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Teledyne Continental Motors CONTINENTAL L/TSIO-360-RB, Maintenance Manual

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Teledyne Continental Motors CONTINENTAL L/TSIO-360-RB Maintenance Manual Download Page 58

6-4

6-5

PREPARATION FOR SERVICE

If the engine is not to be installed within five (5) days after removing shipping plugs, it must
be represerved in accordance with procedures listed in Chapter 8.

If the engine is to be installed within five (5) days after unpacking, remove the shipping plugs
installed in the lower spark plug holes and turn the crankshaft through at least two complete
revolutions in order to remove the cylinder preservation oil from the cylinder. Remove the
shipping plugs installed in the upper spark plug holes and inspect the cylinder bore with a
borescope for rust or contamination.  Contact your Teledyne Continental Motors Distributor if
any abnormal condition is noted.

Apply Champion® thread lubricant to spark plugs in accordance with the manufacturer's
instructions (see Chapter 3).  Install the spark plugs and torque to 300-360 in. lbs.Install the
upper spark plugs finger tight.

CAUTION . . . During installation of propeller governor in accordance with the airframe
manufacturer's instructions ,insure that the governor gear splines align properly with the
camshaft governor drive gear and that the governor is fully seated to the crankcase prior to
installing the attaching hardware.  This will eliminate the possibility of misalignment forcing
the governor bevel gear over the camshaft governor drive gear.  Also insure that the proper
gasket is used and lubrication holes are properly aligned.

WARNING

Oil pressure is applied to the face of the accessory drive pads.  If gasket, accessory
or cover is not properly installed and hardware is not properly torqued oil leakage will
occur.

CAUTION . . . When a test club or fixed pitch propeller is used for testing purposes the

governor pad cover 

must have an 

internal grooved surface 

to allow the circulating oil to

lubricate the front main bearing. The governor pad cover is not needed if a propeller
governor is installed.

WARNING

Do not connect the ignition harness to the spark plugs until the propeller installation
is completed.  Failure to comply could result in bodily injury when the propeller is
rotated during installation.

NOTE . . . Remove all protective plugs from the following locations: exhaust outlets,
crankshaft flange and fuel pump fittings.

NOTE . . . Drain preservative oil from sump.  Engines that have a complete set of
overhauled or new cylinders and new piston rings installed must be serviced with clean
Engine Break-In and Preservation oil conforming with MIL-C-6529 TYPE II until it has been
determined that the engine oil consumption has stabilized (approximately 25 hours of
operation.)  Thereafter, the engine must be serviced with clean ashless dispersant oil.  See
Section 7-2, "Approved Ashless Dispersant Oils."

Summary of Contents for CONTINENTAL L/TSIO-360-RB

Page 1: ...L TSIO 360 RB FORM X30645 CHANGE 2 CONTINENTAL AIRCRAFT ENGINE MAINTENANCE MANUAL TECHNICAL PORTIONS APPROVED BY THE FAA 2008 TELEDYNE CONTINENTAL MOTORS INCORPORATED APRIL 2008 ...

Page 2: ...5 thru 17 8 0 23 1 thru 23 7 0 5 1 thru 5 17 0 12 1 thru 12 4 0 18 1 thru 18 3 0 23 8 1 5 18 1 12 5 thru 12 6 1 18 4 1 23 9 thru 23 12 0 5 19 0 12 7 thru 12 14 0 19 1 thru 19 9 0 5 20 1 13 1 thru 13 6 0 19 10 thru 19 12 1 6 1 thru 6 9 0 13 7 thru 13 10 1 19 13 thru 19 14 0 6 10 thru 6 10 1 14 1 thru 14 2 0 20 1 1 6 11 thru 6 12 0 14 3 1 20 2 thru 20 7 0 7 1 thru 7 2 0 14 4 0 20 8 thru 20 20 1 Publ...

Page 3: ...LICATION IS OCTOBER 1996 INSERT LATEST PAGES DESTROYSUPERSEDEDPAGES WARNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors Do not perform any operation maintenance installation or other operation until the manual is confirmed current OCTOBER 1998 iii ...

Page 4: ...l Aviation Administration FAA Form 8130 3 Airworthiness Approval Tag An Airworthiness Approval Tag identifies a part or group of parts that have been approved by an authorized FAA representative 2 FAA Technical Standard Order TSO number and identification mark indicatingthat the part or appliance was manufactured in accordancewith the requirementsof FAR 21 Subpart 0 3 FAA Parts Manufacturer Approv...

Page 5: ... 1 etc To locate information easily use the Publication Table of Contents and the Chapter Contents provided at each division WARNING The Operator and Installation manual Maintenance manual Overhaul manual Service Documents and the Parts Catalog constitute the instructions for Continued Airworthiness prepared by TCM as approved by the FAA pursuant to FAR Part 33 As required by FAR 43 13 each person...

Page 6: ...ccessories WARNING Used to provide warning with respect to information andlor instructions which if disregarded will endanger personnel andlor severely damage the engine resulting in subsequent engine malfunction or failure Notes cautions and warnings do not impose undue restrictions They are inserted to obtain maximum safety efficiency and pelformance Abuse misuse or neglect of equipment can caus...

Page 7: ...ackingiDe inhibitingllnstallation Test 6 1 7 Servicing Fluids 7 1 8 Engine Preservationand Storage 8 1 9 Standard Practices 9 1 Engine Maintenance 10 1 Exhaust System 11 1 IgnitionSystem 12 1 Fuel Injection System 13 1 InductionSystem 14 1 Air Conditioning System 15 1 16 ElectricalCharging System 16 1 17 Starter Starter Adapter 17 1 18 Accessory Case 18 1 19 Lubrication System 19 1 20 Cylinder Ass...

Page 8: ...tNTENTIONALLY LEFT BLANK viii OCTOBER 1998 ...

Page 9: ...s 1 5 1 8 Service Reports and Inquiries 1 5 1 9 Suggestions and Corrections 1 6 1 10 TCM Contact Information 1 6 1 11 Engine Model Description 1 7 1 12 Engine Design Features 1 7 1 13 General 1 10 1 14 Engine Specifications 1 10 1 15 Operating Limits 1 11 LIST OF ILLUSTRATIONS Figure 1 1 L TSIO 360 RB Top and Front View 1 8 Figure 1 2 L TSIO 360 RB Side and Aft View 1 9 1 1 Change 2 ...

Page 10: ...1 2 Change 2 INTENTIONALLY LEFT BLANK ...

Page 11: ... manual the terms front rear left and right refer to the engine as viewed by a pilot sitting in the crew compartment The accessory end is at the rear and the propeller is at the front of the engine Cylinders are numbered from the rear with odd numbers on the right and even numbers on the left 1 4 MANUAL REVISIONS The instructions in this manual represent the best and most complete information avai...

Page 12: ...ter Service Instructions Form X30592 4 TCM Ignition Systems Master Service Manual Form X40000 5 TCM Aircraft Engine Service Documents For TCM product pricing information request a TCM Publication Pricing Index from your local TCM distributor or TCMLINK com Powerstore 6 Slick Ignition Systems Master Service Manual Index and Order Form No F 1100 Order through Slick Aircraft Products Unison Industrie...

Page 13: ...ctive May contain updates to TCM s Instructions for Continued Airworthiness to address a safety issue Category 3 Service Bulletin SB Information which the product manufacturer believes may improve the inherent safety of an aircraft or aircraft component this category includes the most recent updates to Instructions for Continued Airworthiness Category 4 Service Information Directive SID The manufa...

Page 14: ...dversely affects safety 1 10 TCM CONTACT INFORMATION Teledyne Continental Motors is available to answer technical questions and encourages suggestions regarding products parts or service If customers have an inquiry or require technical assistance they should contact their local TCM distributor or TCM field representative To contact TCM refer to the contact information below 1 6 Change 2 Teledyne ...

Page 15: ...rovided to utilize a hydraulic controlled governor for a constant speed propeller The engine is designed with a wet sump and a positive displacement oil pump When properly adjusted under normal conditions desired oil pressure is maintained by a pressure relief valve Engine cranking is accomplished by a geared right angle driven starter adapter and a direct current starter motor The L TSIO360 RB in...

Page 16: ...1 8 Change 2 Figure 1 1 L TSIO 360 RB Top and Front View ...

Page 17: ...1 9 Change 2 Figure 1 2 L TSIO 360 RB Side and Aft View ...

Page 18: ...220 Cylinders Arrangement horizontally opposed individual cylinders Compression ratio 7 5 1 Firing Order TSIO 360 RB 1 6 3 2 5 4 L TSIO 360 RB 1 4 5 2 3 6 Number of cylinders 6 Bore inches 4 438 Stroke inches 3 875 Piston Displacement cubic inches 360 Fuel Fuel Control System Precision RSA 5 Minimum Fuel Grade Refer to Section 7 3 Ignition Timing Right magneto degrees BTC 22 1 Left magneto degrees...

