Continental A50 A65 A75 A80 Operator Manual Owner Manuals*
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Continental
A50
A65
A75
ABO
Engines
Combined Manual
Operator's, Maintenance, Overhaul
&
Parts Manuals
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ii
CONTINENTAL A 50, A 6 5 , A 7 5 , A80 ENGINES
INTRODUCTION
THIS book is a combined Operator's Manual, Maintenance and
Overhaul Manual and Illustrated Parts and Price List for the
Continental A50, A65, A 75, and A80 series 8 and 9 engines.
This manual is intended for use by operators and mechanics
as a guide and reference book in the operation and servicing of
these engines.
The book is divided into five main groups: Operating and
Maintenance Instructions, Overhaul Instructions, Table of Limits,
the Illustrated Parts List, and Accessories.
It is suggested that a careful study be made of this manual.
A strict adherence to the instructions outlined herein will assure
a fine operating record. However, if any point is not entirely
clear, do not hesitate to contact the nearest Authorized Conti-
nental Service Station or the factory Service Department.
In the event of failure of any engine part, notify the nearest
Authorized Continental Service Station at once, giving the engine
serial number, and full particulars. Do not attempt any repairs
without factory permission if any adjustment is expected.
CONTINENTAL MOTORS CORPORATION
Muskegon, Michigan
iii
CONTINENTAL A 50, A 6 5 , A 7 5 , A80
TABLE OF CONTENTS
OPERATING AND MAINTENANCE INSTRUCTIONS •
Section 1 - Introduction
Section 2 - Table of Specifications •
Section 3 - General Description •
1 • Differences Between Engine Models •
2. Cylinder Construction
3, Valve Operating Mechanism •
4.
5.
6.
7.
8.
9.
10.
a. General
b. Hydraulic Tappets
Crankshaft Construction
Crankcase and Oil Sump Construction
Connecting Rods •
Piston and Piston Pin Construction •
Crankcase Cover •
Lubricating System •
Fuel Injector •
Section
1.
2.
3.
4.
5.
4 - Packing, Unpacking, and Preparation for Storage
Shipping Boxes •
Packing
Unpacking the Engine •
Treatment of Engines for Periods of Idleness •
Preparation of Engines for Service after Treatment
Section
1.
2.
3.
4.
Section
1.
2.
3.
4.
5.
6.
7.
5 - Installation in Airplane and Removal
Engine Mounting •
Fuel and Carburetion System •
Oil System
Engine Removal .
6 - General Operating Instructions
Procedure Preliminary to Starting
Starting
Warm-up and Ground Test
Take-off
Flight •
Landing
Stopping
(a) Preliminary Procedure.
(b) Regular Procedure.
Carburetor Heat Control
Mixture Control •
8.
9.
10. Gasoline and Oil Recommendations
Section 7 - Engine Troubles and Service Repairs •
1 • Failure of Engine to Start •
, a. Lack of Fuel •
b. Under-priming or Over-priming
c. Defective Ignition
d. Valve Action •
e. Cold Oil
f. Hot Engine
2. Low Oil Pressure •
3. High Oil Temperature •
4. Low Power
5. Rough Running
6. Engine Fails to Accelerate Properly •
'7. Engine Fails to Idle Properly •
'.
Section 8 - Service Inspection and Associated Maintenance
1. General
2. Inspection and Maintenance
Sect'ion 9 - Adjustment, Replacement, and Minor Repair •
1. General
2. Carburetor
iv
..
ENGINES
Pages
3
3
6
6
8
8
8
8
8
9
9
9
10
10
10
14
14
14
14
14
15
15
15
15
17
17
20
20
20
20
21
21
21
21
21
21
21
21
22
22
22
22
22
22
22
22
22
22
23
23
23
23
23
23
23
23
25
25
25
CONTINENTAL A 50, A 6 5 , A 7 5 ,
TABLE Of CONTENTS - Continued
3. Magnetos.
4. Magneto Installation and Timing to the Engine
5. Ignition Wiring •
6. Removal of Parts
7. General Inspection •
8. Reassembly
a. General
b. Valves.
c. Valve Springs.
d. Piston Pins, Pistons, and Cylinders
e. Rocker Arms and Push Rods
f. Rocker Box Cover
g. Spark Plugs •
h. Adjustment of Valve Tappet Clearance
OVERHAUL INSTRUCTIONS •
Section
1.
