Continental Motors GTSIO-520 SERIES User manual

Publication X30079
©CONTINENTAL MOTORS, INC. AUGUST 2011
GTSIO-520-D
CONTINENTAL® AIRCRAFT ENGINE
OPERATOR’S
MANUAL
FAA APPROVED

A GTSIO-520-D Operator’s Manual
31 August 2011
Supersedure Notice
This manual revision replaces the front cover and list of effective pages for Publication Part
No. X30079, dated June 1974. Previous editions are obsolete upon release of this manual.
Effective Changes for this Manual
0.......................June 1974
1...............31 August 2011
List of Effective Pages
Document Title:GTSIO-520-D Operator’s Manual
Publication Number: X30079 InitialPublication Date:June1974
Page Change Page Change Page Change Page Change
Cover..............................1
A......................................1
i.......................................1
ii thru iv............................0
1 thru 40..........................0
Published and printed in the U.S.A. by Continental Motors, Inc.
Available exclusively from the publisher: P.O. Box 90, Mobile, AL 36601.
Copyright © 2011 Continental Motors, Inc. All rights reserved. This material may not be reprinted,
republished, broadcast, or otherwise altered without the publisher's written permission. This
manual is provided without express, statutory, or implied warranties. The publisher will not be held
liable for any damages caused by or alleged to be caused by use, misuse, abuse, or
misinterpretation of the contents. Content is subject to change without notice. Other products and
companies mentioned herein may be trademarks of the respective owners.

OPERATOR'S MANUAL
F,OR
GTSIO-520 SERIES
AIRCRAFT ENGINES
NOTICE
IN ORDER TO PROPERLY
USE THIS ENGINE,
THE USER MUST COMPLY WITH
ALL INSTRUC-
TIONS CONTAINED HEREIN.
FAILURE TO SO
COMPLY WILL BE DEEMED MISUSE, RELIEVING
THE ENGINE MANUFACTURER OF ANY RE-
SPONSIBILITY.
THIS
MANUAL CONTAINS NO WARRANTIES,
EITHER EXPRESS OR IMPLIED. THE PURPOSE
OF THE DATA PRESENTED IS INSTRUCTION,
INFORMATION, AND SAFETY.
FORM NO. X30079
FAA APPROVED
REVISED JUNE 1974
1

TABLE OF CONTENTS
FOREWORD PAGE
III
INTRODUCTION ............................. 1
DESIGN FEATURES . .
.. . . . . . . . .. . . . . . .. .. .. . 1
1. General
............................... 1
2. Tabulated
Data ......................... 5
3. Oil System ..... '. . . . . . . . . . . . . . . . . . . . . . . . 9
4. Turbocharger.. . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Induction System
....................... 12
6. Ignition System
......................... 14
7. Fuel System
......... . . . . . . . . . . . . . . . . . . 14
OBERATING INSTRUCTIONS..... .. . . . . . . . . . . . . 15
1. Before Starting
......................... 15
2. Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. Warm Up . .. . . . . . . .. . . . . . . .. . . . . . . . . . . . . 17
4. Take-Off & Climb
....................... 20
5. Cruise..................... . . . . . . . . . . . . 21
6. Descending and
Landing. . . . . . . . . . . . . . . . . . . 21
7. Stopping Engine
......................... 22
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 22
. Trouble Shooting Chart
....................... 23
INSPECTION AND MAINTENANCE
............. 30
1. General
............................... 30
2. Daily Inspection
......................... 30
3. 50-Hour Inspection ..................... 31
4. 100-Hour Inspection ................. , . . . 32
FIG.
1.
2.
3.
4.
5.
6.
7.
8.
LIST
OF ILLUSTRATIONS
Sea Level Performance Curve
.............. .
Fuel
Flow V s. Brake Horsepower .......... .
Altitude Performance Curves
.............. .
Schematic
of Lubrication System .......... .
Turbocharger Sectional View
.............. .
Induction System .................... , ..
Schematic of Differental Pressure Tester
Idle
Adjustment Points .................. .
11
PAGE
3
3
4
10
12
13
33
38

