Teledyne TSIO-360 Series Overhaul Manual Download

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Summary of Contents for TSIO-360 Series

Page 1: ...OVERHAUL MANUAL MODELS TSIO 360 A AB B BB C CB D DB E EB F FB GB H HB JB K KB LB MB SB FORM NO X30596A O 1997 TELEDVNE INDUSTRIES INC FAAAPPROVED OCTOBER 1997 ...

Page 2: ...S NOVEMBER 9988 INSERT LATEST PAGES DESTROY SUPERSEDED PAGES WRNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors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 1997 are for the ii REVISED OCT 97 ...

Page 3: ...modelof the type certificatedproduct on which the part is eligiblefor installation stamped on the part An FAA Parts ManufacturerApproval FWPMA is issued under FAR 21 305 The makeand model informationmay beon a tag attached to the part d By shippingticket invoice or other documentwhich providesevidencethat the partwas produced by a manufacturer holdingan FAA Approved Production InspectionSystem iss...

Page 4: ...ructions applicable to proper overhaul procedures Prior to overhaul the mechanic must meet requirements of Federal Aviation Regulation 65 and must follow FAR parts 43 91 and 145 as applicable This manual must be used in conjunction with the FAA Advisory circular 43 13 1A Acceptable Methods Techniques and Practices Aircraft Inspection and Repair as well asTeledyneContinentalMotors TSIO 360 Series P...

Page 5: ...e engine will be covered inthis System Chapter The major System Chapters are then broken down into Sub system Sections These sections are identified by the second element of the standardized numbering system The number 10 of the basic number series 72 10 00 isfor the disassembly of the engine The Subsection is the third element of the standardized numbering system 72 10 12 This number is the final...

Page 6: ...ode 1 10 06 1 10 04 Basic DesignFeatures 1 10 07 1 20 00 TOOLS 1 20 01 SpecialTools 1 20 01 1 30 00 PRODUCTS 1 30 01 Product List CHAPTER 4 AIRWORTHINESS LIMITATIONS 4 00 00 Airworthiness Limitations 4 00 01 CHAPTER 5 TlME LIMITS MAINTENANCE CHECKS 5 00 00 GENERAL 5 00 03 5 10 00 TIME LIMITS INSPECTION PROGRAM 5 10 01 5 20 00 SCHEDULED MAINTENANCE 5 20 01 5 20 01 PreflightInspection 5 20 01 5 20 0...

Page 7: ... PreliminaryCleaning 72 60 04 IgnitionSystem 72 10 04 FuelInjectionSystem 7 2 1 0 06thru 08 Accessory Case 72 10 10 InductionSystem 72 10 12thru 22 Oil Sump 72 10 24 Oil Cooler 72 10 25 Alternator Assembly 72 10 26 Starter and Starter DriveAdapter 72 10 28thru 32 Oil PumpAssembly 72 10 34 Cylindersand Pistons 72 10 37thru 39 Crankcase 72 10 40 Camshaft Assembly 92 10 42 Crankshaft Group 72 10 42 E...

Page 8: ...al 72 30 03 Visual Inspection 72 30 04 Magnetic ParticleInspection 72 30 05 Crankshaft UltrasonicInspection 72 30 06 FlourescentParticleInspection 72 30 08 DimensionalInspection 72 30 08 DimensionalLimits 7230 08 TaMe of Limits 72 30 09thru 16 CriticalNew Part Dimension 7230 1 7 18 ProtectiveCoating 72 30 18 Applicationof Alodizing 72 30 18 Repair of Alodized Surfaces 72 30 18 EnamelCoatings 72 30...

Page 9: ...s and Pistons 72 60 08 Accessory Case 72 60 09 FuelPump 72 60 10 Starter DriveAdapter 72 60 10 Alternator Assembly 72 60 10 Oil Coder 72 60 11 Valve Mechanism 72 60 11 IntercylinderAir Baffles 72 60 11 Oil Sump 72 60 13 InductionSystem 7240 13 thru 15 FuetlnjectionSystem 72 60 15 IgnitionSystem 72 60 15 ExhaustSystems 72 60 17 CHAPTER 72 70 TESTING AFTER OVERHAUL Test Stand 72 70 03 Test Club 72 7...

Page 10: ...00 07 Fuel SystemTroubleshootingChart 73 0048 09 CHAPTER 74 IGNITION TCM IGNITIONSYSTEM GENERAL 74 00 02 MagnetoInstallation 7440 02 HarnessAssembly Installation 7440 03 SLICK IGNITIONSYSTEM GENERAL 74 00 05 Magneto Installation 74 00 05 HarnessAssembly Maintenance 74 00 06 IGNITIONTROUBLESHOOTING 74 00 08 CHAPTER 75 AIR GENERAL 7575 00 03 CHAPTER 76 ENGINECONTROLS GENERAL 76 00 03 CRUISECONTROL B...

Page 11: ...DUCTS LUBRICATING SYSTEMTROUBLESHOOTINGCHART CHAPTER 80 STARTING GENERAL Prestarting Starting GroundWarm Up Pre takeoffCheck FloodedEngine CddWeather Operation Preheating HotWeather Operation GroundOperatingAt HighAltitude Airports CHAPTER 81TURBINES GENERAL TURBOCHARGER WASTEGATES CONTROLLERS LUBRICATIONSYSTEM TROUBLESHOOTING CHART March 1989 i ...

Page 12: ...rs Piston RingCompressors FloatingHolder Valve SpringCompressor PushRodSpringCompressor FlaringToolfor Push RodHousing Valve Guide Remover Valve Seat InsertRemoverand Replacer InstallerValve Seat inserts Valve Guideto Valve Seat Alignment System Valve Stem Hole Reamers BoringBars BoringBars ExpandingGuide Bodies Valve Seat Insert Cutters Step Side Cutters RosanStud Remover ConnectingRod Reamingand...

Page 13: ...le Remover and Installer CrankcaseThru Boit Removers Hex Drive For Hex Tube Nuts RotabroachCutters Pullers Pullers Pullers Pullers Outside Micrometers Dial Bore Gauges Blade Micrometers Screw Thread Micrometer Depth Micrometers Reamers Rocker Shaft Support Boss Reamers Valve Guide Boss Valve Guide Stem Hole Reamers Adapter Square Shank Reamers Plug Gauges Valve Stem Hole Dial Thickness Gauge Preci...

Page 14: ...Oil Sump Oil Cooler Alternator Assembly Starter and Starter DriveAdapter TSIO 360 A AB D DB OP LB Starter and Starter DriveAdapter TSIO 360 B BB C CB H HB JB Starter and Starter DriveAdapter TSIO 360 E EB F FB GB KB MB SB LTSIO E EB KB Oil Pump Assembly IntercylinderAir Baffles TSIOILTSIO 360 D DB F FB GB KB LB MB SB Cylinder and Piston Assembly Crankcase Assembly CamshaftAssembly Crankshaft Group...

Page 15: ...seon Stand Alignment of Timing Marks Right Crankcase and Support Torquing Sequence InstallationNo 6 Cylinder TighteningCylinder Base Nut Cylinder FlangeTorque Sequencefor SingleCylinder Installation Torquing Thru Bolts InstallingPushrodHousing BottomView Valve Mechanism Coupling Drive Lugs Wiring Diagram PAGE AEROflCHE GRID NO 72 20 09 HI7 72 20 09 HI9 72 20 09 HI9 72 20 09 HI9 72 20 09 HI9 72 20 ...

Page 16: ... 30 15 Table of Limits Chart 5B 72 30 16 Critical New Part Dimensions 72 30 17 18 InspectionChart 72 40 11 GeneralUse TighteningTorques 72 50 03 Table of TighteningTorques 72 50 04 PipePlugs 72 50 05 Hydraulic LineFittings 72 50 05 Fuel ManifoldValve FittingLocations 72 50 10 Air Throttleand MeteringAssembly Fitting Orientation 72 50 11 Fuel PumpFiing Locations 72 50 12 StandardAcceptanceTest 72 7...

Page 17: ...ed Publications Service Bulletins ServiceReportsAnd inquiries 100 ReplacementParts DEFINITIONS ABBREVIATIONS Abbreviations Symbols Definitions Descriptionof Engine Model Code Basic Design Feature TOOLS SpecialTools PRODUCTS Product List ...

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Page 19: ...ssued fo emphasize certain instructions or to prevent possible damage to engine or accessories WARNiNG Information which if disregarded may result in severe damage to or destructionof the engine or endangermentto personnel 1 00 01 RELATED PUBLICATIONS A Engine Manuals 1 Operator s Manualfor TSIO 360 except LB and MB SB Series Aircraft Engine FormX30583 Operator s Manual for TS10 360 MB SB Series A...

Page 20: ...ircraft 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 are candidates for incorporationin an Airworthiness Directive issued by the FAA but may not be CATEGORY 3 SERVICE BULLETIN SB Service documents not included in categories 1 and 2 considered by the product manufacturer to ...

Page 21: ...ocking Washers Plain Exhaust Clamps Turboto Tailpipe CounterweightBushings IntakeGuide Seals All 10 346 10 360 LTSIO TSIO 360 0 470 10 470 TSIO 470 GIO 470 and 6 285 Models All Models All Models All Models All Models All models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Models All Mod...

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Page 23: ... of Gravity Cubic Feet Per Minute Cylinder HeadTemperature Counterclockwise Rotation Clockwise Rotation Degrees of Angle Degrees Fahrenheit ExhaustGasTemperature Figure Illustration PropellerEnd of Engine Foot or Feet FullThrottle Foot PoundsTorque Gallons Per Minute Grams Hexagon Water Mercury Hour InsideDiameter lnch PoundsTorque Inches Side on which No s 2 4 and 6 cylindersare located Rearto Fr...

Page 24: ... applying a brake to the power shaft of an engine The required effort to brake the engine could be converted to horsepower hence brakehorsepower BSFC Brake Specific Fuel Consumption Fuel consumption stated in pounds per hour per brake horsepower For example an engine developing 300 horsepower while burning 150 pounds of fuel per hour hasa BSFCof 5 FuelConsumptionin PPH Brake Horsepower Cavitation ...

Page 25: ...the maximum amount of moisture the air could contain at a given tempera ture Inability or restriction of piston rotation at TBC due to fluid accumula tion in excess of combustion chamber displacement A mechanical device used in some magnetos to retard the ignition timing and providehighervoltage at cranking speeds for starting The leanest mixture approved for any given power condition It is not ne...

Page 26: ... For example an engine with high compression and high temperature needs a higher Performance Rated fuel than a low compression engine A rating of 100 130 denotes performance characteristics of lean 100 and rich 130 mixtures respectively A term used to describe a process by which a crankcase is made An engine with a permold crankcase has a front right hand mounted gear driven alternator Altitude us...

Page 27: ...e Ignition and valve timing are stated in terms of degrees beforeor after TDC Regarding engines the percent of total heat generated which is converted into useful power Turbine Inlet Temperature The measurement of E G T at the turbocharger turbine inlet Twisting moment or leverage stated in pounds foot or pounds inch A device used to supply increased amounts of air to an engine induction system In...

Page 28: ...ivert exhaust gas through or around the turbine as necessary to maintain turbine speed As more air is demanded by the engine due to throttle operation the compressor must work harder In order to maintain compressor and turbine speeds more exhaust must be flowed through the turbine The wastegate valve closes and causes gas which would go directly overboard to pass through the turbine The wastegate ...

Page 29: ... propeller flange A mounting pad is provided to utilizea hydraulic controlled governor for the constant speed propeller The TSIO 360 series engines are of a wet sump design with a positive displacement oil pump installed in the lower portion of the accessory case The desired oil pressure is maintained by a pressure relief valve located on the left side of the accessory case Engine cranking is acco...

Page 30: ...INTENTIONALLY LEFT BLANK 1 10 08 March 1989 ...

Page 31: ...FIGURE 1 10 04 THREE QUARTER RIGHT FRONTVlEW OFTHE TSlO 360 SERIES ENGINE FlGURE 1 10 04 THREE QUARTER RIGHT REARVlEW OF THE TSIO 360 SERIES ENGINE ...

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Page 33: ...FIGURE 1 10 04 lNSTAbbATlONDRAWING REVISED OCT 97 4 10 11 ...

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Page 35: ...OLS Specific tools illustrated or similar tools marketed by other manufacturers are necessary for service and maintenance of the aircraft engine Tool illustrations shown on the following pagesare usedwith the permissionof the respectivemanufacturers Illustrations in this section show only the general appearance of tools and do not correspond to the actual size or shape Details of special tools fix...

Page 36: ...Hartford CT 06108 2031528 9821 FuelPressureTest Equipment Measuring lnstruments PrecisionTools PistonPositionIndicators Printed and StandardCircuits FEDERALTOOL SUPPLY CO INC 10631Capital Oak Park Michigan 48237 800 521 1508 TOLL FREE or 313 543 9300 PrecisionInspection lnstruments SpecialTools OTC TOOLS EQUIPMENT Divisionof OwatonnaTool Company PrecisionTools Owatonna Minnesota 55060 SpecialTools...

Page 37: ...he applicable tool photograph CODE SUPPLIER ALR BTC CSPC EEI FfSC OTC MCSC SOT ALCBR INC BORROUGHSTOOLAND EQUIPMENT CORP CHAMPION SPARK PLUG CO EASTERN ELECTRONICS INC FEDERALTOOL SUPPLY CO INC OTCTOOLS EQUIPMENTCO McMASPER CARRSUPPLY CO SNAP ONTOOLS KTC KELL STROMTOOL COMPANY INC CODE Numbers referenced in the left hand bottom corner of each photograph correspond to the numbers located inthe Spec...

Page 38: ...Insert R R Installer Valve Seat Insert Installer Valve Seat Insert Common Parts Kit Valve Stem Hole Reamers Boring Bars Reamers Oil Filter Removal 3 to 3 3 8 Oil Filter Removal 3 1 2 to 37 8 Oil Filter Removal 4 1 8 to 47 16 Oil Filter Sludge Inspection Cylinder Removal Cylinder Removal Piston Removal Cylinder Reconditioning Cylinder Hold Down Cylinder Hold Down Cylinder Reconditioning Cylinder Re...

Page 39: ...itioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Stud Remover Connecting Rod Inspection Connecting Rod Inspection Connecting Rod Reconditioning Connecting Rod Reconditioning Connecting Rod Reconditioning Cylinder Reconditioning Cylinder Reconditioning Needle Bearing Replacement Needle Bearing Replacement Crankshaft Rec...

Page 40: ...Reamer Rocker Shaft Bushing Reamer Rocker Arm Bushing Reamers Valve Guide Boss Reamers Valve Guide Boss Reamer Carbide Tipped Reamer Carbide Tipped Crankcase Modification Cylinder Reconditioning Cylinder Reconditioning Multi Use Cylinder Reconditioning Stud Installation Stud Installation Crankcase Separation Installation of seal over Propflange Removal of surface Material around holes Removal of s...

Page 41: ...er Voltage Circuit Tester Timing Indicator Magneto Timing Light Cold Cylinder Tester Hi Voltage Tester Master Orifice Tool Alcor Portable Digital EGT Unit Alcor Portable Digital CHT Unit Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioning Cylinder Reconditioni...

Page 42: ...l filters a Insert threaded adapter in female threads of filter or screw rotating bushing on male threads of filter b Slightly tighten cutter blade against filter and rotate 360 Repeat operation until mounting platesection separates c Lift mounting plate to expose complete filter mediafor inspection 3 Using a clean plastic bucket containing approximately 1 pt clean varsol swish filter element arou...

Page 43: ...Wrench Special modified 3882 type wrench this special wrench is perfed for those occasional situations when the 3882 wrench won t fit It s a slightly different configuration as shown 3882 style shown in TI phantom to scale 80799 16 hex Piston Pin Removers 8121 Series Design allows piston pin removal without removing adjoining cylinder Sizes to fit Continentalengines BodyAssy PistonSize 8121A 4 7 1...

