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20-4

20-3

CYLINDER ASSEMBLY DETAILED DESCRIPTION

Cylinder, Valve Guides, Valves, Rotocoils

- The externally finned aluminum alloy head

castings are heated and valve seat inserts installed before the head is screwed and shrunk
onto an externally finned steel alloy barrel to make the permanent head and barrel
assembly. The cylinder barrel is nitrided for wear resistance. Intake and exhaust valve
guides are pressed into the cylinder head. Special helical coil thread inserts are installed in
upper and lower spark 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

ROTOCOIL

EXHAUST

VALVE GUIDE

OUTER SPRING
INNER SPRING

SPRING RETAINER

INTAKE VALVE GUIDE

INTAKE VALVE
SEAT INSERT

INTAKE VALVE

CYLINDER BARREL

EXHAUST

VALVE

COOLING FINS

CYLINDER HEAD

CYLINDER BARREL

COOLING FINS

CYLINDER BASE

FLANGE

CYLINDER SKIRT

ROCKER COVER

FIGURE 20-3. CYLINDER ASSEMBLY DESCRIPTION

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Summary of Contents for TSIO-360-RB

Page 1: ...Courtesy of Bomar Flying Service www bomar biz MAINTENANCE MANUAL TSIO 360 RB PART NO X30645A FAA APPROVED 1996 TELEDYNE INDUSTRIES INC OCTOBER 1996 ...

Page 2: ...n Air Act which require warning statements accompany all products manufactured with or which contain a Class 1 ozone depleting substance as defined in EPA regulation 58 Federal Regulation 8136 February 11 1993 Teledyne Continental Motors is pursuing alternatives to these substances to eliminate their use as soon as possible WARNING Manufactured with 1 1 1 trichloroethane and or CFC 113 substances ...

Page 3: ...T PAGES DESTROY SUPERSEDED PAGES WARNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors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 MODEL TSIO 360 MB SB FORM X30645A PAGE STATUS PAGE STATUS PAGE STATUS PAGE STATUS ALL ORIGINAL ...

Page 4: ...d make and model of the type certified product on which the part might be installed stamped on the part An FAA PMA is issued under FAR 21 305 The make and model information may be on a tag attached to the part d Shipping ticket invoice or other document which verifies the part was manufactured by a facility holding an FAA Approved Production Inspection System issued under FAR 21 Subpart F or by a ...

Page 5: ...lars This manual contains no warranties either expressed or implied Publication Format This publication is formatted for practical use and ease of reference Chapter and page numbering are independent so that revisions can be made without affecting the entire publication Due to the large volume of information necessary for maintenance maintenance chapters are independently numbered For example chap...

Page 6: ...imitations 4 1 5 Time Limits Operational Insp Troubleshooting 5 1 6 Unpacking De Inhibiting Installation Test 6 1 7 Servicing Fluids 7 1 8 Engine Preservation and Storage 8 1 9 Standard Practices 9 1 10 Engine Maintenance 10 1 11 Exhaust System 11 1 12 Ignition System 12 1 13 Fuel Injection System 13 1 14 Induction System 14 1 15 Air Conditioning System 15 1 16 Electrical Charging System 16 1 17 S...

Page 7: ... 4 Service Reports and Inquires 1 3 1 5 Description of Engine Model Code 1 4 1 6 Definition of Terms 1 4 1 7 Engine Design Features 1 4 1 8 General 1 9 1 9 Engine Specifications 1 9 1 10 Operating Limits 1 9 FIGURE PAGE 1 1 Engine Description L TSIO360 RB 1 5 1 2 Engine Description L TSIO360RB 1 6 ...

Page 8: ...ion Manual Form 30593A 6 Starter Service Instructions Form X30592 7 TCM Ignition Systems Master Service Manual Form No X40000 8 Alternator Maintenance and Parts Catalog Form No X30631A The above publications can be ordered through your Teledyne Continental Motors Distributor or ordered directly if prepaid from Teledyne Continental Motors P O Box 90 Mobile Alabama 36601 ATTN Publications Sales Depa...

