Continental Motors TSIO-520-BE User manual

Publication X30570 CHANGE 2
©2011-2013 CONTINENTAL MOTORS, INC. OCT 2013
TSIO-520-BE
CONTINENTAL®AIRCRAFT ENGINE
PERMOLD SERIES
MAINTENANCE
AND
OPERATOR’S MANUAL
TECHNICAL CONTENT ACCEPTED BY THE FAA

A TSIO-520-BE Permold Series Engine Maintenance and Operator’s Manual
CHANGE 2 15 October 2013
Supersedure Notice
This manual revision replaces the front cover and list of effective pages for Publication Part No. X30570, dated
February 1990. Previous editions are obsolete upon release of this manual.
Effective Changes for this Manual
0 ..............February 1990
1 ............ 31 August 2011
2 .......... 15 October 2013
List of Effective Pages
Document Title: TSIO-520-BE Permold Series Engine Maintenance and Operator’s Manual
Publication Number: X30570 Initial Publication Date: February 1990
Page Change Page Change Page Change Page Change
Cover............................ 2
A................................... 2
i thru iv.......................... 0
1-1 thru 1-10.................0
2-1 thru 2-42.................0
3-1 thru 3-8................... 0
4-1 thru 4-4................... 0
5-1 thru 5-8................... 0
6-1 thru 6-8................... 0
7-1 thru 7-6................... 0
8-1 thru 8-6................... 0
9-1 thru 9-12.................0
10-1 thru 10-12.............0
11-1 thru 11-4 ............... 0
12-1 thru 12-2...............0
13-1 thru 13-15.............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 © 2011-2013 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.

FORM NO. X30570-1
i
MAINTENANCE AND OPERATOR’S MANUAL
FOR
TSIO-520-BE AIRCRAFT ENGINE
- NOTICE-
The operator must comply with all the instructions contained in this manual in order to assure safe and reliable
engine performance. Failure to comply will be deemed misuse, thereby relieving the engine manufacturer of
responsibility under its warranty.
This manual contains no warranties, either expressed or implied. The information and procedures contained
herein provide the operator with technical information and instructions applicable to safe operation.

CHAPTER INDEX
c~~~ P~e
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 Tools and Equipment .................................................. 2-1
3 Detailed Engine Description ............................................. 3-1
4 Engine Specifications and Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 Unpacking, Installation, Testing & Removal .................................. 5-1
6 Normal Operating Procedures ............................................ 6-1
7 Emergency Operating Procedures ......................................... 7-1
8 Abnormal Environmental Conditions ....................................... 8-1
9 Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
1 O Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11 Engine Preservation and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13 Engine Performance and Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
ii

FIGURE INDEX
Figure No. Page
3- 1 Lubrication System Schematic
3-3
3- 2 Induction and Exhaust System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3- 3 Turbocharger Sectional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3- 4 Ignition Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3- 5 Fuel Injection System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
5- 1 Installation Drawing
5-4
5- 2 Installation Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6- 1 Priming Time Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
13- 1 Sea Level Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
13- 2 Constant Speed Sea Level Performance Full Rich Mixture ....................... 13-5
13- 3 Constant Speed Sea Level Performance Best Power Mixture ..................... 13-6
13- 4 Altitude Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 7
13- 5 Mixture Ratio Curve - 80% 2500 RPM and 32.8" Hg. ADMP ...................... 13-8
13- 6 Mixture Ratio Curve - 75% 2400 RPM and 32.5" Hg. ADMP ...................... 13-9
13- 7 Mixture Ratio Curve - 65% 2300 RPM and 30.0" Hg. ADMP ..................... 13-10
13- 8 Mixture Ratio Curve -
50% 2200 RPM and 25.8" Hg. ADMP
13-11
13- 9 Fuel Flow Vs. Brake Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
13-10 Metered Fuel Pressure Vs. Fuel Flow ..................................... 13-13
13-11 Fuel Injection Fuel Pump Pressure - PSIA Vs.
% Rated Horsepower - 100°F AVGAS .................................... 13-14
13-12 Fuel Flow Vs. Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
iii

INTENTIONALLY
LEFT
BLANK
iv

Section
1-1
1-2
1-3
1-4
CHAPTER 1
INTRODUCTION
Section Index
Page
Scope..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Abbreviations and Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-1