Page 44: ...izes and locations is included with adapters UniversalCylinder HoldingFixture5221B This is a heavy duty precision fixture manu factured to extremely close tolerances Suitable for use on vertical mills or drill presses it allows quick indexing of required angles for valve work FEATURES For all ContinentalEngines Fixture indexes in all present positions requiredto machinevalve guides Locks in at the...

Page 45: ...te for wear SpringChecker 7521A Per ContinentalBulletinM74 16 Check valve spring quickly and easily Hy draulically actuated extremely accurate readout 0 160 pounds Includes step gauges for all required dimensions 7521 Checker is less step gauges Max spring dimensions Ht 2 1 2 0 D 2 Heat ShrinkType Valve Guide Removers Cold ForceRemovalType Tough heat treatedsteel 3611 375 1 D Guide 2874 436 438 1 ...

Page 46: ...ies also available individually The 8098 10 Base must be used with 8118G 81IH 8118J and 8118K Driver and Adapter Assemblies Makes rocker arm bushing removal installation fast and easy All components of 8118 set are alsoavailable individually PistonRingCompressors FlexibleBandType 4901 for 3 718 and 4 116 boreengines 2839 for 5 and 5 114 boreengines 3618 for 4 7116 boreengines TaperedType 4901B for...

Page 47: ... with spring loaded tubes The 68 3 compresses the spring which can then be removedwithfurnished clips Eliminates wiring springs together to install simply insert spring then pull off clip Includes instructions FlaringTool for Push RodHousing 4951A For A C Series expanding ball type tool Balls rotate inside housing expanding it into aluminum boss Valve GuideRemover4981 Removes guides by heat shrink...

Page 48: ...520 and 10 550 Set includes 1 Handle lever assembly 12 Puller heads size to fit all Continental engines 10 Installerpilots 1 Removerplug 6 feet of super flexible hose to attach to water supply Instructions Storage case Tool is rigged for removal Center is plugged to route water out thru small holes in rim of removing head Fig 1 Installer Valve Seat Inserts 4910 For 1 45 64 O D Exhaust and 1 53 64 ...

Page 49: ... Here s howit s done Step 1 Removedold guidesand seats Step2 Install Expanding Guide Body into valve seat boss Step3 Place Boring Bar into Guide Bore valve guide boss concentric and perpendicular to valve seat Follow upwith Reamer Step 4 Use your drill press for bore or ream operations as shown in this picture The same guide set up works for both 8116 36 BRIDGE 7 1116 19 NUT 8116 1A GUIDE BUSING 8...

Page 50: ...eof highspeed M2tool steel precision Valve Guide Boss Takes place of ground 4914 and 4943 Series reamers Reamers Hole Dia BoringBars Tool No Hole Dia Example Use 8116 68 Boring Bar to bore hole to 555 then finish with 8116 6R Reamerto 561 dia Expanding Minimum Maximum Bodv NO Retracted Dia Ex anded Dia Expanding Guide Bodies ...

Page 51: ...4 30 Int 2 547 030 5225 5 Exh 1 793 005 5225 10 Exh 1 798 010 5225 15 Exh 1 808 015 5225 20 Exh 1 808 OX 5225 30 Exh 1 818 O W F osanQ Stud Remover Step Side Cutters Small Large Small Large Part No Diameter Diameter O Part No Diameter Diameter Q STD w 010 015 o m w STD 005 OlV This stud remover is for use in extracting studs 1 from cylinder assemblies using o s a n t y p e Studs Using the hammer d...

Page 52: ...ts contain the indicator gauge assembly which as a dial indicator reading in ten thou sandths of an inch 000In The gauge body is lapped into the mating bushing for accurate readings Instructionsare included Adapter Kits 8042Cfor 520 470 E Series 1 125 807X for 0 200 O 300 360 1 W 922 Completetod combining 8111A Basewith one of the 3 listed adapter kitsshown checking rodfor alignment Reamers Connec...

Page 53: ...between handle and cutter By using the 8122A with the proper pilot from below you may choose to pilot into vafve stem hole or valve guide boss Pilots All pilots are hardened and precision ground for accuracy Two choices pilot into valve stem holeor valveguide boss PilotChoice No 1 Pilot IntoValve Stem Hole On new installations only Part No Pilot Dia 8139 343 8410 374 8141 435 CAUTION DO NOTUSEONWO...

Page 54: ...he crankshaft Once the bushing is removed or installed a turn of thevalve returnsactuatorfor another cycle 8077A includes 10 000 p s i pump and cylinder 5 ton output cylinder 34 long flex hydraulic hose all adapters to fit 0 300 and 360 470 and 520 Series 80778 less hydraulics includes Items shown above in 8077A except no hydraulics are furnished The actuator head has 1 4 NPT female port for conne...

Page 55: ...ing plate also rotates 360 and locksin placewith heat treatedlock pin Flange holder is predrilled to accept all Con tinental engines Threaded adapters included to mount non flanged crankshafts Shipping weight 400 Ibs Tork BandTension Adjustgr 7726 Adjust belt tension without damage to compo nents Use on alternators compressors a Allows grabbingdifficult roundcomponents Generator DriveHolder Hold d...

Page 56: ...oses t t i n g s 1 PropaneRegulator 2 Controls 1 Y Connector 1 Stand 2 Cylinder Risers All screws nuts and washers needed and instructions Starter Clutch Shaft BearingPullers Y Connector Standard 20 Ib Propane Tank 80931 for removing314 I D bearings DifferentialPressureGauge 5210 For turbo superchargers A rugged high precision gauge needed to set differential fuel measures 50 0 50 psi 4 1 2 dia fa...

Page 57: ...easesefficiency of beltdrivenopponents Compact only 3 114 wide to f i t in crowded areas Easy to use just apply gauge to belt release ball handle and read tension on rotating dial Calibrated for A section V belts 318 to 112 top width and K section 4 5 and 6 rib poly V befts Range 30 to 180 lbs and 130 30 808 newtons dual scale HydraulicValve BTBOC LifterTester For checking Meed down rate on hydmul...

Page 58: ...protected Two point hook up field term and cigarettelighter EngineTimingDisc 3608A For all engines universal application from J3 to DC3 Fastensto prop tip and accurate to 2 1 4 degree Includespistonstop 3608A 15 PulleyHoider 4974 For holding 2 1 2 to 3 1 2 dia pulleys grip in pulley groove PulleyAlignment Gage Bar 8082 The 8082 gage bar allows a quick and easy alignment check between driver sheave...

Page 59: ... diameter Applies even pressure on outside of pulley in pulley groove All components are tough heat treatedalloy steel Spark PlugInsert Replacer 4918 Features1 2 squaredrive Useon all engines Thru Bolt BoreStep Cufters PerContinentalBulletinM77 9 Use to chamfer step in thru bolt dowel boss prior to inserting improved thw bolt with O ringseal Spark PlugInsertTap 504 1 For use on all engines High sp...

Page 60: ...ries removers Spark PlugTap 445 18millimeterthreads High speedsteel Rosa Lock Ring Installer 80 74 Heat treated tough alloy steel Knurled for sure grip Approximately 4 long Stud Drivers Six 6 different thread sizes CrankcaseSplitter Set L423 Makes splitting Continental crankcases easier and faster Prevents crankcase damage Puller assembliesboltonto crankcasestuds ...

Page 61: ...s material removal Cutter Mades are heat treated highspeedsteel 8048 Spot Facerfor 470 and 520 RunoutBlockSet 8177A Use this set to check runout on crankshafts etc up to 4 diameter Blocks are aluminum alloy with Teflon bearing surfaces Approx size 4 w x 8 1 x 5 h each PolishingTools for Crankshafts Bearings Special aluminum frame and felt polishing surfaces 8087A 1 718 to 2 1 4 dia 8087B 2 1 4 to ...

Page 62: ... made of heat treated steel for durability Torque input and output is markedon extension Installer is special thin walled 6 pt 1 2 hex socket CrankcaseThru Bolt Removers Use with 8054 Slide Hammer to remove stubborn bolts 8114 8 Remover 1 2 20 threads 8114 7 Remover 7 16 20threads 8114 6 Remover 3 8 24threads Hex Drivefor HexTubeNut 7912A Tubing nut wrench set for fuel systems RotabroachCuners 371...

Page 63: ...Pullers These pullers provide a more controlled method to remove press fit parts ...

Page 64: ...om inside of holes to outsideedges DialBoreGages Dial Bore Gages used for large volume go no go inspections or for determination of actual dimensions Three point contact two guide pins and one interchangeable rod assure alignment within bore Zero point may be set with ring gage micrometer height master or gage Mocks All precision measuring devices must have a current calibration and that calibrati...

Page 65: ...eableV Anvil Type 60 degree V Anvil and Conical Spindle are made of high grade special steel hardened and precisionground Depth Micrometers The Depth Micrometer is one of the basic measuringtools selected by machinists Rachet stop for consistent and repetitive measurements All precision measuring devices must have a current calibration and that calibration must be traceable to the National Bureau ...

Page 66: ...h 5129 1 5129 2 786 Pilot 5129 4 818 Finishing Usewith 5129 1 5129 3 815 Pilot 5129 5 833 Finishing Usewith 5129 1 5129 2 5129 3 5129 4 815 Pilot Reamer Rocker Shaft Bushing Reamer RockerArm Bushing 7232 751 Std 732 Pilot Reamers Valve Guide Boss Useat 275 RPM maximum USE MORSE ADAPTER 4914 1HS 537 005 O S 531 Pilot 2689 4914 2HS 542 010 O S 2334 Pilot 2689 4914 3HS 552 020 O S 539 Pilot 2689 4914...

Page 67: ...re usedto check for new limits and servicelimits where applicable Gaugesare heat treated alloy steel precisionground 284 1 436 1 0 Guide 2 W 2 438 I D Guide 3615 375 1 0 Guide Suggestions For Reaming Valve GuideStem Holes 1 Use high quality cutting oil 2 Reamersare madeto cut right hand onlydo notturn backwards even a partialturn 3 If using power run high speed reamers at 400 RPM maximum and carbi...

Page 68: ...hthe Englishand MetricMeasure Inside Measuring Instruments Three measuring surfaces are lapped parallel to the longitudinal axis of the Micrometer and stay aligned with the bore while measurements aretaken Large ratchet stop provides constant measuring pressure to the wall surface and insures repet itive reading to 0002 or 000lU smaller ranges All precision measuring devices must have a current ca...

Page 69: ...ester ModelEl00 Designed to test alternators regulators batteries on 12 and 24 volt systems with currents up to 32 volts DC Has a pointer zero adjustment screw on the face of the instrument Circuitry is entirely solid state and no battery or power source is required Power for the unit isderivedfromthe systems undertest MultipleVQItage Circuit fester For 12 24 Volts Model29 Designed to test continu...

Page 70: ...craft Timing Indicator ModellE25 Improves the accuracy and speeds up the process of timing an aircraft magneto to the engine Easily attached to the propeller spinner with mounting bands Has top dead center locator Cold Cylinder Test ModelEl0 Attach one wire with an alligator clamp and use another cable with a hand held probe to test comparative temperatures from cylinder to cylinder in a matter of...

Page 71: ...e pulses test insulation for leak Built in cotdinuity lamp provides handy test of electrical connections Uses two c cell flashlight batteries Includes top graincowhidecarrying case Master Orifice Fool PIN646953 Attach to differential cylinder pressure tester to check calibration and determine the low leakage limit Ref TCM Service bulletin M84 15 ...

Page 72: ...e This device is lightweight 9 volt LCD unit with a disposabie battery TemperatureRange1000 1800 Afcor Portable DigitalCHTUnit This device is used with Type J Thermocouple It is a lightweight 9 volt LCD unit with disposable battery TemperatureRange2 0 0 6 0 0 Indicationfrom 32 6000 Part Number85328 IL cJ Part Number 85329 ...

Page 73: ...HART SEAMNTS LUBRICANTS Grease Molyshield AmericanLubricants Co e Fuel Injection Controls GTSIO 5204 hichuse Grade5 e Connecting Rod Bearings 0 Camshaft Bearings e AccessorySpur GearTeeth e Starter ClutchSpring 1 D ...

Page 74: ...il FilterAdapter Seals 646943 Anti Seize e ConnectingRod Nuts all models except Tiara malethreads only e PressureRegulatorThreads e All Class 4 Studs e 0 Ringson Fuel Pumps e MixtureShaft Bushing Crankcase Threading Pro 641543 Silk Thread ...

Page 75: ...Em cxxmamLMQIISRS AkmitRodrcCs e Gasket Idler Pin e Gasket Intake Manifold e Oil Brain BackTubes e Gasket Oil Fitter Neck All 360 Models eal at Alt Drive OD Area of 3 way Joints e Oil SealAccessory Drive ...

Page 76: ...AkdtRoductS TELOWN xMwtmLMOIDRS LcrrrftRPdrets e VTC Unit Housing to Top Accessory Drive Gear Breather Slinger Bolts TaWN MOTORS AkdtRoductS ...

Page 77: ...easeagenS 1 Mold Release Oil Preservative DaubertChemical Inc Pennsylvania Refining Co TCM PIN626531 2 Enamel Gold 1 gal 032 in dia Steel Turco Products Interior and Exterior Tucker GA 30084 Aluminum Parts ...

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Page 79: ...oes 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 certificationfor this engine 4 Distributionof Changes to Airworthiness Limitations Changes to the Airworthi...

Page 80: ...INTENTIONALLY LEFT BLANK REVISED OCT 97 4 00 02 ...

Page 81: ...TS MAINTENANCE CHECKS 5 00 00 GENERAL 5 40 00 TlME LIMITS INSPECTION PROGRAM 5 20 00 SCHEDULED MAINTENANCE 5 20 01 Preflight lnspection 5 20 02 50 Hour lnspection 5 26 03 100 Hour Inspection 5 30 00 UNSCHEDULEDMAINTENANCE ...

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Page 83: ...maintenance always treat the engine as if the ignition switch was on Do not stand nor allow anyone else to stand within the arc of the propeller since a loose or broken wire or a component malfunction could cause the engine and propeller to rotateand or start ...

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Page 85: ...ide to assist the owner or operator in meeting their responsibilities This inspection guide is not intended to be all inclusive no guide can replace the good judgement of a certified airframe and power plant mechanic in the performance of his duties As the one primarily responsible for the airwor thiness of the airplane the owner or operator should select only qualified personnel to maintainthe ai...

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Page 87: ...gine specifications so that necessary repair or adjustment can be accomplished 2 Oil Filter Replacefilter inspect cartridge 3 Oil Change oil if integral screen or smallfilter is used 4 Air Filter Inspectand clean or replaceas necessary 5 FuelSystem Cleanfuel nozzlesas required 6 HighTension Leads Inspectfor chafingand deterioration 7 Magnetos 8 MagnetoFilter 9 Visual Check and adjust only if non c...

Page 88: ...lve screen and adjust as necessary see TCM Service Bulletin M84 6RI M78 11 or current revision as applicable Check compression Referto Chapter 70 50 00 Inspect Inspect clean regap i necessary reinstall Rotate plugs from upper to lower positions to lengthen plug life 8 HighTension Leads Inspectfor chafingand deterioration 9 Magnetos Check Adjust pointsand timing if necessary NOTE Minor changes in m...

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Page 90: ...ultingthe applicable related publications NOTE In case of engine overspeed refer to the current Overspeed Limitations Service BulletinM87 9or current revisionas applicable NOTE In case of engine overboost refer to the current Overboost of Turbocharged Engines Service BulletinM67 12or current revisionas applicable NOTE In case of prop strike refer to Sewice Bulletin M 84 16 or current revision as a...

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Page 93: ...f anything is dropped into the engine work should be stopped immediately and the item removed even if considerabletime and labor is required Insureall partsare thoroughly clean before assembling especiallyduring engine build up All lockwire and cotter pins must fit snugly in holes drilled in specific hardware On castellated nuts the cotter pin head must fit into a recess of the nut with the other ...

Page 94: ...70 10 00 LOCKWIRE PROCEDURE 1 LOCKWIRE 2 INSERTING WIRE 3 BENDING WIRE 4 TWISTING WIRE HOLES PARALLEL AROUND BOLT 6 BENDING WIRE AROUND BOLT 9 CUTTING EXCESS WIRE ...