Page 19: ...ockwise 24 73 1 Propeller Governor1 Clockwise 1 1 Fuel injection Pump Counterclockwise 1 1 Freon Compressor2 Clockwise 1 545 1 Accessory Drive Pad3 Counterclockwise 1 545 1 1 Drive is a modified AND 20010 supplied with a cover plate 2 Ration is for six inch diameter driven sheave 3 Drive is a modified AND 20000 supplied with a cover plate 1 15 OPERATING LIMITS Rated Maximum Continuous Operation 22...

Page 20: ...1 12 Change 2 INTENTIONALLY LEFT BLANK ...

Page 21: ...2 1 CHAPTER 2 TOOLS AND EQUIPMENT Section Page 2 1 General Information 2 2 2 2 Possible Special Tool Procurement Sources 2 3 2 3 Special Tools 2 4 ...

Page 22: ...hets 1 4 3 8 1 2 Drive 5 Sockets 1 4 Drive 5 32 through 1 2 3 8 Drive 3 8 through 1 1 2 Drive 7 16 through 1 1 4 6 Sockets Deepwell 1 2 Drive 7 16 through 1 7 Feeler Gauges 8 Leather or Soft Plastic Mallet 9 Torque Wrenches 0 500 In Lbs 0 100 Ft Lbs 10 Micrometers 11 Slide Hammer 12 Pullers 13 Thickness Gauges 14 Vernier Calipers 15 Small Hole Gauges 16 Ford Wrench Must be currently calibrated and...

Page 23: ...ertsSt East Hartford CT 06108 2031528 9821 Fuel PressureTest Equipment Measuring Instruments PrecisionTools Piston Position Indicators FEDERAL TOOL SUPPLY CO 1NC 1144 Eddy St Providence Rhode Island 02940 8001343 2050 Precision Inspectionlnstruments Special Tools AIRCRAFT TOOL SUPPLY P O Box4525 2840 Breard St Monroe LA 71201 5071451 5310 PrecisionTools Special Tools McMASTER CARR SUPPLY CO P O Bo...

Page 24: ...tage Regulator Tester available from Eastern Electronics E l00 AlternatodReguiatorlBatteryTester available from Eastern Electronics Inc Model29 Voltage CircuitTester availablefrom Eastern Electronics Inc STARTING SYSTEM Borrough s8093C BearingPulleror equivalentfor needle bearing removal Borroughs23 1 Needle BearingInstaller or equivalent LUBRICATION SYSTEM 8155 Oil Pressure ReliefSpot Facer avail...

Page 25: ...16 Expanding Guide Bodies or equivalent 43 4909 Valve Seat Straight Side Insert Cutters available from Kent Moore 4954 Valve Seat Straight Side Insert Cutters available from Kent Moore 4985 Valve Seat Straight Side Insert Cutters available from Kent Moore 5224 Valve Seat Straight Side Insert Cutters available from Kent Moore 5225 Valve Seat Straight Side Insert Cutters available from Kent Moore 44...

Page 26: ...on 68 Borrough s 8087A Polishing Tools for Crankshaft Bearings or equivalent 69 3604 8068 Crankshaft Blade and Damper Bushing Remover Replacer available from Kent Moore 70 Borrough s 8077C Bushing Remover Replacer Counterweight or equivalent 71 Borrough s 8111A Connecting Rod Fixture or equivalent 72 Borrough s 8072C Adapter Kit or equivalent for connecting rod inspection 73 8071 Reamers for conne...

Page 27: ...3 1 CHAPTER 3 SEALANTS AND LUBRICANTS Sealants Lubricants 3 2 ...

Page 28: ...n Multiviscosity Oil SAE 20W50 SAE 20W60 Quaker State Oil Refining Company Quaker State AD Aviation Engine Oil Red Ram Limited Canada Red Ram X C Aviation Oil 20W50 Shell Australia Aeroshell R W Shell Canada Limited Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W50 Shell Oil Company Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W15 Si...

Page 29: ...istered trademark of Dow Corning Corporation For Distributor information call 1 800 248 2481 have state city information available Camshaft lobes and lifter faces Alvania Shell 2 For Distributor information Shell Product Information Center Phone 1 800 231 6950 Front crankshaft oil seal MIL S 3545C Grease Shell 5 Shell Product Information Center Phone 1 800 231 6950 Fuel injection linkage pivot poi...

Page 30: ...asket Eliminator 515 Sealant For Distributor information call Permatex Customer Service Phone 1 800 641 7376 May be purchased through your local TCM Distributor May be purchased through your local TCM Distributor For Distributor information call Loctite Customer Service Phone 1 800 243 4874 Crankcase parting face oil pump covers scavenge pump covers 653692 Primer or Loctite LocQuic Primer 7649 May...

Page 31: ...er Stephenson Customer Service Phone 1 800 992 2424 Ignition harness terminals at magneto block end Adhesives TYPE SUGGESTED SOURCES APPLICATION 646941 High Strength Adhesive Sealant or Loctite 271 653696 Primer or Loctite LocQuic Primer 7471 May be purchased through your local TCM Distributor For Distributor information Loctite Customer Service Phone 1 800 243 4874 Cylinder deck studs squirt nozz...

Page 32: ...ection TCM P N 535001S Lockwire 032 in dia Steel Corrosion Resistant May be purchased through your local TCM Distributor Where applicable for lockwiring ACCELAGOLD Turco Products Tucker GA 30084 Accelagold is manufactured by Turco Products Inc For sales and service Elf Atochem N A Turco Products Div P O Box 195 State Route 95 West Marion Ohio 43302 215 419 5376 Corrosion protection interior and ex...

Page 33: ...tion the engine does not require specific intervals of inspection pursuant to type certification 3 Other Related Procedures Subject to additional information contained in the Airworthiness Directives AD issued after the date of certification there are no other related procedures required pursuant to the type certification for this engine 4 Distribution of Changes to Airworthiness Limitations Chang...

Page 34: ...4 2 INTENTIONALLY LEFT BLANK ...

Page 35: ...CTION PAGE 5 1 General 5 2 5 2 Overhaul Periods 5 2 5 3 Operational Inspection 5 3 5 4 Test Operating Limits 5 4 5 5 Time Interval Inspections 5 5 5 6 Scheduled Maintenance 5 6 5 7 Unscheduled Maintenance 5 11 5 8 General Information 5 14 5 9 Engine Troubleshooting Chart 5 14 ...

Page 36: ...omponents must be replaced refer to the applicable system maintenance chapter Adjustment information will be found in the individual system chapters of this section NOTE The figures depicted in this section are for illustration purpose only They are not intended to be accurate detailed illustrations of any specific engine model part or equipment WARNING When performing any inspection or maintenanc...

Page 37: ...System Grounding Check _________ CAUTION The magneto system grounding check must be accomplished at idle RPM only Damage to the engine may result at engine speeds above idle RPM WARNING Absence of RPM drop when checking magnetos is an indication of a malfunction in the ignition system resulting in a hot magneto This type of malfunction must be corrected prior to continued operation of the engine T...

Page 38: ...00LL 100 Fuel Flow at Full Throttle Lbs Hr 140 150 140 150 Oil Temperature Limit 240 F 240 F Oil Pressure Max Oil Cold 100 100 Minimum at Idle 10 10 Oil Pressure Operational Range 30 80 30 80 Magneto Drop Max Magneto Spread 150 RPM 50 RPM 150 RPM 50 RPM Cylinder Head Temperature with Bayonet Thermocouple Max 460 F 460 F Maximum RPM may not be attainable at static run up depending on setting of pro...

Page 39: ... Publications and Airworthiness Directives 1 After the first 25 hours of operation on new rebuilt or overhauled engines perform a complete 100 hour inspection Drain the oil used for engine break in If engine oil consumption has stabilized service the engine with TCM approved oil If oil consumption has not stabilized service engine with a mineral oil conforming to MIL C 6529 Type II First 25 hours ...

Page 40: ... as provided in the aircraft or engine manufacturer s Maintenance Operator s and Overhaul Manuals WARNING Operation of a malfunctioning engine can result in additional engine damage engine failure bodily injury or death After the operational inspection inspect isolate and repair any leaks found 3 Reference the applicable Airplane Flight Manual for operational values 4 Remove and inspect induction ...

Page 41: ... chapter 10 Place a thin film of Dow Corning DC 4 compound on new oil filter gasket Install new oil filter Torque filter to 192 216 and safety wire 11 Inspect all induction system or cylinder drain s for clogging or restriction 12 Inspect ignition leads for chafing deterioration and proper routing 13 Visually inspect magnetos for condition Inspect repair and adjust as required if magneto drop or s...

Page 42: ...ndicate that the integrity of the cylinder or the head to barrel junction has been breached 6 Cylinder Head Inspect the external surfaces of the cylinder head including the cylinder head fins intake and exhaust ports top and bottom spark plug bosses and fuel nozzle boss Inspect for cracks exhaust flange leakage or any signs of leakage of oil fuel soot or any conditions that could indicate that str...

Page 43: ...ect the oil inlet and outlet fittings and surrounding area for evidence of oil leakage 19 Remove the induction air supply duct to the turbocharger compressor and inspect the compressor blades for evidence of foreign object damage Turn compressor wheel by hand check for freedom of rotation Inspect the interior of the air supply duct for general condition 20 Remove the turbocharger exhaust stack and...

