Continental Refrigerator CD-300 Manual

Operation & Maintenance
Manual
 CAUTION:
The Operation Manual must be read completely before
operating the engine, as it contains important safety
information and information about the operation of the
engine.
 Note:
The Operation Manual must be included at the time of sale of
the engine / aircraft.
CD-300
Doc. No.: OM-06-01
Version: 2 / 4
Continental
Aerospace Technologies GmbH
Platanenstraße 14
D - 09356 St. Egidien
Tel. [phone]
Fax [phone]
www.continentaldiesel.de
[email protected]
Operation & Maintenance Manual - Issue 2 / Revision 4
P/N: 06-7200-H200008

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Table of Contents
Chapter Description Page
Table of Contents ...............................................................................3
List of Figures .....................................................................................5
0.1 List of Revisions .................................................................................7
0.2 List of applicable chapters .................................................................9
0.3 Preliminary Remarks .......................................................................10
1 Introduction ......................................................................................1
1.1 Engine Identification ..........................................................................1
1.2 Copyright © ........................................................................................2
1.3 Safety Recommendations ..................................................................2
1.4 Validity of this Manual ........................................................................2
1.5 Abbreviations .....................................................................................2
1.6 Packaging and Transport ...................................................................3
1.7 Storage ..............................................................................................3
1.8 Scope of Supply .................................................................................3
1.9 Qualifications of the Operating and Maintenance Personnel .............4
1.10 Update Information Service ...............................................................4
1.11 Service Life of this Engine .................................................................4
1.12 Safety Information ..............................................................................5
2 Description and Dimensions of the Engine ..................................1
2.1 Engine Designation ............................................................................1
2.2 Description and Standard Production Version ...................................1
2.3 Engine Views .....................................................................................2
3 Technical Data .................................................................................1
3.1 Dimensions and Weights ...................................................................1
3.2 Performance Data ..............................................................................1
3.3 Operational Data ................................................................................2
3.4 Operation Limits .................................................................................3
3.5 Fuel / Oil / Coolant .............................................................................4
3.6 Power Curve ......................................................................................6
4 Operation ..........................................................................................1
4.1 Pre-Flight Inspection ..........................................................................1
4.2 Start-up ..............................................................................................1
4.3 Engine Warm-up ................................................................................2
4.4 Before Takeoff Check ........................................................................2
4.4.1 FADEC and propeller pitch functional check .....................................2
4.4.2 Engine test run for maintenance purposes ........................................4
4.4.3 FADEC-Warning ................................................................................5
4.5 Takeoff and climb ..............................................................................7
4.6 During flight ........................................................................................7
4.7 Shutting down the engine ..................................................................7

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5 Airworthiness Limitation Section ...................................................1
5.1 Airworthiness Limitations ...................................................................1
6 Maintenance Schedules ..................................................................1
6.1 "Pre-flight Check" ...............................................................................2
6.2 Maintenance Actions .........................................................................3
Annex 1 - Replacing the V-Ribbed Belt ..............................................................6
Annex 2 - Inspecting the Oil and Fuel System for Leakage ...............................7
Annex 3 - Inspecting the Cooling System for Leakage ......................................8
Annex 4 - Engine Test Run ................................................................................9
Annex 5 - Exchanging the Engine Oil and Oil Filter .........................................10
Annex 6 - Cleaning the Engine ........................................................................13
Annex 7 - Checking the FADEC Sensors ........................................................14
Annex 8 - Exchanging the Gearbox Oil ............................................................15
Annex 9 - Checking the Gearbox Oil Level ......................................................17
Annex 10 - Reserved .........................................................................................18
Annex 11 - Replacing the High-Pressure Pump ................................................19
Annex 12 - FADEC Software Update .................................................................20
Annex 13 - Exchanging the Coolant ...................................................................22
Annex 14 - Replacing the Gearbox ....................................................................23
Annex 15 - Replacing the Fuel-Feed Pump .......................................................24
Annex 16 - Replace the Alternators ...................................................................25
Annex 17 - Engine was not started for up to 6 months ......................................26
Annex 18 - Perform an Engine Oil Analysis .......................................................27
7 Emergency Procedures ...................................................................1
7.1 Power Loss ........................................................................................1
7.2 FADEC Operation ..............................................................................1
7.3 Engine System Malfunction ...............................................................2
7.3.1 One FADEC light flashing ..................................................................2
7.3.2 Both FADEC lights flashing ...............................................................2
7.3.3 Abnormal engine behavior .................................................................2
7.4 Re-Start after Engine Failure .............................................................3
7.5 Fire in the Engine Compartment ........................................................3
7.6 Air in the Fuel System (During Flight) ................................................4
7.7 Oil Pressure too Low (During Flight) ..................................................4

