. Measurevoltagebetweenvibratorterminalmarkedinandgroundterminalwhileoperatingstarter.Mustbeatleast8voltsona12voltsystem,or13voltsona24voltsystem.

8. Inoperativeordefectivevibrator. 8. Checkandreplacevibrator,ifnecessary.

8. Ifvoltageisokay,listenforinterruptedbuzzingofvibratorduringstarting.Ifnobuzzingisheard,eithervibratorisdefectiveorthecircuitfromtheoutputterminalonthevibratortotheretardcontactassemblyisopen.Checkbothswitchandretardcircuit.Alsocheckforgoodelectricalground.

9. Retardcontactassemblyinmagnetonotoperatingelectrically.Enginemaykickbackduringcranking.

9. Checkallconnectionsatswitchandvibrator.Adjustretardpoints.SeeappropriateBendixManualforprocedures.

9. Retardpointsmaynotbeclosingduetoimproperadjustmentormaynothaveagoodelectricalconnectionincircuit.Checkforgoodcontactofswitchandretardleadsatmagnetoandvibrator.Checkconditionofwire.

10. VibratorMagnetocombinationnotputtingoutelectrically.

10. Checkandreplace,ifnecessary. 10. DisconnectStarterandallSparkPlugLeads. Turnengineinrightdirectionuntilretardpointsopenon#1cylinderfiringposition.Hold#1plugleadapproximately3/16in.fromground,energizevibratorbyturningswitchtostart.Plugleadshouldthrowashowofsparkstoground.Ifsparkisweakormissing,replacevibrator.Alsocheckmagnetoforcorrectinternaltiming.Properdurationofshowerofsparksmaybe

1

HARTSTARTING(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION10. VibratorMagnetocombinationnot

puttingoutelectrically.(Cont.)10. Checkandreplace,ifnecessary.

(Cont.)10. (Cont.)checkedbyholdingswitchin

startposition,andhandturningpropelleruntilsparksstop.Degreesofpropellerrotationmaybemeasuredorestimatedtodetermineifretardpointsareadjustedproperly.NOTE:Allchecksmustbemadewithstarterandplugleadsdisconnected.

11. Magnetoimproperlytimedtoengine.

11. Checkmagnetotimingasperenginemanufacturersinstructions.

11. Disconnectstarter.Turnengineinproperrotationto#1cylinderfiringposition.Attachtiminglighttoprimaryleads(markedswitch)ofmagnetoandgroundleadtoengine.Rotateengineuntiladvancepointsbreak,indicatedbytiminglightsgoingoutorcomingon,dependingontypeoflightused.Observethatwhenpointsbreak,timingmarksonengine arealigned.Enginetimingmarksarelocatedonengineasfollows:DirectDrive Lineonstarterringgeartodotonstarterhousing.TIGO Degreemarkingsoncrankshafttosplitofcaseobservedattopfrontofengine.GearedSupercharged Pointermountedtoaccessoryhousingtolinedbeveltoothoncamshaftgearobservedonrightsideofengineinaccessoryhousing.

12. MagnetointernaltimingnotadjustedproperlyorEgapdriftingbecauseofpointorfollowerwear.

12. Adjustmagnetointernaltiming,orreplacepointsifeitherfollowerorpointsareworn.

12. Removemagnetofromengineandturnmagnetoto#1firingposition,attachtiminglight,turnmagnetoinproperrotation.Observethatwhenlightsgoout,builtinpointersinthemagnetoarealignedintheobservationwindowprovided.(SeeBendixMaintenanceInstructionManualforyourparticularmagneto.)

13. Impulsecouplingonmagnetoinoperative.

13. Repairorreplaceimpulsecoupling. 13. Removemagnetofromengine,turninproperdirectionbyhandandobserve thatflyweightsinimpulsecouplingcontactstoppins.Ifthisconditiondoesnotexist,flyweightaxlesarewornexcessivelyandimpulsecouplingmustbereplaced.Ifflyweightsareingoodcondition,rotatemagnetoseveraltimestosnapimpulseanddeterminethatimpulsespringisnotbroken.Checktorqueonimpulsecouplingnuttobesureitisnotbindingduetoanovertorquecondition.

2

HARDSTARTING(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION13. Impulsecouplingonmagneto

inoperative.(Cont.)13. Repairorreplaceimpulsecoupling.

(Cont.)13. (Cont.)Forcompleteinformationon

magnetoimpulsecouplings,getacopyofthebooklet,IAMYOURIMPULSECOUPLING,#L1019fromBendixatSidney,N.Y.

14. Impulsecouplingismagnetized. 14. Removeanddemagnetizeorreplaceimpulsecoupling.

14. Solutionisselfexplanatory.

ROUGHIDLE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Mixtureistoorichortoolean.(If

mixtureislean,pooraccelerationmaybenoticed.)

1. Adjustidlemixture. 1. Leanengineifmixtureistoorich.EnginewillsmoothoutandpickupRPMasitisleaned.Ifmixtureistoolean,conditionwillbecomemoreaggravatedasengineisleaned.Adjustforpropermixturebyturningscallopedwheelatsideofinjectortoeitherrichorleancondition,asindicatedbyarrowandletterRlocatedoninjectorlinkage.NOTE:Aftermixtureisset,readjustidlespeedtodesiredRPM,ifnecessary.

2. Pluggednozzles.(Usuallyaccompaniedbyindicatedhighfuelflow.)

2. Cleannozzles,inspectwithmagnifyingglassbefore cleaningifcontaminationisfound,removesame.Noneedtocheckfurther.NOTEMaylocateproblembyfeelingforcoldcylinder.

2. WashinacetoneorMEK,blowoutwithcompressedair. NOTE: Flowchecknozzlesincontainersofequalorpartiallypluggednozzles.(SeelatestrevisionofServiceInstructionNo.1275.)

3. Inductionairleakatoneofthefollowinglocations:a. Hosesandhoseclamps.b. Crackedintakepipes.c. Badgaskets.d. Looseflangebolts.e. Looseplugsinintakeportof

cylinders.f. Fueldrainvalvenotseating

properly.

3. Checkpreviouslymentionedlocationsandtightenorreplaceasnecessary.


4. Crackedenginemountsordefectivemountbushings.

4. Replacesame. 4. Solutionisselfexplanatory.

5. Mountbushingsimproperlyinstalled.

5. Installaspermanufacturersinstructions.


6. Internalinjectorleak(usuallyunabletoadjustinjectoratidle)orwillnotholdadjustment.

6. Replaceinjector. 6. Checkbydisconnectinginductionsystematinjectorinlettoobserveimpacttubes,thenputthrottleinfullforwardpositionandmixtureinfullrichposition,capfuellinetoflowdivider,turnonboostpump,andiffuelisobservedcomingoutofimpacttubes,theninjectorhasinternalleakandmustbereplaced.

7. Fuelvaporizinginlinesanddistributor,(encounteredonlyathighambienttemperaturesandprolongedoperationatloworidleRPM).

7. Keepgroundoperationtoaminimumandoperatewithcowlflapsinfullopenpositions.(Ifnecessary,operatewithboosterpumpon.)


3

ROUGHIDLE(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION8. Nozzlescreenandshrouddeformed

toextentitblocksorpartiallyblocksairbleedhole.

8. Replacenozzle. 8. Removenozzlesfromcylindersothattheymaybeadequatelyinspected.

9. Stickingvalveinfuelflowdivider. 9. Disassembleandclean. 9. Removedividerfromengine.Disassembleandflushoutdirt.Alsodividervalvemaybehandlappedinseattoremoveanyburrsthatmaybepresent. NOTE:Neverinterchangefuelflowdividerpartsanddonotdamagediaphragm.

10. Unevencylindercompression. 10. Differentialcheckcylinderstodetermineiffurtherdisassemblyandrepairsarenecessary.

10. Differentialcompressioncheckisaccomplishedbyrotatingcylindertobecheckedto T.D.C.oncompressionstrokeandintroducing80psiairintocylinderandobservinghowmuchisretained.StepbystepproceduresandequipmentrequirementswillbefoundinthelatestrevisionofServiceInstructionNo.1191.