Page 9: ... airworthiness authority CATEGORY 2 CRITICAL SERVICE BULLETIN CSB Service documents determined by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to persons or property on the ground unless some specific action inspection repair replacement etc is taken by the product owner or operator Documents in this category may be candidates for incorporation in a...

Page 10: ...5 inch stroke The L TSIO 360 RB series engines are fuel injected The crankshaft is equipped with pendulum type counterweight dampers that suppress torsional vibrations The L TSIO 360 RB series engine have a doweled six bolt hole configuration propeller flange A mounting pad is provided to utilize a hydraulic controlled governor for a constant speed propeller The L TSIO 360 RB series engines are de...

Page 11: ...1 5 FIGURE 1 1 Engine Description L TSIO 360 RB ...

Page 12: ...1 6 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d ...

Page 13: ...1 7 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d ...

Page 14: ...1 8 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d ...

Page 15: ...1 9 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d ...

Page 16: ...linders Arrangement Individual cylinders in a horizontally opposed position Compression Ratio 7 5 1 Firing Order TSIO 360 RB 1 6 3 2 5 4 Firing Order LTSIO 360 RB 1 4 5 2 3 6 Number of cylinders 6 Bore Inches 4 438 Stroke Inches 3 875 Piston Displacement cu in 360 Brake Horsepower Rated Maximum Continuous Operation L TSIO 360 RB 220 BHP 1 10 OPERATING LIMITS NOTE The following specifications apply...

Page 17: ... F Recommended Operational Range 160 180 F Cylinder Head Temperature TSIO 360 RB Recommended maximum at cruise 420 F Limit 460 F Turbine Inlet Temperature Maximum Continuous 1650 F Maximum 60 seconds 1700 F Ignition Timing Compression stroke breaker opens Right Magneto degrees BTC 22 1 Left Magneto degrees BTC 22 1 The following spark plugs are approved for use in engine models according to the fo...

Page 18: ...ION A removable oil transfer plug conducts oil under pressure from the propeller governor through the crankshaft to the propeller hub 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 bearings The governor pad cover is not needed if a propeller governor is inst...

Page 19: ...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 20: ...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 21: ...Oil Filters Special Tools EASTERN ELECTRONICS INC 180 Roberts St East Hartford CT 06108 203 528 9821 Fuel Pressure Test Equipment Measuring Instruments Precision Tools Piston Position Indicators FEDERAL TOOL SUPPLY CO INC 1144 Eddy St Providence Rhode Island 02940 800 343 2050 Precision Inspection Instruments Special Tools AIRCRAFT TOOL SUPPLY P O Box 4525 2840 Breard St Monroe LA 71201 507 451 53...

Page 22: ...age available from Kent Moore 16 5 9 Borrough s 4973 Generator Drive Holders or equivalent 16 5 10 Borrough s 61 5 Pulley Pulled or equivalent for gen alt sheave removal 16 5 11 Borrough s 8091 GEN ALT Output Tester or equivalent 16 5 12 647 Alternator Analyzer Voltage Regulator Tester available from Eastern Electronics Inc 16 5 13 E100 Alternator Regulator Battery Tester available from Eastern El...

Page 23: ...rough s 8116 1 through 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 avail...

Page 24: ...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 25: ...3 1 CHAPTER 3 SEALANTS AND LUBRICANTS Sealants Lubricants 3 2 ...

Page 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...4 2 INTENTIONALLY LEFT BLANK ...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ... 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 38: ... 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 39: ... 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 40: ...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 41: ...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 42: ...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 43: ... 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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ... Excessively worn cylinder walls Replace cylinder piston rings See Section 20 6 Cylinder Assembly Maintenance Slow Engine Acceleration On A Hot Day Mixture too rich Momentarily pull mixture control back until engine acceleration picks up Engine Will Not Stop At Idle Cut Off Fuel manifold valve not seating properly Repair or replace fuel manifold valve See Section 13 5 Fuel System Maintenance Fuel ...