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List of Figures
Chapter Figure Description
Table of Contents
List of Figures
Fig. 0.1 Explanation of the chapter numbering system
1Introduction
Fig. 1.2 Engine identification
Fig. 1.3 Preservation of the engine
2 Description and Dimensions of the Engine
Fig. 2.1 CD-300 (XYZ-Axis)
Fig. 2.2 CD-300 - overview
Fig. 2.3 CD-300 - overview
Fig. 2.4 CD-300 - overhead view (dimensions in mm)
Fig. 2.5 CD-300 - side view BANK1 / LH (dimensions in mm)
P/N: 06-7200-K0001
Fig. 2.6 CD-300 - gearbox side view (dimensions in mm)
P/N: 06-7200-K0001
Fig. 2.7 CD-300 - timing side view (dimensions in mm)
P/N: 06-7200-K0001
Fig. 2.8 CD-300 - side view BANK1 / LH (dimensions in mm)
P/N: 06-7200-K0002 / 06-7200-K0003
Fig. 2.9 CD-300 - gearbox side view (dimensions in mm)
P/N: 06-7200-K0002 / 06-7200-K0003
Fig. 2.10 CD-300 - timing side view (dimensions in mm)
P/N: 06-7200-K0002 / 06-7200-K0003
3 Technical Data
Fig. 3.11 Power curve
4 Operation
5 Airworthiness Limitation Section

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6 Maintenance Schedules
Fig. 6.12 Replacing the V-Ribbed Belt
Fig. 6.13 Inspecting the Oil and Fuel System for Leakage
Fig. 6.14 Inspecting the Cooling System for Leakage
Fig. 6.15 Exchanging the Engine Oil
Fig. 6.16 Exchanging the Engine Oil Filter
Fig. 6.17 Exchanging the Gearbox Oil Filter
Fig. 6.18 Exchanging the Gearbox Oil
Fig. 6.19 Check the oil level
Fig. 6.20 Replacing the High-Pressure Pump
Fig. 6.21 coolant drain screw plug
Fig. 6.22 Replacing the Gearbox
Fig. 6.23 Replacing the Fuel-Feed Pump
Fig. 6.24 Replace the Alternators
Fig. 6.25 Endoscopy / boroscopy of the combustion cham-
bers
7 Emergency Procedures

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0.1 List of Revisions
Document No. Issue/Rev. Remark Date Approved by
Issue 1 / Revision -:
06-OM-00-00 1/- first release 15.05.2014 Hartung
06-OM-01-01 1/- first release 15.05.2014 Hartung
06-OM-02-01 1/- first release 15.05.2014 Hartung
06-OM-03-01 1/- first release 15.05.2014 Hartung
06-OM-04-01 1/- first release 15.05.2014 Hartung
06-OM-05-01 1/- first release 15.05.2014 Hartung
06-OM-06-01 1/- first release 15.05.2014 Hartung
06-OM-07-01 1/- first release 15.05.2014 Hartung
Issue 1 / Revision 1:
06-OM-00-00 1/1 18.06.2017 Hartung
06-OM-01-01 1/1 18.06.2017 Hartung
06-OM-02-01 1/1 18.06.2017 Hartung
06-OM-03-01 1/1 18.06.2017 Hartung
06-OM-04-01 1/1 18.06.2017 Hartung
06-OM-05-01 1/1 18.06.2017 Hartung
06-OM-06-01 1/1 18.06.2017 Hartung
06-OM-07-01 1/1 18.06.2017 Hartung
FOBL E8-01 04 new 07/2014
Issue 1 / Revision 2:
06-OM-00-00 1/2 Revision 24.09.2018 Hartung
06-OM-02-01 1/2 Correction 24.09.2018 Hartung
06-OM-03-01 1/2 Correction 24.09.2018 Hartung
06-OM-06-01 1/2 Correction 24.09.2018 Hartung