Page 44: ...urer or STC holder s instructions 2 Observe the drain location s in the engine cowling and make certain that fuel drains from each 3 Remove clean or replace any drain that does not function properly 500 HOUR INSPECTION In addition to the items listed for 100 hour inspections perform the following inspections and maintenance every 500 hours of engine operation 1 Magnetos require a thorough detailed...

Page 45: ... engines replacement of all counterweight pins bushings end plates and snap rings regardless of their condition B MINOR FOREIGN OBJECT DAMAGE FOD INSPECTION For instances where the propeller is damaged by a small foreign object during operation such as a small stone inspection and repair must be accomplished in accordance with the propeller manufacturer s published instructions Any time foreign ob...

Page 46: ...Overhaul Manual 2 If all rods meet the criteria specified by TCM reassemble the engine in accordance with the overhaul manual 3 If any connecting rod does not meet TCM acceptance criteria remove and disassemble the engine to allow inspection of the crankcase and crankshaft in accordance with the applicable TCM Overhaul Manual Replace any part that does not meet Overhaul Manual inspection criteria ...

Page 47: ...e and test the engine in accordance with the manufacturer s current overhaul manual c After five and ten hours of engine operation remove oil filter and inspect filter element for debris RPM EXCEEDING 3300 1 Remove engine and clearly identify Removal For Overspeed 2 Engine and accessories must be completely overhauled in accordance with the respective manufacturer s current overhaul instructions o...

Page 48: ...arily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start Fuel Tank Empty Service aircraft fuel system in accordance with the airframe manufacturer s instructions See Chapter 7 Servicing Fluids for correct fuel grade Improper starting procedure Refer to the airframe manufacturer s Airplane Flight Manual AFM for engine starting procedures Check for performance of each it...

Page 49: ...ed exhaust valves worn seat scored valve guides Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Engine Runs Too Lean At Cruising Power Improper manual leaning procedure Refer to the airframe manufacturer s Airplane Flight Manual AFM for engine operating instructions Fuel injection system maladjusted See Section 13 4 Fuel Injection System Troubleshooting Engine Runs Too Rich At Cruis...

Page 50: ...orn Remove and clean or replace See Section 20 6 Cylinder Assembly Maintenance Hydraulic Valve Tappets Sluggish Operation And Low Power Throttle not full open Check and adjust linkage See Rigging of Mixture and Throttle Controls in the applicable airframe manufacturer s instructions Restrictions in air intake passages Inspect air intake and remove restrictions Ignition system malfunction See Secti...

Page 51: ...plugs fittings and gaskets due to loosenessor damage Torque or replace See the applicable disassembly reassembly portions of the UTSIO 360 Series Overhaul Manual Form X30596A for correct torque values Low Compression Piston rings excessivelyworn Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Valve faces and seatsworn Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Ex...

Page 52: ...e fuel pump See Section 13 5 Fuel System Maintenance Fuel Pump Replace fuel pump See Section 13 5 Fuel System MaintenancelFuelPump Replace fuel pump See Section 13 5 Fuel System Maintenance Fuel Pump Check and adjust in accordance with Chapter 23 Replace malfunctioning pumps See Section 13 5 Fuel System Maintenance Fuel Pump Drain gauge line and torque connections in accordance with the airframe m...

Page 53: ...age by moving control from idle to full throttle Make proper adjustments and replace worn components Service air cleaner in accordance with the airframe manufacturer s instructions Malfunctioning ignition system component lnspect spark plugs for fouled electrodes heavy carbon deposits erosion of electrodes improperly adjusted electrode gaps and cracked porcelains Test plugs for regular firing unde...

Page 54: ...en or filter plugged oil filter or screens Clean manufacturer s instructions st oil pressure in accordance Chapter 23 Oil Pressure uge Replace malfunctioning parts accordance with the airframe anufacturer s instructions 5 20 OCTOBER 1998 ...

Page 55: ...Preparationfor Service 6 4 6 6 Engine InstallationInstructions 6 5 6 7 Engine Pre oiling 6 1 0 6 8 Preflight and Run Up 6 10 6 9 Flight Testing 6 11 FIGURE INDEX 6 1 InstallationDrawing UTSIO 360 RB 6 6 InstallationDrawing UTSIO 360 RB continued 6 7 InstallationDrawing LITSIO 360 RB continued 6 8 InstallationDrawing L TSIO 360 RB continued 6 9 OCTOBER A 998 6 1 ...

Page 56: ...INTENTIONALLY LEFT BLANK ...

Page 57: ...ontainer 1 Remove the 4 four lag screws attaching the wooden cover to the base 2 Lift the wooden cover vertically and remove 3 Open the moisture proof plastic bag 4 Attach a hoist to the engine lifting eye located at the top of the crankcase backbone Take up slack on the hoist prior to loosening the engine mount bolts then remove the bolts from the shipping shock mounts Lift the engine vertically ...

Page 58: ...of misalignment forcing the governor bevel gear over the camshaft governor drive gear Also insure that the proper gasket is used and lubrication holes are properly aligned WARNING Oil pressure is applied to the face of the accessory drive pads If gasket accessory or cover is not properly installed and hardware is not properly torqued oil leakage will occur CAUTION When a test club or fixed pitch p...

Page 59: ...and damage to its components Install the engine and make airframe to engine connections in accordance with the airframe manufacturer s instructions Install all airframe manufacturer required components including cooling baffles hoses fittings brackets and ground straps in accordance with the airframe manufacturer s installation instructions WARNING Do not connect the ignition harness to the spark ...

Page 60: ...6 6 FIGURE 6 1 INSTALLATION DRAWING ...

Page 61: ...6 7 FIGURE 6 1 INSTALLATION DRAWING cont d ...

Page 62: ...6 8 FIGURE 6 1 INSTALLATION DRAWING cont d ...

Page 63: ... 2A TORQUE TO 75 85 INCH POUNDS GROUNDTERMINAL I9044 UNC 2A TORQUE TO 21 25 INCH POUNDS 313 18 UNC 2A INCH POUNDS STARTER TERMINAL p TORQUE TO 180 220 1 r O I FIELD TERMINAL I 90 24 UNC 2A TORQUE TO 21 25 I AUX TERMINAL INCH POUNDS an TA II N C 3 a 1 1 7 TORQUE TO 21 25 6300 321 300 VIEW G G INCH POUNDS 12 90 13 23A 1 8 SO SO ALTERNATOR 6 HOLES THDS PER MS3365664 FUEL SECTION W H FIGURE 6 1 INSTAL...

Page 64: ...ed to specification prior to starting See Section 12 5 IgnitionSystem Maintenanceof this manual Apply Champion0 thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 lnstallthe upper spark plugs and torque to 300 360 inch pounds Install the ignition harness B nuts on the spark plugs The nuts are stamped with a position identifier i e It which means the to...

Page 65: ...me manufacturer s Pilot s Operating Handbook Airplane Flight Manual Conduct a normal take off with full power and monitor the fuel flow RPM oil pressure cylinder head temperatures and oil temperatures Reduce to climb power in accordance with the flight manual and maintain a shallow climb attitude to gain optimum airspeed and cooling Rich mixture should be used for all operations except leaning for...

Page 66: ...6 12 INTENTIONALLY LEFT BLANK ...

Page 67: ...RVICING FLUIDS SECTION PAGE 7 1 Servicing Oil 7 2 7 2 Approved Engine Lubricating Oils 7 3 7 3 Fuel 7 3 7 4 Oil Filter Element Inspection 7 4 7 5 Spectrographic Oil Analysis 7 4 FIGURE PAGE 7 1 Oil Servicing Points 7 2 ...

Page 68: ...rmal If excessive consumption or any abrupt change in rate of consumption is detected this condition must be corrected before further flight Maintain the engine compartment nacelle and the fuselage adjacent to the nacelle in a clean condition in order that an oil leak can be detected and corrected before further flight WARNING Engine operation with no oil or severely reduced oil levels will cause ...

Page 69: ...imited Aeroshell Oil W 15W 50 Anti wear Formulation Shell USA Aeroshell Oil W 15W 50 Anti wear Formulation Shell USA Aeroshell Oil W100 Plus W80 Plus Sinclair Oil Company Sinclair Avoil Texaco Inc Texaco Aircraft Engine Oil Premium AD Total France Total Aero DM 15W 50 Union Oil Company of California Union Aircraft Engine Oil HD APPROVED MINERAL OIL MIL C 6529 TYPE II 7 3 FUEL 7 3 Change 2 Aviation...

Page 70: ...tal Tin will not be attracted magnetically It looks similar to nickel but is soft a malleable 7 4 Change 2 7 5 SPECTROGRAPHIC OIL ANALYSIS Spectrographic oil analysis was developed by the railroads as of method of identifying wear characteristics in large diesel engines and was later adopted by the military commercial and general aviation It has become popular with general aviation piston powered ...

Page 71: ...nformation relative to normal or abnormal wear that occurs during the course of engine operation Deviations from an established wear trend pattern should alert the owner operator and oil analysis technician to further investigate Limitations Variations in operation use and maintenance may be reflected in the parts per million content reported Deviations from standard or previously used sampling pr...