FOREWORD
This booklet is intended to serve pilots and maintenance mechanics
as a pocket size guide to operation and maintenance requirements.
Subjects are limited to engine operation and inspection normally·
carried out on engines installed in aircraft of the personal and
executive transport types. No effort is made herein to describe
extensive
repair work or overhaul. For such instructions, refer to the
applicable overhaul manual. Careful observation of operating limits
and compliance with recommended inspection procedures herein will
result
in greater engine reliability.
world wide use of Continental ® engines in personal aircraft has led
to an extensive factory approved distributor network.· This system
receives the constant attention of our Service Department with the
aim of bringing spare parts, repair facilities and technical information
to the aircraft operator. These distributors, together with their
dealers, bring Teledyne Continental Motors approved spare parts and
service as close as the nearest airport.
Continental distributors are regularly supplied with Service Bulletins,
which are available for study by engine owners and other interested
parties. These bulletins may also be obtained on an annual
subscription basis for a nominal fee. Subscription order forms are
available
from authorized distributors.
The extent of this service organization, and the demands which it has
placed on our Service Department personnel, have made it impossible
to communicate directly with all individuals in regard to service
matters.
It is suggested that all technical questions, orders and
reports can best and most quickly be handled by your nearest
authorized distributor and that you should become acquainted with
that organization. There you will find a sincere interest in helping
you get the best service from your Continental engine.
No engine leaves
our factory until it has passed a rigid operational
test and inspection. Each engine, therefore, is believed to be free of
defects. If any Continental engine or part is suspected of failure or
does not perform properly, advise your nearest authorized
distributor giving model and serial number, hours operated, and
complete details. Do not attempt repalrs without proper
authorization if engine is within warranty.
111

CONTINENTAL MODEL GTSIO-520 ENGINE
INTRODUCTION
The Continental model GTSIO-520-D and Hare 6-cylinder,
fuel-injected, turbocharged, geared engines rated at 375
HP at 3400
RPM. These air cooled engines have a wet sump oil system, dual
magnetos and continuous-flow injection system. An exhaust driven
turbocharger provides a full supply
of intake air as the airplane
climbs away from sea level and enters rarified air
at altitudes.
Turbocharging provides a means for maintaining take-off power from
sea level
to altitudes up to 16,000 feet. The fuel injection system
supplies metered fuel
to the individual cylinders through injector
nozzles
to assure the proper fuel-air ratio for desired performance at
all altitudes.
DESIGN FEATURES
1. GENERAL
The engines have overhead valves, air cooled, horizontally opposed
cylinders with 5.25 inch bore, 4.00 inch stroke, 520 cubic inch
displacement, and a compression ratio
of 7.5:1. The cylinders have
down-directed exhaust outlets. The propeller flange has six bolt
holes, two dowel pins and a center pilot extension provided for
attaching
the propeller. The propeller drive shaft gear is driven by a
reduction gear, which in
turn is driven by the crankshaft through a
splined shaft. Provisions are made in the pilot extension for the
hydraulic propeller control oil which
is supplied internally from the
governor pad. The crankshaft
is also equipped with pendulum type
torsional damper weights. The engines have removable type hydraulic
tappets. Positive rotation
is provided for the exhaust valves by the
use of rotators. Tappets, push rod ends and rocker arm bearings are
lubricated
by the engine main oil pressure system.
1

~----------------~----~--~~--~~-=~--~~~==~~~----~---~
The engines are furnished with a scavenge pump to return engine oil 'II
from the turbocharger. A directdrive 24 volt, 50 amp alternator and
a direct cranking starter are furnished with
the engines. . J
The turbocharger, furnished with the engines must be suitably
mounted to the airframe in accordance with Continental
Specifications.
The turbocharger has a dual scroll feature to provide
turbo-bleed air for cabin pressurization in addition
to the engine air
requirements.
The induction system includes an intercooler
to provide for cooler
intake air from
the turbocharger.
A variable pressure controller,
mounted integrally with the throttle
and bleed air housing, is cam operated through the throttle linkage
and will control compressor discharge pressure according
to cam
positioning.
The relatively high power delivered
by these engines, per pound of
weight, is achieved by utilization of carefully selected high strength
materials,
by improvements in design calculated to make the
optimum use ,of these high quality materials, and by very close
control
of critical dimensions, surface finishes, heat treatment and
hardening processes. Careful work has produced more rugged engines
than could be built by less exacting methods. However, no amount
of ruggedness built into an engine will enable it to withstand serious
mistreatment. Overheating, neglect, and inferior fuels and lubricants
will seriously affect engine performance, particularly when
the
specific power rating is high and each part must be free to function
properly in order
to withstand the imposed loads with minimum
wear. These considerations are mentioned here in order
to emphasize
the necessity
of using the manufacturer's recommended gasoline and
oil and
the importance of keeping the fuel, oil and air filters clean.
The octane rating
of engine fuel should be as specified in the
tabulated data.
2