Page 95: ...a thin even coat of gasket maker between 010 and 020 of an inch thick to all areas listed in paragraph 2 above onthe non threadcrankcasehalf 4 Apply grade D silk thread P N 641543 as shown in illustration being sure that free ends are coveredby gasket except at oil seal 5 Assemble crankcase halves using bolts for alignment to prevent movement of the thread and torque all bolts in proper sequence a...

Page 96: ...acewith new pre inspectedgasket Gasket surfaces must be clean and free of oil and grit Apply a thin coat of TCM Copper Coat 642188 to both sides of gasket unless otherwise specified Refer to Item No 10 in Chapter 1 Sealants and Lubricants for application of Copper Coat Once Copper Coat has been applied position gasket with the Copper Coat to its respective side according to Chapter 1 Sealantsand L...

Page 97: ...RK PLUG THREADS 18MM N O T E THREAD HAND TIGHT TO SPARK PLUG ADAPTER FIGURE 70 50 01 MASTER ORIFICE ASSEMBLY TOOL BORROUGHS PIN 646953 Borroughs Tool Equipment Corp 2429 N Burdick St Kalamazoo MI 49007 Tel 616 345 2700 AND CHOKE STATIC SEAL DYNAMIC SEAL FIGURE 70 50 02 ...

Page 98: ...gines must be 0 040 inch orifice diameter 0 250 inch long with 60 approach angle and must flow 120 2 cubic feet per hour at 30 p s i differential pressure Master OrificeTool For conformity in tester equipment a Master Orifice Tool has been developed to calibrate equipment and determine the low indicated leakage limit prior to the engine leakage check Connect compressed air at 100 120 p s i to the ...

Page 99: ...Closed position Slowly open the cylinder pressurevalve and pressurizethe cylinder not to exceed 20 p s i Continue rotating the engine against this pressure until the piston reaches top dead center TDC Reaching TDC is indicated by a flat spot or sudden decrease in force required to turn the crankshaft If the crankshaft is rotated too far back up at lease one half revolution and start over again to ...

Page 100: ...ading in this manner rotate the propeller so the piston will not be at TDC This is necessay to prevent the valve from striking the top of the piston in some engines Rotate the propeller again before rechecking leakage to reset the valves in the nonnal manner i If leakage is noted between the cylinder head and barrel REPLACE THE CYLINDER If leakage cannot be corrected at the valves by staking the c...

Page 101: ...r to betested NOTE Piston ring rotation within the ring land is a normal design characteristic As illustrated in Figure 70 50 04 the compression ring location may have a direct bearing on the dynamic seal pressure check Therefore we suggest you complete the test in the opposite direction if readingsare below prescribedlimits m If recheck of cylinder pressure gage reading indication remains below a...

Page 102: ...CHECK FOR in Exhaust Port S fATlC SEAL NO LEAKAGE PERMISSIBLE SECOND CHECK CHECK FOR DYNAMIC SEAL FIGURE 70 50 05 ...

Page 103: ...INTENTIONALLY LEFT BLANK ...

Page 104: ...ENGINERECIPROCATING 72 00 00 GENERAL Introduction Crankcase Crankshaft Connecting Rods Camshaft Pistons Lifters Cylinders Gear Train LubricationSystem Valve Mechanism InductionSystem Exhaust System IgnitionSystem ...

Page 105: ...INTENTIONALLY LEFT BLANK ...

Page 106: ...ontinental Motors Model TSIO 368 Cylinders Arrangement Individualcylinders in a horizontallyopposed position Compression Ratio 7 5 1 Firing Order 1 6 3 2 5 4 Cylinder HeadTemperature MaximumAllowable 460 F Indicatestemperature measured by BayonetThermocouple AeronauticalStandard AS234 element or equivalent installed in boss in bottom of cylinder head Number of Cylinders 6 Numbering Accessorytoward...

Page 107: ...0 165 165 Crankshaft Speed RPM Rated Maximum ContinuousOperation A AB B BB C CB D DB H HB JB KB 2800 Rated MaximumContinuousOperation EB FB 2575 Rated MaximumContinuousOperation GB LB MB 2700 Rated Maximum ContinuousOperation SB 2600 Rated MaximumTake Off A AB B BB C CB D DB H HB JB KB 2800 Rated MaximumTake Off EB FB 2575 Rated MaximumTake Off GB LB MB 2700 Rated MaximumTake Off SB 2600 Recommend...

Page 108: ... Capacity See Operating Limits Section 77 00 01 Max Oil Consumption Lb lBHP Hr Max at Rated Power at RPM ALL MODELS 006 LBS X POWER 100 Oil Pressure Idle Minimum psi All Models 10 Normal Operation psi TSIO 360 A AB B BB C CB B BB H HB JB 30 60 Normal Operation psi TSIO 360 E EB F FB GB KB LB MB SB 30 80 I Oil Temperature Limits Minimumfor Take Off All Models 100 F MaximumAllowable 1I 0 C 2400F Rec...

Page 109: ...ings are joined along the vertical center plane to form the complete crankcase The individualcastings with studs and inserts will be referredto as the left crankcase and the right crankcase throughout this publication A Bosses molded in the crankcase castings are line bored in the assembled castings to form bearings for the camshaft and seats for precision steel backed lead alloy lined crankshaft ...

Page 110: ...ly if a vibration occurs fives times per revolution the counteracting counterweight is designated a 5th order counterweight Crankshaftvibrations are caused bythefiring of the cylinders Counterweights are installed on hanger blades located on the crankshaft 2 cheek 2 counter weight configuration The crankshaft gear is heated prior to installation to obtain a shrink fit The gear is located bya dowel...

Page 111: ... externally finned steel alloy barrel to make the permanent head and barrel assembly Prefinished aluminum bronze intake valve guides and nitralloy or niresist exhaust valve guides are pressed into the cylinder assembly Special 18mm helical coil thread inserts are installed in upper and lower spark plug holes The exhaust ports are on the bottom and intake ports are on the top of the head when the c...

Page 112: ...ate a scavenge pump in the starter adapter gear The scavenge pump gears 2 1 3 are driven by the starter shaftgear 17 The scavenge pump gear 21 is keyedto the starter shaft gear 17 B Torque from the crankshaft gear 1 istransmitteddirectlyto the camshaft gear 3 C The camshaft gear 3 drives the magneto gears 11 12 The alternator drive gear 23 meshes with the inner camshaft gear and turns the alternat...

Page 113: ...aft 9 Oil pump drive gear 10 Oil pump driven gear 11 Right magnetodrive gear 12 Left magnetodrive gear 13 Starter 14 Worm drive shaft 15 Starter worm gear 16 Starter worm wheel 17 Starter shaft gear 18 Accessory drive gear 19 Accessory driven gear 20 Accessory driven shaft 21 Scavenge pump drive gear 22 Scavenge pump driven gear 23 Alternat r drive gear 72 00 10 REVISEDOCT 97 ...

Page 114: ... oil pump C From the pressure side of the oil pump a cored passage conducts the oil to the pressure oil screen assembly From the pressure oil screen a cored passage in the sump conducts the oil to the left crankcase main oil gallery The rear end of the right crankcase main gallery is aligned with a passage in the crankcase cover which directs pressurized oil to the oil pressure relief valve D An o...

Page 115: ...FIGURE 72 00 70 LUBRICATION SYSTEM 72 00 1 2 DECEMBER 1992 ...

Page 116: ...reservoir 12 Oil is withheld from reservoir 15 by check valve ball 5 which is supported by a spring 4 and retainer 3 The check valve is opened by outward motion of a plunger under pressure of the expanding spring whenever a clearance occurs in the valve train Thus the body reservoir is kept full of oil which transmits lifting force from the body of the plunger The plunger and socket are selectivel...

Page 117: ...pins on the magneto case and hold back the latch plate until forced inward by the coupling cover When the latch plate is released the coupling spring spins the magnet shaft through its neutral position and the breaker opens to produce a high voltage surge in the secondary coil The spring action permits the latch plate magnet and breaker to be delayed through a lag angle of 30 degrees of drive gear...

Page 118: ...LOWER SPARX PLUGS FIGURE72 00 14A WIRING DIAGRAM FlGURE92 80 14B PRESSURIZEDMAGNETOINSTALLATION ...

Page 119: ...INTENTIONALLY LEFl BLANK ...

Page 120: ...rtsto be Discarded PreliminaryCleaning IgnitionSystem Fuel InjectionSystem Accessory Case InductionSystem Oil Sump Oil Cooler Alternator Assembly Starter and Starter DriveAdapter Oil PompAssembIy Cylinders and Pistons Crankcase CamshaftAssembly Crankshaft Group ExhaustSystem ...

Page 121: ...INTENTIONALLY LEFT BLANK ...

Page 122: ...y ground cable 4 Disconnectthe starter cable 5 Tag and disconnect the enginewiring bundlefromthefollowing components a Magnetos b Alternator c Tach Generator d OilTemperature Bulb e Cylinder HeadTemperatureBulb f EGTThermocouple Probe s g Remove all clamps attaching engine wire bundle to engine components and route clear of the engine 6 Disconnect propeller throttle and mixturecontrol cables 7 Dis...

Page 123: ... scraping Such removal should be delayed until the part is to be cleaned See TCM Service Bulletin 87 11R2 or current revisionapplicable 100 Replacement Parts 72 10 04 PRELIMINARY CLEANING Spray or brush with a solvent used for general cleaning of engine parts Remove caked dirt on bolt heads and nuts especially At the same time the oil sump drain plugsshould be removedto drain any remainingoil CAUT...

Page 124: ...et clamp Six wire clamp Four wire clamp Two wire clamp Strap lgnition cable eylet Distributor cable grommet lgnition cable ferrule Distributorcable plate Ground terminal kit Washer Insulating sleeve Innerferrule Outer ferrule Coupling nut Coupling bushings Retainer Needle bearing Washer Pilot sleeve bushing Magneto drive gear Additional equipment for pressurized models Reference Figure 72 00 148 ...

Page 125: ...markedfor ease of reassembly C Remove two sets of attaching parts and lift off fuel manifold valve and mounting bracket as one unit Any further disassembly will disturb the calibration and should be accomplished only inaccordance with the FuelInjectionManual FormX30593A D Remove four sets of attaching parts 35 36 37 and remove fuel pump 2 and gasket 1 NOTE Removeand discardall used gasketsand seal...

Page 126: ... Elbow Elbow Elbow Elbow Throttle cont assy Leverassy Bushing Nut Tee Adapter Elbow Fitting Gasket Adapter air thr Screw Plainwasher Washer lock Nut plain Fitting Fitting Valve assy Fuel manifold Tubeassy Nozzleassy 0 Ring Tubeassy Tubeassy Tubeassy Blainwasher Washer lock Nut plain Tee Bolt Bracket W se ...

Page 127: ...E For further information refer to Teledyne Continental Fuel InjectionSystems Overhaul Manual and Parts CatalogX30593A FIGURE 72 10 068 FUEL INJECTION SYSTEM 1 Gasket F P 2 Fuel pump 3 Lever 4 Bushing 5 Nut 6 Elbow 90 7 Elbow 90 8 Elbow 45 9 Elbow 90 10 Elbow 45 1I Elbow 45 12 Rod link assembly 13 Lever controller 14 Pin lever 15 Washer wave 16 Washer 17 Cotter pin 18 Throttle metering assembly 19...

Page 128: ...FIGURE92 10 6B FUEL INJECTION SYSTEM TSIQ 360 MB 4 3 SB REVISED OCT 97 92 10 09 ...

Page 129: ...er removal C Remove attaching hardware 1 thru 6 and carefully separate accessory case from crank case studs Removeand discard gasket 7 D Remove attaching hardware 23 24 25 cover 26 or tach drive assembly 42 thru 44 as applicable Remove nut 371 and discard gasket 27 For oil pump disassembly see Figure 72 10 13 E Removerelief valve assembly items 28thru 36 Discardgaskets 29 34 F Removescreen 18 plug...

Page 130: ......

Page 131: ...emove air reference tubes 16 18 29 from air throttle adapter 21 and fuel pump Removefittings 26 27 from air throttle adapter C Remove attaching hardware 22 thru 25 and separate adapter 21 from air throttle body 13 Removeand discard gasket 20 D Loosenhoseclamps 10 tl Removehoses 12 and clamps 10 ll E Remove attaching hardware 7 8 9 Lii off induction riser assemblies 2 thru 6 Removeand discard gaske...

Page 132: ...sher lock Nut plain Clamp hose Clamp hose Hose Air throttle andfuel meteringassembly Bolt Nut Tube air reference Seal Tube air reference Seal Gasket Adapter throttle Bolt Washer plain Washer lock Nut Fiing straight Fitting straight Tube air reference Tube air reference to fuel pump Seal Sleeveassembly Seal Washer rubber Washer steel Elbow Hose ...

Page 133: ...33 34 B Removeattaching hardware 35 36 37 bracket 23 and air referencetubes 27 29 C Remove attaching hardware 19 thru 22 and separate adapter 18 from throttle and meteringassembly 14 Removeand discard gasket 17 D Loosen hose clamps 10 11 Remove hoses 12 13 and clamps 10 11 E Remove attaching hardware 7 8 9 and lift off induction riser assemblies 1 thru 6 Removeand discardgaskets 1 F Remove hose 39...

Page 134: ...plain Washer lock Nut Clamp Clamp Hose Hose Air throttle and fuel meteringassembly Bolt Nut Gasket Adapter Throttle Bolt Washer plain Washer lock Nut Bracket Grommet Tube air reference Tube air reference Tube air reference Seal Tube air reference to fuef pump Seal Sleeve Seal Washer rubber Washer plain Bolt Washer Nut Elbow 90 Hose ...

Page 135: ...om air throttle adapter 36 C Loosen clamps 25 remove hoses 26 clamps 25 and induction tubes 27 2 8 Removeattaching bolts 31 and overboost valve 30 Removeand discard O ring 29 D Remove attaching hardware 8 9 37 38 Separate adapter 36 from throttle and meteringassembly 13 Removeand discard gasket 40 E Loosen clamps 10 1I remove hoses 12 clamps 10 11 attaching hardware 7 8 9 and lift off inductionris...

Page 136: ...elbow Washer plain Washer lock Nut Clamp Clamp Hose Air throttle and metering assembly Screw Nut Tube air reference Seal Tube air reference Seal Tube air reference Sleeve Seal Washer rubber Washer plain Clamp Hose Tube induction Tube induction O ring Overboost Valve Bolt Washer plain Nut Elbow90 Hose Adapter Washer Screw Fittings Gasket ...

Page 137: ...ttleadapter 36 C Loosen clamps 25 and remove hoses 26 clamps 25 and induction tubes 27 28 Removeattachingbolts 31 and overboostvalve 30 Removeand discard o ring 29 D Remove attaching hardware 8 9 37 38 and separate adapter 36 from throttle and meteringassembly 13 Removeand discard gasket 40 E Loosen clamps 10 1 I remove hoses 12 clamps 10 1 I attaching hardware 7 8 9 and lift off induction riser a...

Page 138: ...asher plain Washer lock Nut Clamp Clamp Hose Air throttleand meteringassembly Screw Nut Tube air reference Seal Tube air reference Seal Tube air reference Sleeve Seal Washer rubber Washer plain Clamp Hose Tube induction Tube induction O ring Overboostvalve Bolt Washer plain Nut Elbow90 Hose Adapter Washer Screw Fiings Gasket ...

Page 139: ...ir throttleadapter 36 C Loosen clamps 25 remove hoses 26 clamps 25 and induction tubes 27 28 Removeattaching bolts 31 and overboost valve 30 Removeand discard o ring 29 D Remove attaching hardware 37 38 Separate adapter 36 from throttle and metering assembly 13 Removeand discard gasket 40 E Loosen clamps 10 11 Remove hoses 12 clamps 10 1I attaching hardware 7 8 9 and lift off inductionriser assemb...