Page 50: ...tions Malfunctioning ignition system Check ignition cables and connections Replace malfunctioning spark plugs See Section 12 4 Ignition System Inspection Engine Runs Rough At Speeds Above Idle Improper fuel air mixture Check fuel manifold connections for leaks Torque loose connections Check fuel control and linkage for setting and adjustment Check fuel filters and screens for dirt Check for proper...

Page 51: ...shooting Low Oil Pressure Indication On Engine Gage Insufficient oil in oil sump oil dilution or using improper grade oil for prevailing ambient temperature Add oil or change oil to proper viscosity See Chapter 7 Servicing Fluids High oil temperature Malfunctioning oil temperature control valve in oil cooler oil cooler restriction Replace valve or clean oil cooler See Section 18 5 Oil Cooler Leaki...

Page 52: ...pring Adjust pressure to 30 60 pounds per square inch in accordance with Chapter 23 Oil Pressure Adjustment High Oil Temperature Indication Prolonged ground operation Limit ground operation to a minimum Malfunctioning gage or bulb unit Check wiring Check bulb unit Check gage Replace malfunctioning parts in accordance with the airframe manufacturer s instructions ...

Page 53: ...6 2 6 5 Preparation for Service 6 3 6 6 Engine Installation Instructions 6 4 6 7 Engine Pre oiling 6 12 6 8 Preflight and Run Up 6 12 6 9 Flight Testing 6 13 FIGURE INDEX 6 1 Installation Drawing L TSIO 360 RB 6 6 Installation Drawing L TSIO 360 RB continued 6 7 Installation Drawing L TSIO 360 RB continued 6 8 Installation Drawing L TSIO 360 RB continued 6 9 ...

Page 54: ...6 2 INTENTIONALLY LEFT BLANK ...

Page 55: ...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 56: ...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 57: ...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 58: ...6 6 FIGURE 6 1 INSTALLATION DRAWING ...

Page 59: ...6 7 FIGURE 6 1 INSTALLATION DRAWING cont d ...

Page 60: ...6 8 FIGURE 6 1 INSTALLATION DRAWING cont d ...

Page 61: ...6 9 FIGURE 6 1 INSTALLATION DRAWING cont d ...

Page 62: ...e magneto attaching nuts were loosened or the magnetos rotated during engine installation magneto to engine timing must be adjusted to specification prior to starting See Section 12 5 Ignition System Maintenance of this manual Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Install the upper spark plugs and torque to 300 360 inch poun...

Page 63: ...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 64: ...6 12 INTENTIONALLY LEFT BLANK ...

Page 65: ...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 66: ...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 67: ...stralia 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 Sinclair Oil Company Sinclair Avoil Texaco Inc Texaco Aircraft Engine Oil Premium AD Total France Total Aero DM 15W50 Union Oil Company of California Union Aircraft Engine Oil...

Page 68: ...netically It looks similar to nickel but is soft and malleable 7 5 SPECTROGRAPHIC OIL ANALYSIS Spectrographic oil analysis has become popular with the owners and operators of general aviation piston powered aircraft This process was developed more than 35 years ago by the railroads as a method of identifying wear characteristics in large diesel engines Eventually oil analysis was adopted by the mi...

Page 69: ...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 70: ...7 6 INTENTIONALLY LEFT BLANK ...

Page 71: ...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 72: ...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 73: ...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 74: ...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 75: ... 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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ... 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...

Page 82: ...10 2 INTENTIONALLY LEFT BLANK ...

Page 83: ...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 84: ... 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 85: ...11 3 FIGURE 11 1 INDUCTION AND EXHAUST SYSTEM ...

Page 86: ... 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 87: ...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 88: ...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 89: ...pected for 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 ...

Page 90: ...ct after clamp assembly has been torqued the clamp assembly must be replaced Inspect clamp outer band flatness using a straightedge especially within two inches of spot weld tabs that retain the T bolt fastener clearance should be less than 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 i...