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Issue 2 / Revision -:
all 2/- Editorial Change 06.04.2020 Hartung
06-OM-00-00 2/- Revision 06.04.2020 Hartung
06-OM-03-01 2/- Correction 06.04.2020 Hartung
06-OM-06-01 2/- Update 06.04.2020 Hartung
Issue 2 / Revision 1:
06-OM-00-00 2/1 Revision 30.04.2021 Hartung
06-OM-01-01 2/1 Update 30.04.2021 Hartung
06-OM-02-01 2/1 Update 30.04.2021 Hartung
06-OM-03-01 2/1 Update 30.04.2021 Hartung
06-OM-04-01 2/1 Update 30.04.2021 Hartung
06-OM-06-01 2/1 Update 30.04.2021 Hartung
06-OM-07-01 2/1 Update 30.04.2021 Hartung
Issue 2 / Revision 2:
06-OM-00-00 2/2 Revision 25.06.2021 Hartung
06-OM-03-01 2/2 Update 25.06.2021 Hartung
Issue 2 / Revision 3:
06-OM-00-00 2/3 Revision 16.06.2022 Hartung
06-OM-01-01 2/2 Update 16.06.2022 Hartung
06-OM-03-01 2/3 Update 16.06.2022 Hartung
06-OM-06-01 2/3 Update 16.06.2022 Hartung
CL 3to 6 2/- new 16.06.2022 Hartung
CL General 2/- new 16.06.2022 Hartung
Issue 2 / Revision 4:
06-OM-00-00 2/4 Revision 19.10.2022 Hartung
06-OM-05-01 2/1 Update 19.10.2022 Hartung
Document No. Issue/Rev. Remark Date Approved by

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0.3 Preliminary Remarks
1. The chapter numbering of the footer is different to the
chapter numbering of the remaining manual.
Fig. 0.1 Explanation of the chapter numbering system
refers to chapter
refers to chapter
refers to the section 
of the chapter

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1 Introduction
This Operation and Maintenance Manual contains basic
information related to the proper operation of the engine in
various situations and under different conditions. It also contains
instructions for maintenance. The information and descriptions of
components and systems in this manual were correct at the time
of publication. Any amendments released through the update
information service must be taken into account.
Please contact Continental Aerospace Technologies GmbH if
you have any questions. We will be glad to provide further
assistance.
Contact address:
Continental Aerospace Technologies GmbH
Platanenstraße 14
D - 09356 St. Egidien
Fon: [phone]
Fax: [phone]
1.1 Engine Identification
The serial number of the engine is provided on the data plate of
the crankcase.
Fig. 1.2 Engine identification
Data plate
Note: If inquiries are made, always have the serial number of the
engine ready.
Note: Further information about the key for serial numbers of the
engine is published in Service Bulletin TM TAE 000-0005.