Page 72: ...7 6 INTENTIONALLY LEFT BLANK ...

Page 73: ...PRESERVATION AND STORAGE Section Page 8 1 General 8 2 8 2 Engine Preservation 8 2 8 3 Temporary Storage 8 2 8 4 Indefinite Storage 8 3 8 5 Indefinite Storage Inspection Procedures 8 4 8 6 Returning An Engine To Service 8 4 ...

Page 74: ...o proper sump capacity with oil conforming to MIL C6529 Type II 2 Perform a ground run up Perform a pre flight inspection and correct any discrepancies Fly the aircraft for one hour at normal operation temperatures WARNING To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are con...

Page 75: ...lock aircraft wheels f Insure that aircraft tie downs are installed and verify that the cabin door latch is open g Do not stand within the arc of the propeller blades while turning the propeller 3 After flight remove all spark plug leads and remove the spark plugs Protect the ignition lead ends with AN 4060 Protectors Install protective plugs P N 22671 in bottom spark plug holes Using a common gar...

Page 76: ...jury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded c Throttle position CLOSED d Mixture control IDLE CUT OFF e Set brakes and block aircraft wheels f Insure that aircraft tie downs are installed and verify that the cabin door latch is open...

Page 77: ... 3 9 3 Tab Washer Procedure 9 5 9 4 Cotter Pin Procedure 9 5 9 5 Application Of Adhesives 9 6 9 6 Installation Of Gaskets 9 6 FIGURE PAGE 9 1 General Lockwire Procedure 9 3 9 2 General Lockwire Patterns 9 4 9 3 Tab Washer Installation Procedure 9 5 9 4 General Cotter Pin Installation 9 6 ...

Page 78: ...re unexposed WARNING Dust caps used to protect open lines must be installed OVER the tube ends and NOT IN the tube ends Flow through the lines will be blocked if lines are inadvertently installed with the dust caps in the tube ends If anything is dropped into the engine work must be stopped immediately and the item removed Insure all parts are thoroughly cleaned properly protected from dust and co...

Page 79: ...isted and caution must be exercised during the twisting operation to keep the wire tight without over stressing See Figure 9 1 General Lockwire Procedure for steps in applying lockwire All lockwire utilized on TCM engines must conform to MS 20995 Condition A Most bolts utilized in TCM engines that require lockwiring will use 032 lock wire and require twisting at a rate of 7 to 10 twists per inch L...

Page 80: ...the loop around the unit comes under the strand protruding from the hole so that the loop will stay down and will not tend to slip up and leave a slack loop 4 Twist the strands while taut until the twisted part is just short of a hole in the next unit The twisted portion should be within one eighth 1 8 inch from the hole in either unit 5 Insert the uppermost strand through the hole in the second u...

Page 81: ...IGURE 9 3 TAB WASHER INSTALLATION PROCEDURE 9 5 COTTER PIN PROCEDURE Cotter pins are installed by inserting the cotter pin through a hole in one part and slots in the other part and spreading the exposed ends Cotter pins are not reusable and must be replaced with a new cotter pin after removal 1 Torque the nut to the lower limit of the torque specification If the slots in the nut do not line up wi...

Page 82: ...ore applying gasket maker at the engine nose seal area 9 7 INSTALLATION OF GASKETS All gaskets must be new and visually inspected prior to installation If the gasket shows any indication of gouges nicks cuts or bends discard it and obtain an undamaged gasket Gasket surfaces must be clean and free of oils and grit Apply a thin coat of TCM Gasket Sealant 642188 to both sides of gasket where specifie...

Page 83: ... recorded findings of operational inspection to Operating Limits Section 1 10 and information listed under applicable system 50 and 100 hour inspection of the following chapters Corrections and adjustments will be found in the individual system chapters of this manual under Maintenance and Chapter 23 Post Maintenance Adjustment and Test At the completion of all 50 100 hour inspection procedures se...

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Page 85: ...ailed Description 11 6 11 5 Turbocharger Lubrication System 11 7 11 6 Exhaust System Inspection 11 7 11 7 Exhaust System Troubleshooting 11 9 11 8 Exhaust System Maintenance 11 11 FIGURE PAGE 11 1 Induction and Exhaust System Schematic 11 3 11 2 Basic Turbocharger 11 4 11 3 Turbocharger Sectional View 11 5 11 4 Wastegate 11 5 11 5 Variable Absolute Pressure Controller 11 6 11 6 Slipjoint Assembly ...

Page 86: ... loaded to the open position and closed by pressurized oil from the engine Oil flow through the wastegate actuator is controlled by a variable absolute pressure controller VAPC that is mounted to the induction system after the turbocharger compressor but before the throttle butterfly valve sensing compressor discharge pressure The controller is mechanically linked to the throttle and using a syste...

Page 87: ...11 3 FIGURE 11 1 INDUCTION AND EXHAUST SYSTEM ...

Page 88: ... turbine compressor shaft bearings retain the oil in the center housing The inlet and outlet check valves prevent oil from flooding the center housing when the engine is not operating During engine operation exhaust gases from the engine pass through the turbine housing and cause the turbine wheel to rotate Since the turbine wheel and compressor are attached to a common shaft the compressor rotate...

Page 89: ...harger turbine The exhaust by pass valve butterfly valve is spring loaded to the open position Pressurized oil from the engine is directed to the inlet of the by pass valve actuator The pressurized oil acting on the actuator plunger and against spring pressure drives the by pass valve butterfly to the closed position A Variable Absolute Pressure Controller VAPC is connected in the oil return line ...

Page 90: ...n the engine intake manifold prior to the throttle plate and in such a way that the pressure sensitive bellows is in the intake manifold and senses turbocharger compressor discharge pressure deck pressure During engine operation compressor discharge pressure is referenced by the VAPC s bellows while the mechanically linked plunger is positioned according to throttle plate position When ever the co...

Page 91: ...ectedfor condition and leaks using the following procedure Cleaning In order to thoroughly inspect the exhaust system components must be clean and free of oil grease etc Use a suitable solvent such as Stoddard solvent and wipe away any debris Wipe any excess solvent dry with a clean cloth CAUTION Never use flammable solvents wire brushes or abrasives to clean exhaust system components Never use a ...

Page 92: ...ga straightedge especiallywithintwo inchesofspot weld tabs that retainthe T boltfastener clearance should be lessthan 062 of an inch Clearances in excess of 062 of an inch are cause for rejection Inner segment and outer band contact must be 100 NOTE When replacement of clamp is required install new clamp insuring V segments go over exhaustflanges using a rawhideor plasticmallet tap clamp circumfer...

Page 93: ...ns and check rotor assembly for possible rubbing in housing damaged rotor or damaged bearings Per component manufacturer s instructions replace if turbocharger damage is noted Exhaust system gas leakage Inspect exhaust system for gas leakage gaskets at cylinder exhaust ports gaskets at turbine inlet flanges etc and correct White Smoke Exhaust Turbo coking oil forced through turbine housing seal Cl...

Page 94: ...Seals Leaking Worn or damaged seals Refer to Turbocharger Manufacturer s Instructions Engine Oil Level Frequently Low After Servicing Prior to Operation Leaking Turbocharger check valves and seals Replace check valves Refer to Turbocharger Manufacturer s Instructions for turbocharger maintenance Lack of Oil to Turbocharger Damaged check valve Replace check valve ...

Page 95: ...0596ASl I Turbochargers Wastegate Controller For replacement of these components see the applicable portion of exhaust system disassernbly reassernbly in the LITSIO 360 RB Overhaul Manual Form X30596AS1 For maintenance of these components refer to the I component manufacturer s instructions Aireseareh 3201 Lomita Blvd Torrance California 90505 Lubrication Plumbing Turbocharger lubrication plumbing...

Page 96: ...INTENTIONALLY LEFT BLANK ...

Page 97: ...ooting 12 4 12 5 Ignition System Maintenance 12 5 FIGURE PAGE 12 1 Magneto Accessory Drive Adapter 12 6 12 2 Reverse Spark Plug Installation Procedure 12 8 12 3 Spark Plug Wear 12 8 12 4 Timing Position Step 1 12 9 12 5 Timing Position Step 2 12 10 12 6 Timing Position Step 3 12 10 12 7 Timing Position Step 4 12 11 12 8 Timing Position Step 5 12 12 12 9 Coating Insulating Sleeve 12 13 12 10 Igniti...

Page 98: ...ar retainer and bushings housed inside the accessory case Two rubber bushings per magneto are installed within a retainer on the drive gear The rubber bushings provide a shock absorbing engagement between magneto and engine drive train The magnetos are attached to the upper rear portion of the accessory case and secured by retainers lockwashers and nuts The magneto drive gear assemblies are driven...

Page 99: ... and failure Magneto ignition harness and spark plugs must be maintained in accordance with the manufacturer s instructions NOTE A single severe kick back while cranking the engine can cause failure of components in the cranking system Kick back can be caused by intermittent operation of the impulse couplings Perform the following operational tests at the specified intervals to insure that these s...