11. Improperfuelpressure. 11. Adjustasnecessary. 11. MinimumandmaximumlimitsarefoundinengineandairframemanufacturersOperatorsManual.

12. Faultyignitionsystem. 12. Checkmagnetodropandconditionofplugsandleads.

12. Setenginetoproduce5065%powerwithpropelleratminimumangle.Checkbothmagnetosforexcessivedropoff.NOTE:Smoothdropoffthatexceedslimitsmayindicatealeanorrichinjectororcarburetor.LeadsmustbecheckedbyremovingdistributorblockfrommagnetoandusingaBendixhightensionleadtester,#118880or1188801orequivalenttypeequipmenttodetermineleadcondition.Avisualcheckisalsohelpful. NOTE: Thedifferenceindropbetweenmagnetosisjustasimportantasthetotalmagnetodrop(notmorethan50RPMdifferencebetweenmagnetos).

13. Fuelpressuretoolow. 13. AdjusttoatleastminimumpressureasfoundinOperatorsManual.

13. NOTEIfunabletoadjustpressure,replacepump.

14. Primernotlockedorleaking. 14. Locksecurelyorreplaceprimerifleaking.


ENGINEWILLNOTIDLEUNLESSBOOSTPUMPISON

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Idlemixtureextremelylean. 1. Enrichidlemixtureatinjector. 1. Turnscallopedwheelatsideof

injectortowardrichcondition.NOTE:Arrowonlinkageindicatesrichandlean.Idlespeedwillhavetobeadjusted.

2. Enginefuelpumpfailed,orpressuretoolowatidlespeed.

2. Replacefuelpump,oradjustpressureasnecessary.


4

ENGINEWONTIDLEUNLESSBOOSTPUMPON(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION3. Fuelpumpbypassingfuelinternally.

(NOTE:ANtypepump.)3. Replacefuelpump. 3. Solutionisselfexplanatory.

4. IfenginehasdiaphragmtypefuelpumpconsidereitheraloosefuelinfittingoramissingordefectiveOring. NOTE:CheckOringseatmachinedinfuelpumptobesureseatissmooth.

4. TightenfittingorreplaceOringasrequired.IfOringseatisdamaged,pumpmayhavetobereplaced.

4. NOTE: Enginemayalsolosefuelpressureasaircraftclimbstoaltitude.SeelatestrevisionofServiceBulletinNo.374.

5. Fuelvaporizinginfuellines. 5. Keepenginenacelleascoolaspossible.


ENGINEWILLNOTIDLEUNLESSBOOSTPUMPISOFF

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Idlemixtureextremelyrich. 1. Leanidlemixtureatinjector. 1. Turnscallopedwheelatsideof

injectortowardleancondition.NOTE:Arrowonlinkageindicatesrichandlean.Idlespeedwillhavetobeadjusted.Conditionindicatedbyexcessiveblacksmoke.

2. Enginepumpfuelpressuresettoohigh.

2. AdjustfuelpressureatpumpifANtype.Replacefuelpumpifdiaphragmtype.


3. Boosterpumppressuretoohigh. 3. Adjustpressureorreplacepump. 3. Solutionisselfexplanatory.

POORIDLECUTOFF

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Improperriggingofmixturecontrol

linkage.1. Adjustsame. 1. Solutionisselfexplanatory.

2. Mixturecontrolvalvescoredornotseatingproperly,orOringonmixturejetbrokenordeformed.

2. Disassembleandremovescratchesandburrs.ReplaceOring,ifnecessary.

2. Removemixturecontrolassemblyfrominjectorlapidlecutoffjetandvalveassemblyonagoodlapplateusingamildabrasiveuntilallscoresandburrsareremoved.Cleanthoroughlyandreassemble.AlsoobservetheconditionoftheOringonmixturecontroljet. NOTE:Checkforaleakbydisconnectingfuellineatentrancetoflowdivider.Keepthrottleandmixoffandboostpumpon.Thereshouldbenofuelflow.

3. Vaporinlines. 3. AvoidprolongedgroundoperationatlowRPMandidle.Keepnacelleascoolaspossible.NOTE:Useboostpump,ifnecessary.


4. Dirtinairbleedholeofnozzle. 4. Removeandclean. 4. WashinacetoneorMEKandblowoutwithcompressedair.

5. Fueljetsinnozzleimproperlylocated.

5. Replace nozzles. 5. NozzlesmaybetestedbyfabricatingatestrigasexplainedinlatestrevisionofServiceInstructionNo.1275. NOTE: Novisualcheckofjetsispossible.

5

POORIDLECUTOFF(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION6. Valveinflowdividersticking. 6. Removeandclean. 6. Removeflowdividerfromengine

anddisassemble.Flushoutanydirtthatmaybepresent.Flowdividervalvemaybehandlappedinseattoremoveanyburrs.Cleanthoroughlyandreassemble.NOTE: Neverinterchangeflowdividerparts.

7. Loosefuellineatflowdividerornozzle. NOTE: Enginemayberichatidle.

7. Tightenallfuelconnections. 7. Checkmainfuellineatflowdividerandfuelinjector.Alsoallfuellinesatdividerandnozzles.Makesurenozzlesaretightincylinders andnotcrossthreaded.

8. Mixturevalvestuck,(corroded)tovalveseat.(Carburetedengines.)

8. Disassemblecarburetortoenablecleaning(andlapping,ifnecessary)themixturevalveandseat.


HIGHFUELFLOW

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Pluggednozzles. 1. Cleanorreplacesame.Inspectwith

magnifyinglensfirst.1. Flowchecknozzlesincontainersof

equalsizetolocatepluggednozzles.Ifplugged,washinacetoneandblowoutwithcompressedair.

2. Airleakorrestrictionindeckpressuregageline(airframe).

2. Locateandrepair. 2. Pressurecheckto9lbs.andobservegagefordropinpressure.

3. Injectorrich. 3. Replacesame.CheckmagnetosforexcessivesmoothdropinRPM.Recalibrateand/oroverhaulinjectoratanapprovedfacility.

3. Runengineatagivenpowersettingfullrich.ObservefuelflowandcomparetofuelflowrequirementsforthatpowersettingasfoundinOperatorsManual.

4. Faultygage. 4. Replacesame. 4. Provebyinstallingmastergageandrunningenginetocomparegages.

5. I.D.offuellinestoosmall. 5. Replacelines. 5. Linesmustbebetween.085.090in.I.D.Checkwithgageandbesurenottomarkinsideoffuellines.

6. Incorrectnozzleflow. 6. Replacenozzles. 6. Flowchecknozzlesincontainersofequalsizetolocate problemnozzles.FlowrateofnozzlesmaybedeterminebyfollowingproceduressetforinthelatestrevisionofServiceInstructionNo.1275.

7. Crackedorbrokenfuelinjectornozzleline. NOTE: Separationmaybeatsilversolderconnection

7. Replacedefectiveline. 7. Whilepressurizingsystemwithboostpump,giveitagoodvisualinspectionforsignsoffueldye.

8. Deckpressuregagelineplugged(turbocharged).

8. Removeanyobstructions. 8. Disconnectlinefromgageandengine.Usecompressedairtoblowthroughlienstoremoveanydirtthatmaybepresent.

LOWFUELFLOW

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Dirtyfuelfilterscreen. 1. Cleansame. 1. Removeandcleaninacetoneor

MEK.Blowoutwithcompressedair.

6

LOWFUELFLOW(CONT.)

CASUE SOLUTION PROCEDUREFORSOLUTION2. Injectorlean. 2. Replacesameorrecalibrateor

overhaulatapprovedfacility.2. Runengineatagivenpowersetting

fullrich.ObservefuelflowandcomparetofuelflowrequirementsforthatpowersettingasfoundinOperatorsManual.Anincreaseincylinderheadtemperature,EGToroiltemperaturemaybeanindicationofaleaninjector.