Page 140: ... Washer lock Nut plain Clamp Clamp Hose Air throttleand meteringassembly Bolt Nut fube air reference Seal Tube air reference Seal Tube air reference Sleeve Seal Washer rubber Washer steel Clamp Hose Tube induction Tube induction O ring Overboostvalve Bolt Washer plain Nut self locking Elbow90 Hose Adapter Washer Screw Fitting Gasket ...

Page 141: ...d sleeves 25 together Disassembleair reference lines 21 and sleeve assemblies discarding used seals 26 and washers 27 28 B Remove air reference tubes 29 31 C Loosenclamps 35 remove hoses 18 34 clamps 35 inductiontubes 19 33 and aftercooler 20 D Loosen clamps 12 and remove hoses 13 clamps 12 attaching hardware 9 10 1I induction tubes 2thru 7 and manifold assembly 14 72 1 0 22 REVISED OCT 97 ...

Page 142: ...l 6 8 Flange inductiontube 9 Washer plain 10 Washer lock 11 Nut plain 12 Clamp 13 Hose 14 Intake manifold 15 Elbow 90 29 Tube air reference 16 Elbow 90 30 Seal 17 Bumper rubber 31 Tube air reference 18 Hose 32 Seal 19 Tube elbow 33 Tube inlet 20 Aftercooler 34 Hose 21 Tube air reference 35 Clamp 22 Gasket 23 Washer lock 24 Screw 25 Sleeve 26 Seal 27 Washer rubber 28 Washer plain REVISED OCT 97 72 ...

Page 143: ...gine disassembly to drainthe engine s oil supply If not removeplug 1 and gasket 2 B Removeattachinghardware 3 4 5 and oil sump 8 Removeand discard gasket 7 C Removeoil suctiontube 6 from oil sump 8 FIGURE 72 10 09 OIL SUMP 1 Plug 5 Washer plain 2 Gasket 6 Tube suction 3 Nut 7 Gasket 4 Washer lock 8 Sump oil ...

Page 144: ...ocker cover C Remove attaching hardware 9 10 and engine mount adapter 11 from crankcase studs Removeand discard o rings 12 13 D Remove plug 16 gasket 17 oil temperature control valve 15 and gasket 14 from engine mount adapter 11 FIGURE 72 10 10 OIL COOLER Nut Bolt Shoe Bolt Washer lock Washer plain Oil c oler Gasket Nut Washer Adapter oil cooler to engine O ring O ring Gasket Oiltemperature contro...

Page 145: ...nd discard C Remove cotter pin 14 nut 13 gear lo sleeve 7 bushings 9 retainer 8 hub 6 oil seal 5 o ring 4 and woodruff key 3 from alternator 2 FIGURE72 10 11 ALTERNATOR ASSEMBLY 1 Gasket 2 Alternator 3 Woodruffkey 4 O ring 5 Oil seal 6 Hub 7 Sleeve 8 Retainer 9 Bushing 10 Gear 11 Coupler 12 Sleeve 13 Nut castellated 14 Pin cotter 15 Washer plain 16 Nut elastic stop ...

Page 146: ...INTENTIONALLY LEFT BLANK ...

Page 147: ... shaft is pressed out retaining ring 44 and gear 41 will fall free inside accessory drive adapter for removal Key 42 should be removed with shaft 43 D Remove oil seals 26 27 Bushings 24 23 can be removed using an arbor press Removegear 40 and bushing 2 5 E Remove attaching hardware 59 64 and separate starter adapter housing 2 from accessory case Removeand discard gasket 1 F Install starter adapter...

Page 148: ...utch Washer tab Screw Shaftgear Key woodruff O ring Adapter accy drive Bushing Bushing Bushing Seal oil Seal oil Stud Plug Gear Bushing Gear Cover Washer plain Washer lock Nut plain Washer plain Screw Bearingneedle Gear bevel Gear bevel Key machine Shaftgear Ring retaining Gasket Cover Washer plain Washer lock Nut Gasket Cover Washer plain Washer lock Screw O ring Starter Washer plain Nut Bolt Bol...

Page 149: ...8 gears 25 2 7 bushings 22 26 and woodruff key 35 from scavengepump housing 21 Removeand discard o ring 20 D Remove attaching hardware 45 50 and separate starter adapter 2 from accessory case Removeand discard gasket 1 E Install starter adapter housing 2 in a shielded vise Slide bushing 34 off shaftgear 19 Remove worm wheel gear 15 bearing 14 spring 16 and shaftgear 19 by turning worm wheel gear 1...

Page 150: ...l Ring retaining Bearing rdler Gear worm wheel Spring clutch Washer tab Screw 35 Shaftgear 36 O ring 37 Housing scav pump 38 Bushing 39 Seal 40 Stud 41 Gear 42 Bushing 43 Gear 44 Cover 45 Washer plain 46 Washer lock 47 Nut 48 Washer 49 Screw 50 Bushing 51 Key woodruff Gasket Cover Washer plain Washer lock Nut O ring Starter Washer plain Nut Bolt Bolt Bolt Washer plain Washer lock Washer plain Nut ...

Page 151: ... 39 from scavenge pump housing 23 Removefittings 27 28 Removeand discard o ring 22 D Remove attaching hardware 49 52 and separate starter adapter 2 from accessory case Remove and discard gasket 1 E Installstarter adapter housing 2 in a shielded vise slide bushing 33 off shaftgear 21 removeworm wheel gear 171 bearing 16 spring 18 and shaftgear 21 by turning worm wheel gear 17 counter clockwise and ...

Page 152: ...ear worm wheel 18 Spring clutch 19 Washer tab TSIO 360 MB 8r SB only 20 Screw 21 Shaftgear 22 O ring 23 Housing scav pump 24 Bushing 25 Oil seal 26 Stud 27 Elbow 90 28 Elbow 45 29 Gear 30 Bushing 31 Gear 32 Cover 33 Bushing 34 Washer plain 35 Washer lock 36 Nut 37 Washer plain 38 Screw 39 Key woodruff 40 Gasket 41 Cover 42 Washer plain 43 Washer lock 44 Nut 45 O ring 46 Starter 47 Washer plain 48 ...

Page 153: ...mp cover 6 B Bend back ears on tab washers 8 loosen bolts 9 and remove Remove oil pump cover 6 C Lift drive gear 4 and driven gear 5 out of accessory case oil pump cavity D Mount accessory case in proper fixture Using arbor press remove bushing 2 If worn beyond serviceable limits bushing 3 may be removed from gear 5 ...

Page 154: ...FIGURE 72 10 13 O I L PUMP ASSEMBLY 1 Accessory Case 6 Cover Oil Pump 2 Bushing 7 Gear Oil Pump Drive 3 Bushing 8 Washer Tab 4 Gear Oil Pump Drive 9 Bolt 5 Gear Qil Pump Driven 10 Nut ...

Page 155: ......

Page 156: ......

Page 157: ... Flanged nut 44 Pistonpin 45 Top piston ring 46 Second piston ring 47 Oil control ring 48 Scraper ring 49 Piston 50 Cylinder basepacking 51 Keys 52 Rotocoil 53 Innerspring 54 Outer spring 55 Retainer 56 Intakevalve Exhaustvalve Retainingring Lier body Nut Exhaust gasket Nipple lnsert Valve guide exhaust Valve guide intake Cylinder Baffle Spring Insert intake Insert exhaust Stud intakemanifold Stud...

Page 158: ...n pin 26 piston 31 and rings 27 thru 30 immediately after removing cylinder 48 Remove hydraulic lifters 41 from crankcase TCM recommends 100 replace ment of hydraulicliftersat engine overhaul regardless of condition E Remove and discard cylinder base packing 32 Use of a cylindrical wood block and a lever type valve spring compressor is recommended to facilitate removal of valve springs 35 36 and t...

Page 159: ... attaching hardware 18 thru 23 bracket 24 or brackets 89 go attaching hardware 25 thru29 and liftingeye 30 Removeattaching hardware 31 thru 42 E Remove attaching parts 43 44 from both ends of thru bolts 45 and from the right crankcase side of thru bolts 46 Remove attaching hardware 47 48 49 from both ends of thru bolts 50 51 Remove attaching parts 53 54 55 from both ends of thru bolt 56 Remove att...

Page 160: ...asher Thru bolt Thru bolt Nut Lockwasher Washer Thru bolt Thru bolt Thru bolt Nut Lockwasher Washer Thru bolt Flanged nut Washer Thru bolt Thru bolt Nut Lockwasher Washer Right rear 82 mount bracket Rightfront 83 mount bracket 84 Leftfront 85 mount bracket 86 Left rear 87 mount bracket 88 Bolt 89 Lockwasher Washer 90 Spacer Cover 91 Gasket 92 On ring 93 OM ring 94 Bushing 95 Helical coil 96 Dowel ...

Page 161: ...cks under front and rear main journals during disassembly of crankshaft 3 Remove cotter pin castellated nuts 8 bolts 9 and separate connecting rod caps 10 and rods 13 Remove connecting rod bearings 11 Loosely reassemble rods caps bolts and nutswith their positionnumbersmatched C Remove retaining rings 14 retaining plates 15 and pins 16 Remove counterweight assemblies 18 WARNING Do not mark cranksh...

Page 162: ...g Thrustwasher Packingcrankshaft bearing Oil seal spring Oil seal Cotter pin Nut castellated Rod bolt Rodcap Rod bearing Rod bushing Connectingrod Retainingring Retainingplate Counterweight pin Counterweight bushing Counterweight Bushing Bolt Crankshaftgear Dowel Plug Crankshaft ...

Page 163: ...ssembly 30 Remove elbow 29 and reducer 28 B Remove attaching hardware 43 clamp 42 and crankcase to turbo hose assembly 44 Removecheck valve 41 elbow 40 and tee 39 C Remove attaching hardware 21 thru 26 support bracket 20 wastegate 13 clamps 19 and turbocharger 18 D Place engine in inverted position Remove attaching hardware 2 exhaust risers 3 thru 8 elbows 9 10 and manifold 11 Removeand discardgas...

Page 164: ...e Riser tee Riser tee Riser elbow Riser elbow Elbow Elbow Manifold Tail pipe Wastegate Bushing Tie rod Nut Bolt Turbocharger Clamp Support Clamp Bolt Washer Nut Bolt Washer Nut Reducer Elbow Tube Nut Washer Bolt Clamp Bracket Checkvalve Hose Nipple Tee Elbow Checkvalve Clamp Screw Hose ...

Page 165: ...re 22 23 24 clamp 25 checkvalve 26 tube 21 elbow 20 and reducer 1 9 B Remove attaching hardware 33 clamp 32 hose 34 nipple 29 plug 30 tee 31 andfitting 28 C Remove wastegate 1I clamps 1 8 tailpipe assembly 1 O turbocharger 17 attaching hardware 12 13 15 16 manifold 9 and elbow 8 D Removeattachinghardware 14 and riserassemblies 2thru 7 from engine ...

Page 166: ...Riser tee Riser tee Riser tee Riser tee Riser elbow Riser elbow Elbow Manifold Tail pipe Wastegate Bushing Tie rod Nut Nut Bolt Turbocharger Clamp turbo Reducer Elbow Tube Nut Washer plain Bolt Clamp Checkvalve Hose Fiing Nipple Plug Tee Clamp Screw Hose ...

Page 167: ...ing 8 attaching hardware 32 33 34 clamp 35 check valve 5 and hose 4 B Remove hose ll elbows 12 15 tee 13 fitting 14 attaching hardware 36 37 38 clamp 39 check valve 10 and hose assembly 9 C Remove turbocharger to bracket clamp 16 turbocharger 17 attaching hardware 18 riser assemblies 19 21 24 25 26 attaching hardware 29 30 bracket 31 riser 22 and elbow 23 ...

Page 168: ...Cross tube Riser Riser elbow Riser tee Riser tee Riser assembly Riser assembly Tail pipe Wastegate Gasket Nut Turbocharger Clamp Suppoft Elbow 90 Hose Check valve Tee Elbow 45 Hose Check valve Clamp Nut Hose Washer Bolt Hose Washer Bolt Clamp Nut ...

Page 169: ...tegate 28 Gasket 12 Fitting 29 Check valve 13 Elbow 30 Hose 14 Gasket 31 Elbow 15 Bolt 32 Hose 16 Washer 33 Bracket 17 Nut 34 Clamp 35 Clamp 36 Washer 72 10 50 REVISED OCT 97 37 Bolt 38 Nut 39 Bracket 40 Clamp slq Bolt 42 Washer plain 43 Nut lock 44 Tee 45 Reducer 46 Nut 47 Adapter 48 Fitting 49 Hose 50 Check valve 51 Bolt 52 Washer plain 53 Washer lock 54 Nut 55 Washer lock 56 Screw 57 Washer loc...

Page 170: ...ttings 23 24 clamp 35 check valve 50 hose 49 tee 44 and fitting 45 Remove hose 21 and fitting 13 B Remove attaching hardware 15 through 17 and wastegate 11 Remove and discardgaskets 1 4 Loosen and remove clamp 10 and tailpipe 9 C Remove attaching hardware 60 61 62 63 and turbocharger 18 Remove and discard gasket 59 Remove nuts 66 risers 3 4 5 6 attaching hardware 64 65 elbow 7 and riser 8 REVISEDO...

Page 171: ...INTENTIONALLY LEFT BLANK ...

Page 172: ...ke Manifold 72 20 11 Castings 72 20 12 Stud Replacement 72 20 13 Helical Coil Insert Installation 72 20 14 Spark Plug Hole Helical Coil inserts 72 20 15 Fin Repairs 72 20 16 Vaive Guides 72 20 17 Valve Rockers 72 20 18 Hydraulic Valve Lifters 72 20 19 Connecting Rods 72 20 20 Piston Pin Bushing Replacement 72 20 21 Crankshaft Assembly 72 20 22 Magneto Gear Support Shaft 72 20 23 Magnetoand Alterna...

Page 173: ...INTENTIONALLY LEFT BLANK ...

Page 174: ...ous methods to use on soft metals like aluminum Scratches resulting from such methodsallow concentratedstressat the scratchand may causefatigue failure Blasting techniques can be employed to remove hard carbon deposits if suitable equipment is available Suitable types of grit for dry blasting are plastic pellets and processed natural materials such as wheat grains and crushed fruit pits or shells ...

Page 175: ...egreased by brushing or spraying with mineral spirit solvent Give particular attention to threads oil holes and recesses Before magnetic inspection the crankpins main journals oil seal race of the crankshaft and all journals cam lobes and gear mount flange of the camshaft must be smoothed with crocus cloth moistened in mineral spirits This is to be accomplished while shaft is rotated in a high spe...

Page 176: ... to determine its size Standard studs have no marking For oversize stud identification refer to Fig 72 20 12B Clean the casting tapped hole with solvent and blow dry with compressed air then examine the thread If it is not torn install the next larger oversize stud If the old stud was of the maximum oversize or if the thread is damaged the hole may be tapped and a helical coil insert installed for...

Page 177: ......

Page 178: ...FIGURE72 20 12C MISCELLANEOUSSTUD SETTlNG HEIGHTS REVISED OCT 97 72 20 07 ...

Page 179: ...ts kerosene to prevent overheating of the metal and tearing of the thread ReferenceNote page 72 20 05 To remove a damaged helical coil insert use the proper size of extracting tool for the nominal thread size Tap it into the insert so that the sharp edges get a good bite then turn the tool to the left and back out the helical coil until it is free To install a new insert in a properly tapped hole ...

Page 180: ...OlL INSERT FIGURE74 20 146 INSTALLING SPARK PLUG HOLE HELICAL COlL INSERT FIGURE 72 20 141 EXPANDINGSPARK PLUG HOLE HELICALCOlL INSERT THESE SURFACES MUST BE SQUARE WITHIN 002 INCH FULL INDICATOR READING FIGURE72 20 17 VALVE ROCKER BUSHING DIMENSIONS ...

Page 181: ...6 375 REF SERVICELIMITSFOR X DfA IS ACTUAL MEASURED D DfA PLUS 001in 07 New Parts and Service Limits FIGURE 72 20 15 CYLINDER ASSEMBLY DIMENSIONS 72 20 1 0 DECEMBER 1992 ...