Page 100: ...specified by the manufacturer See Chapter 1 Related Publications for manual ordering information 12 4 IGNITION TROUBLESHOOTING The following troubleshooting chart is provided as a guide Review all probable causes given check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE C...

Page 101: ...cemen impulse coupling replacement or internal magneto timing must be performed in accordance with the magneto manufacturer s instructions See Slick Order Form F I100 See Section 1 4 Related Publications for orderinginformation Magneto Drive Assemblies Remove the magneto drive assemblies for repair or replacement in accordance with the applicable portion of the Magneto And Accessory Drive disassem...

Page 102: ...Replace any spark plug that does not meet the manufacturer s specifications Insure that each spark plug is free of any residue from cleaning process If all requirements of cylinder compression test in Section 20 4 have been accomplished apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Re install used spark plugs using the reverse spark...

Page 103: ... not meet the manufacturer s specifications Insure that each spark plug is free of any residue from cleaning process If all requirements of cylinder compression test in Section 20 4 have been accomplished apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Re install spark plugs using the reverse spark plug installation order Torque spark...

Page 104: ...FROM TO 1 TOP 6 BOTTOM 1 BOTTOM 6 TOP CYLINDER ROTATION 2 TOP 5 BOTTOM 2 BOTTOM 5 TOP 3 TOP 4 BOTTOM 3 BOTTOM 4 TOP 4 TOP 3 BOTTOM 4 BOTTOM 3 TOP 5 TOP 2 BOTTOM 5 BOTTOM 2 TOP 6 TOP 1 BOTTOM 6 BOTTOM 1 TOP FIGURE 12 2 SPARK PLUG ROTATION PROCEDURE FIGURE 12 3 SPARK PLUG WEAR ...

Page 105: ...rk plugs Attach a sign stating Hot Magneto Do Not Turn on each propeller blade In conducting magneto timing check use a top dead center locator protractor and pointer such as the Eastern Electronics Model E25 Timing Indicator or equivalent Use the following basic timing procedure to insure that timing is accomplished in accordance with the required specifications 1 Remove all top spark plugs Rotat...

Page 106: ...R DISC WILL DIFFER FROM ENGINE TO ENGINE FIGURE 12 5 TIMING POSITION STEP 2 6 Move the disk to exactly one half of the number of degrees observed toward the top center mark POSITIVE DEAD CENTER LOCATOR INSTALLED PISTON LIGHTLY TOUCHING 1 CYLINDER NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED NORMAL DIRECTION OF ROTATION EXAMPLE 42 5o POSITION 40 50 NOT...

Page 107: ...ime the magneto to the engine move the propeller in the opposite direction of normal rotation past the specified magneto timing setting and then back in the direction of normal rotation until the desired setting before top dead center is under the pointer to remove the gear backlash Disconnect the ground switch leads from the magnetos Place a Bendix 11 851 timing light or equivalent on the engine ...

Page 108: ... position needed Push gear back into mesh WARNING Prior to any engine or magneto timing procedure disconnect all ignition harness spark plug leads from the spark plugs Do not attach any ignition harness spark plug leads to the spark plugs until all magneto engine timing procedures and magneto to switch connections have been entirely completed The magneto is in a SWITCH ON condition when the switch...

Page 109: ...ns with the correct degree both lights on the magneto timing light must indicate that the points just open within one half degree of crankshaft rotation If timing light does not indicate the above re adjust the magnetos NOTE Point opening is indicated by light illumination on some timing lights while other timing lights operate in the reverse manner i e the light goes out when the points open CAUT...

Page 110: ...manufacturer s instructions see Chapter 3 Install all spark plugs and torque to 300 360 inch pounds D Secure the ignition leads to the cylinder rocker covers using the ignition lead clamps and rocker cover screws Use caution routing and attaching leads Keep leads away from high heat sources such as the exhaust manifold Keep the leads away from any engine component that may cause chafing CHAFING A ...

Page 111: ...5 1 3 6 RIGHT MAG LEFT MAG MAGNETO FIRING ORDER ENGINE FIRING ORDER 1 6 3 2 5 4 1 2 3 4 5 6 1 3 5 5 3 1 6 4 2 6 2 4 UPPER SPARK PLUGS UPPER SPARK PLUGS LOWER SPARK PLUGS LOWER SPARK PLUGS FIGURE 12 10 IGNITION WIRING DIAGRAM ...

Page 112: ...12 16 INTENTIONALLY LEFT BLANK ...

Page 113: ...50 100 Hour 13 4 13 4 Fuel Injection System Troubleshooting 13 6 13 5 Fuel System Maintenance 13 7 FIGURE PAGE 13 1 Fuel Pump Description L TSIO 360 RB 13 2 13 2 General Fuel Manifold Valve Description 13 3 13 3 General Fuel Nozzle Description 13 3 13 4 General F I Sealant Application 13 4 13 5 General Control Linkage Lubrication Points 13 5 13 6 Fuel Pump Drive Fits and Limits 13 8 ...

Page 114: ...mp inlet where it is directed to the fuel pump blades The fuel pump blades create fuel flow and the fuel is directed to the fuel pump outlet Fuel leaving the fuel outlet is directed through various fittings and fuel line to fuel servo assembly The use of a positive displacement engine driven pump means that changes in engine speed affect pump flow and pressure proportionally The fuel pump provides...

Page 115: ...r which retains the diaphragm loading spring When the plunger is down in the body bore fuel passages to the nozzles are closed off The plunger is drilled for passage of fuel from the fuel inlet chamber to its base As fuel flow increases pressure overcomes diaphragm spring tension causing the plunger to move to the open position and fuel flows from manifold valve outlets through fuel lines to the f...

Page 116: ...s The nozzle shrouds are referenced to upper deck pressure This provides a positive air pressure differential to insure proper fuel atomization at all operating parameters Nozzles are calibrated in several ranges and all nozzles furnished for one engine are of the same range identified by a letter stamped on the hex of the nozzle body 13 3 FUEL INJECTION SYSTEM INSPECTION 50 Hour Inspect the fuel ...

Page 117: ...one or acetone for several hours Blow dry with compressed air Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 13 4 General F I Sealant Application Install fuel nozzles in cylinders 1 through 6 Torque fuel nozzles to 55 65 inch pounds Re install fuel lines on fuel nozzles Torque fuel line B nuts to 40 45 inch pounds CAUTION Never use Teflon tape on fu...

Page 118: ...t or motion between components Such movement may cause abnormal wear resulting in component malfunction or failure and subsequent loss of power Inspect all engine control cables for proper routing and security in accordance with the airframe manufacturer s instructions Inspect all engine control cables for signs of damage or wear caused by chafing and heat distress in accordance with the airframe ...

Page 119: ...evers or lever bushings must be replaced in accordance with Precision Airmotive Corporation RSA 5 Operationand Service Manual See Related PublicationsSection 1 4for ordering information Consult the airframe manufacturer and or their most current published instructions concerning aircraft engine control cable attach point inspection cleaning repair installation and lubrication After the preceeding ...

Page 120: ...able causes given check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability WARNING Starting an engine flooded intake system will re 5 Operation and n 13 5 Fuel Nozzles Fuel Manifold 13 8 OCTOBER 1998 ...

Page 121: ...est calibration equipment must be available for overhaul of any TCM fuel injection system component Fuel Nozzles For replacement of fuel nozzles see the applicable portion of disassembly and reassembly procedure in the L TSIO 360 RB Overhaul Manual Form X30596ASl If nonles are obstructed and cannot be cleaned by soaking in lacquer thinner methyl ethyl keytone or acetonefor several hours and blownd...

Page 122: ...l for minimum fits and limits 4 FIGURE 1316 FUEL PUMP DRIVE FITS AND LIMITS 13 5 FUEL SYSTEMMAINTENANCE cont d Fuel Servo Unit For removal and replacement of the fuel servo unit see the applicable portion of disassembly I and reassembly procedurein the LlTSIO 360 RBOverhaulManual FormX30596AS1 The fuel servo unit may be replaced with new or it must be repaired and calibrated in accordance with the...

Page 123: ... Induction System Description 14 3 14 2 Overboost Valve Detailed Description 14 3 14 3 Induction System Inspection 50 100 Hour 14 4 14 4 Induction System Troubleshooting 14 4 14 5 Induction System Maintenance 14 5 FIGURE PAGE 14 2 Overboost Valve 14 3 ...

Page 124: ...through induction tubes to the throttle assembly Installed on the controller overboost valve adapter assembly is an overboost valve that will relieve excessive deck pressure in the event of wastegate controller malfunction Air exiting the fuel metering throttle assembly flows into the balanced induction manifold and is distributed to the individual cylinder intake ports through induction tubes Ind...

Page 125: ...troller linkage levers and bushings must be cleaned inspected and lubricated in accordance with the instructions in section 13 3 Fuel Injection System Inspection 100 Hour 144 INDUCTION SYSTEM TROUBLESHOOTlNG This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms Items are presentedin sequence of approximate ease of ...

Page 126: ...INTENTIONALLY LEFT BLANK ...