2.
3.
4.
5.
Section
1.
2.
Section
1.
2.
10 - Disassembly, Cleaning and Inspection
General
Preliminary Operations •
Disassembly •
a. Oil Sump and Suction Tube •
b. Intake Pipes and Manifold •
c. Rocker Box Covers •
d. Push Rods and Rocker Arms
e. Cylinder and Pistons
f. Crankcase
g. Crankcase Cover Assembly (Series 8)
h. Crankcase Cover Assembly (Series 9)
Cleaning
a. General
b. Cleaning of Engine Parts
Inspection •
a. General
b. Inspection of Engine Parts
(1) Crankcase
(2) Cylinders
(3) Valve Mechanism
(4) Oil Sump.
(5) Crankshaft and Connecting Rods
(6) Pistons and Piston Pins
(7) Crankcase Cover
(8) Camshaft
(9) Gears
11 - Repair and Replacement
General •
Repair and Replacement of Engine Parts
a. Crankcase
b. Cylinders •
c. Valve Mechanism
d. Crankshaft and Connecting Rods
e. Pistons and Piston Pins •
f. Crankcase Cover Assembly
g. Camshaft and Hydraulic Tappets
h. Gear •
i. Intake Pipes, Connections and Clamps
j. Push Rod Housing Flanges, Connections and Clamps
k. Ignition System •
12 - Reassembly, Final Assembly, Timing and Testing
General • •
Reassembly of Major Sub-Assemblies
a. Cylinder and Valve Assembly Procedure
b. Connecting R~d to Crankshaft •
v
A80 ENGINES
Pages
26
26
26
27
27
27
27
27
27
27
28
28
28
28
29
29
29
.29
29
29
29
29
29
29
30
31
31
31
31
31
32
32
32
32
32
32
33
33
33
33
33
33
34
34
35
35
35
35
36
36
36
36
36
36
36
37
37
37
37
37
37
CONTINENTAL A 50, A 6 5 , A 7 5 ,
TABLE Of CONTENTS - Continued
c. Pistons and -Piston Pins • •
d. Crankcase Cover Assembly (Series 8)
e. Crankcase Cover Assembly (Series 9)
f. Intake Pipes and Hose Connections •
3. Final Assembly Procedure •
a. Preliminary
b. Installing Crankshaft and Connection Rods •
c. Assembly of Crankcases and Component Parts •
d. Installing Gears and Crankcase Cover •
e. Installing Oil Sump and Oil Suction Tube •
f. Installing Hydraulic Units and Push Rod Housing Flanges.
g. Installing Cylinders. •
h. Installing Air Intake System •
i. Installing Ignition System •
j. Installing Radio Shielded Ignition Wires
k. Testing Engine After Overhaul •
TABLE OF LIMITS
ILLUSTRATED PARTS LIST •
Section 13 - Introduction •
Section 14 - Group Assembly Parts List
Section 1 5 - Numerical Parts List
Section 16 - Oversize and Undersize Parts
ACCESSORIES. •
Section 1 7 - Stromberg NA-S3A 1 Carburetor
Service Instructions
Service Parts List •
Section 1 8 - Bendix-Scintilla Magneto
Service Instructions ' •
Service Parts List •
Section 1 9 - Wilcox Rich Hydraulic Lifters
Service Instructions
, .
vi
.,
A80 ENGINES
Pages
37
37
38
38
38
38
39
40
41
42
42
42
43
44
45
45
49
51
51
53
78
89
91
91
94
96
96
98
102
102
CONTINENTAL
INDEX
Figure
No.
A 5 0,
FOR
Title
A 6 5 , A 7 5 , A80
ILLUSTRATIONS
ENGINES
Page
No.