Page 91: ...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 92: ...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 93: ...erhaul Manual Form X30596A Turbochargers Wastegate Controller For replacement of these components see the applicable portion of exhaust system disassembly reassembly in the L TSI0 360 Series Overhaul Manual X30596A For maintenance of these components refer to the component manufacturer s instructions Airesearch 3201 Lomita Blvd Torrance California 90505 Lubrication Plumbing Turbocharger lubricatio...

Page 94: ...11 12 INTENTIONALLY LEFT BLANK ...

Page 95: ...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 96: ...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 97: ... 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 98: ...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 99: ... s specifications Magnetos out of time Inspect internal timing of magnetos in accordance with magneto manufacturer s instructions See Section 12 5 Placing The Crankshaft In Timing Position and Magneto Timing And Installation On Engine Damaged magneto breaker points or condenser Replace points and condenser in accordance with magneto manufacturer s instructions 12 5 IGNITION SYSTEM MAINTENANCE Harn...

Page 100: ...mits must not be re used Parts with values up to and including service limits may be re used however judgment should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See the current L TSIO 360 Overhaul Manual for minimum fits and limits 12 5 IGNITION SYSTEM MAINTENANCE cont d FITS LIMITS REF LEFT AND RI...

Page 101: ... 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 102: ...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 103: ...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 104: ...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 105: ...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 106: ... 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 107: ...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 108: ...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 109: ...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 110: ...12 16 INTENTIONALLY LEFT BLANK ...

Page 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...ion 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 preceding procedures have been accomplished verify that each control has full limit of travel the required safeties are in place that no binding of levers or linkages is occurring and that cont...

Page 118: ...5 Fuel Nozzles Improper idle mixture Adjust fuel mixture in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for ordering information Poor Acceleration Idle mixture incorrect Adjust fuel mixture in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for orderin...

Page 119: ...y and reassembly procedure in the L TSIO 360 RB Overhaul Manual Form X30596A The manifold valve may be replaced with new or it must be repaired and calibrated in accordance with the applicable instructions in the Fuel Injection Systems Parts and Overhaul Manual Form X30593A NOTE The appropriate test calibration equipment must be available for the overhaul of any TCM fuel injection system component...

Page 120: ...0 011L 5 Fuel pump drive shaft in governor gear diameter 0 055L 6 Governor driven gear in crankcase diameter 0 005 7 Governor driven gear bore in crankcase diameter 0 876 8 Governor drive gear to camshaft gear diameter 0 012 1 3 2 4 8 5 6 7 FIGURE 13 6 FUEL PUMP DRIVE FITS AND LIMITS FUEL SYSTEM MAINTENANCE cont d Fuel Servo Unit For removal and replacement of the fuel servo unit see the applicabl...

Page 121: ... 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 122: ...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 123: ...ion properly 14 4 INDUCTION SYSTEM TROUBLESHOOTING This 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 approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start Induction system intake obstructed Locate and remov...

Page 124: ...14 4 INTENTIONALLY LEFT BLANK ...

Page 125: ...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 126: ...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 127: ... s Instructions 15 5 COMPRESSOR MOUNTING KIT MAINTENANCE Remove and replace worn or malfunctioning compressor mounting kit components in accordance with applicable portions of disassembly reassembly in the L TSIO 360 Overhaul Manual Form X30596A Supplement 1 Freon compressor drive belt inspection removal installation alignment and tensioning must be performed in accordance with airframe manufactur...

Page 128: ...15 4 INTENTIONALLY LEFT BLANK ...

Page 129: ...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 130: ...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 131: ...nspection of charging system any indication of an 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 Overhaul Manual Form X30596A alternator disassembly reassembly 16 4 CHARGING SYSTEM TROUBLESHOOTING Refer to the airframe manufacturer s applicable charging system troubleshootin...

Page 132: ...16 4 INTENTIONALLY LEFT BLANK ...

Page 133: ...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 134: ...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 135: ...UMP GEAR BUSHING DRIVE SHEAVE BEVEL GEARS STANDARD ADAPTER TSIO 360 RB FIGURE 17 2 STARTER ADAPTER DESCRIPTION 17 3 STARTER AND STARTER ADAPTER INSPECTION 50 Hour Visually inspect starter drive adapter to engine starter adapter cover to adapter housing and starter to adapter attaching hardware for security Visually inspect for oil leakage at cover oil seal area cover to adapter and starter adapter...