Page 182: ...ng Support cylinder with barrel up Use wooden blocks to keep from damaging rocker cover surface 4 Allow cylinderto coolto roomtemperature VALVE GUIDE INSTALLATION TCM requiresthe next O S guide to be used 1 Measure valve guide boss and select proper No 4914 or No 4943 series reamer to ream valve guide boss to required oversize Consult Table of Limits Figure 72 30 08 for proper interference fit Gui...

Page 183: ...vingretainer 6 lifting spring 5 and ball 4 NOTE If major engine overhaul hydraulicvalve liftersare recommended 100 replacement Ring Retaining Socket Hydraulic Lifter Plunger Check Ball Ball Check Spring Ball Check Retainer Spring Plunger Body Valve Lifter FIGURE72 20 18 HYDRAULICLIFTER 72 20 19 CONNECTING RODS CAUTION In order to assure good dynamic balance connecting rod assemblies for new engine...

Page 184: ...before removal These operations should precede magnetic particle inspection Hardened steel bushings in the crankshaft blades must be removed and replaced if excessively worn It is recommended that these bushings be replaced during major engine overhaul regardless of condition It may be necessary to chill the old bushings to free them New bushings must be chilled before installation and the holes m...

Page 185: ...kcase half and intersects a short hole in the center of the needle bearing counter bore Holecan be enlargedto diameter shown aboveafter removal of the starter adapter 72 20 26 OIL PUMP ASSEMBLY Replace worn gears bushings and studs Nicks on parting flanges may be stoned out The pump gear chamber must not be enlarged If it is scored or the driven pump gear pilot shaft is loose TCM recommends 100 re...

Page 186: ...FIGURE 72 20 27 WIRING DIAGRAM ...

Page 187: ...S EXCEEDED 3 UNDERCUT SEAT WITH 4 5 STONE TO ESTABLISH 07 12 SEAT WIDTH AS REQUIRED FIGURE 72 20 28A INTAKE VALVE SEAT REFACING 1 85 DIA MAX 1 67 DIA MAX EXHAUST SEAT GRINDING ALL 10 360ENGINES PROCEDURE 1 CLEAN UP SEAT WlTH 45 STONE 2 TOP OFF WlTH 15 STONE TO ESTABLISH 1 67 MAX SEAT O D NOTE SEAT MUST BE REPLACED IF 1 85 DIA MAX IS EXCEEDED FIGURE 72 20 288 EXHAUSTVALVE SEAT REFACING 72 20 16 DEC...

Page 188: ...ip Subtract 4 249 from new length the remainder will be the amount to be removedfrom 5 After grinding measureoveralllengthof valve ifnewoverall length is lessthan4 352 longdiscardvalve and replace with new 80 WELD CONTACT 4 246 FROM STEM TIP 4 252 TO GAGE DIMLlNE GREATER AFTER GRINDING THIS POINT WILL CHANGE AFTER GRINDING INCREASING DISTANCE FROM STEM TIP TO GAGE DIM LlNE GRIND STEM TIP TO REGAIN...

Page 189: ...INTENTIONALLY LEFT BLANK 72 20 18 DECEMBER 1992 ...

Page 190: ...tion Crankshaft Ultrasoniclnspection FluorescentParticle inspection Dimensional lnspection Dimensional Limits 72 30 08 Table of Limits 72 38 09 Original Dimension 72 30 18 ProtectiveCoating 72 30 11 Application of Nlodizing 72 38 12 Repair of Aloditing Surfaces 72 30 13 EnamelCoatings ...

Page 191: ...INTENTIONALLY LEFT BLANK ...

Page 192: ...cles of the softer metal beingtorn away and welded to the harder metal INDENTATION Dentsor depressionsina surface caused by severe blows OXIDATIONS Chemical combining of a metal with atmospheric oxygen Aluminum oxide forms a tough hard film and protects the surface from further decomposition however iron oxides do not form a continuous cover or protect underiying metal Oxidation of steel parts is ...

Page 193: ...he methods and data in the table before dimensional inspection The Magnaglow method is recommended whenever the necessary equipment is available This method employs magnetic particles coated with a fluorescent organic material which may be illuminated with a black light as in the Zyglo process to amplify an indication of weakness If a crankshaft is doubtful after a circular magnetization and inspe...

Page 194: ...ular and Longitudinal Circular and Longitudinal Critical Areas Journals fillets oil holes thrust flanges propflange All areas Lobes Journals drilled hole edges Shear planes ends center Pad socket under side arms and boss Teeth Splines Keyways Teeth Splines Splines Keyways Changeof Section Threads Under Head All areas Possible Defects Fatiguecracks heat cracks flange cracks from prop strike Fatigue...

Page 195: ...er end of the same journal If an ultrasonic reflector in the form of a crack exists in the region the sound is reflected back along the same path to the surface applied transducer and displayed as a signal on the screen of the inspection instrument In the absence of a reflector in the region into which the sound is directed no signal is displayed C EQUIPMENT 1 Instrument Krautkramer Branson Model ...

Page 196: ...INTENTIONALLY LEFT BLANK REVISED OCT 97 72 30 07 ...

Page 197: ... bore gauge is preferred rather than tools not specifically designed for this purpose 72 30 07 DIMENSIONAL LIMITS After comparative measurements of mating parts and determination of running clearance refer to the Table of Limits Section 72 30 08 and to the Limits Charts 1 2 etc to locate the reference number of each fit and the acceptable limits assigned to it Limits under the column heading New P...

Page 198: ...sleeve dia 9 Coupling retainer in coupling hub slot side clear 10 Coupling bushingson drive gear lugs replace if worn side clear 11 Oil pumpdriver todrivengear backlash 12 Alternator gear to camshaftgear backlash 13 Driver gear shaft in oil pumpdrivegear dia 14 Drive gear to camshaftgear backlash Oiltemperature control valve 0 090 inch minimumtravel at temperature Valve must befully closed against...

Page 199: ...rcle diameter Not morethan 25 pits of any one size in entire cylinder bore is acceptable 7 Cylinder barrel in crankcase diameter 8 Intakevalveguide in cylinder head diameter 9 Exhaustvalve guide in cylinder head diameter 10 Exhaustvalve seat to valve guide axis angle 11 Intakevalve seat to valve guideaxis angle 12 Intakevalve seat insert in cylinder head diameter 13 Exhaustvalve seat insert in cyl...

Page 200: ...l1 Fourthpiston ring in cylinderat 1 00 from bottom of barrell Piston pin in std or 0 005 oversized piston Piston pin in cylinder Piston pin in connecting rod bushing Bushing in connectingrod side clear side clear gap gap gap gap diameter end clear diameter diameter 36 Valve spring 625957 inner Free length 1 97 2 04 in 37 Valve spring 625958 outer Free length 2 17 2 24 in FIGURE72 30 08 TABLE OF L...

Page 201: ...re 8 O Crankcase rear and intermediatemain bearing bore 9 GI Crankcasefront main bearingbore 10 Crankcase camshaft bearing bore 11 Fuel pumpadapter pilot in crankcase 12 Fuel pump body pilot in adapter 13 Oil seal in adapter 14 Fuel pumpdrive shaft in impellershaft 15 Fuel pumpdrive shaft in governor gear Ref No Descri tion diameter diameter diameter diameter diameter diameter diameter diameter di...

Page 202: ...enceper inchlength 35 Connecting rod beamsection at narrowest point 36 Connectingrod bearingon crankpin diameter 37 Connectingrod bolt in connectingrod diameter 38 Camshaft incrankcase diameter 39 Camshaft incrankcase end clear 40 Camshaft run outat center journals shaft supported 41 Camshaft gear on camshaft diameter 42 Governordrive gear on camshaft diameter 43 Crankshaftgear to camshaftgear bac...

Page 203: ... Sleeve indrive gear diameter 3 Washer indrive gear diameter 4 Magneto coupling retaineron gear sleeve diameter 5 Magneto coupling retainer indrive gear slot 6 Magneto coupling rubber bushings on magneto drive lugs replace if worn side clear Magneto pilot in crankcasecover diameter 7 Magnetogear to camshaftgear backlash ...

Page 204: ...on Service New Parts I irnit Min I Max I I Worm wheel drum outside Diameter See Chart 5C NOTE See the new style starter adapter and scavenge pump cover fits and limits Chart 5D for fits and limits relevant to both old and new style starter adapters FIGURE 72 30 08 CHART 5A REVISED OCT 97 72 30 1 5 ...

Page 205: ...lNTENTIONALLY LEFT BLANK 72 30 15A REVISED OCT 97 ...

Page 206: ...DETAIL A CHART 5B OLD STYLE SHAFTGEAR DRUM DIMENSIONS SEE DETAILA CHART 5C OLD STYLE WORM WHEEL DRUM DIMENSIONS REVISED QCT 97 72 30 15B ...

Page 207: ...FIGURE 72 30 08 CHART 5D 72 30 15C REVISEDOCT 97 ...

Page 208: ... of worm gearshaft to starter adapter thrust pads 0 252 17 1 Needle bearing bore Diameter 0 7495 0 7485 0 7495 18 Starter worm drive shaft Diameter 0 5600 0 5620 0 5626 19 1 Ball bearing in starter adapter Diameter 0 001 L 0 001 L 0 001T 20 1 Worm gearshaft in ball bearing Diameter 0 00041 0 0004T 0 0004L 21 1 Starter pilot to starter drive adapter Diameter 0 0065L 0 001 L 0 0065L 22 1 Starter dri...

Page 209: ...INTENTIONALLY LEFT BLANK 72 30 15E REVISEDOCT 97 ...

Page 210: ...EN DIAMETERS B C SURFACE 32 RMS CHART 5E NEW STYLE SHAFTGEAR DRUM DIMENSIQNS SEE DETAIL A SMOOTHTAPER BETWEEN DIAMETERS B C SURFACE 32 RMS DETAILA CHART 5F NEW STYLE WORM WHEEL DRUM DIMENSIONS REVISED OCT 97 72 30 4 5F ...

Page 211: ...FIGURE 72 30 08 CHART 5G 72 30 15 6 REVISED OCT 97 ...

Page 212: ...iameter 0 002L 0 0005L 0 002L 5 Starter adapter shaftgear knurled drum Diameter See Chart 5B 6 Starter adapter shaftgear rear journal Diameter 6235 6340 7 Starter adapter shaftgear oil pump cover bushing area Diameter 0 9995 1 0000 8 Worm wheel inside Diameter 1 3125 1 3115 1 3125 Worm wheel drum outside Diameter See Chart 5C 9 Clutch spring outside Diameter 2 374 2 376 10 Clutch spring inside Dia...

Page 213: ...FIGURE 72 30 08 CHART 5H 72 30 151 REVISEDOCT 97 ...

Page 214: ...earing in starter adapter housing Diameter 0 001L 0 001 L 0 001T 19 Starter pilot to starter drive adapter Diameter 0 00651 0 001 L 0 0065L 20 Starter drive tongue to worm shaft drive slot Side Clearance 0 0301 0 0101 0 021 L 21 Needle bearing to worm gear shaft Diameter 0 00311 0 0005L 0 00291 22 Starter worm drive shaft Diameter 0 5600 0 5620 0 5626 23 Starter gear to crankshaft gear Backlash 0 ...

Page 215: ...lNTENTIONALLY LEFT BLANK 72 30 15K REVISEDOCT 97 ...

Page 216: ...INTENTIONALLY LEFT BLANK ...

Page 217: ...cavenge pump driven gear on shaft 2 Scavenge pumpdrive gear inadapter 3 Scavenge pumpgears inadapter 4 Scavenge pumpgears inadapter end clear 5 Scavenge pumpdrive gear instarter shaftgear 6 Starter shaftgear inscavenge pumpcover 7 Scavenge pumpdrivengear to drive gear backlash ...

Page 218: ...y Pin Bore Diameter 0 9988 0 9990 ConnectingRod Bushing Bore Diameter 1 0620 1 0630 BushingCenter to CrankpinCenter 6 373 6 377 Bushing Bore DiameterAfter Reaming CrankshaftAssembly Damper Pin Bushing I D 0 6062 0 6072 DECEMBER 1992 72 30 17 CamshaR Hydraulic Lifters Crankcase Journal Diameter Outside Diameter Camshaft BearingsDiameter Lifter Guides Diameter Governor Driven Gear BearingDiameter St...

Page 219: ...OTECTIVE COATING The manufacturer protects all aluminum alloy castings sheet metal and tubing from corrosion by treating all surfaces of the parts with Accelagold Turco Products 3300Montreal IndustryWay Tucker Georgia 30084 Oil Pump Drive Gear Oil PumpGear Top Oil PumpGear Bottom Shaft Oil Pump Gear Bottom Shaft Magneto DriveGear 72 30 11 APPLICATION OF ALODIZING After any machining or repair oper...

Page 220: ...atelythe same as original D Flush part with clear water and dry with warm air current Do not air blast or rub with clothto dry newfilmarea If color istoo light repeatstep C untildesired color is obtained NOTE If Accelagold does not adhere to metal a more severe cleaning method must be used 12 to 14 ounces of OaMite No 61 or equivalent solution per gallon of water is prefer red Apply and remove the...

Page 221: ...INTENTIONALLY LEFT BLANK ...

Page 222: ...haft CounteweigM Pins and Bushings 72 40 04 Camshaft 72 40 05 Connecting Rods 72 40 06 Gears 72 40 07 Pistonsand Wings 72 40 08 Cylinders 72 40 09 HydraulicValve Lifters 72 40 10 IntakeTubes 72 40 11 LubricationSystem 72 40 12 FuelInjectionSystem 72 40 13 Ignition System 72 40 14 Exhaust System 72 40 15 inspectionChart ...

Page 223: ...INTENTIONALLY LEFT BLANK ...

Page 224: ... supporting the front and rear main journals and rotated under a dial indicator placed on the center main journal in order to detect excessive bending This is important if the aircraft has been involved in an accident resulting in a broken or bent propeller Refer to the Table of Limits 72 30 09 for limits of run out at the center journal NOTE In case of prop strike sudden stoppage refer to TCM ser...

Page 225: ...fied inSection 72 30 08 Table of Limits 72 40 06 GEARS lnspect gear teeth for signs of overheating and excessive wear Normal wear produces a fine polish on the tooth thrust faces Alteration of the tooth profiles score marks and pittingare sufficient causefor rejection 72 40 07 PISTONS AND RINGS lnspect the skirt for long deep scores which indicate overheating and would be sufficient cause for reje...

Page 226: ...t with straight edge Do not pushthe secured straight edge away from the piston 4 Insert feeler gage to approximately 1 8 inch depth between top of piston ring and top of piston ring groove next to straight edge Check the Table of Limits for the approved side clearance dimension NOTE It is recommended that piston rings be replaced whenever the cylinder is honed and pistons and rings be replaced at ...

Page 227: ... be checked for warpage before refacing and all valves should be measuredin length if the stem tips were ground If there was any evidence of overheating of cylinder or piston check for possible turning of the head in relation to the barrel flange Security between cylinder head and barrel is dependent on metal to metal contact of cylinder barrel top threads within the head shoulder Dark stains at t...

Page 228: ...eto filter should be inspected at periodic inspection If inner content of filter is pink moisture is present and filter should be replaced At the same time inspect hoses for weather checking and leaking Magnetos should be disassembled and inspected at each 500 hour interval according to Magneto Service Manual Refer to Service Bulletins SID96 6 M 85 14 MSB94 8 M93 10 M 85 7 and M 78 8 or current re...

Page 229: ... spark plugs SEVERE WORN OUT CONDITION Excessivelyeroded center and ground electrodes plus extensive neckingof fine wire ground electrodes indicateabnormal engine poweror plugs longover due for replacement Check fuel meteringand magneto timing Discardspark plugsand check heat range before installingnew ones ELECTRODEWEAR PATTERNS Constantpolarity occurswith even numberedcylinder magnetos One plugs...