3. Faultygage. 3. Replacesame. 3. Provebyinstallingmastergageandrunningenginetocomparegages.

4. Flowdividerdoesnotopenalltheway(problemmaynotoccuratalltimes).

4. Disassemble,checkfordirt,anddragondiaphragmstem.Alsopartsmaybelappedtogethertoinsurefreeoperation.

4. NOTE:NEVERINTERCHANGEFLOWDIVIDERPARTS.THEYAREFLOWEDASANASSEMBLY.

5. Fuellinetofuelflowgagebroken,loose orplugged.

5. Repairorreplaceline. 5. Todetectbrokenorlooseline,checkforfueldyestains.Tocheckpluggedline,disconnectatgageandinjectorandblowoutwithcompressedair.

6. Lowfuelpressure. 6. IncreasefuelpumppressuretolimitsinOperators Manualandalsocheckforleaks.


7. Impropergasketinstalledoncoverplateinflowdivider.

7. Replacewithcorrectgasket. 7. StepbystepprocedureforinspectionandrepairofthisproblemarefoundinlatestrevisionsofLycomingServiceBulletinNo.382orBendixServiceBulletinNo.RS43.

ENGINEWILLNOTTURNSTATICRPM

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Restrictionininductionairsystem,

incorrectairbox,orairboximproperlyinstalled.

1. Inspectandremoverestrictions. 1. Solutionisselfexplanatory.

2. Injectortoorichortoolean. 2. Replacesameorrecalibrateoroverhaulatapprovedfacility.

2. Runengineataknownpowersetting,fullrich.ObservefuelflowandcomparetofuelrequirementsasfoundinOperatorsManual.Leaninjector.IftoorichenginewillpickupRPMandrunsmooth.Ifinjectoristoolean,enginewillbemoreaggravated.

3. Propelleroutofadjustment(lowpitch).

3. Adjustsame. 3. Solutionisselfexplanatory.

4. Governorlinkagenotadjustedproperly.

4. Adjustforfulltravel. 4. Solutionisselfexplanatory.

5. Crankshafttocamshafttimingoff. 5. Removeaccessoryhousingandtimecorrectly.

5. Thisconditionmaybecheckedbyfirstdisconnectingstarter.Removetopsparkplugsandrockerboxcoveron#2cylinder.TurnenginetoT.D.C.oncompressionstrokeon#1cylinder,observethatwhenpistonin#1cylindergoesoverT.D.C.oncompression,theintakevalvein#2cylinderisjuststartingtoopenandtheexhaustisjustclosing.Ifthisconditiondoesnotexist,thecrankshafttocamshafttimingisoff.

7

ENGINEWILLNOTTURNSTATICRPM(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION6. Exhaustmufflerinternalbaffles

brokenandblockingexhaustoutlet6. Removemufflerforthorough

inspectionandreplacesame,ifnecessary.

6. NOTE:Ifbafflesarebrokenandarefreetomovearoundinmuffler,enginemayturnstaticanddeveloppowersometimesandothertimesitmaynotduetotherestrictedflowofexhaustgases.Strikemufflerwithrubbermalletorsoftobjectandlistenforrattleinmuffler.

7. Excessivelydirtyairfilter. 7. Replaceatregularintervals.Timebetweenfilterchangeswilldependonoperatingconditionsofindividualaircraft.

7. NOTE:Sometimesnewfiltersmayhaveanexcessiveairdropthroughthem.Ifthisconditionissuspected,removefilterandrunenginetoF.T.withoutfilterinstalledtoobservewhethertheengineperformsbetter.(Thistestshouldbeperformedinadustfreeareaandonahardsurface.)

8. Carburetorheatdoornotriggedproperly.

8. Rigso thatdoorgoesfromfullopentofullclosed.

8. NOTE: Eventhoughdoorisgoingfromfullopentofullclosedpositionwhenaircraftisshutdown,whenaircraftengineisoperatingvibrationsandairflowmaycausedoortoopenslightly.Ifthisconditionissuspected,tapeorwirethedoorshutfortestpurposes.Ifthissolvestheproblem,adjustandreplacepartsasnecessary.

9. Incorrectmagnetotoenginetiming. 9. Checkandadjustasnecessary. 9. Solutionisselfexplanatory.10. Fouledsparkplugs. 10. Removeandcleanorreplaceas

necessary.10. Solutionisselfexplanatory.

11. Tachometerreadingisincorrect. 11. Havetachometerrepairedorreplacesame.


ENGINESURGES

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Injectornozzlesdirty. 1. Removeandclean. 1. Cleanbyflushinginacetoneor

MEKandblowoutwithcompressedair.

2. Faultygovernor. 2. Replacegovernor. 2. Solutionisselfexplanatory.3. Airinoillinesorwastegateactuator

(turbocharged).3. Bleedsystem. 3. Enginewillusuallybleedairoutof

actuatorandcontrolsystembyrunning.Ifthisdoesnotwork,loosenlinesandbleedsystem.

4. Breatherplugged. 4. Removeanyobstructionsfrombreather.


5. Injectornozzlepressurereferencesystemleaking(turbocharged).

5. Repairleak. 5. Checkallhoseconnections,Orings,tubingandhosesforbreaksorlooseconnections.

6. Incorrectpropellergovernor. 6. Replacegovernor. 6. NOTE:CheckPartNumberofgovernortobesurethataworngovernorwasnotinstalled.

7. Defectiveoilpump. 7. Repairorreplaceoilpump. 7. Erraticoilpressuremaybetracedtothefactthatpumpmaybesuckingair.OnTIOandTIGO541enginesinspectOringsoninletandoutletofpump,alsohighpressureoilreliefatpumpmaybedefective.

8

ENGINESURGES(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION7. Defectiveoilpump.(Cont.) 7. Repairorreplaceoilpump.(Cont.) 7. (Cont.) NOTE: Toremoveoilpump

from541engines,thesumpmustberemoved.

8. Propellerbladesstickinginhubintermittently.

8. Removeandoverhaulpropeller. 8. Checkforpropellerblademovementandsticking.Checkstopsandangleonbladeswhenagainstflatpitchstops.

9. Carburetortoorich. 9. Repairorreplacecarburetor. 9. Solutionisselfexplanatory.10. Wastegatebindingintermittently. 10. Freewastegatebutterfly witha

corrosionpenetrantorreplacesame.10. NOTE:Useawrenchtomove

butterflyfromfullopentofullclosedtodetermineifshaftbindingisoccurring.

FAILUREOFENGINETODEVELOPRATEDPOWER

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Leaksininductionsystemand

exhaustsystem(turbocharged).1. Tightenallplugsandclampsand

replaceanydefectiveparts.1. Solutionisselfexplanatory.NOTE

Thisconditionismorenoticeableataltitude.

2. Improperfuelflow. 2. Checkscreenandgage,andreplaceinjector,ifnecessary.

2. Removescreensandflushoutdirt.Disconnectgageandinstallmastertodetermineaccuracyofaircraftinstrument.

3. Restrictioninairinletormanifold. 3. Checkandcleanorrepairasnecessary.

3. NOTE:Alwaysmakesureairfiltersarekeptcleanandtherearenobreaksinductingtoallowforeignmaterialorheatedairfromnacelletoenterinductionsystem.

4. Improperfuel. 4. Draintanksandrefillwithrecommendedoctanefuel.

4. NOTE:Neverusealowerthanrecommendedgradeoffuel.Consultlatest revisionofServiceInstructionNo.1070.

5. Controllersoutofadjustment(turbocharged).

5. Adjustsame. 5. Variableabsolutecontrollerisadjustedbyturningadjustmentscrewatcamendofcontrollercounterclockwisetoincreaseboost,andclockwisetodecreaseboost.Controllersaresettoobtainaspecificmanifoldpressureandnocompensationfordensityandtemperatureisnecessary.RequiredmanifoldpressuresettingswillbefoundinOperatorsManual.Adjustforfullthrottlesettingonly.Densitycontrollersdocompensatefortemperatureandpressureandrequirespecialequipmenttoadjust.ThelatestrevisionofServiceInstructionNo.1187setsforthproceduresandrequiredequipmentforadjustingdensitycontrollersinthefield.Differentialpressure controllersaresettomaintain6in.differentialbetweendeckandmanifoldpressure,specialequipmentisrequiredforadjustment. NOTE: Thisisnotnormallyadjustableinthefield.