Page 136: ...96A Supplement 1 Disassembly maintenance and reassembly of the starter motor must be performed in accordance with the starter manufacturer s instructions Starter Adapter The starter adapter may be removed from the engine and disassembled in accordance with the applicable portions of starter and starter adapter disassembly reassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A Suppl...

Page 137: ...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 138: ...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 139: ...17 7 FIGURE 17 4 STARTER ADAPTER FITS LIMITS ...

Page 140: ...17 8 INTENTIONALLY LEFT BLANK ...

Page 141: ... 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 142: ... 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 143: ...18 3 FIGURE 18 1 ACCESSORY CASE DESCRIPTION ...

Page 144: ...askets Loose or stripped studs Insufficient torque See Section 18 5 Accessory Case Cracked accessory case See the L TSIO 360 Series Overhaul Manual Form X30596A for accessory case replacement Loose Accessories Loose or stripped studs Insufficient torque See the L TSIO 360 Series Overhaul Manual Form X30596A for stud replacement and torque values 18 5 ACCESSORY CASE MAINTENANCE Accessories If oil l...

Page 145: ...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 146: ...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 147: ...19 3 FIGURE 19 1 LUBRICATION SYSTEM SCHEMATIC ...

Page 148: ...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 149: ...19 5 ACCESSORY CASE INTERNAL VIEW TSIO 360 FIGURE 19 2 OIL PUMP DESCRIPTION TSIO 360 ...

Page 150: ...19 6 ACCESSORY CASE INTERNAL VIEW LTSIO 360 FIGURE 19 3 OIL PUMP DESCRIPTION LTSIO 360 ...

Page 151: ...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 152: ...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 153: ...nger tight to 30 inch pounds torque Check for proper stud extension height in accordance with Figure 19 7 Oil Filter Adapter Stud Inspection F Allow the parts to cure for a minimum of thirty minutes prior to installation of the oil filter CAUTION Curing times may vary depending on ambient temperature Consult Loctite instructions After installation of a new oil filter adapter stud stamp a 125 high ...

Page 154: ...abnormal wear Visually inspect 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 replaced with new 100 HOUR Perform all inspection requirements of 50 hour inspection and the following If oil pressure does not conform with 10 psi minimum 30 to 60 psi normal operation ...

Page 155: ... X30596A See Section 23 4 for oil pressure adjustment NOTE Repairs other than stoning nicks on parting flanges replacement of studs worn parts and refacing the oil pressure relief valve seat on the oil pump housing are not possible The oil pump driven gear shaft is pressed into the accessory case pump housing and cannot be replaced The pump gear chamber must not be enlarged If it is scored the acc...

Page 156: ...y cases with oil pressure relief valve housings that exceed specified limits must be discarded CAUTION Thoroughly clean oil pressure relief valve cavity after refacing procedure All debris from the refacing procedure must be removed Reassemble serviceable or new relief valve housing and adjusting screw Turn adjusting screw into housing about halfway Install new copper washer and nut Assemble plung...

Page 157: ...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 158: ...19 14 INTENTIONALLY LEFT BLANK ...

Page 159: ... Airflow Diagram 20 2 20 2 Cylinder Piston And Valve Train 20 3 20 3 Cylinder Assembly Description 20 4 20 4 Piston Assembly Description 20 5 20 5 Valve Train Description 20 6 20 6 Hydraulic Tappet Description 20 7 20 7 Master Orifice Tool 20 8 20 8 Static Seal 20 9 20 9 Dynamic Seal 20 9 20 10 Differential Pressure Tester Calibration 20 10 20 11 Ring Positioning 20 12 20 12 Cylinder Assembly Serv...

Page 160: ...ders providing 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 Increasing or decreasing outlet size with the use of airframe cowl flaps changes airflow and is used as an aid in controlling engine operating temperatures Below is a general illustration showing engine...