Page 127: ...System Description 15 2 15 2 Air Conditioning System Component Detailed Detail Description 15 2 15 3 Compressor Bracket Inspection 15 3 15 4 Air Conditioning Troubleshooting 15 3 15 5 Compressor Bracket Maintenance 15 3 FIGURE PAGE 15 2 Compressor Drive TSIO 360 RB 15 2 ...

Page 128: ...IR CONDITIONING SYSTEM COMPONENT DETAIL DESCRIPTION Compressor Mounting Kit The accessory drive adapter and compressor mounting brackets are attached to the rear of the starter adapter assembly The accessory drive adapter houses the scavenge pump gears and gearing for two right angle drive adapter pads and a shaftgear for the compressor drive sheave Two compressor mounting brackets are attached to...

Page 129: ...Manufacturer s Instructions COMPRESSOR MOUNTING KIT MAINTENANCE Remove and replace worn or malfunctioning compressor mounting kit components in accordance with applicable portions of disassembly reassembly in the USIO 360 RE3 Overhaul Manual Form X30596AS1 Freon compressor drive belt inspection removaliinstallation alignment and tensioning must be performed in accordance with the airframe manufact...

Page 130: ...INTENTIONALLY LEFT BLANK ...

Page 131: ...E 16 1 Electrical Charging System Description 16 2 16 2 Electrical Charging System Component Detailed Description 16 2 16 3 Charging System Inspection 50 100 Hour 16 2 16 4 Charging System Troubleshooting 16 2 16 5 Charging System Maintenance 16 2 ...

Page 132: ...right front crankcase half for mounting a belt driven alternator The alternator generates electrical current for powering the aircraft electrical system For description of the aircraft electrical and charging system see the applicable Airframe manufacturer s Instructions FIGURE 16 1 BELT DRIVEN ALTERNATOR ...

Page 133: ...ng system any indication alternator malfunction will require alternator removal The alternator may be removed for repair or replacement in accordance with the applicable portions of the L TSIO 360 RB Overhaul Manual Form X30596AS1 alternator disassembiyireassembly 16 4 CHARGING SYSTEM TROUBLESHOOTING Referto the airframe manufacturer sapplicable charging system troubleshootinginformation 16 5 CHAR...

Page 134: ...INTENTIONALLY LEFT BLANK ...

Page 135: ...ter And Starter Adapter Inspection 17 3 17 4 Starting System Troubleshooting 17 4 17 5 Starting System Maintenance 17 4 FIGURE PAGE 17 1 Starter And Starter Drive Adapter Description 17 2 17 2 Starter Adapter Description 17 3 17 3 Starter Adapter Fits And Limits L TSI0 360 RB and Optional TSIO 360 RB 17 5 17 4 Starter Adapter Fits And Limits TSI0 360 RB 17 7 ...

Page 136: ...ARTING SYSTEM COMPONENT DETAIL DESCRIPTION Starter For a detailed description of TCM electric starter motors see TCM Form X30592 Starter Service Instructions See Section 1 4 Related Publications for ordering information Starter Adapter The starter adapter assembly uses a worm drive gear shaft and worm gear to transfer torque from the starter motor to the clutch assembly The shaft is supported in t...

Page 137: ...ARD ADAPTER ROLLER BEARING TSIO 36Q RE3 FIGURE 17 2 STARTER ADAPTER DESCRIPTION 173 STARTER AND STARTER ADAPTER INSPECTION 50 Hour Visually inspectstarter driveadapterto engine starteradaptercoverto adapterhousing and starter to adapter attaching hardwarefor security Visually inspectfor oil leakage at cover oil seal area cover to adapter and starter adapter to engine area 100Hour Performallvisuali...

Page 138: ...sembly instructions in the UTSIO 360 RB Overhaul Manual Form X30596ASl Whenever the starter adapter is removed from the engine because of malfunction it must be disassembled cleaned inspected and repaired in accordance with the UTSIO 360 RB Overhaul Manual Form X30596AS1 During maintenancethe service limits on the next page can be used CAUTlON When performing dimensional inspection the following S...

Page 139: ...g in starter adapter Diameter 0 001L 14 Worm gearshaft in needle bearing area Diameter 0 5600 15 Worm gearshaft in ball bearing Diameter 0 0004L 16 Starter pilot to starter drive adapter Diameter 0 0065L 17 Starter drive tongue to worm shaft drive slot Side Clearance 0 030L 18 Needle bearing to worm gear shaft Diameter 0 0031L 19 Starter gear to crankshaft gear Backlash 0 016 20 Starter worm wheel...

Page 140: ...17 Needle bearing to worm gear shaft Diameter 0 0031L 18 Worm gearshaft in needle bearing area Diameter 0 5600 19 Starter gear to crankshaft gear Backlash 0 016 20 Starter worm wheel gear and worm shaft gear Backlash 0 020 21 Scavenge pump driven gear on shaft Diameter 0 004L 22 Scavenge pump gears in adapter Diameter 0 0080L 23 Scavenge pump drive gear on starter shaftgear Diameter 0 0017L 24 Sca...

Page 141: ...17 7 FIGURE 17 4 STARTER ADAPTER FITS LIMITS ...

Page 142: ...17 8 INTENTIONALLY LEFT BLANK ...

Page 143: ... PAGE 18 1 Accessory Case 18 2 18 2 Accessory Case Detailed Description 18 2 18 3 Accessory Case Inspection 18 4 18 4 Accessory Case Troubleshooting 18 4 18 5 Accessory Case Maintenance 18 4 FIGURE PAGE 18 1 Accessory Case Description 18 3 ...

Page 144: ... accessory case 18 2 ACCESSORY CASE DETAILED DESCRIPTION See Figure 18 1 for accessory locations A machined threaded boss is located on the lower right hand side of the L TSIO 360 RB and lower left hand side of the TSIO 360 RB accessory case for installation of an oil pressure relief valve The front face of the accessory case is machined flat to mate with the crankcase Oil pump gear chambers are m...

Page 145: ...OIL SUCTION OIL FILTERADAPTER SCREEN BOSS MOUNT FLANGE FIGURE 18 1 ACCESSORY CASE DESCRIPTION ...

Page 146: ...h similar symptoms Items are presented in sequence of the approximate ease of checking not in order of probability Insufficienttorque 18 5 ACCESSORY CASE MAINTENANCE Accessories If oil leaks are found remove applicable component replace gasket and re install component in accordance with the applicable system or component Disassembly Reassernbly portions of the LTTSIO 360 RB Overhaul Manual Form X3...

Page 147: ...tem Inspection 19 7 19 4 Lubrication System Troubleshooting 19 9 19 5 Lubrication System Maintenance 19 10 FIGURE PAGE 19 1 Lubrication System Schematic 19 3 19 2 Oil Pump Description TSIO 360 19 5 19 2 Oil Pump Description LTSIO 360 19 5 19 3 Oil Cooler and Oil Temperature Control Valve Description 19 6 19 4 Oil Sump and Suction Tube Description 19 7 19 5 Stud Identification 19 8 19 6 Oil Filter ...

Page 148: ...rnals the right main gallery and hydraulic valve tappet bosses Oil flow is also directed upward to each of the crankshaft main bearings and forward to the propeller governor pad Oil from the rear crankshaft main bearing is directed upward to the starter shaft gear bushing Oil flow is tapped off the left main oil gallery and directed to the turbocharger through various hoses fittings and a check va...

Page 149: ...19 3 FIGURE 19 1 LUBRICATION SYSTEM SCHEMATIC ...

Page 150: ...haft is supported by bushings pressed into the accessory case As the engine starts rotating the oil pump drive gear turns looking from the rear of the engine forward counterclockwise this drives the driven gear in a clockwise direction The two gears turning create a suction that draws oil from the sump through the oil suction tube to the oil pump gears The oil is then forced around the outside of ...

Page 151: ...19 5 ACCESSORY CASE INTERNAL VIEW TSIO 360 FIGURE 19 2 OIL PUMP DESCRIPTION TSIO 360 ...

Page 152: ...19 6 ACCESSORY CASE INTERNAL VIEW LTSIO 360 FIGURE 19 3 OIL PUMP DESCRIPTION LTSIO 360 ...

Page 153: ...e control valve and out to the crankcase left main oil gallery When oil temperature reaches 168 F 172 F the oil temperature control valve closes and the oil flows through the cooler core As the oil flows through the cooler core cooling air fins between the core oil passages dissipate heat from the oil maintaining normal operational oil temperatures OIL FLOW OIL AT NORMAL OPERATING TEMPERATURE OIL ...

Page 154: ...must be properly disposed of Cut safety wire and remove oil filter Oil Filter Adapter Inspection A new stud P N 653489 must be installed if the old stud is a plain steel color with a length of 1 440 inch if it is found to be loose or it is installed beyond the stud setting height specified in Figure 19 7 Oil Filter Adapter Stud Inspection Install new stud in accordance with the following procedure...

