Gipsy major overhaul manual
This manual compiles with British Civil Airworthiness Requirements Section A, Chapter A6-2. The technical accuracy of this manual has been verified and is certified as correct.
CONTENTS AND LIST OF CHAPTERS
NOTE : A list of its contents and illustrations appears at the beginning of each chapter.
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FRONTISPIECE | |
|
TORQUE LOADING TABLE | |
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CHAPTER |
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I.
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Description of Engine. |
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II.
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Lubrication. |
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Ill.
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Carburation. |
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IV.
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lgnition. |
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V.
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Installation. |
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VI.a.
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Operating Instructions. |
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VI.b.
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Defect Diagnosis. |
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VI.c.
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Storage and Anti-Corrosion Treatment. |
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V I.d.
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Components containing asbestos. |
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VII.
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Maintenance Schedule and Routine Servicing. |
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VIII.
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Tools and Equipment. |
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IX.
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Dismantling. |
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Xl.
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Rectification and Salvage. |
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XII.
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Reassembling. |
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XIII.
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Testing after Overhaul. |
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XIV.
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Table of Fits and Clearances. |
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XV.
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BTH Magnetos. |
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XVI.
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Rotax Electric Starter. |
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XVII.
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K.L.G. Sparking Plugs. |
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XVIII.
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Lodge Sparking Plugs. |
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XIX.
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Hobson Carburettor. |
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XX.
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Fuel Pump. |
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Accessory Manufacturers' Addresses. | |
''''TORQUE LOADING TABLE
To assist overhaul and maintenance operators to ensure that correct loads are applied when tightening certain nuts on Gipsy Major Series 10 engines, the table set out below lists the respective torque loading values. These values are subject to threads being lubricated, and not being stiff to turn during any part of their travel ; they are not the loadings to be applied when the appropriate studs are being inserted. The table will be amended accordingly when appropriate torque loading values are issued for other components of the engine.
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Nut Part No. |
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800-CN-1 |
Nut, Intermediate and Rear Main Bearing |
MSW 208, TQ.S0A |
|
800-CN-2 |
Nut, Front Main Bearing |
MSW 207, TQ.S0A |
|
N.372 or N.376 |
Nut, Rocker Bracket (pre-mod. 2197) |
|
|
N.6542 |
Nut, Rocker Bracket (mods. 2197 or 2282)* |
Tighten to 360, slacken completely and then retighten to 275. MS W 204, TQ.S0A |
|
1900/3 |
Nut, Connecting Rod |
|
|
801/16B |
Nut, Cylinder, Holding Down |
T79013 T86451 |
Cylinder Heads (mods. 2197 and 2282)
Modification 2197 introduces a redesigned cylinder head of L.35 (' Y' alloy) which provides for the attachment of the rocker bracket to the cylinder head with three studs and one bolt. The rocker platform provides better support by improved cylinder head webbing ; the valve rocker bracket supports the valve rocker cover thus dispensing with the stirrup bracket ; the cylinder head cooling is improved by additional finning in the vicinity of the exhaust port ; and 14 mm. sparking plug adapters replace the l 2 mm. type. When this modification is embodied, the / 2 mm. sparking "plug end fittings of unscreened, and screened ignition cables are replaced with end fittings suitable for use with the 14 mm. screened type sparking plugs.
As an alternative to the cylinder head mod. 2197, a cylinder head mod. 2282 is introduced incorporating 12 mm. plug adapters to permit the use of 12 mm. sparking plugs.
When assembling the rocker bracket to the cylinder head, it is important that all the rocker bracket attachment nuts are tightened in rotation with small torque increments until the final torque loading value is obtained.