Page 161: ... 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 162: ...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 163: ...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 164: ...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 165: ...3 14 4 15 FIGURE 20 6 HYDRAULIC TAPPET DESCRIPTION 20 4 CYLINDER ASSEMBLY INSPECTION 50 HOUR Visually inspect cylinder to engine attaching hardware for security Inspect exhaust and intake flange areas for leaks Inspect induction and exhaust tube attaching hardware for security Inspect rocker box cover hardware for security and safetying Inspect rocker cover to cylinder gasket area for evidence of ...

Page 166: ...tructure can destroy the assembly preloads and casting strength resulting in cylinder assembly failure 100 HOUR Perform all visual inspection requirements of 50 hour inspection Perform the following cylinder compression test which is to be done soon after the operational engine test in Section 5 4 Cylinder Compression Test The differential pressure test is an accepted method of determining cylinde...

Page 167: ...e piston rings to the cylinder wall seal This seal leakage can vary from cylinder to cylinder ring gap position wear or the amount of engine oil on the cylinder wall EQUIPMENT Testing equipment must be kept clean and checked periodically for accuracy as follows using a line pressure of 100 to 120 pounds per square inch close the cylinder pressure valve then set the regulator pressure valve to 80 p...

Page 168: ...r See the schematic diagram of a typical differential pressure tester shown below CYLINDER PRESSURE GAUGE RESTRICTOR ORIFICE REGULATOR PRESSURE VALVE COMPRESSED AIR SOURCE CYLINDER PRESSURE VALVE CYLINDER ADAPTER CYLINDER REGULATOR PRESSURE GAUGE CYLINDER PRESSURE GAUGE RESTRICTOR ORIFICE REGULATOR PRESSURE VALVE COMPRESSED AIR SOURCE CYLINDER PRESSURE VALVE REGULATOR PRESSURE GAUGE CYLINDER ADAPT...

Page 169: ...e completely Check the regulator pressure gauge and adjust if necessary to 80 pounds per square inch 5 Observe the pressure indication on the cylinder pressure gage The difference between this pressure and the pressure shown by the regulator pressure gauge is the amount of leakage through the cylinder If the cylinder pressure gauge reading is higher than the previously determined master orifice ca...

Page 170: ... determined master orifice calibrated reading proceed to 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 the compression ring location may have a direct bearing on the dynamic seal pressure check Therefore complete the test in the opposite direction if readings are below prescribed limits FI...

Page 171: ...cked or out of limits Replace Piston Worn rings Replace rings Cylinder wall dimensions out of limits Replace Cylinder Test gauge above tolerance None None NOTE Perform all corrective actions in accordance with Section 20 6 Cylinder Assembly Maintenance 20 5 CYLINDER ASSEMBLY TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of t...

Page 172: ...troubleshooting test is recommended when excessive crankcase pressures are suspected An airspeed indicator may be used as a substitute for a water manometer The indicator can be plumbed into a field modified oil cap dipstick housing or timing plug depending on engine model to determine excessive crankcase pressure Engines with timing plugs can be modified or use P N 630415 plug which is already dr...

Page 173: ...360 Series Overhaul Manual Form X30596A 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 at the static seal areas When cylinder is removed use the following information to clean pistons prior to dimensional inspection Pistons Do not use wire brushes or scraper...

Page 174: ...face roughness Nitride Barrels using 180 grit stone cross hatch Angle Microfinish measured in direction of piston travel RMS 22 32 25 5 Cylinder bore surface roughness Channeled Chrome using 180 grit stone cross hatch Angle Finish all area within ring travel Must show evidence of contact with honing stone Partially honed areas shall not exceed 10 of bore surface and no area shall exceed one inch i...

Page 175: ...ter 0 0010L 37 Piston pin Diameter Piston pin 0 005 oversize Diameter 0 9984 1 0034 38 Piston pin in cylinder End Clearance 0 050L 39 Piston pin in connecting rod bushing Diameter 0 0040L 40 Hydraulic tappet in crankcase Diameter 0 0035L SPRING TEST DATA 41 Inner valve spring 625957 compressed to 1 100 in length Load Inner valve spring 625957 compressed to 1 500 in length Load 62 LBS 33 LBS 42 Out...