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1.2 Copyright ©
1.3 Safety Recommendations
The following symbols and warning signs are used in the manual.
They must be heeded strictly to prevent personal injury and
material damage, to avoid impairment of the operational safety of
the aircraft and to rule out any damage to the aircraft as a
consequence of improper handling.
The indications "right", "left", "front" and "rear" are always given
in relation to the flight direction. The following symbol is used:
Example of flight direction to the right:
1.4 Validity of this Manual
Updates and modifications must be taken into account.
1.5 Abbreviations
The following abbreviations are used in this manual:
These technical data and the information contained therein are
the property of Continental Aerospace Technologies GmbH and
may not be reproduced either in full or in part or passed on to a
third party without written consent from
Continental Aerospace Technologies GmbH.
This text must be included in any full or partial reproduction of
this documentation.
Copyright © Continental Aerospace Technologies GmbH
WARNING: Disregarding these safety rules can cause personal injury or
even death.
CAUTION: Disregarding these special instructions and safety measures
can cause damage to the engine or other components.
Note: Additional note or instructions for better understanding of an
instruction.
CAN Controller Area Network
FADEC Full Authority Digital Engine Control
MAP Manifold Air Pressure

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1.6 Packaging and Transport
The engine has been packaged at the factory for transport as
follows:
•Wrapped on a support in a wooden crate
The package should be kept for re-use in a possible future
shipment.
1.7 Storage
The following must be observed during transport and subsequent
storage:
•Store only in workplaces that are suitable for the purpose.
•Never store outdoors.
•Ambient temperature: -30°C to +70°C.
•Relative humidity: less than 70%.
•The shipping crate must be kept in a horizontal position
during storage.
•The max. storage time is noted on the delivery note of the
engine.
•Preservation of the engine. See Fig. 1.3.
1.8 Scope of Supply
The scope of supply is specified in Chapter 2.2.
Fig. 1.3 Preservation of the engine
Customer / Distributor
Customer / Distributor
Re-preservation
Engine installed and
filled with fluids and lubricants
Engine started every month
Engine was not started
for up to 6 months
see Chapter Annex 17

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1.9 Qualifications of the Operating and Maintenance
Personnel
Maintenance work should only be performed by persons
authorized through the competent authority of the respective
country.
In order to ensure a high quality standard for our product,
Continental Aerospace Technologies GmbH strongly
recommends that operators only
utilize the service centers recommended by
Continental Aerospace Technologies GmbH through
Service Bulletin TM TAE 000-0003.
1.10 Update Information Service
This manual is covered by a continuous update information
service. The engine / aircraft operator is responsible for keeping
up-to-date with all amendment bulletins issued by Continental
Aerospace Technologies GmbH and integrating them into this
manual.
Please inform Continental Aerospace Technologies GmbH if the
owner of the engine / aircraft changes. This is the only way to
ensure that information about any necessary / recommended
changes to the engine / manual can be passed on. A form is
included for this purpose in this manual.
See FOBL E8-01 - Change of Hands.
1.11 Service Life of this Engine
WARNING: The service life of the engine is limited. Continental Aerospace
Technologies GmbH therefore most strongly recommends that
the engine should be replaced when it reaches.

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1.12 Safety Information
•This engine is not suitable for aerobatics use.
•Intentionally initiating negative-G flights is prohibted.
•This engine is not approved for rotor craft (helicopters,
gyrocopters, etc.).
•Never leave the aircraft unattended while the engine is
running.
•Secure all tools before starting the engine to prevent
personal injury or damage.
•When the engine is not in use, protect it and the fuel system
from contamination and accidental / unauthorized
manipulation.
•Never operate the engine without the specified quality and
quantity of fluids.
•Let the engine cool down a few minutes before shutting it
off.
•Engine monitoring instruments are not included in the
scope of supply of the engine. Use only suitable, approved
instruments.
•In some areas, at some flight altitudes and under certain
operating conditions, it may be necessary to protect the
engine from extreme humidity, dust or sand using further
special equipment. Please consult the aircraft manufacturer
or distributor.
•Under extreme conditions such as low usage combined
with operation in a oceanic atmosphere, or in a very dusty
or sandy environment, shorter maintenance and inspection
intervals are recommended for your own safety.
WARNING: Any Aircraft Engine Ground Run must be conducted in a secure
area that is protected from the unauthorized movement of
personnel!
Any rotating propeller is a potential safety hazard that can cause
severe personal injuries or even death!