INTRODUCTION
1-1 SCOPE
Recommendations, cautions and warnings regarding operation of this engine are not intended to
impose undue restrictions, but are inserted to enable the pilot to obtain maximum performance from
the engine commensurate with safety and efficiency. Abuse, misuse,
or neglect of any piece of
equipment can cause eventual failure. In the case of
an aircraft engine it should be obvious that a
failure may have disastrous consequences. Failure
to obseive the instructions contained in this
manual constitutes unauthorized operation in areas unexplored during development
of the engine,
or in areas which experience
has proved to be undesirable or detrimental.
Notes, Cautions and Warnings are included throughout this manual, Application is as follows:
NOTE
... Special interest information which may facilitate the operation of equipment.
CAUTION ... Information issued to emphasize certain instructions or to prevent possible damage
to engine or accessories.
WARNING ... Information which, if disregarded, may result in severe damage to or
destruction of the engine or endangerment to personnel.
1-2

1-2 RELATED PUBLICATIONS
I. Engine Manuals:
A Overhaul Manual for TSI0-520-BE Series Aircraft Engine. Form No. X30574A.
8. Illustrated Parts Catalog for TSI0-520-BE Series Aircraft Engine. Form No. X30576A.
C. Teledyne Continental Motors Aircraft Engine Service Bulletins.
D. Fuel Injection Manual. Form X30593A.
The above publications can be ordered through your Teledyne Continental Motors Distributor
or ordered directly, if prepaid, from:
Teledyne Continental Motors
Aircraft Products
P. 0. Box 90
Mobile, AL 36601
Attn: Accounts Receivable
For price information see TCM Optional and Current Publications Service Bulletins.
II. Accessory Manuals:
A. Magnetos
B. Starter Motor
C. Alternator
Service Manual
Teledyne Continental Motors
Aircraft Products
P. 0. Box 90
Mobile, AL 36601
Attn: Accounts Receivable
Teledyne Continental Motors
Aircraft Products
P. 0. Box 90
Mobile, AL 36601
Attn: Accounts Receivable
Alternator Service Instructions
Form X30531-3
Teledyne Continental Motors
Aircraft Products
P. 0. Box 90
Mobile, AL 36601
Attn: Accounts Receivable
1-3

1-3 DEFINITIONS AND ABBREVIATIONS
ABBREVIATIONS/SYMBOLS
TERM
A,B,C
ADMP
Approx.
A.T.C.
Bar.
B.B.C.
B.H.P.
BSFC
B.T.C.
F.A.A.
C.A.R.
c.f.m.
C.G.
C.H.T.
ccw
cw
OF.
EGT
Fig.
Front
ft.
F.T.
FT-LBS
G.P.M.
gms
H20
Hg.
l.D.
in.(")
Hex.
hr.
IN-LBS
Left Side
Lbs.
Lockwire
100LL
Man.
Max.
Min.
30'
N.P.T.
N.C.
N.F.
NRP
OAT
O.D.
oz
Press.
p.s.i.
EXPLANATION
After Bottom Center
Absolute Dry Manifold Pressure
Approximately
After Top Center
Barometric
Before Bottom Center
Brake Horsepower
Brake Specific Fuel Consumption
Before Top Center
Federal Aviation Administration
Civil Air Regulations
Cubic Feet Per Minute
Center of Gravity
Cylinder Head Temperature
Counterclockwise Rotation
Clockwise Rotation
Degrees of Angle
Degrees Fahrenheit
Exhaust Gas Temperature
Figure (Illustration)
Propeller
End
Foot or Feet
Full Throttle
Foot Pounds Torque
Gallons Per Minute
Grams
Water
Mercury
Inside Diameter
Inches
Hexagon
Hour
Inch Pounds Torque
Side on which Nos.
2, 4 and 6 cylinders are located (Rear to Front)
Pounds
Stainless Steel Wire Used To Safety Connections, Etc.
100 Octane Low Lead Fuel
Manifold Manometer
Maximum
Minimum
Thirty Minutes of Angle (60' equals one degree)
National Pipe Thread (tapered)
National Course (thread)
National Fine (thread)
Normal Rated Power
Outside Air Temperature
Outside Diameter
Ounce
Pressure
Pounds Per Square Inch
1-4