Page 230: ...s maintained in exhaust system apply soapy water over systemand monitorfor bubbles If bubblesare noted investigate D Stack Risers Elbows lnspect these components for burned areas cracks and looseness During this inspection give special attention to the condition of welded areas and seams for cracks E Heater Muff Special attention should be given in the pressurized exhaust system inspec tion If air...

Page 231: ...INSPECT FOR BULGES OR HOTSPOTS FIGURE 72 40 14A SLIPJOINT ASSEMBLY SPOT WELDS MLlST NOT I b FIGURE 72 40 148 MULTI SEGMENT V BAND CLAMP ...

Page 232: ...MS of 10 of cylindersas a qualitycheck Scoring diameter flare at ends Roughness caused by honing Cracks and brokenareas Defects not permissibleafter removalof glaze Referto Table of Limitsfor standard size bore or for oversize bore Dimensional honing should remove ring step of more than 0 002 inch diameter Taper limit Table of Limits must not be exceeded by honing Referto Table of Limits Diameters...

Page 233: ...ding has not cut through Stelliteface of exhaust valve or entered roundededge on intakevalve head Use height gage to detect stretchand check for re ductiondue to tip grinding Scoring diameter Obstruction Side clearancebetween cylinder head supports Diameter scoring roughends Measureusingair gauge with correct size air plugand master setting ring Special Considerations Allow not over 0 001 inch out...

Page 234: ...tempt to pull out by hand only Obstruction of oil hole tight fit Burring scoring wear enough to alter profile Damaged or dirtythreads Diameterand fit in crankcase bearings Scoring pittingand corrosion Pittingalongtoe line loss of slopealongtoe line width across heeland toe at center of length Distortionof threads Nicks peening other irregularities Scoring burring pitting wear enoughto alter profil...

Page 235: ...ies main and camshaft bearing supply holes using inspec tor s flashlight to illumi nate Probe other oil holes with brass rod Deformed or dirtythreads Distortion Check for backingouts Usetoolmaker s square to check studs suspected of bending Roughnessor excessiveplay Warpage cracks Observe that old seal has been removedwithout damage to retainer Attempt to rock and pull out by hand only Lookfor ben...

Page 236: ... Surfaces All Areas Gearshaft Plugs lnspectvisually for dents deformedfins punctures stripped plug holethreads cracks and scratches Warpage and scratches Cracks Roughness Damagedthreads cracks around holes Scratches warpage cracks Cracks Lookfor distortion Look for damaged corners Damagedthreads dented tube cracks intube distortedor plugged filter Scratches cracks Cracks scratches on machined surf...

Page 237: ...ore Diameters UseTelescoping gage and Referto Table of Limits micrometer caliper Outside Surface Measurediameter Look for scoring nicks etc Must seat perfectlyin Spread Prussian blueoil base pigment on face of plunger and turn on seat all around plungerface Measurediameters Referto Table of Limits Seethat old oil seal was seal counterbore screen out of roundpilot Cracks scratches on machined surfa...

Page 238: ... out of round excessivedepthand Cracks scratches on INDUCTION SYSTEM IntakeManifold Clamps Shaft Bearing Bore Oil Seal Flanges Tubes Plug Bosses Shape machined surfaces damaged mountingholes Lookfor scoring Measurediameter Seethat oil seal was removed without damage to casting Check for warping by placing flanges on surface plate Look for cracks Look for dents out of round ends cracks Damagedthrea...

Page 239: ...mage Cracks damaged mounting holes lnspecttapped hole Measureborediameter Lookfor chipped cracked and brokenteeth scoring burringandwear enough to alter tooth profile Measure outside diameter and compare with bore diameter Makesure that new plugwas installed after magnetic particle inspectionof gear and visual inspectionfor cleanlinessof center bore Check for looseness lnspectionis limited strictl...

Page 240: ...ll Areas Tubes Pipe Fittings I Threads I 1 Wrench Flats MAGNETO DRIVE ASSEMBLY Gear Teeth Shaft Check for warpage Lookfor cracks flat spots out of roundends Distortionor stripping Lookfor damaged corners Scoring burring or wear enoughto alter tooth profile Measurediametersand compare with bushing diameter Referto Table of Limits ...

Page 241: ...INTENTIONALLY LEFT BLANK ...

Page 242: ...IES ASSEMBLY OF SUBASSEMBLIES General Oil PumpAssembly Starter and Starter Adapter CylinderAssembly Pistonand RingAssemblies Pushrod Housing Crankshaft and ConnectingRods Camshaft Crankcase Fuel Injection Air Throttleand MeteringAssembly ...

Page 243: ...INTENTIONALLY LEFT BUNK ...

Page 244: ...sion resistantlockwire TIGHTENING TORQUES The accuracy of any torque indicating wrench depends on a smooth application of force Do not back up a nut or bolt and leave it in that condition If part is accidentally tightened too much loosen it and retighten it to a value within the specified limits If a nut slot cannot be aligned with a cotter pin hole within the specified limits substitute another s...

Page 245: ...lic ExhaustGasket Assy Attaching Manifold FlangeNuts Adapter Tach Reduction Fuel InjectionLine Nut Vapor Separatorto Fuel Pump Oil Temperature Control a l v ScreenAssy ScavengeOil PumpTS10 360 C Oil FilterAdapter Locknut Aneroid Housingto Fuel Pump Oil PressureReliefValve Cap Tach Shaftto Oil PumpDriveGear RockerShaft Holddown nuts Alternator Shaft Nut THREAD SIZE Tighten two lower screws first I ...

Page 246: ...sembly in a housing additional oil should be applied to assure full coverage Before installing tapered pipe plugs or straight thread plugs to prevent seizure and leakage of oil coat the male threads with anti seize compound Coat both sides of gaskets with lightweight tight seal compound to assure a perfect seal and to counteract the permanent set caused by compression 72 50 02 PUMP ASSEMBLY See Fi...

Page 247: ...re 72 10 12B A lnstall worm wheel gear 15 in shielded vise and assemble clutch spring 16 to worm wheel gear Secure spring 16 using bolt 18 and tab washer 17 B Assemble worm wheel gear 15 clutch spring 16 and bearing 14 to shaft gear 19 C lnstall starter adapter housing 2 in shielded vise lnstall shaft and clutch assembly items 14 thru 19 into starter adapter housing 2 turning clockwise to seat clu...

Page 248: ...eads Clamp cylinder base flange to prevent cylinder from rising Again apply molyshield grease to valve stems C Temporarily install rocker shaft 11 and thrust washers 12 Secure with attaching parts 8 9 10 lnstall retainers 37 inner and outer springs 35 36 and rot0 coils 34 Compress springs and install keys 33 insuring that they are properly seated before releasing pressure on springs Remove cylinde...

Page 249: ...of the seal with molyshield grease Twist the seal and slide it over the crankshaft Bring the ends back together Wrap the spring around the crankshaft in the seal area Turn the spring ends in an unwinding direction then join and allow one end to wind into the other end Wih hooked ends opposite the seal split lift the spring into the seal recess Work the remainder in by moving the fingers in both di...

Page 250: ... 360 MB SB Fitting orientation charts are providedfor the manifoldvalves and fuel pumps B On the TSIO 360 MB SB See Figure 72 10 06B install new gasket 36 and controller 35 on throttle assembly 18 Secure using attaching hardware 37 38 39 Connect linkage assembly 12 to throttle 18 and controller 35 using attaching hardware 13 thru 16 Install new O ring 41 and overboost valve 40 on throttle assembly...

Page 251: ...I D C D FIGURE72 50 10A FUEL MANIFOLD VALVE FITTING LOCATIONS NOTES O These fittings are part of Fuel InjectionTube Assemblies See Figures 72 10 06A and 9 72 50 10 REVISED OCT 97 ...

Page 252: ...FIGURE72 50 IOB AIR THROTTLE AND METERINGASSEMBLY FlmlNG ORIENTATION REVISED OCT 97 72 50 14 ...

Page 253: ...RICH I 72 50 12 REVISED OCT 97 ...

Page 254: ...FIGURE 72 58 IOD FITTING ORIENTATION AIR THROTTLE AND METERING UNIT TSIO 360 MB SB REVISED OCT 97 72 50 1 3 ...

Page 255: ...INTENTIONALLY LEFT BLANK ...

Page 256: ...EMBLY General Crankcase Cylindersand Pistons Accessory Case Fuel Pump Starter DriveAdapter Alternator Assembly Oil Cooler Valve Mechanism IntercylinderAir Baffles Oil Sump InductionSystem Fuel injectionSystem IgnitionSystem Exhaust System ...

Page 257: ...INTENTIONALLY LEFT BLANK ...

Page 258: ...ift crankshaft assembly by No 1 connecting rod and propeller flange while an assistant holds No s 3 and 5 rods Carefully lower the assembly into the crankcase bearing Make certain the oil seal enters the oil seal cavity If properly installed the connecting rod position numberswill be toward the upper crankcase flange D Lubricate governor driven gear with clean engine lubricating oil and insert it ...

Page 259: ... lower corner of the rear mount brackets four thru bolts 52 through No 3 and 5 cylinder mount pads two thru bolts 56 below camshaft level one thru bolt 59 in lower hole of No 1 cylinder pad and one thru bolt 60 in upper hole of No 1 cylinder mount pad Tap all thru bolts to a centered position with a non marring hammer These bolts alignthe crankcasecastings and bearings FIGURE72 60 02A LEFTSIDE OF ...

Page 260: ...FIGURE 72 60 Q2BALIGNMENT OF TIMING MARKS FIGURE92 60 02C RIGHTCRANKCASEAND SUPPORT ...

Page 261: ...ter 70 2 Installthru bolts cylinderassemblies and retaininghardware 3 Torque bolts and nuts to 50 of their specified torque following the sequence shown in Figure72 60 02D TorquingSequence 4 Apply final ratedtorque to all nutsand bolts following sequenceshown CRANKCASE TORQUE VALUES Toraue Inch Lbs Seauence Number 590 610 at cylinder flange nut 1 4 10 13 19b 22b 30a 33a 440 460thru bolt at cad pla...

Page 262: ...u bolts 59 60 J Attach the manifold valve and bracket assembly 22 thru 25 39 and a Figure 72 10 06 and lifting eye 30 Figure 72 10 15 to backbone and secure using spacers 27 84 washers 28 bolts 29 lockwashers 26 and nuts 25 lnstall throttle body bracket 24 using attaching parts 18 thru 23 On TSlO 360 C D engines install bracket 90 in place of bracket 24 lnstall bracket 90 on backbone Install attac...

Page 263: ...on ring gaps should be positioned 180 apart with the first or top ring gap toward top of piston D Install pistons and cylinders in desired order It is suggested that Nos 4 and 5 be installed first to minimize turning of the crankshaft and to prevent excessive unbalance Turn the crankshaft for Nos 2 and 3 and install the assemblies Then turn the shaft for Nos 1 and 6 and installthe lasttwo assembli...

Page 264: ...st Figure72 60 03B H After installing all pistons and cylinders tighten and torque nuts according to sequence shown in Figure 72 60 02C Torquing Sequence For single cylinder installation refer to Figure 72 60 03Cfor torque sequence I Installspark plugsand gaskets in upper cylinder holes 72 60 04 ACCESSORY CASE See Figure 72 10 07 Refer to Serwice Bulletin M 79 15 or current revisionas applicable A...

Page 265: ...hand to be certain they mesh freely before installing sub assembly on accessory case mount pad B Lubricate shaft gear and mesh it with crankshaft gear as adapter is pushed into position Seat adapter assembly against gasket Secure using attaching hardware 59 thru 66 or 45 thru 51 or 49thru 54 as applicable 72 60 07 ALTERNATOR ASSEMBLY See Figure 72 10 11 A lnstall new o ring 4 on shaft of alternato...

Page 266: ...er assembly I3 14 15 lnstallthrust washers 12 lnstall rocker and shaft on cylinder rocker studs Be sure that thrust washers turn freely lnstall retainers 10 on both ends of shaft 1I Secure shaft using attaching hardware 8 9 After tightening nuts bend ears of tab washers up against flat of nuts lnstall pushrods and rockers on remaining cylinders in same manner Check valve rocker toe to valve stem c...

Page 267: ...FIGURE72 60 10 INSTALLING PUSHROD HOUSING FIGURE72 60 11 BOnOMVIEW WITH MECHANISM 72 60 12 ...

Page 268: ...w seals 19 E lnstall injector nozzles 30 figure 72 10 06A and sleeve assemblies 31 using new seals 32 washers 33 34 72 60 128 INDUCTION SYSTEM TSIO 3604 CB D DB See Figure 72 10 08B A lnstall riser and elbow riser assemblies 2 thru 6 using new gaskets 1 Loosely install attaching hardware 7 8 9 lnstall throttle assembly and secure to engine using attaching hardware 15 16 B Slide clamps 10 onto rise...

Page 269: ...ylinder intake flanges and tighten hardware 7 8 9 Center hoses 12 and securewith clamps 10 D Using hoses 26 clamps 25 35 connect induction tubes 27 28 to throttle adapter 36 and throttle adapter 36 to throttle assembly 13 using new gasket 40 and attaching hardware 8 9 37 38 lnstall overboost valve 30 using new o ring 29 onto induction tube 28 E lnstall fittings 39 and air reference lines 16 18 20 ...

Page 270: ...el discharge tubes 29 to manifold valve and injector nozzles lnstall fuel hoses 34 and 41 72 60 13B FUEL INJECTIONTSIO 360 MB SB See Figure 72 10 06B I A Fuel injector nozzles and air reference sleeves were installed during induction system assembly 3 lnstall manifold valve 44 on engine using bracket 46 and attaching hardware 47 thru 53 C Connect fuel discharge tubes 19 to manifold valve and injec...

Page 271: ...down but do not tighten two sets of attaching parts 6 5 4 NOTE The LTSIO 360E EB KB are counter rotational E lnstall the ignition harness assemblies Secure each outlet plate 26 with four sets of attaching parts 3 2 F Connect a timing light lead to the magneto ground terminal or according to manufac turer s instructions Tap magneto case with a non marring hammer counterclockwise from the rear to ma...

Page 272: ...rbocharger and secure by clamp 18 D Install fittings 28 thru 31 19 20 oil line 21 hoses 27 34 and check valve 26 Secure using attaching hardware 22 thru 25 32 33 72 60 15C EXHAUST SYSTEM TSIO 360 GB LB See Figure 72 10 18C A Place engine in inverted position install new gaskets lo exhaust risers I thru 7 and secure to cylinders using attaching hardware 11 B Bracket 14 should have been installed du...

Page 273: ...u 17 Tighten clamp 10 D Install new gaskets 26 28 and adapter 25 27 on turbocharger securing with attaching hardware 55 thru 58 Connect hoses 20 32 30 49 and check valves 29 50 to proper fittings and secure to engine using attaching hardware 33 thru 43 E Install fittings 12 13 in wastegate and connect hoses 21 22 Connect all opposite hose ends to their proper fittings ...

Page 274: ...2 70 00 TESTING AFTER OVERHAUL Test Stand Test Club Cooling Air Scoop InductionAir Intake Exhaust System Controls ElectricalWiring Instruments Breather FuelSystem Governor Pad Cover EngineTest Starting Procedure OverhaulTest Run Test Flight ...

Page 275: ...INTENTIONALLY LEFT BLANK ...

Page 276: ...ir to the center cylinder and the oil cooler CHT should not vary more than 50 F beween coolest and hottest cylinders Provideanair duct to the alternator vent tube 72 70 04 INDUCTION AIR INTAKE An air filter and housing should be attached to the inlet flange The filter area must be sufficient to avoid restriction of air flow Always clean filter before eachtest 72 70 05 EXHAUST SYSTEM For testing pu...

Page 277: ...he propeller hub Crankshafts are equipped with an oil transfer collar to supply the governor controlled oil to the crankshaft for use with an oil controlled propeller 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 oil transfer collar The governor pad cover is not neede...