9

FAILUREOFENGINETODEVELOPRATEDPOWER(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION6. Damagedturbochargerimpeller,

bindingortightturbochargerwheels(turbocharged)

6. Visuallyinspectfordamageandcheckforfreerotationofturbocharger.Disassembleandclean,ifnecessary.

6. NOTE:Ifturbochargerwheelisdamagedortipsofbladesaremissing,turbochargermustbereplaced.Becausethisconditionwillcauseturbochargertobecomeunbalancedandseverelywearthebearingscausingcompleteturbochargerfailure.

7. Throttlelevernotproperlyadjusted. 7. Checkandadjust, asnecessary. 7. Solutionisselfexplanatory.8. Excessivedirtbuildupin

compressorhousingoroncompressorwheel(turbocharged).

8. Inspectandclean. 8. Solutionisselfexplanatory.NOTE:Excessivedirtbuilduponcompressorwheelmaycreateanoutofbalanceconditionandacceleratebearingwear.

9. Kinkedorrestrictedoillinesfromenginetoactuator,andactuatortocontroller.

9. Removeandinspectorreplace,asnecessary.


10. Wastegateoutofadjustment(turbocharged).

10. Adjustsametocorrectopenandclosedlimits.

10. Thewastegateisadjustedtofullclosedpositionfirst,thenfullopen.Toadjustfullclosed,capoffoutletofactuatorandapply50to60lbs.oilpressuretoinlet.Whenoilpressurecloseswastegate,measureclearancebetweenbutterflyandhousing.Ifadjustmentisimproper,disconnectlinkageandlengthenorshortenasrequired.Afterfullclosedadjustmentiscorrect,setfullopenbydisconnectingoilsupplyandallowingspringinactuatortoopenwastegate.Again,measureclearancebetweenbutterflyandhousing.Ifadjustmentisimproper,loosenjamnutatendofcylinderandturnadjustmentrodinoroutasrequiredtoobtainproperfullopensetting,thenretightenjamnut.

11. Inletorificeinactuatorplugged(turbocharged).

11. Removeinletlineatactuatorandcleanorifice.

11. NOTE:Iforificeispluggedtight,itmaybenecessarytoremovecylinderfromactuatorinordertobeabletocleanorifice.

12. Wastegatestuckopen(turbocharged).

12. Removeactuatorandloosenwastegatebutterfly.

12. Wastegatebutterflymaybefreedbyremovingfromengine,andusingawrenchonthebutterflyshaft.Rotatebackandforthuntilallcorrosionisremovedandbutterflymovesfreely.Thisoperationmaybeaidedbyusingacorrosionpenetranttohelploosenbutterfly.Onepenetrantusedbysomepeopleinthefieldismousemilk,manufacturedbyWorldwideAircraftFilterCorp.,1685AbramCt.,SanLeandroCA94577.Thispenetrantcouldbeusedateach25hourinspectionasapreventativemeasure.Alittleateachendoftheshaftmayhelpkeepshaftfrombinding.

10

FAILUREOFENGINETODEVELOPRATEDPOWER(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION13. Pistonsealinwastegateactuator

leaking.Notedbyexcessoilcomingoutofdrain(turbocharged).

13. Disassemble,cleancylinder,andreplaceseal,orreplacewastegateactuatorassembly.

13. NOTE:Anytimewastegateactuatorisdisassembledorpartsarereplaced,thefullopenandfullclosedpositionsofthebutterflyshouldbecheckedandreset,ifnecessary.(Resetaccordingtoitem#10ofthissection.)

14. Oilpressuretoolowtoclosewastegate(turbocharged).

14. Adjustoilpressuretoatleastminimumlowlimitinmanual.

14. Checktomakesurethattheproperoilpressurereliefspringisinengineandthatitisnotbroken,orthatreliefvalveballdoesnothaveanydirtunderitcausingthelowoilpressure.

15. Injectorandcontrollerlinkagenotadjustedproperly(541seriesengine).

15. AdjustasperlatestrevisiontoServiceInstructionNo.1211to getfulltravelonbothcontrollerandinjector.

15. ProceduressetforthinthelatestrevisionofServiceInstructionNo.1211includetheuseoftwospecialtools,ST318andST319,topositionthecrossshaftandestablishtheclearancesettingsatfullthrottleandidlewhenmakinglinkageadjustments.Thesestepbystepproceduresshouldbefollowedtoinsureaccuratelinkageadjustment.

16. Brokenbafflesinmuffler(normallyaspiratedengines).

16. Removefromengineandreplacemufflersystem.

16. NOTE:Ifsectionofbaffleislooseinmuffler,enginemayoperatesatisfactoryattimesandmaybelowonpoweratothertimes.Thisindicatesbaffleismovingaroundinmuffler,blockingexhaustgasesattimesandatothertimesallowinganunrestrictedflowofexhaust.

17. Poorcombustion. 17. Doadifferentialcompressioncheckandborescopeinspectiontolocateexcessivelyleakingvalves,valveguidesorringsandtolocateanybrokenrings.

17. Doatopoverhaultocorrectthisproblem.

18. Butterflyinwastegateiswarped. 18. Replacewastegate. 18. Solutionisselfexplanatory.19. Crankshafttocamshafttiming

incorrect.19. Removeaccessoryhousingand

correcttiming.19. Thisconditionmaybecheckedby

firstdisconnectingstarter,removetopsparkplugsandrockerboxcoveron#2cylinder.TurnenginetoT.D.C.oncompressionstrokeon#1cylinder,observethatwhenpistonin#1cylindergoesoverT.D.C.oncompressiontheintakevalvein#2cylinderisjuststartingtoopenandtheexhaustvalveisjustclosing.Ifthisconditiondoesnotexist,thecrankshafttocamshafttimingisoff.NOTE:OnengineswithfixedpitchpropellerstheengineprobablywillnotturnstaticR.P.M.OnengineswithconstantspeedpropellerstheenginewillprobablyturnupstaticR.P.M.butmanifoldpressurewillbealittlelow.

11

LOSSOFPOWERGOINGTOALTITUDE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Leakinturbochargersystem. 1. Checkallclampsandboltson

inductionandexhaustsystem.NOTE:Makesurealternateairdoorclosescompletely,andsuckopendoorisproperlyadjustandgasketisnotdamaged.

1. Observethatallclampsaretightonturbochargerinductionandexhaustsystem.InspectallgasketsandOringsonintakepipestobesuretheyareinplaceandproperlyseated.Checkforcracksonbothintakeandexhaustsystem.Greenstainoninductionsystemindicatesinductionleak.Whitestainsonexhaustsystemindicatesanexhaustleak.Makesurethatallnutsonexhauststacksaretightandthatnoexhaustgasketsareburnedout.

2. Densitycontrollerdoesnotfollowcurvetoaltitude.

2. Replacecontroller. 2. Tocheckdensitycontroller,disconnectdifferentialcontrollerfromsystemandblockoillines.Flyaircrafttoaltitudeandobservethatyougetasteadyriseinmanifoldpressurenottoexceedairframemanufacturerslimits.Ifnoriseisindicated,densitycontrollermustbereplaced.NOTE: Exerciseextremecautionastherewillbeseverelystaggeredthrottlesatpartthrottleconditions.

3. Oillinetoactuatorinletkinkedorblocked.

3. Removeline.Cleanorreplaceandeliminatekinkedcondition.


4. Actuatorpistonsealfailedandleakingexcessively.

4. Disassemble,cleancylinder,andreplaceseal.

4. NOTE:Anytimewastegateactuatorisdisassembledyoumustcheckthefullclosedandfullopenpositionsofthewastegate.Ifadjustmentisnecessary,alwaysadjustfullclosedfirstthenfullopen.(Neverplugthewastegateactuatordrainasitmaycauseahydrauliclock.)

5. Differentialcontrollerpoppetvalveleaking.

5. Replacedifferentialcontroller. 5. Apply80psioiltoinletportofdifferentialcontroller,onlyminutedrainageshouldbeobservedatdrainport.Ifexcessive,oilisobservedatdrainport,thisindicatescontrollervalveisleakingoilatalltimesandmustbereplaced.