Page 155: ...ter finger tight to 30 inch pounds torque Checkfor proper stud extension height in accordance with Figure 19 7 Oil FilterAdapter Stud Inspection F Allow the parts to cure for a minimumof thirty minutes prior to installationof the oil filter CAUTION Curingtimes may vary depending on ambient temperature Consult Loctite instructions After installation of a new oil filter adapter stud stamp a 125 high...

Page 156: ...bnormal wear Visually insped oil pressure gauge plumbing for oil leaks security and deterioration Any components exhibiting cracks dents punctures or that are worn beyond serviceable limits must be discarded and replacedwith new 100 HOUR Perform all inspection requirementsof 50 hour inspection and the following If oil pressure does not conform with 10 psi minimum 30 to 60 psi normal operation and ...

Page 157: ...cement and stoning nicks on parting flanges are not possible Discard oil filter adapters that exhibit cracks The oil filter adapter stud must be inspected and replaced if necessary in accordance with Section 19 3 Oil FilterAdapter Inspection Oil Filter Cut safety wire and remove the filter Using an oil filter can cutter open can and inspect the oil filter element Oil Sump If repair or replacement ...

Page 158: ... oil pressure relief valve housings that exceed specified limits must be discarded CAUTION Thoroughlyclean oil pressure relief valve cavity after refacing procedure All debris from the refacingprocedure must be removed Reassembleserviceable or new relief valve housing and adjusting screw Turn adjusting screw into housing about halfway Install new copper washer and nut Assemble plunger spring washe...

Page 159: ...ump gear shafts in cover Diameter 0 004L 5 Oil pump driven gear on shaft Diameter 0 004L 6 Oil pump driver gear to driven gear Backlash 0 027 7 Driver gear shaft in oil pump drive gear Diameter 0 003L 8 Oil pump driver gear to camshaft gear Backlash 0 019 9 Oil pressure relief valve spring compressed to 1 58 inches Load 14 5 15 5 Lbs 10 Oil pressure relief valve seat Depth 1 19 1 29 11 Oil tempera...

Page 160: ...19 14 INTENTIONALLY LEFT BLANK ...

Page 161: ...5 20 6 20 7 20 8 20 9 20 10 20 11 20 12 20 73 20 14 PAGE Engine CoolingAirflow Diagram 20 2 Cylinder PistonAnd Valve Train 20 3 CylinderAssembly Description 20 4 PistonAssembly Description 20 5 Valve Train Description 20 6 HydraulicTappet Description 20 7 Master OrificeTool 20 9 Static Seal 20 9 Dynamic Seal 20 9 Differential PressureTester Calibration 2 0 0 1 Ring Positioning 20 12 Single Cylinde...

Page 162: ...viding uniform cylinder temperatures Ram air induced by the aircrafts forward speed provides the source of cooling air Airflow is regulated by the size of the cooling air inlets and outlets Increasingor decreasing outlet size with the use of airframe cowl flaps changes airflow and is used as an aid in controlling engine operatingtemperatures Below is a general illustrationshowing engine cooling ai...

Page 163: ... crankshaft throw rotates past half of one revolution the connecting rod and piston start moving outward on the exhaust stroke toward the cylinder head During this movement the exhaust valve begins to open allowing the burned mixture exhaust to escape Momentum from the crankshaft forces the piston toward the cylinder head in preparation of the next intake stroke event Proper mechanical timing betw...

Page 164: ...ark plugs holes The cylinder intake port is located on top of the cylinder and the exhaust port is located on the bottom Rotocoil assemblies retain two concentric springs surrounding each valve and are locked to the stems by tapered semi circular keys which engage grooves around the valve stems Valve rocker covers are stamped sheet steel and zinc plated ROCKER SHAFT ROCKER ARM VALVE RETAINER KEYS ...

Page 165: ...e groove below the pin hole contains an oil scraper A center slotted oil control ring and expander is installed in the third groove which has six oil drain holes to the interior Weight differences are limited to 1 2 ounce or 14 175 grams in opposing bays Piston pins are full floating with permanently pressed in aluminum end plugs PISTON STEEL INSERT TOP COMPRESSION RINGS SECOND COMPRESSION THIRD O...

Page 166: ...th forged steel ball ends which are center drilled for oil passages The pushrod housings are beaded steel tubes The bead at the cylinder end retains an o ring The bead at the crankcase end retains a heavy spring washer packing ring and second washer PRESSED BEAD SPRING WASHER SEAL WASHER HYDRAULIC TAPPET PUSHROD HOUSING LUBRICATION PASSAGE PUSHROD PRESSED IN BALL END O RING PRESSED BEAD CAMSHAFT C...

Page 167: ...ULIC TAPPET DESCRlPTlON 20 4 CYLINDER ASSEMBLY INSPECTION 50 HOUR Visually inspect cylinder to engine attaching hardwarefor security lnspectexhaust and intake flange areas for leaks lnspect induction and exhaust tube attaching hardware for security lnspectrocker box cover hardwarefor security and safetying lnspect rocker cover to cylinder gasket area for evidence of oil leakage lnspect pushrod hou...

Page 168: ... manner to insure accurate results To accurately accomplish a leakage check use the following information on leakage and use the Master Orifice tool to calibrate the leakage checking equipment used on Teledyne Continentalengines Leakage Checks Cylinder leakage is broken down into two areas of concern the Static Seal and the Dynamic Seal Static Seal The static seal consists of the valve to valve se...

Page 169: ...to a cylinder spark plug adapter Turn the cylinder pressure valve on and readjust regulator pressure gauge to read 80 pounds per square inch At this time the cylinder pressure gauge indication will be the low allowable limit for cylinder leak checks The low allowable limit is referred to as the master orifice calibrated pressure reading After the master orifice calibrated pressure reading has been...

Page 170: ...l lubricated and at operating conditions 2 Turn the crankshaft by hand in the direction of rotation until the piston in the cylinder being checked is coming up on its compression stroke 3 Install an adapter in the spark plug hole and connect the calibrated differential pressure tester to the adapter NOTE Cylinder pressure valve is in the Closed position Slowly open the cylinder pressure valve and ...

Page 171: ... a soapy solution at the cylinder head to barreljunction and watch for bubbles Use a soapy solution around both spark plug seals for leakage NO LEAKAGE IS ALLOWED IN STATIC SEALS 7 If leakage is occurring in the intake or exhaust valve areas try staking the valves Remove rocker covers from applicable cylinder Place a fiber drift on the rocker arm directly over the valve stem and tap the drift seve...

Page 172: ...d center in the normal direction of engine rotation Adjust regulated pressure to 80 pounds per square inch and determine amount of loss If the gauge reading is higher than the previously determined master orifice calibrated reading proceedto next cylinder to be tested NOTE Piston ring rotation within the ring land is a normal design characteristic As illustrated in Figure 20 11 Ring Positioning th...

Page 173: ...otingchart as a guide Review the probable causes and other listings of problems that have similar symptoms The probable causes are listed in order of easiest to find which is not necessarily in order of probability of occurrence Perform all corrective actions in accordancewith CylinderAssembly Maintenance in this chapter OCTOBER q998 20 13 ...

Page 174: ...sing or timing plug depending on engine model to determine excessive crankcase pressure Engines with timing plugs can be modified or use PIN 630415 plug which is already drilled for attachment of the fitting for the airspeed indicator On engines that incorporate a separate dip stick tube the rubber hose to the airspeed indicator can be connected directly to this tube and secured with a clamp By th...

Page 175: ... any airframe supplied accessories in accordance with the airframe manufacturer s instructions Remove cylinder using cylinder and piston removal instructions in the UTSIO 360 RB Overhaul Manual Form X30596AS l NOTE When the cylinder is removed with the spark plugs installed inspection can be accomplished by filling the inverted cylinder bore with nonflammable solvent and then inspected for leaks a...

Page 176: ...596AS1 Loosely install spark plugs and gaskets in cylinder Have an assistant hold nuts on opposite end of cylinder through bolts when torquing cylinder attaching hardware 2 Cylinder torquing must be accomplished by two people install and tighten cylinder attaching hardware Torque fasteners to the specified torque and in the sequence specified in Figure 20 12 Position numbers I 4 590 610 Position n...

Page 177: ...L TSIO 360 RB Overhaul Manual for minimum fifs and limits If the cylinder and it s components meet the required visual fluorescent penetrant and magnetic particle inspections the cylinder and its components must be dimensionally inspected CYLINDER ASSEMBLY SERVICE LIMITS I I CYLINDERAND HEADASSEMBLY Ref No I I 7 1 O Intakevalve seat insert in cylinder head Diameter 0 00551 Description 6 ROCKERARMS...

Page 178: ... reworked worn exhaust valves must be replaced 100 O See TCM Service Bulletin M90 13 or current revisionas applicable 8 intake and exhaust valve seats may be reworked in accordancewith the UPSIO 360 RB Overhaul Manual FormX30596ASl O Valve guides may be replaced in accordancewith the L TS10 360 RB Overhaul Manual FormX30596ASl If the required rocker arm to roto coil clearance cannot be obtained wi...

Page 179: ...OCTOBER 1998 20 1 g ...