Page 278: ...ld it until 2 5 3 0 or 4 0 p s i nozzle pressure depending on type pump used is obtained then release boost pump buttonand press starter button NOTE During operation of the starter the boost pump may be used intermittently to maintain 2 5 to 3 0 or 4 0 p s i nozzle pressure depending on type pump used DO NOT use boost pumpafter engine is runningsmoothly ...

Page 279: ...mperature M A P C H T and Alternator Magneto drop and spread to be taken at 2100 RPM Engine must be throttled to specified RPM and temperature allowed to settle out beforetaking magnetodrop and spread Cooling Period 300 Max C H T BeforeShut Down Recheck ldleAdjustments Runs8 And 9 Must Be Made With Stops For Leak ChecksAt The End Of Each Run The engine will not be accepted until two successive 15m...

Page 280: ...mitsSection77 10 00 Adjust engine fuel flow and pressure ReduceRPMfor adjustments Check fuel injection oil pressure oil temperature M A P C H T and alternator Magnetodrop and spread to betaken at 2100 RPM Enginemust be throttledto specified RBM and temperature allowedto settle out beforetaking magnetodrop and spread Refillsump with clean oil Readingsmust be recordedafter completionof each 10minute...

Page 281: ...x for Cruising 75 Power EB FB GB LB MB 2450 RecommendedMax for Cruising 75 Power KB SB 2500 Intake Manifold Pressure In Hg MaximumTake Off See Performance Chart Maximum Continuous See Performance Chart Recommended Continuous Max for Cruising See Performance Chart Fuel Control System Continental Continuous Flow Injector Unmetered Fuel Pressure P S I G See OperatingLimits77 00 04 Fuel Min Grade Avia...

Page 282: ...Minimum psi All Models 10 Normal Operation psi TSIO 360 A AB B BB C CB D DB H HB JB 30 to 60 Normal Operation psi TSIO 360 E EB F FB G GB KB LB MB SB 30 to 80 1 Oil Temperature Minimumfor Take Off All Models 100 F MaximumAllowable 110 C 2400F RecommendedCruising 710 820C 1600F 1 80 F REVISEDOCT 97 72 70 09 ...

Page 283: ... aircraft attitude should beadjustedas requiredto maintainengine instrumentationwithin specifications Descent from high altitude should be accomplished at cruise power settings with the mixture control positionedaccordingly C4UTION Rapid descents at high RPM and idle manifoldpressure are to be avoided During descent monitor cylinder head and oil temperatures maintaining above the minimum specified...

Page 284: ...SECTION 72 80 ENGINE PRESERVATION 72 80 00 ENGINEPRESERVATION 72 80 01 General 72 80 02 FlyableStorage 72 80 03 Temporary Storage 72 80 04 IndefiniteStorage ...

Page 285: ...INTENTIONALLY LEFT BLANK ...

Page 286: ...ach normal operating temperatures which will vaporize moisture and other by products of com bustion In consideration of the circumstances mentioned TGM has listed three reasonable minimum preservation procedures that if implemented will minimize the detriments of rust and corrosion It is the owner s responsibility to choose a program that is viable to the particularaircraft s mission Aircraft engi...

Page 287: ...he top spark plug and spray preservative oil Lubrication Oil Contact and Volatile Corrosion Inhibited MIL L 46002 Grade 1 at room temperature through upper spark plug hole of each cylinder with the piston in approximately the bottom dead center position Rotate crankshaft as each pair of opposite cylinders is sprayed Stop crankshaft with no piston at top dead center A pressure pot or pump up type g...

Page 288: ...ne part compound MIL C 6529 Type I Essor Rust Ban 628 Cosmoline No 1223 or equiva ient with three parts new lubricating oil sf the grade recommended for service all at roomtemperature Single grade oil is recommend b Apply preservative to engine interior by spraying MIL L 46002 Grade 1 oil ap proximatelytwo ounces throughthe oil filler tube 2 Install dehydrator plugs MS27215 1 or 2 in each of the t...

Page 289: ...Drainthe corrosionpreventivemixtureand re servicewith recommendedlubricating oil WARNING When returning the aircraft to service do not use the corrosion preven tive oil referenced in paragraph C 1 a for morethan 25 hours 3 If the carburetor has been preserved with oil drain it by removing the drain and vapor vent plugs from the regulator and fuel control unit Wih the mixture control in Rich positi...

Page 290: ...erior of at least one cylinder on each engine through the spark plug hole If cylinder shows start of rust spray cylinder corrosion preventive oil and turn prop over six times then re spray all cylinders Remove at least one rocker box cover from each engine and inspectthe valve mechanism The above procedures are a general recommendation for our customers Since local conditions are different and Tel...

Page 291: ...INTENTIONALLY LEFT BLANK ...

Page 292: ... FUEL SYSTEM 73 06 00 ENGINEFUELSYSTEM 73 IQ OQ SET UP PROCEDURE 73 10 01 TurbochargedEngines 73 10 02 Special Set Up Procedures 73 10 03 FuelSystem Pressureand FlowValue Charts 73 10 04 FuelSystemTroubleshooting Chart ...

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Page 294: ...mits the use of a typical rotary vane pump with integral relief valve With this system there is no need for an intricate mechanism for timing injection to the engine The fuel injector pump is equipped with a vapor separator where the vapor is separated by a swirling and augmentor system from the fuel and returned to the tank The fud injector pumpforces sdid fuel intothe metering unit assembly The ...

Page 295: ...ure at idle and full throttle Fuel pressures of fixed orifice pumps can only be adjusted with the relief valve screw located on the centerline at the rear of the pump Adjustable orifice or variable orifice aneroid pumps have an additional facility for adjusting pump pressure at both idle and full throttle RPM 73 10 01 TURBOCHARGED ENGINES To make full rich adjustments on engines equipped with adju...

Page 296: ...ncrease pressure and CCW to decrease pressure or on adjustable orifice pumps adjusting screw located on the aneroid housing CW to decrease CCW to increase pressure NOTE If at static run up rated RPM cannot be achieved at full throttle adjust nozzle pressure or fuel flow to obtain specified values when rated RPM is achieved during takeoff roll G Reset idle stop screw to appropriate engine specifica...

Page 297: ...s bolt is extremely important This setting determines Full Throttle manifold pressure and critical altitude and must be properly adjusted before the fuel system can be set up accurately NOTE See General Instructionsfor adjustingturbocharged engine fuel systems C Rated manifold pressure for a given altitude should be achieved on take off roll If rated MAP cannot be obtained check for exhaust leaks ...

Page 298: ...e shown for max rated RPM and manifoldpressure NOTE Unmetered or pump pressurevalues are for a gauge vented to atmosphere O See Aircraft Specificationsfor other values where applicable O Limitsare based on aircraft manufacturer sgauge calibrations O Limitsalso apply to the B configuration of these engines i e TSIO 360 AB TSIQ 360 BB NOTE Forfurther informationsee TCM Service BufletinSlD97 3 or cur...

Page 299: ...it in accordance with adjustment procedures Lower unmeteredfuel pressure Replaceworn elements of linkage Removeand cleanall nozzles Improper pump pressure replace Pump Check mixture control for full travel Check for clogged fuel filters Adjust engine drivenfuel pump approximate TROUBLE Engine Will Not Start And No Fuel Flow Gage Indication Engine Will Not Start With Fuel Flow Gage lndication Rough...

Page 300: ...e Unmetered Fuel Pressure Drop Very High idleAnd FullThrottle Fuel Pressure Present No Fuel Pressure Air in fuel flow gage line Leak at gage connection Enginegetting fuel Internalorifices plugged Relief valve stuck open Relief valve stuck closed Check valve stuck open jet in vapor separator cover Clean only with solvent nowires Repair leak and purgeline Check mixture control is infull idle cut off...

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Page 302: ...SYSTEM 74 00 00 GENERAL 74 00 01 Magneto lnstallation 74 00 02 Harness Assembly lnstallation SLICK IGNITION SYSTEM 74 10 00 GENERAL 74 10 01 Magneto lnstallation 74 10 02 Harness Assembly lnstallation 74 20 00 IGNITION TROUBLESHOOTING ...

Page 303: ...g magnetviewed from drive end R for right hand L for left hand D N indicatesmanufacturedbyTCM E The dash number suchas 25 indicatesa certain executionof the basictype magneto 74 00 01 MAGNETOINSTALLATION Referto ServiceBulletin M 88 8R1 or current revision as applicable Insure that magneto is proper part number for engine installation Insure that internal timing of magneto is correct as per TCM fo...

Page 304: ...om magneto Make connections between magneto and ignition switch using 18gagewire followingairframe manufacturer swiring instructions WARNING The magneto is in a SWITCH ON condition when the switch wire is disconnected Therefore the usualprecautionmust be observed 74 00 02 HARNESSASSEMBLY INSTALLATION Before installing harness on magneto check mating surfaces for cleanliness Spray entire face of gr...

Page 305: ...spark plugs and torque as specified in Table 74 00 03 Tighten elbow assembly nuts to outerferrule fluorocarbon Spray MS S122 Miller StephensonChemical Co inc 16Sugar Hollow Road Danbury Connecticut06810 Go Jo No Lok No 72 Compound Gojer Inc Akron Ohio 44309 or Molykote Type G The Alpha Molykote Corp Stamford Connecticut06904 NOTE Hold ferrules while tightening or loosening spark plug coupling nuts...

Page 306: ...to The following detailed explanation gives the meaning of the various numbers appearing in the serial number E G 2 0 3 1 3 2 The year of Manufacture The numberof a 2 1982 particular model manufactured inthe m nth specified The month of Manufacture 03 March 74 10 01 MAGNETO INSTALWWONAND TIMINGTO ENGINE Before magnetos are installed on the engine the rotation and internal magneto timing must be co...

Page 307: ...degree indication on the ring gear aligns with the drill hole in the starter housing If points open early loosenmagnetos and rotatecounterclockwise Secure magnetosand removetiming lights CAUTION When installing the magneto on the engine using the available nuts and clamps please take the following precautions Tighten both nuts by hand to finger tightness Tighten each nut to 8 ft 1bs and then tight...

Page 308: ...kNo 72 Compound Gojer Inc Akron Ohio 44309 or MolykoteType G The Alpha Moiykote Corp Stamford Connecticut 06904 NOTE Hold ferrules while tightening or loosening spark plug coupling nuts to protect againsttwisting conduilt or cable B Clamp harness leads as required FIGURE 74 10 01 COUPLING NUT TORQUE VALUES CouplingThread ...

Page 309: ...tointernaltiming incorrect or timed for opposite rotation Spark plugsfouled or improperly gapped Weak condenser Loose or improperly gapped spark plugs Hightensionleak in ignition harness Weak or burned out condenser as evidencedby burnedor pitted breaker points Fouled or dead spark plugs Improperlygapped spark plugs Magnetos out of time with plugs Damaged magneto breaker points or condenser Replac...

Page 310: ...CHAPTER 95 A1R 75 00 00 GENERAL ...

Page 311: ...INTENTIONALLY LEFT BLANK ...

Page 312: ...rmit more efficient engine and turbocharger operation The induction air passes through the core of the aftercooler and transfers some of its heat to the cooling fins which are exposed to the relatively cooler ramair The manifold is an air distribution system mounted in several different configurations according to engine model It servesto carry inductionair to the individualcylinder intake ports T...

Page 313: ...INTENTIONALLY LEFT BLANK ...

Page 314: ...CHAPTER 76 ENGINE CONTROLS 7600 00 GENERAL 76 10 00 CRUISE CONTROL BY PERFORMANCECURVE 7620 00 CRUISE CONTROL BY E G T 76 30 00 PERFORMANCE CHARTS ...

Page 315: ...INTENTIONALLY LEFT BLANK ...

Page 316: ...n that order Whenreducingpower retard throttle then adjust RPM and mixture NOTE It may be necessary to make minor readjustments to fuel flow mixture after changing RPM 76 20 00 CRUISE CONTROLBY E G T If exhaust gastemperature indicator is usedasanaidto leaningproceedas follows 1 Adjust RPM for desired cruisesetting 2 Slowly move mixture control toward lean while observing E G T gage Note position ...

Page 317: ...INTENTIONALLY LEFT BLANK ...

Page 318: ...60 GB Altitude Performance2700 RPMTSIO 360 GB Critical Altitude VS EngineSpeed Standard Day TSIO 360 GB Power Management OperatingRecommendationsTS10 360 GB Fuel FlowVS BHPTSI0360 H HB Sea LevelPerformanceTSIO 360 H HB Sea Level Performanceto AttitudeTS10 360 H HB Altitude Performanceat 2200 RPMTSIO 360 H HB Altitude Performanceat 2300 RPMTS10360 H HB Altitude Performanceat 2400 RPMTSIO 360 H HB A...

Page 319: ...tions TSIO 360 LB 76 00 80 Compressor MAP Rayjay Turbocharger Model 300E TSIO 360 LB 76 00 81 Speed Correction Chart Sea Levelto 2000 MSL TSIO 360 LB 76 00 82 Fuel Flow Limits TSIO 360 LB 76 00 83 Sea Level PerformanceTSIO 360 LB 76 00 84 Altitude Performance 1 800 RPM TSIO 360 LB 76 00 85 Altitude Performance2000 RPM TSIO 360 LB 76 00 86 Altitude Performance2200 RPM TSIO 360 LB 76 00 87 Altitude ...

Page 320: ...Fuel Flow VS BHP TSIO 360 A AB B BB ...

Page 321: ...ENGINE RPM Sea LevelPerformanceTS1 3WA AB B BB ...

Page 322: ...t60 f 40 20 0 3 20 e 40 1 60 5 PIESSUIIZ ALTITUDE IN f l ...

Page 323: ...v F U E L F L O W LBS HR Fuel Flow VS BHP YSl 36 C CB ...

Page 324: ...2200 2400 ENGINE RPM Sea LevelPerformanceTSl0 360 G GB ...

Page 325: ...SEA LEV PERFORMANCE ALTITUDE PERFORMANCE ...

Page 326: ...BRAKE HORSEPOWER ...

Page 327: ...ENGINE RPM Sea LevelPerformanceTSIO 360 D DB ...

Page 328: ...SEA LEVEL PfiRFORMANCE ABS DRY MANIFOLD PRESSURE IN HG ALTITUDE PERFORMANCE PRESSURE ALTITUDE IN THOUSANDS FEET ...

Page 329: ...h of peak T I T is prohibited for all conditions 150 140 130 120 n C 110 m r n r 0 100 I I r w 90 V x 80 70 60 50 40 60 80 100 120 140 160 180 200 220 BRAKE HORSEPOWER 30 40 50 60 70 80 90 100 PERCENT SEA LEVEL POWER ...

Page 330: ...SUPPRESSION WHEN A BOOST PUMP IS PROVIDED IT MUST BE ABLE TO SUPPLY ENGINE Fuel Pump Inlet Press VS BHP 110 F AVGAS L VSIO 360 E EB ...

Page 331: ...ENGINE RPM Sea Level PerformanceCurves b TSlG360 E EB ...

Page 332: ...Altitude Performance L TSIO 360 E EB ...

Page 333: ...0 0 8 53 8 51 8 Q 2 0 0 0 0 c Z 5 C r OD w I n u FUEL FLOW LBS HR Fuel Flow VS BHP TSlG360 F FB ...

Page 334: ...1800 2000 2200 2400 2600 ENGlNE RPM Sea Level PerformanceTS10 366F FB a W i5 120 U J a 0 loo ...

Page 335: ...Altitude Pepformance TSlG360 F FB ...

Page 336: ...SFC approx 42 LBIBHP HR as longas 1650 F TIT is not exceeded cylinder head temperaturesremain below 440 F 3 Manual leaningto TIT 1550 F maximum permitted as long as cylinder head temperatures remain below 425OF and 100 120 140 160 180 200 BRAKE HORSEPOWER Proviler Load Curve Fuel FlowVS BHPTSIO 360 GB ...

Page 337: ...SPEC FUEL CONS LBS BHP H R ABS D R Y MAN PRESS IN HG L 2 2 2 4 A 2 2 4 g 2 h J W P C J l m 4 03 c o 0 0 0 0 0 0 0 0 0 O 0 0 2 BRAKE HORSEPOWER ...