6. Poorcombustion. 6. Doadifferentialcompressioncheckandborescopeinspectiontolocateexcessivelyleakingvalves,valveguidesorringsandtolocateanybrokenrings.


7. Bindingturbocharger. 7. Overhaulorreplaceturbocharger. 7. Solutionisselfexplanatory.8. Leaninjector. 8. Replaceinjectororrecalibrateor

overhaulatapprovedfacility.8. Solutionisselfexplanatory.

9. Differentialpressurecontrollerlineshookedupimproperly.

9. Attachcontrollersensinglinestoproperlocations.

9. Onesideofdifferentialcontrollerdiaphragmsensesdeckpressureandtheothersidesensesmanifoldpressure.

12

CANNOTREACHSPECIFIEDCRITICALALTITUDE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Dirtyinductionairfilter. 1. Replacesame. 1. NOTEAlsocheckforanytypeof

blockageininductionsystem.2. Damagedcompressororturbine

wheel(turbocharged).2. Replaceoroverhaulturbocharger.

NOTE:Determinereasonfordamageandeliminate.

2. Visuallyinspecttoseeiftheturbineorcompressorwheelsaredamagedortipsofbladesaremissing.Ifthishashappened,turbochargerreplacementisnecessarybecausethisdamagecausesasevereoutofbalanceconditionwhichwillrapidlywearouttheturbochargerbearings.

3. Wastegatedoesnotgoto fullclosedposition(turbocharged).

3. Adjustforfulltravel.Ifbutterflyissticking,workfreeandapplycorrosionpenetrant.Ifactuatorsealisleaking,disassemble,cleancylinderandreplaceseal.

3. Whensettingclosedandopenpositions,alwayssetfullclosedpositionfirst,thenfullopen.Theprocedureforcheckingfullclosedpositionistocapoffactuatordischarge,apply6065lbs.oilpressuretoinlet.Whenwastegatecloses,measureclearancebetweenbutterflyandhousing.Ifadjustmentisnecessary,disconnectlinkageandlengthenorshortenasrequired.Tocheckfullopen,releaseoilpressureandallowwastegatetoopenfullandmeasureclearancebetweenbutterflyandhousing.Ifadjustmentisnecessary,loosenjamnutattopofcylinderandturnadjustmentinoroutasrequired.Retightenjamnut.Ifbutterflyissticking,loosenbymanuallymovingbackandforthuntilfree,thelubricatewithacorrosionpenetrantlikemousemilk,manufacturedandsoldbyWorldwideAircraftFilterCorporation,1685AbramCt.,SanLeandro,CA.Itmayalsobeusedasapreventativebyapplyingtobutterflyshaftat25hourinspections.Ifactuatorcylinderisleaking,disassemble,cleancylinderandreplaceseal.Ifanypartsarereplaced,checkopenandclosedlimitsasdescribedabove.

4. Badbearingsinturbocharger. 4. Replaceoroverhaulturbocharger.NOTE:Spinturbinebyhandtocheckforfreerotation

4. Checkradialandaxialbearinglimits,asperAiResearchTurbochargerManual.

5. Suckopendooroncompressordischargehousingnotfullyclosedordoorgasketdamaged(TIO540engines).

5. Adjustmagnetsodoorclosesproperly.Replacegasket.

5. Observethatnophysicaldamagehasoccurredtodoorandnoforeignmaterialislodgedbetweendoorandgaskets.

6. Faultycontroller. 6. Repairorreplace. 6. AbsoluteVariable.Ifenginelosespower,considerleakingpoppetvalveoroilleakingintoinductionsystembecauseofbrokenbootbellows.Removecontrollerandcheckforoilininductionhousing.Ineithercase,controllerwillhavetobereplaced.

13

CANNOTREACHSPECIFIEDCRITICALALTITUDE(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION6. Faultycontroller.(Cont.) 6. Repairorreplace.(Cont.) 6. (Cont.)DensityController. Checkas

persolution#2underLossofPowerGoingto Altitude.DifferentialController.Apply80psioiltoinletport.Observethatonlyminutedrainingoccursatdrainport.

7. Improperlyadjustedcontrollers. 7. Adjustsame. 7. AbsoluteVariable.Thevariableabsolutepressurecontrollerisonlysensitivetopressuresettingssonospecialequipmentisnecessaryforadjustment.Toincreasemanifoldpressureturnadjustingscrewatcamendofcontrollercounterclockwise.Todecreasemanifoldpressure,turnadjustingscrewclockwise.Theseadjustmentstobemadeforfullthrottlepowersettingsonly.ManifoldpressuresettingswillbefoundinOperatorsManual.DensityControllerissensitivetotemperatureandpressureanddoesrequirespecialequipmenttoset.ProceduresforsettingdensitycontrollersaresetforthinlatestrevisionofServiceInstructionNo.1187.DifferentialController.Ifdifferentialcontrollerisleakingthencriticalaltitudewouldnotbereached.Checkbyapplying80psioiltoinletportandobservingthatonlyminuteoilisseenatdrainport.Ifexcessoilisseenatdrainport,controllerisleakingatalltimesandmustbereplaced.

8. Insufficientoilpressuretoclosewastegate.

8. AdjustoilpressuretospecificationsfoundinOperatorsManual.Checkforlinksorrestrictionsinactuatorsupplyline.

8. Checktobesuretheproperspringisintheoilpressurereliefvalveandisnotbrokenorthatnoforeignmaterialisunderthereliefball.Eliminaterestrictionsinactuatorsupplylineandroutelinetoeliminateanykinks.

9. Damagetocompressororturbinewheel.

9. Replaceturbocharger. 9. Visuallyinspectturbochargerwheelsfordamagesuchasbentorbrokenblades,rubmarksoncompressororturbochargerhousing.Ifpartsofbladesaremissing,checkforexcessivebearingwearcausedbysevereoutofbalancecondition.

10. Leaksinexhaustsystem. 10. Repairorreplaceasrequired. 10. Tightenallclampsandboltsonturbochargersystem.Checkgasketsforgoodconditionandproperseating.Alsoinspectforanycracks(maybelocatedbythepresence ofwhitestainsonexhaustsystem).Makesureallnutsonexhauststackflangesaretightandnogasketsareburnedout.

14

CANNOTREACHSPECIFIEDCRITICALALTITUDE(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION11. Poorcombustion. 11. Doadifferentialcompressioncheck

andborescopeinspectiontolocateexcessivelyleakingvalves,valveguidesorringsandtolocateanybrokenrings.


LOWOILPRESSURECAUSE SOLUTION PROCEDUREFORSOLUTION

1. Insufficientoil. 1. Filloilsumportanktoproperlevel. 1. NOTE:Makesureyouareusingthecorrectgradeandweightofoil.

2. Pressurereliefoutofadjustment. 2. Adjustoilpressuretoproperlimits. 2. Onexternaladjustabletypeincreaseoilpressurebyturningadjustingscrewclockwise,andtodecreaseturncounterclockwise.Ontypeswithsolidtowerstandardinchflatwashersareusedtocontroloilpressure.Addwasherstoincreaseoilpressureandremovewasherstodecreaseoilpressure.Onshorttower,amaximumofthreewashersmaybeusedonatalltower,amaximumofninewashersmaybeused.

3. Dirtormetalchipsunderoilpressurereliefvalve.

3. Remove,disassemble,andclean. 3. Solutionisselfexplanatory.

4. Damagedoilpressurereliefseat. 4. Replaceorrepair. 4. Onengineswiththeremovableseat,seatmaybepulledoutandanotherpressedintoplace.Onenginesthathaveseatmachinedinthecase,repairsmustbemadebyrepairingexistingseatwithSpecialToolsST243,ST248andST340thatmakeupthereseatingtoolassembly.(RefertolatestrevisionofServiceInstructionNo.1172.)

5. Highoiltemperature. 5. Checkallareasthatinvolvelubesystemandlubeoilcoolingsystem.

5. Inspectthefollowingareasfortrouble:(a)Properoillevel.(b)Propergradeandweightofoil.(c)Thermostaticbypassvalveworkingproperlyandseatingsquarely.(d)Pluggedorpartiallypluggedoilcoolerlinesoroilcooler.(e)Excessiveblowby.(f)Airducttocoolerblockedorcoolerpartiallycovered.(g)Defectivetemperaturegage.