Page 180: ...4 44 CYLINDER t 88 GAUGE DM 7 MEASUREPARALLELAND PERPENDICULARTO PIN AXIS NOTE DIMENSIONS SHOWN ARE FINISH SIZE AFTER HONING FIGURE 20 14 MAINTENANCECYLINDER DIMENSIONS 20 20 OCTOBER 1998 ...

Page 181: ...etailed Description 21 2 21 3 Crankcase Inspection 50 100 Hour 21 3 21 4 Crankcase Troubleshooting 21 5 21 5 Crankcase Maintenance 21 5 FIGURE PAGE 21 1 Crankcase Description 21 2 21 2 Inspection of Crankcase Non Critical Area 21 3 21 3 Inspection of Crankcase Critical and Non Critical Areas 21 4 ...

Page 182: ...needle bearing is installed between the left and right rear upper crankcase halves to support the front end of the starter adapter shaft gear Guides are bored through lateral bosses for hydraulic tappets Cylinder mounting pads on the left crankcase are farther forward than the corresponding pads on the right crankcase to permit each connecting rod to work on a separate crankpin There are six studs...

Page 183: ...21 3 FIGURE 21 1 CRANKCASE DESCRIPTION ...

Page 184: ...at is less than two 2 inches in length the crack should be scribe marked at its extremities and re inspected for crack progression at the next 50 hours of operation If no progression is observed and no additional cracks are found continue to inspect at regular intervals not to exceed 100 hours duration If a crack is observed in any non critical dark gray areas that is more than two 2 inches in len...

Page 185: ... be performed by FAA approved repair facilities only TCM has established that welding of the crankcase is an acceptable repair process The weld procedure must conformwith approved FAA repair standards andthe dimensionalintegrityof the crankcase must be maintained Refer to TCM Service Bulletin M90 17 or current revision as applicable continuedon next page ...

Page 186: ...ents are properlytorqued and safetied Studs The replacement of crankcase studs or helical coils will require component removal and replacement in accordance with the applicable component system section in the UTSIO 360 RB Overhaul Manual Form X30596AS1 Replace studs or helical coils in accordance with the L TSIO 360 RB Overhaul Manual Form X30596ASl During reassembly insure that ail reinstalledcom...

Page 187: ...onal inspection insure that the part conforms with all visual fluorescentpenetrant magneticparticle or ultrasonicinspection requirements All crankcase repairs must be performed in accordance with the UTSIO 360 RE3 Overhaul Manual Form X30596AS1 Any non TCM supplied accessory that was disassembledfor maintenance must be re assembled in accordance with the applicable accessory manufacturer s instruc...

Page 188: ...1NTENTIONALLY LEFT BLANK ...

Page 189: ... 3 22 3 Engine Drive Train Inspection 22 5 22 4 Engine Drive Train Troubleshooting 22 5 22 5 Engine Drive Train Maintenance 22 6 FIGURE PAGE 22 1 Engine Drive Train Description 22 2 22 2 Crankshaft Description 22 3 22 3 Connecting Rod Description 22 4 22 4 Camshaft Description 22 5 22 5 Helix Pattern Application 22 6 22 6 Crankshaft Oil Seal 22 7 ...

Page 190: ... governor driven bevel gear 7 The governor drive bevel gear 6 is keyed to the camshaft 4 and meshes with and drives the governor drive bevel gear 7 The oil pump drive gear 8 mates with the internal teeth of the camshaft gear 3 The scavenge pump is part of the starter adapter assembly and is driven by the starter shaft gear 16 which drives gear 17 and 18 FIGURE 22 1 ENGINE DRIVE TRAIN DESCRIPTION 1...

Page 191: ...ation frequency occurs six times per revolution the counterweight is designated a 6th order counterweight Similarly if a vibration occurs five times per revolution the counteracting counterweight is designated a 5th order counterweight One sixth order counterweight is installed on one 2 cheek hanger A four and one half order counterweight is installedon the opposite hanger It does not matter on wh...

Page 192: ... by machined bearing saddles The hydraulictappets move inwardand outward intheir boresbythe eccentric shape of the cam lobes The lobes and journals are ground and hardened Movement of the tappets open and close the intake and exhaust valves within the cylinder by mechanical linkage of the pushrods and rocker arms Valve opening and closing is synchronizedwith piston positionby timing the camshaft a...

Page 193: ...replaced in accordance with the following instructions WARNING To prevent starting of engine before moving the crankshaft accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded c Throttle position CLOSED d Mixture control IDLE CUT OFF e Set brakes and block aircraft wheels f Insure th...

Page 194: ...n oil seal and spring PIN 530974 Check the spring length It should be 7 9116 k 1 32 in length See Figure 22 6 Crankshaft Oil Seal 2 Remove spring from new oil seal Unhook the spring ends using an unwinding motion Wrap spring around shaft in seal area Turn spring ends in unwinding direction thenjoin and allow one end to wind intothe other end 3 Lubricate the oil seal lips using Alvania Shell 2 Twis...

Page 195: ... in determiningthe extent of disassembly Maintenance of removed engine systems and components must be performed in accordancewith that particular system or componentsection of this manual CAUTION Dimensional inspection of the crankcase and crankcase internal components must be performed in accordance with the U7 SIO 360 RB Series Overhaul Manual Form X30596AS7 Prior to dimensional inspection insur...

Page 196: ...INTENTIONALLY LEFT BLANK ...

Page 197: ...3 1 General Oil Pressure Adjustment 23 4 23 2 Fuel Pump Adjustment Idle Speed 23 5 23 3 Fuel Servo Adjustments 23 6 23 6 Controller Adjustment 23 7 23 7 ADMP VS Oil Temperature 23 8 23 8 Constant Speed Sea Level Performance Curve 23 9 23 10 Fuel Flow Vs Metered Fuel Pressure 23 10 23 13 Fuel Flow Vs Brake Horsepower 23 11 TABLE PAGE 23 1 Fuel System Pressure and Flow Value Chart 23 3 ...

Page 198: ...or 100 green The aircraft fuel system must be serviced in accordance with the airframe manufacturer s instructions Check engine oil sump for proper servicing See Chapter 7 for oil type specification and servicing point Start engine using the starting procedure given in the airframe manufacturers Airplane Flight Manual AFM Oil Pressure Check If no oil pressure is noted within 30 seconds shut engine...

Page 199: ...y experience ignition or start up anytime the propeller is moved Damage injury or death may result If engine continues to run when magnetos are switched Off a malfunction is occurring in the ignition system Slowly move mixture control to IDLE CUT OFF and record Mixture RPM Rise 25 to 50 RPM __________ Positive Fuel Cutoff __________ When propeller stops rotating place ignition switch master switch...

Page 200: ...urned clockwise to increase oil pressure and counterclockwise to decrease oil pressure With normal operating oil temperature 180 200 F adjust oil pressure to maintain 30 80 pounds per square inch at full power RPM Torque locknut and safety as required FIGURE 23 1 OIL PRESSURE ADJUSTMENT ...

Page 201: ...st be connected and operated in accordance with the manufacturer s instructions Engine driven fuel pump With the engines operating at 2600 rpm and 38 0 inches Hg Manifold pressure mixtures to 24 0 to 25 0 gallons per hour and the emergency fuel pumps in the off position verify the the engine driven fuel pump discharge pressure is set to 35 45 psig If the engine driven fuel pump pressure does not f...

Page 202: ...eed and stabilize it at 700 25 RPM c Slowly but positively move the mixture control from FULL RICH toward IDLE CUTOFF The engine speed should increase 25 to 50 rpm before beginning to drop toward zero d If the engine speed increase is less that 25 rpm the mixture is too lean and you will need to adjust the idle mixture set screw to enrich the mixture If the engine speed increase is more that 50 rp...

Page 203: ... pointedinto the prevailingwind and run engine at 1500to 1800 rpm untilthe oil temperature is 160 F to 180 F b Usinga handhelddigitaltachometer adjustthe propellercontrolsto 2600 rpm With thethrottle in the full fonnrard position set the intake manifold pressureto the value shown in Figure23 5 0 5 In Hg by adjustingthe screw on the top of the controller Turningthe screwclockwisedecreasesmanifoldpr...

Page 204: ... not exceed 15 clicks in the counter clockwise LEAN direction Recheck a Recheck idle settings 700 i 25 RPM and adjust as required b Recheckfull power settings as specified above and adjust as required c Removetest equipment in accordance with the manufacturer sinstructions d After all ground checks and adjustments are completed check to insure that all lines that were disconnected during setup hav...

Page 205: ...23 9 FIGURE 23 6 CONSTANT SPEED SEA LEVEL PERFORMANCE CURVE ...

Page 206: ...23 10 FIGURE 23 7 FUEL FLOW VS METERED FUEL PRESSURE ...

Page 207: ...23 11 FIGURE 23 8 FUEL FLOW VS BRAKE HORSEPOWER ...

Page 208: ...ings should alternate between 65 and 75 power with the appropriate best power mixture settings The best power mixture setting is 100 to 125 rich of peak turbine inlet temperature Engine controls or aircraft attitude should be adjusted as required to maintain engine temperatures and pressures within specifications Descent from high altitude should be accomplished at low cruise power settings During...

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