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•The CD-300 engine must only be taken into operation by
persons who are familiar with the corresponding manuals
and who have the required level of authorization.
•Only the approved equipment must be used. The use of any
unapproved equipment absolves the manufacturer from
any liability.
•Improper installation, the use of non-suitable lines for the
fuel, cooling and oil circuits, and operation with non-
approved fuels or lubricants/oils absolves the manufacturer
from any liability.
•Any unauthorized modifications made to the engine or the
aircraft absolve the manufacturer from liability for related
damages.
•The pertinent accident prevention regulations as well as
other commonly accepted safety, occupational health and
air traffic legal requirements must also be observed.
•Operators must also observe any additional regulations and
requirements which are applicable in their territory.

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2 Description and Dimensions of the Engine
2.1 Engine Designation
Centurion 3.0 (sales name CD-300)
2.2 Description and Standard Production Version
The CD-300 is a liquid-cooled V6-cylinder-four-stroke diesel
engine with Double Overhead Camshaft. The valves are
actuated by cam follower.
The direct diesel-injection engine operates based on the
common-rail technique and is turbocharged.
The engine is controlled by a FADEC-System.
The propeller is driven by a gearbox with a Dual-Mass-Flywheel.
Scope of supply
The following components and assemblies are included in the
scope of supply of the CD-300
•2 Turbochargers (LH & RH)
•Integrated propeller controlling and adjusting unit
•2 Alternators (LH & RH)
•Starter
•FADEC System
•Wiring harness
•All of the actuators and sensors required for engine
operation
•Oil pump
•Water pump
•Gearbox
•Engine shock mounts
•Injection system
•Fuel feed pump and high-pressure pump
•Oil Heat Exchanger
•Gearbox Oil Heat Exchanger
Note: To maintain compliance with the airworthiness requirements for
operation of this engine, only components, materials and
procedures for workmanship, that have been approved by
Continental Aerospace Technologies GmbH are to be used.
Deviations from approved components, materials and
procedures can be reasonable cause to cancel manufacturer’s
guarantees and warranties.

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Ground/ Flight-Idle Option
The CD-300 can be equipped with an ground/ flight idle option.
The ground/ flight idle function reduce idle power and idle thrust
on ground and ensured the operability of the FADEC-Test at
airfields with an elevation from 6,000ft up to 10,000ft.
The load lever must have a mechanical ground idle lock which
avoid unintentional pulling in the ground idle position during flight.
Increasing the load command by moving the load lever over the
mechanical lock activates the Flight-Idle function.
2.3 Engine Views
Main dimensions of engine and gearbox:
Length: ...................................................................... ca. 980 mm
Width: ........................................................................ca. 790 mm
Height:.......................................................................ca. 700 mm
WARNING: Ground idle operation during flight is prohibited and may lead to
an engine flame out and total power loss.
Note: The coordinate system defined in these views forms the basis
for all dimension specifications in the installation manual.
Note: The indications "right", "left", "front" and "rear" are always
relative to the flight direction. The following symbol is used: 
Example of flight direction right:

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Fig. 2.1 CD-300 (XYZ-Axis)
Direction
Reference
point:
Prop
flange center
unit
X
- Axis
531
mm
Y
- Axis
-
13
mm
Z
- Axis
-
68
mm
Z
X
Y
Fig. 2.2 CD-300 - overview
compressorair
intake
plenum air
intakes
compressor air
outlet
gearbox oil
cooler
front engine
mounts
compressorair
intake
compressor air
outlet
gearbox oil drain
plug
gearbox oil filter
engine breather

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Fig. 2.3 CD-300 - overview
Fig. 2.4 CD-300 - overhead view (dimensions in mm)
water inlet
alternator 1
waterpump
oil filter
high pressure
fuel pump
engine oil
filler cap
low pressure
fuel pump
rear engine
mounts
alternator 2
oil dip stick
* 398
* 790
* 392
Y
X
BANK 2
BANK 1
Gearbox Side Timing Side