6. Restrictionatinletsideofoilpump. 6. Removeandcleanoilsuctionscreenandoilpassagetoinletsideofoilpump,ifnecessary.


7. Excessiveinternalspilloffofoil. 7. Checkthefollowingareasforexcessiveoilflowandrepairorreplace.(a)Looseormissingplugsinoilgalley.(b)Pistoncoolingsquirtsblockedopen. NOTE: LowoilpressureusuallyoccursatloworidleRPM.(c)Excessivebearingclearance.(d)Crackedcrankcaseinareaofoilgalley.


15

LOWOILPRESSURE(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION8. Relocatingtheoilpressuretakeoff

pointontheengine.8. Useonlytheoilpressuretakeoff

pointapprovedbytheenginemanufacturer.


9. Oilpressurereliefseatincrankcasecocked(couldbecagetypeorflattype).

9. Removeandreplaceseat. 9. Solutionisselfexplanatory.

HIGHOILCONSUMPTION

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Impropergradeofoil. 1. ConsultOperatorsManualfortype

andweightofoil.1. NOTE:Consultlatestrevisionof

ServiceInstructionNo.1014forinformationonapprovedlubricatingoilsforLycomingengines.

2. Failureofnewringstoseatproperly. 2. Usecorrectgradeofoilandproperoperatingprocedures.

2. Onnewandrebuiltengines,usemineraloiluntilconsumptionstabilizes(usuallyfrom50to100hours)thenifdesired,changetoashlessdispersantoil.Onthe541seriesofengines,ashlessdispersantoilmustbeusedfromthebeginning.NOTE:ConsultlatestrevisionofServiceInstructionNo.1014forrecommendedlubricatingoils.Forbestringseating,alwaysusefullthrottletakeoffwherevertheapplicationapplies(theonlyexceptionisthegearsuperchargedengineswheretakeoffpowerislimitedbyaspecificmanifoldpressure).Alsouseahighcruisepowersettingforbreakin.

3. Failedorfailingbearings. 3. Replacesame. 3. Disassembleengineforinspectionandreplacementorbearings.Priortodisassembly,excessivebearingwearmaybedeterminedbythepresenceofmetalinoilsuctionscreenoroilfilter.

4. Wornpistonringsand/orcylinderbarrels.

4. Removecylindersanddeglazebarrels,replacewithnewpistonrings.

4. Priortodisassembly,theconditionoftheringsmaybedeterminedbydoingadifferentialcompressioncheck.ThisisaccomplishedbyrotatingthecylindertobecheckedtoT.D.C.oncompressionstroke.Afterinsuringthatthepropellerwillnotturn,introduce80psiairincylinderandobservehowmuchisretained.Airleakingbyringscanbedetectedbylisteningatbreatherentranceforahissingsoundincrankcaseindicatingairescapingaroundtherings.Forequipmentrequiredandprocedures,consultlatestrevisionofServiceInstructionNo.1191.

16

HIGHOILCONSUMPTION(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION5. Wornvalveguides. 5. Replacesame. 5. Removecylindersfromengineand

takeoutvalves.MeasureguidesandifwornbeyondtolerancesallowedinthelatestrevisionofTableofLimits,theguideswillhavetobereplaced.UseproceduressetforthinapplicableOverhaulManual.

6. Excessiveoilleaks. 6. Inspectexternalofengineforleaksandrepairsame.


7. Oilbeingsiphonedfromengineinflight.

7. Insurethatoilfillercapisontightandoilaccessdoorclosesproperly.Alsobesurethatthebreatherhoseiscutproperlyandlocatedsothereisnochangeofsiphoningoilfromengine.


8. Expanderinoilcontrolringimproperlyinstalledorlostitstension.

8. Whenusingoilcontrolringwithcorrugatedtypeexpander,makesureendsofexpanderarebuttedtogethernotoverlapped.Whenusingoilcontrolringwithspiralwoundtypeexpander,ringdesignissuchthatimproperassemblyisnotlikely.


9. Oilleveltoohigh. 9. Maintainoilatmanufacturersrecommendedlevel.


10. Oilpassingthroughturbochargerseals.

10. Overhaulorreplaceturbocharger. 10. NOTE:Onengineswherethelubricatingoiltotheturbochargerisreturnedtothecrankcasebygravitydrain,inspectthecrankcasebreatherlinetobesureitisnotplugged.Ifitis,thiswillcausehighcrankcasepressureandnotallowtheoiltoreturntothecrankcasefreelyandeventuallypushtheoilpasttheturbochargersealsintothecompressorandturbinesectionoftheturbocharger.

HIGHCYLINDERHEADTEMPERATURE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Sparkplugsofimproperheatrating

installedinengine.1. Useonlyapprovedsparkplugsfor

yourengine.1. NOTE:Consultlatestrevisionof

ServiceInstructionNo.1042forapprovedsparkplugs.

2. Coolingbafflesmissing,brokenorimproperlyinstalled.

2. Insurethatallbafflesareinstalledproperlyandnotbroken.

2. NOTE:Neverattempttomodify,relocateoreliminateanycoolingbaffles.

3. Partially pluggedfuelnozzles. 3. Cleaninmethylethylketoneoracetoneandblowoutwithcompressedair.


4. FuellinesofimproperI.D.beingused.

4. FuellineI.D.shouldbe.085.090in. 4. NOTE:Primerlineshavesamethreadedconnections arefuellinesbutareofmuchsmallerI.D.NOTE: TheonlyexceptiontothisruleistheIO540E1B5usedintheAeroCommander500S.Thisengineusesprimerlinesforfuellinesandtheyare.060in.I.D.

17

HIGHCYLINDERHEADTEMPERATURE(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION5. Engineimproperlytimed. 5. Checkmagnetotoenginetimingand

insurethatengineistimedtothecorrectnumberofdegreesB.T.C.

5. NOTE: Eventhoughmagnetosynchronizationiscorrect,ifengineistimedat25BTCwhenit shouldbe20BTC,enginewillrunhotter.

6. Enginebeingoperatedexcessivelylean.

6. CheckOperatorsManualforminimumfuelflowforvariouspowersettingsandnevergobelowthem.

6. NOTE:Ifthisconditionissuspected,checkcombustionchamberforcarbondeposits.Iftherearenone,thisissufficientreasontobesuspiciousofacontinuousleanengineoperation.

7. Mixcontrolimproperlyrigged. 7. Rigforcompletetravel. 7. NOTE: Eventhoughmixcontrolleveratpilotseatappearstohavefulltravel,besuretocheckatcarburetororinjectortoinsurethatmixleverisgoingagainsttheF.R.(fullrich)andI.C.O.(idlecutoff)stops.

SPLITINMANIFOLDPRESSURE(TwinEngine)

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Propellerbladeanglenotadjusted

properly.1. Adjustpropellersforcorrectblade

anglewhenagainstflatpitchstops.1. Solutionisselfexplanatory.

2. Controllersoutofadjustment(turbocharged).

2. Adjusttoproperlimits. 2. VariableabsolutepressurecontrollerisadjustedtoaspecificmanifoldpressureasfoundinOperatorsManualwithnocompensationfortemperature.DensitycontrollersareadjustedasperlatestrevisionofServiceInstructionNo.1187.Whereproceduresandequipmentrequirementsaresetforthondensitycontrolledengines,somesplitinmanifoldpressuremayhavetobeacceptedbecauseofvariationsinturbochargerefficiency.NOTE:Bothcontrollersareadjustedforfullthrottlesettingconditiononly.

3. Excessivelydirtyairfilter. 3. Replacewithnewfilter. 3. NOTE:Problemmaybemorenoticeablewhenaircraftisflowntoaltitudebecauseofthedecreaseinairdensity.

4. Alternateairdoorleaking. 4. Replacedoororadjustforcompleteclosing

4. NOTE:Althoughdoormayappeartoclosecompletelyontheground,itmaybeopeningslightlyinflightduetovibrationoraircurrents.Todetermineifthisishappening,tapealternateairdoorshutandflyaircrafttoaltitudeandobservemanifoldpressure.