1 Three-Quarter Left Front View (Series 8) ................................... 1
2 Three-Quarter Right Rear View (Series 8) .................................. 2
3 Performance and Fuel Consumption Curves for A50, A65, A75, A80 Engines .. 5
4 Left Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
5 Right Side View.............................................................. 7
6 Section Through Hydraulic Tappet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
7 Fuel Injector Engine .......................................................... 11
8 Cutaway View Showing Gear Train .......................................... 13
9 Hoisting Engine with Crankshaft Lifting Eye ................................ 14
10 Hoisting Engine with Lifting Sling ........................................... 16
11 Typical Installation Diagram ................................................. 17
12 Installation Drawing .......................................................... 18
12a Installation Drawing .......................................................... 19
13 Ignition Wiring Diagram ..................................................... 26
14 Compressing· Valve Springs for Installation and Removal of Locks ........... 30
15 Removal of Hydraulic Unit from Cam Follower Body ......................... 30
16 Assembling and Removing Connecting Rods .................................. 31
17 Stud Identification ............................................................ 34
18 Assembling Rocker Shaft Bushings ........................................... 35
19 Installing Cam Follower Body into Crankcase ................................ 38
20 Installing -Crankshaft Bearings into Crankcase .............................. 39
21 Installing and Removing Crankshaft and Connecting Rods ................... 39
22 Installation of Crankcase 1-3 over Crankcase 2-4 ........................... .40
23 Installation of Gears in 'Crankcase ........................................... 41
24 Installation of Crankcase Cover to Crankcase .............. , ................. 41
25 Installation of Cylinder on Crankcase ........................................ 43
23 Determining Firing Position ................................................. 44
27 Lubrication Chart - Cross-sectional View .............................. , ..... 46
28 Lubrication Chart - Longitudinal View ...................................... 47
29 Lubrication Chart - Rear View ......................... : ................... 48
30 Crankcase - Illustrated Parts ·List ........................................... 52
31 Crankshaft, Connecting Rods and Pistons - Illustrated Parts List ............ 55
32 Cylinder and Valves - Illustrated Parts List ................................. 57
33 Rear Crankcase Cover and Gear Train - Illustrated Parts List .............. 59
34 Oil Sump and Suction Tube - Illustrated Parts List ......................... 62
35 Ignition System - Unshielded - Illustrated Parts List ....................... 64
36 Ignition System - Radio Shielded - Illustrated Parts List ................... 66
37 Carburetor, Carburetor Air Intake and Filter System - Illustrated Parts List. 68
38 Camshaft, Push Rods, Valve Tappets and Propeller Hub - Illustrated
Parts List .................................................................. 70
39 Fuel Injector Equipment - Illustrated Parts List ............................ 72
40 Fuel Pump and Oil Cooler Equipment - Illustrated Parts List ................ 75
41 Showing Magneto Timing Markers ............................................ 96
42 Timing Magneto ............................................................. 96
43 Breaker Mechanism .......................................................... 97
44 Magneto Illustrated Parts ................................................... 100
vii
A.5 0 I A 6 5, A 7 5 , A80 ENG I N ES
Page I
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CONTINENTAL A 50, A 6 5 , .l 7 5 , A80 ENGINES
....
Page 2
CONTINE.NTAL A 50, A 6 5 , A'Z 5 , A80 ENGINES
OPERATING AND MAINTENANCE
INSTRUCTIONS
Section 1
INTRODUCTION
1. This publication is the Service Instructions
for the model A50, A65, A 75, A80 engines, manu-
factured by Continental Motors Corporation, Mus-
kegon, Mich.
2. In this publication the following definitions
will be used:
(a) The propeller end of the engine will be
referred to as the "front" of the engine, and the
anti-propeller end will be referred to as the "rear."
The terms "right" and "left" are referred to as
viewing the engine from the rear looking in the
direction the propeller shaft points.
(b) Direction of rotation of the crankshaft is
clockwise when looking from the rear toward the
front of the engine. Cylinders are numbered as
follows:
Cylinder No. 1-
Right, rear side of crankcase
Cylinder No. 2-
Left, rear side of crankcase
Cylinder No. 3-
Right, front side of crankcase
Cylinder No. 4-
Left, front side of crankcase
Section 2
TABLE OF SPECIFICATIONS
GENERAL
Engine Type Certificate ..... _________ . __ . ________________________________ . __ A50 : No. 190; A65 : No. 205; A 75 : No. 213; A80 : No. 217
Models . __ ._. __ . ___ ............... ___ ...... ______ ... _ .. ______ . _______ ... ________ . _______ . _____ ........... __ . __ ._ .......... _._ .. ___ .A50, A65, A 75, A80, Series 8 and 9
Type ....................... _ .. ___ ..... _ .... __ .......... _______________________ . ______________ ...... Horizontally Opposed, 4 Cycle, Overhead Valve, Air Cooled
Number of Cylinders __ .. ____________ .. ______ ... ___ .___________ _ ______________ . ____ ....... _. ________ ............. _._ ........ __ . _______ ....... _. ___ . ___ ........ __________________ .. ____ ...... Four
Bore .. ____ ..... _ .. ___ .. ___ ... ___________ . __ . ______________________________________________ . _____________ .. ________ _ ____ . _________ .. ___ ... _. _____ . ________ .... __ . ___ ....... _. _____ . _____ . _________________ .. __________ ...... 3 0/8 in.