Page 176: ...20 18 FIGURE 20 12 CYLINDER ASSEMBLY SERVICE LIMITS For Maintenance Cylinder Dimensions see next page ...

Page 177: ...piston ring gaps given in the table of limits must be maintained When engine is being overhauled TCM requires that all Parts be brought back to new parts limits by rework or replacement See New Parts and Service Limits in L TSIO 360 Series Overhaul Manual Form X30596A NOTE DIMENSIONS SHOWN ARE FINISHED AFTER HONING FIGURE 20 13 MAINTENANCE CYLINDER DIMENSIONS ...

Page 178: ...596A 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 Hydraulic Valve Tappets Malfunctioning hydraulic valve tappets must be removed discarded and replaced with new Remove and replace tappets in accordance with the applicable instructions in the L TSIO 360 Series Overhaul Manual Form ...

Page 179: ...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 180: ...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 181: ...21 3 FIGURE 21 1 CRANKCASE DESCRIPTION ...

Page 182: ...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 183: ... 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 conform with approved FAA repair standards and the dimensional integrity of the crankcase must be maintained Refer to TCM Service Bulletin M90 17 or current revision as applicable continued on next page ...

Page 184: ...of the L TSIO 360 Series Overhaul Manual Form X30596A Exercise judgment as to the extent of disassembly required During reassembly insure that all reinstalled components are properly torqued 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 L TSIO 360 Series Overhau...

Page 185: ...re that the part conforms with all visual fluorescent penetrant magnetic particle or ultrasonic inspection requirements All crankcase repairs must be performed in accordance with the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A Any non TCM supplied accessory that was disassembled for maintenance must be re assembled in accordance with the applicable accessory manufact...

Page 186: ...21 8 INTENTIONALLY LEFT BLANK ...

Page 187: ... 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 188: ... 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 189: ...rweight is absorbing If a vibration 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 installed on the opposite ...

Page 190: ...s are supported in the crankcase by machined bearing saddles The hydraulic tappets move inward and outward in their bores by the 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 synchronized with p...

Page 191: ...AINTENANCE Crankshaft Nose Oil Seal The crankshaft nose oil seal may be replaced according to 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 contr...

Page 192: ... seal and spring P N 530974 Check the spring length It should be 7 9 16 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 then join and allow one end to wind into the other end 3 Lubricate the oil seal lips using Alvania Shell 2 Twist the...

Page 193: ...ent of disassembly Maintenance of removed engine systems and components must be performed in accordance with that particular system or component section of this manual CAUTION Dimensional inspection of the crankcase and crankcase internal components must be performed in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Prior to dimensional inspection insure that the part conforms ...

Page 194: ...22 8 INTENTIONALLY LEFT BLANK ...

Page 195: ...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 196: ...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 197: ...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 198: ...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 199: ...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 200: ...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 201: ...ows a Orient the aircraft so that it is pointed into the prevailing wind and run engine at 1500 to 1800 rpm until the oil temperature is 160 F to 180 F b Using a handheld digital tachometer adjust the propeller controls to 2600 With the throttle in the full forward position set the intake manifold pressure to the value shown in Figure 23 5 0 5 In Hg by adjusting the screw on the top of the control...

Page 202: ... 15 clicks in the counter clockwise LEAN direction Recheck a Recheck idle settings 700 25 RPM and adjust as required b Recheck full power settings as specified above and adjust as required c Remove test equipment in accordance with the manufacturer s instructions d After all ground checks and adjustments are completed check to insure that all lines that were disconnected during setup have been rec...

Page 203: ...23 9 FIGURE 23 6 CONSTANT SPEED SEA LEVEL PERFORMANCE CURVE ...

Page 204: ...23 10 FIGURE 23 7 FUEL FLOW VS METERED FUEL PRESSURE ...

Page 205: ...23 11 FIGURE 23 8 FUEL FLOW VS BRAKE HORSEPOWER ...

Page 206: ...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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