5. Incorrecthydraulicliftersorhydraulicliftersbleedingdowntoorapidly.

5. Replacehydrauliclifters. 5. NOTE:Onturbochargedenginesmanifoldpressureswillcomebacktogetherwhenmanifoldpressuregetsabove30in.

18

SPLITINMANIFOLDPRESSURE(TwinEngine)(CONT.)

CAUSE SOLUTION PROCEDUREFORSOLUTION6. Restrictioninairframeorengine

inductionsystem.6. Inspectandremoverestriction. 6. Solutionisselfexplanatory.

7. Leaksinairframeorengineinductionsystem.

7. Inspectandrepairleaks. 7. Solutionisselfexplanatory.

HIGHOILTEMPERATURE

CAUSE SOLUTION PROCEDUREFORSOUTION1. Insufficientoilsupply. 1. Checkoilatregularintervalsand

maintainproperlevel.1. Solutionisselfexplanatory.

2. Insufficientcoolingair. 2. Checkairinletandoutlettocoolerandreplaceorrepairpartsandductingasrequired.


3. Impropergradeofoil. 3. Useonlygradeandweightofoilspecifiedforengine.

3. NOTE:ConsultlatestrevisionofServiceInstructionNo.1014forpropergradesandweightofoilsusedinLycomingengines.

4. Oilcoolerorlinespluggedorpartiallyplugged.

4. Removecoolerandlinesandflushout.


5. Thermostaticbypassvalvenotoperatingproperlyorseatingsquarely.

5. Replacethermostaticbypassvalve. 5. NOTE:Ifvalveisnotseatingproperly,thefilterbasemayhavetobereplaced.

6. Excessiveblowby. 6. (Doatopoverhaul.)Thisconditionusuallycausedbywornorstuckrings.

6. NOTE: Tolocateexactlywheretheblowbyisoriginatingfrom,doadifferentialcompressioncheckasdescribedinlatestrevisionofServiceInstructionNo.1191.

7. Defectivetemperaturegage. 7. Replacesame. 7. Solutionisselfexplanatory.

HIGHMANIFOLDPRESSUREATIDLE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Improperlyadjustedfuelinjectoror

carburetor.1. Adjustidlemixturetogeta25to50

RPMrisewhenmovingmixturecontrolfromfullrichtoidlecutoff.

1. NOTE:Speedmayhavetobeadjustedalso.

2. Incorrecthydraulicliftersinstalled. 2. Replacewithcorrectpartnumberlifters.


3. Hydraulicliftersbleedingdowntoorapidly.

3. Replacewithnewhydrauliclifters. 3. NOTE:Anytimehydraulicliftersareremovedfromanengineforcleaningandinspectionbe sure tokeepthecylinderandplungertogetherasanassembly.Iftheybecomeseparated,donotjustarbitrarilyassembleanybodyandplungertogetherbecauseyoumaychangetheleakdownrate.Ontwinengineinstallations,asplitinmanifoldpressurewillbenoticedduringacceleration.

4. Airleakininductionsystem. 4. Checkinductionsystemandrepairleak.

4. NOTE: Enginewillberoughatidle.

19

HIGHOILPRESSURE

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Oilpressureimproperlyadjusted. 1. Adjusttowithinminimumand

maximumrangeasfoundinOperatorsManual.

1. Onexternaladjustabletypeoilpressurereliefadjustment,turnadjustmentcounterclockwisetodecreaseoilpressure.Onenginesusingthepressurereliefthatisnotexternallyadjustable,removethepressurereliefvalvefromtheengineandtakeoutwashersfrombehindspring.

2. Improperweightofoil. 2. Usethesuggestedweightof oilfortheambienttemperatureinwhichtheengineisbeingoperated.

2. ConsultlatestrevisionofServiceInstructionNo.1014forlubricatingoilrecommendations.

3. Oilpassagefrompressurereliefvalvetosumpplugged.

3. Removeblockagefromoilpassage. 3. Removepressurerelieffromengineandrunasoftcopperwiredownthroughoilpassagetosumpifblockageisfound,removesame.NOTE:Ifblockagepersists,sumpmayhavetoberemovedtoclearpassage.

4. Incorrectpressurereliefspringbeingused.

4. Replacewithcorrectpressurereliefspring.


5. Relocatingtheoilpressuretakeoffpointontheengine.

5. Useonlytheoilpressuretakeoffpointonengineapprovedbymanufacturer.

5. NOTE:Iftheoilpressuretakeoffpointontheengineismovedclosertooilpumpdischarge,ariseinoilpressurewillbenoted.

6. Oiltemperaturetoocold. 6. Allowoiltemperaturetoincreasebeforeincreasingthrottle.


MANIFOLDPRESSUREFLUCTUATES

CAUSE SOLUTION PROCEDUREFORSOLUTION1. Wastegatesticksintermittently. 1. Freewastegatebyturningitwitha

wrenchatthebutterflyandapplyacorrosionpenetrant.(Replacewastegateifnecessary.)


2. Oilsumpbafflemodificationrequired.Modelsaffected,TIO540A,S1AD,T2AD, AA1B5,AE2A(L)TIO540F2BD,J,N2BD,R2AD,U2A.

2. Forinformationconcerningthisproblem,consultlatestrevisionofServiceInstructionNo.1279.

2. StepbystepproceduresfoundinlatestrevisionofServiceInstructionNo.1279.

3. Oilinfittingondifferentialpressurecontrollernotrestricted.Modelsaffected,TIO540A, F, JLTIO540F, J

3. Replacewithoilinfittinghaving.075in.restriction.


4. Linkagefromfuelinjectortocontrollernotriggedproperly.(TIOandTIGO541seriesenginesonly.)

4. ProceduresforproperlyrigginglinkageisfoundinlatestrevisionofServiceInstructionNo.1211.


20

APPENDIXI

TROUBLESHOOTINGTHEBENDIXRSAFUELINJECTOR

TherearesomesectionsoftheBendixfuelinjectorthatamechanicmaynotworkoninthefield,suchastheregulatorsectionwhich consists of the air and fuel diaphragm and associated parts. Anymodification of the regulator section by a mechanicwithouttheuseofaflowbenchcouldresultinachangeinfuelflowthroughtheinjector.However,therearesomethingsthatamechanicmaydothatwillnotaffecttheoperationofthefuelinjector.

In the following paragraphs we would like to discuss some of the things that amechanic can do, and some procedures amechaniccanusetodetermineiftheproblemisinthefuelinjectororanassociatedpart,i.e.flowdivider,fuelnozzles,fuellines,etc.

Wheneverafuelinjectorproblemarises,thefirstthingamechanicshoulddobeforeheremovestheinjectororanypartofit,istomakesuretheriggingiscorrect,andthatthethrottleandmixturecontrolsarebothtravelingtotheirfullopenandfullclosedstopsandmakesuretherearenofuelleaks.AnotherimportantitemtoconsiderisDoyougetariseof25to50RPMatidlewhenthemixturecontrolismovedfromfullrichtoidlecutoff?Ifyouareexperiencingpooraccelerationoftheengine,thismaybetheproblem.Toadjusttheidlemixture,turnthescallopedwheelatthesideoftheinjectoreitherrichorlean,asrequired,untilthedesiredriseinRPMisreached.Whenadjustingtheidlemixture,youwillhavetoadjusttheidleRPMtoo.AgoodidleRPMisaround600to650RPM.

We would like tomake everyone aware that there is a filter screen at the fuel inlet to the injector.This screen should beremovedandcleanedat100hourinspection.Somecleaningsolventsthatcanbeusedaremethylethylketoneoracetone.It isalsopermissibletouseasoniccleaner.Afterthescreenhasbeencleaned,blowitoutwithcompressedair.Whenremovingthescreenfromthefuelinjector,alwaystakeitfromthesamesideoftheinjectortowhichthefuellineisattached.Thisistopreventdepositinganydirtbackinthefuelinjectorthatmighthavebeepickedupinthescreen.Onearlyinjectors,thescreenisattachedtotheinletadapter,soitcanonlyberemovedfromthatside.Onlatermodelinjectorsthe screenisspringloadedtoprovideafuelbypassincaseitbecomesplugged.Thistypeofscreencanberemovedfromeitherside.