Stroke .. _._ .. _____ . ____ .. _____ ........... _. ______ . __________ .______ _ ___________________ .... ___ . __________ ... _ .... __________ ....... _. _____ .. _. __ .... _____ . __ . _____________ . ___ ._----...... 30/8 in.
Piston Displacement in Cu. In .... _______ _________ ......... _. ___ . ___ .___ _ ____________ .... ____. _____ .. __________ . ____ .. _____ ....... ___ ... ___ ._. ____ ... ____ . _____ ... __ ... _________ 171·
Compression Ratio .......... _____ ... _____ ..... _____ ... ___ . __ . __ . ___ .. ____ .. ___ .. __ ._. __ ..... ___ ...... __ . ______ ._ .. _____ .. ___ . ____ A50-8, 9 A65-8,9 A75-8,9 A80-8,9'
5.4 :1 6.3:1 6.3:1 7.55:1
Rated Brake Horsepower and R.P.M. at Sea Level (A50-8, 9) ______ ... _ .. _. __ . __ ... _ .... _. __ .. _ .... _. __ .___. ____ . _____ 50/1900
Rated Brake Horsepower and R.P .M. at Sea Level (A65-8, 9) ... __________________ ... _____ . ________ . _________ ..... _. ___________ . _________________ 65 /2300
Rated Brake Horsepower and R.P.M. at Sea Level (A75-8, 9) ............ ________ .. _ ... ____ . _____ ............... __ ... ___ ........ _____ ..... _______ 75/2600
Rated Brake Horsepower and R.P .M. at Sea Level (A80-8, 9) . ___________ . __ . __ .. ______ ..... _________________ ....... _________________ . __________ .80 /2700
Direction of Rotation of Crankshaft, (from anti-propeller end) __ .. ________ .. ____ ......... __ .... _ ... _____ .. _. ______ .... _ .......... __ ......... Clockwise
Number of Mounting Bolts ....... ___________ ........ ___ .. _ .. _ ............. _ ...... _____ ... _ .. _ ... _ .. ______ .... _ .. ____ .. ____________ ... ______________ . ___________ .. _ ...... ___ . ___________ . _________________ ._. ____ ... __ 4
Size of Mounting Bolts________ _ ________________________________ .. _________ . ___ .... ______________________ . _____ ... __ . ______________ . ___ . ___________ ........ ____ . ____ ..... __ . __ ._.7 /16 in.
Average Weight of Engine ___ ... ____________ . ________ . ___________ ._. __ . ___ . ___ ........ _._____. ___________ .. _______Series 9 engines Series 8 engines
177.0 lbs. 176.0 lbs.
Overall Width of Engine __ .... _____ .. __ . __ .. ____ . ___________ . _______ .. __ ..... _. ___________ .. _______________ . ______ ._....... ______ . _______ ................ __ .. _______ .. _. __ . _____ 31-11 /16 in.
Overall Length of Engine .... _. ______ .... ______ ........ _____ .. _ ....... __ .. ______ .. _ .. ____________________ ..... ____ ..... _______ ._. __ Series 9 engines Series 8 engines
33-11/32 in. 30-13/32 in.
Page 3
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This is the Operators Handbook for the Continental Aircraft Engines:
- A50 series 5, 6, 7, 8 & 9
- A65 series 1, 3, 6, 7, 8 & 9
- A75 series 3, 6, 8 & 9
- A80 series 3, 6, 8 & 9
This handbook contains necessary information for operating, servicing, and overhauling the A50, A65, A75 & A80 engines. It is our suggestion that you study this entire manual closely. A strict adherence to the instructions outlined herein will assure you a fine operating record.
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