Ifyouareexperiencingaroughshutdownandtheenginedoesnotwanttoquitwhenthemixturecontrolisretarded,itmaybebecausethereisascoreoneitherthemixturecontroljetorrotatingplate,orabadOringonthejet.Priortodisassemblyofthefuelinjector,atestcanberuntoseeifthisistheproblemarea.Disconnectthefuellinecomingoutofthefuelinjectorandleavethefittingopen.Pullthemixturecontrolandthrottleallthewayback(off)andturnontheboosterpump.Ifanyfuelisobservedcoming out of the open fitting, there is a score on themixture control jet, or rotating plate, or the O ring is damaged ordeformed.Therepairistoremovethemixturecontrolassemblyandeliminatethescoresbylappingthemixturecontroljetandrotatingplateonagood lapplateusingamildabrasive.The finalrepair shouldbedoneby lapping thejetandplate together,usingBonAmiorequivalenttypeabrasive.Afterthisisaccomplished,cleanandreassemblethepartsusinganewOringeachtime.

Ifnofuelisobservedcomingoutoftheopenfittingontheinjectorwhenthetestisperformed,themixturecontrolassemblyisworkingcorrectlyandothercausesshouldbelookedat.Somethingstoconsiderarethefuelinjectornozzles.Iftheairbleedholebecomesplugged,theenginewillnotshutdownsmoothly.Onnormallyaspiratedengines,thereisascreencoveringtheairbleedhole which makes a visual inspection impossible. Therefore, you must remove the nozzles from the engine and clean themthoroughly and blow them out with compressed air. If this does not solve the problem, then there may be a nozzle that isimproperlyassembled,ortheonlyothersolutionistoreplacethenozzles.

Onturbochargedengines,theairbleedholeisshroudedandventedbacktothecompressordischargepressuredeckpressure.Inspect these linesand fittings tomakesure theyare free ofdirt, leaksorobstructions.After theshroud isremoved from thenozzle,itcanberemovedfromthecylinder,cleanedthoroughlyandblownoutwithcompressedair.

NOTE

Whenanynozzlethatisinstalledhorizontallyisreassembledintoacylinder,makesurethattheletterAthatisstampedonthehexportionofthenozzleispointingdownthispositionstheairbleedholeup,andthecorrecttorquevalveisappliedat60in.lbs.

21

APPENDIXI(CONT.)

Anotherareatoconsiderwouldbeaninternalleakinthefuelinjectorbodyseal.Allofthefuelthatisdeliveredtotheengineshouldgothroughtheindividualfuellinestothenozzlesandonintothecombustionchamber.Ifthereisaninternalleakintheinjector,therewillalsobe fuelenteringtheinjectoratthethroat,andgoingtothecylindermuchlikeacarburetedengine.Ifacenterbodyseal is suspected of leaking, there isabrief test thatcanbe run.First,removeenoughof the induction system toenableonetoseetheimpacttubesonthefuelinjector.Thendisconnectthefuellinefromthefuelinjectortotheflowdividerandcapoffthefittinginthefuelinjector.Movethecontrolstothefullthrottleandfullrichpositionandturnontheboosterpump.Ifanyfuelisobservedcomingoutoftheimpacttubesoftheinjector,thisindicatesthatthereisacenterbodysealleaking.Sincethis is part of the regulator system themechanicmaynotmake thenecessary repairs, butmust remove the injector from theengineandsendittoanoverhaulfacilityforreconditioningandrecalibration.

Inadditiontoaroughshutdown,theenginemaydisplaysomeothersymptomsthatmayindicatethatthereisacenterbodysealleak.Someoftheseindicatorsare:

Theengineisrichatidleandlowpowersettings,orthepilothastoretardthemixturecontroluponflareoutandlandingtopreventtheenginefrombecomingtoorichandstopping,orifthemechanichastoadjusttheidlemixtureleaneveryfewdaysorweeksbecauseithasdriftedrich.Eachofthesesymptomsindicatesadrifttotherichsideandmaybeawarningofaninternalleakintheinjector.

Another areawhereproblemsmaybe encountered in the fuel injector is thepossibility of scores on themainmeter jet androtatingplateassembly.Anyscoresinthisareamayberemovedbylappingthemainmeterjetandrotatingplateonagoodlapplateusingamildabrasive.Thefinalrepairshouldbemadebylappingthejetandplatetogether.Whenallscoresareremoved,cleanthoroughlyandreassembletheinjector.Anyindicationthatthemainmeterjetisscoredwouldbearichidlemixture,andbyadjusting themixture control lean, themechanic could get a satisfactory idle, but when the enginewas accelerated, itwouldstumbleandnotacceleratesmoothly.

Ifthereisanyoccasionwhenthefuelinjectoridlemixtureadjustingwheelhasbeenturnedtoitslimit,eitherrichorlean,andthe idle isnot satisfactory, the linkage between the air valve and the fuel valve on the injectormaybe removed and the idlemixtureadjustingwheelpositionedbacktothecenterofitstravel.Priortoremovingthelinkagefromtheinjector,measuretheoveralllengthofthelinkage.Thismustbethesameafterrepositioningthewheelbackoncenterasitwasbeforeremovingitfromtheinjector.Afterthelengthofthelinkagehasbeenestablished,adjustthewheelbacktocenteroftravelbybackingoneendofthelinkageassemblyouthalfthedistanceandadjustingtheotherendofthelinkageinuntilyouhavethesameoveralllengthyouhadpriorto removing it fromthe injector.Afterthe linkage isadjusted,assemble theinjector,makingsure to installthepins,wavewashersandcotterkeyscorrectly.

Otheritemsinthefuelinjectionsystemthatcouldbeasourceoftroublearetheflowdivider,fuellinesandinjectornozzles.Ifyoususpectthattheflowdividervalveissticking,removetheflowdividerfromtheengineanddisassembleit.Thevalvecanbefreedbypolishingthevalveandboretogetherusingamildabrasive.Donotinterchangeflowdividerpartsbecausetheyareamatchedassembly.Afterthevalveisoperatingfreely,cleanthoroughlyandreassembletheflowdivider.

NOTE

AlsoreferencethelatestrevisionofLycomingServiceBulletinNo.382orBendixBulletinNo.RS43forlatestmodificationtoflowdividers.

Ifthefuelflowgagesuddenlyshowsanincreaseinflow,thefirstthingtodoischeckforapluggedorpartiallypluggedfuelnozzle.Theprocedurefordoingthisisasfollows:

Disconnect the fuel linesandremove thenozzles from thecylinders.Thenattach thenozzles to the fuel linesanddirect thenozzlesintobottlesofequalsize.Babyfoodorcokebottlesworkverywell.Movethethrottleandmixturecontrolsfullforwardandturnontheboosterpump.Fillthebottlesapproximatelyonehalffull.Turnofftheboosterpumpandretardthethrottleandmixture.Removethebottlesfromtheengineandsetthemonatableorotherflatsurface.Avisualcheckofthefuelcontentsinthebottleswilltellyouwhichnozzleisplugged.

NOTE

Whileflowingfuelintothebottles,checkeachnozzletomakesureallofthefueliscomingoutofthe dischargerendofthenozzleinasolidstreamapproximatelythesizeoftheleadinamechanicalpencilandnotsomefuelcomingoutoftheairbleedhole.

22

APPENDIXI(CONT.)

Afterlocatingthepluggednozzle,itcanbecleanedinmethylethylketoneoracetoneandblownoutwithcompressedair.Ifathoroughcleaningfailstoremovethedirt,thenozzlewillhavetobereplaced.Priortoreplacingthenozzle,checkthefuellinetobesurethataprimerlineisbeingusedforafuelline.Primerlinesaresmallerontheinsidediameter,andwillgiveafalsereadingonthefuelflowgage.Alsochecktheflowdividerforobstructions.

NOTE

Whencleaningfuelnozzles,fuellinesorflowdividers,never useasmalldrillorapieceofwire.

23

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