Page 338: ......

Page 339: ...Altitude Performance 2000 RPM TSl8 360 GB ...

Page 340: ...Altitude Performance 2200 RPM TSlG360 GB ...

Page 341: ......

Page 342: ......

Page 343: ...2 BEST POWER MIXTURE BELOW 75 POWER 3 CORRECT BHP FOR INLET A1R TEMPERATURE AS ...

Page 344: ......

Page 345: ......

Page 346: ...Add 1 for each ÿ OF Below 6 0 b Subtract 1 for each OF Above 6 0 2 The above correction is for Induction atr temperature at the 20 22 24 26 28 30 32 34 36 38 40 MANIFOLD PRESSURE IN HG Power ManagementOperating RecommendationsTS10 360 GB ...

Page 347: ...110 130 150 Brake Horsepower ...

Page 348: ...2000 2200 2400 2600 2800 ENGINE RPM Sea LevelPerformanceTSIO 360 H HB ...

Page 349: ...18 20 22 24 26 28 30 32 34 36 ABS DRY MANIFOLD PRESSURE iN HG Sea LevelPerformanceto AltitudeTSlG360 H HB ...

Page 350: ...isil 3 dn3i i l v als BRAKE HORSEPOWER Altitude Performance at 2200 RPM TSIO 360 H HB ...

Page 351: ... 0 0 5 2 0 M 0 40 40 I I I I I I I I I I I I I I I I I I I I I I I 1 I I I I 1 7 t J 9 t w 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 5 l 5 PRESSUREALTITUDE IN THOUSANDS FEET Lo ...

Page 352: ...83AnOd3StiOt I 3YVU8 Altitude Performance at 2400 RPM TSIQ 360 W HB ...

Page 353: ...B R A K E H O R S E P O W E R Altitude Performance at 2500 RPM TSIO 360 H HB ...

Page 354: ... 2 d w a n v ais U3MOd3SUQH 3NVUZ3 Altitude Performance at 2600 RPM TSIO 360 H HB ...

Page 355: ...0 0 0 0 0 0 0 0 0 0 0 0 0 0 8 9 i O m a 3 b a m b O a r o m a a r r r r r r r r r 15Li 3 dW31 L l V CllS tf3MOd3StilOt 1 f rVtlld Altitude Performance at 2700 RPM TSIO 360 H HB ...

Page 356: ... U 4 dW31 1 O l S BRAKE HORSEPOWER Altrtude Pertormanee at 2800 HPM I s lw 360 H HB ...

Page 357: ...Fuel Flow Lbs Hr Fuel Flow VS BHP TS16 360 JB ...

Page 358: ...2000 2200 2400 2600 2800 ENGINE RPM Sea Level PerformanceTSlG360 JB ...

Page 359: ...ABS DRY MANIFOLD PRESSURE IN HG Sea LevelPerformanceto Altitude TSIO 360 JB ...

Page 360: ...Altitude Performance 2200 RPM TS10 360JB ...

Page 361: ...Altitude Performance 2300 RPM TSIO 360 JB ...

Page 362: ...Altitude Performance 2400 RPM TSlC36O dB ...

Page 363: ......

Page 364: ...Altitude Performance 2600 RPM TSIO 360 JB ...

Page 365: ...Attitude Performance 2700 RPM TSIO 36WB ...

Page 366: ...Altitude Performance 2800 RPM TSIO 360 JB ...

Page 367: ...BRAKE HORSEPOWER Critical Altitude VS Engine Speed Standard Day L TSIO 360 KB ...

Page 368: ...PRESSURE DROP P S I FuelFlowVS PressureDropTSIB 360 GB KB ...

Page 369: ...Fuel Pump Inlet PressVS BWP 110 FAVGAS TSlG360 F FB GB KB ...

Page 370: ...2 VAPOR RETURN OUTLET PRESSURE 3 INLET TO PUMP 2 5 PSlG 4 AVGAS 84 F NOTE TYPICAL PERFORMANCE Performance is subject to installation effects VAPOR RETURN FUELFLOW bbs Hr Vapor Return FlowVS Pump PressureTSIO 360 F FB GB KB ...

Page 371: ......

Page 372: ...0 A T O F Speed C rrection Chart S L to 2000 ft MSLTSlG360 F FB GB KB ...

Page 373: ...Sea Level PeFformanceL TSIO 360 KB ...

Page 374: ...HP Hr as long as 1650 F T I T is not exceeded cylinder head tempera tures remain below 420 F and oil temperature does not exceed 200 F 3 Manual leaning to T I T 1525 F maximum permitted as long as cylinder head tempera tures remain below 420 F and oil temperature does not exceed 200 F BRAKE HORSEPOWER Propeller Load Curve ...

Page 375: ...Altitude Performance 2200 RPM L TSiO 360 KB 76 00 62 ...

Page 376: ...ALTITUDE X 1000 FEET ...

Page 377: ......

Page 378: ...R MIXTURE BELOW 3 CORRECT BHP FOR INLET AIR TEMPERATURE AS FOLLOWS m a a ADD 1 FOR EACH 6 F x BELOW Ts rn I b SUBTRACT 1 FOR EACH 6 F ABOVE Ts In rn NOTE TYPICAL PERFORMANCE v 0 Performance is subject to s inslallatlon effects m a ALTITUDE X 1000 FEET ...

Page 379: ...MIXTURE 165 BHP AND ABOVE 2 BEST POWER MIXTURE BELOW 3 CORRECT BHP FOR INLET AIR TEMPERATURE AS FOLLOWS a ADD 1 FOR EACH 6 F BELOW Ts b SUBTRACT 1 FOR EACH 6 F ABOVE Ts NOTE TYPICAL PERFORMANCE ALTITUDE X 1OOQ FEET ...

Page 380: ......

Page 381: ......

Page 382: ...Power Managemernt Operating RecommendationL TSIO 360 KB ...

Page 383: ...FUEL FLOW Lbs Hr Metered Fuel Pressure VS Fuel Flow All Models Except TSlG360 LB MB ...

Page 384: ...CESS VAPOR INGESTION BOOST PUMP OPERATION MAY BE REQUIRED TO STAY RICHER THAN LEAN LIMIT SHOWN 0 CK 2 0 I CK W a V CI Z 2 B I 3 3 A 1 W i Typical Engine Fuel System Operating Characteristics 2600 RPM Sandard at S b All Models Except TSIO 360 LB MB ...

Page 385: ...1 5 2 5 3 5 4 5 5 5 6 5 PRESSURE P S I G Fuel FlowVS Pressure Drop TS110 360 LB ...

Page 386: ...40 45 50 55 FUELFLOW LBSIHR Mixture Ratio Curve 2200 RPM 24 9 He ADMP TS18 360 MB SB REVISEDOCT 97 76 00 73 ...

Page 387: ...BRAKE SPECIFIC Consumption LbslBHPIHr EXHAUST GAS TEMPERATURE O F BRAKE HORSEPOWER ...

Page 388: ...BRAKE SPECIFIC Consumption LbslBHPIHr EXHAUST GAS TEMPERATURE OF BRAKE HORSEPOWER ...

Page 389: ...nimum SFC approx 42 LBIBHP HR as long as 1 6 5 0 TIT is not exceeded cylinder head temperatures remain below 440 F and oil temperature does not exceed 3 Manual leaningto TIT 1550 F maximum 100 120 140 160 180 BRAKE HORSEPOWER Propeller Load Curve Fuel FlowVS Observed Brake HorsepowerTSIO 360 LB ...

Page 390: ...METERED FUEL PRESSURE psi Metered Fuel Pressure VS Fuet Flow TS10 360 LB ...

Page 391: ...1 Ejector P N 642955 2 Vapor return outlet pressure 3 Inlet to pump 2 5 PSlG 50 60 70 80 VAPOR RETURN FUEL FLOW LBSfHR Vapor Return FlowVS Pump PressureTSIG360 LB ...

Page 392: ...60 50 a 5 40 U P B W W a V 3 a U 0 V I W 30 n Y s rn 20 40 IDLE 20 40 60 80 100 PERCENTAGE RATED POWER ENGINE RPM Fuel Injection Pump Inlet Pressure RequirementsTSIO 360 LB ...

Page 393: ...Power ManagementOperatingRecommendationsTSIO 360 LB ...

Page 394: ...Compressor MAP Rayjay Turbocharger Model300E TSIO 360 LB ...

Page 395: ...Speed CorrectionChart Sea Levelto 2000 MSLTSIO 360 LB ...

Page 396: ...100 Power RPM 10 Flow Limits 135 145 Lbs Hr 75 Power RPM 10 Flow Limits 71 93 Lbs Hr FuelFlowLimitsTSIO 360 LB ...

Page 397: ...ENGINE RPM X 100 Sea Level PerformanceTSlG360 LB ...

Page 398: ......

Page 399: ......

Page 400: ...BRAKE HORSEPOWER Altitude Performance 2200 RPM TSlG360 LB ...

Page 401: ...3 CORRECT BHP FOR INLET AIR TEMPERATURE AS a ADD 1 FOR EACH 60 F BELOW Ts b SUBTRACT 1 FOR EACH 60 F ABOVE Ts ...

Page 402: ......

Page 403: ...Altitude Performance 2600 RPM TSIO 360 bB ...

Page 404: ......

Page 405: ...1100 1200 1300 1400 1500 1600 1700 TURBINE INLETTEMPERATURE O F Max Speed VS T I T TSIO 360 MB SB 76 00 92 REVISED OCT 97 ...

Page 406: ......

Page 407: ...0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 PRESSURE PSlG Fuel FlowVS Pressure Drop TSIO 360 MB SB 76 00 94 REVISED OCT 97 ...

Page 408: ...3 INLETTO PUMP 2 5PSIG 60 70 80 90 VAPOR RETURN FUEL FLOW LBSlHR Vapor Return Flow MS Bump PressureTSIO 360 MB SB REVISED OCT 97 76 00 95 ...

Page 409: ...PERCENTAGE RATED POWER ENGINE RPM Fuel Injection Pump Inlet PressureRequirementsTS10 360 MB ...

Page 410: ...ill 8 E TSIO 360SB Metered Fuel Pressure VS Fuel Flow TSIO 360 MB SB RE IISED OCT 97 76 00 97 ...

Page 411: ...75 power by reading directly 75 Power RPM 2450 f 10 Flow Limits Lbs Hr pump inlet For every 10 F increase in fuel temperature subtract 1 add 1 Ib of fuel to the curve FuelFlow LimitsTSIO 360 MB ...

Page 412: ...ABS DRY MANIFLOD PRESSUREIN HG CONSTANTSPEEDSEA LEVEL PERFORMANCETS10 360 MB 20 22 24 28 28 30 32 34 38 38 40 MAN4FW PRESSUREIn Hg 1 ConstantSpeed Sea Level PerfomanceTS10 360 SB REVISED OCT 97 76 00 99 ...

Page 413: ...100 Pump PressureLimitsTSle360 NIB ...

Page 414: ...ded Cylinder head temperature 5 F and oil temperature does 50 F maximum permitted ...

Page 415: ...Sea Level PerformanceTS10 360 MB ...

Page 416: ...Critical Altitude IS Engine Speed Standard Day Conditions TSIO 360 bB ...

Page 417: ...0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 DENSITY ALTITUDE X I000 FEET ...

Page 418: ...0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 DENSITY ALTITUDE X 1000 FEET ...

Page 419: ...0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 DENSITY ALTITUDE X I000 FEET ...

Page 420: ...MPERATUREAS FOLLOWS 220 200 180 160 140 120 100 80 60 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 DENSITYAL F1UDE X 1000 FEET TSIO 360 MB 0 2 4 6 8 10 12 14 18 18 20 2 2 24 28 28 DWSrPl ALTWUDEX 1000FT TSIO 360SB Altitude Performance2600 RPM TS10 360 MB S B REVISEDOCT 97 76 00 107 ...

Page 421: ......

Page 422: ... 10 0 I 0 20 AMBIENT TEMPERATURE OF DELTA FROM T STANDARD CriticalAltitude Variations TSlG360 LB ...

Page 423: ...INTENTIONALLY LEFT BLANK ...

Page 424: ...CHAPTER 77 ENGINE INDICATING 77 00 00 GENERAL 77 10 00 OPERATING 77 20 00 ENGINE TROUBLESHOOTING CHART ...

Page 425: ...INTENTIONALLY LEFT BLANK ...

Page 426: ...llowing spark plugsare approvedfor use inengines covered inthis manual ALL MODELS ACCESSORY DATA Accessory drives and mountingprovisionsare asfollows Direction Drive Ratio of to Accessory Rotation Crankshaft Magneto Alternator Propeller Gov FuelInjectionPump Vacuum Pump Pad Compressor Drive Optional Alternator Optional CW CCW cw CCW ccw CW Clockwiseand CCW Counterclockwise Governor Pad Modified AD...

Page 427: ...360 LB 135 145 TSIO 360 MB 125 135 I TSIO 360 SB 136 148 Fuel Pump Pressureat FullThrottle PSI TSIO 360 A AB B BB 27 0 31 0 TSIO 360 C CB D DB 34 0 37 0 UTSIO 360 E EB 43 0 46 0 TSIO 360 F FB 43 0 46 0 TSIO 360 GB 45 0 49 0 TSl0 360 H HB 29 0 33 0 TSIO 360 JB 34 5 37 5 UTSIO 360 KB 36 0 39 0 TSIO 360 LB 34 0 38 0 I TSIO 360 MB 28 0 32 0 TSIO 360 SB 31 0 3 6 0 Fuel Pump Pressure at ldle PSI TSIO 36...

Page 428: ... 50 F Ambient Air Sea bevel SAE 30 or 10W 30 Above 30 F Ambient Air Sea Level SAE 50 Max Oil Consumption Lb BHP Hr Max at Rated Power at RPM 006 1bs x Power All TSIO 360 I00 Oil Temperature Max 240 F All TSIO 360 Oil Temperature Min For Take off All TSIO 360 75 F Oil Pressure Desired Range TSIO 360 A AB B BB C CB D DB H HB JB 30 60 TSIO 360 E EB F FB G GB KB bB MB SB 30 80 Oil Pressure Max Cold Al...

Page 429: ...ted Air leak in intakemanifold Fuel injectionsystem im properlyadjusted Mixturelevers set for im proper mixture Fouledspark plugs Fillwith correct grade fuel Referto Pilot s Checklistfor startingproceduresand check for performanceof each item Placemixturelevers in IDLE CUT OFF position Openthrottle wide Turn engine over several revolutionsto clear cylinders Tighten or replacelooseor damaged hose c...

Page 430: ...ed rnount pads Pluggedfuel nozzle IPropeller out of balance Ignitionsystem malfunction Continuous Missing At Brokenvalve spring High Speed Pluggedfuel nozzle Hydraulictappet dirty or worn Burnedor warped valve CORRECTION Removeand clean lifters Inspect and clean oil filter at more frequent intervals Repair cylinder Referto Chapter 76 for proper fuel flow settings Checkfuel strainer for clogging Cl...

Page 431: ...etosout of time No appreciabledrop detected during pre flightcheck Magnetodistributor block contamination Exhaust system gas leakage Exhaust valve leaking At front of engine damaged crankshaft oil seal Around propeller mounting flange damaged hub O ring seal Check and adjust linkage See Rigging of Mixtureand ThrottleControls Check SeeTroubleshooting ignitionSystem SeeTroubleshooting Fuel Injection...

Page 432: ...Mixturetoo rich Mixturetoo rich Mixturetoo rich Fuel manifold valve not seating tightly Fuel manifold valve sticking closed Fuel manifold valve vent obstruction Fuel manifold valve sticking or not free Fuel vaporization Restrictedflow to fuel meteringvalve Momentarilypull mixture control back until engineacceleration picks up then set proper mixture Pull mixture control back to where where the eng...

Page 433: ...l tempera ture control valve in oil cooler oil cooler restriction Replacevalve or clean oil cooler Checkfor restricted lines and loose connections and for partiallyclogged oil filter or screens Clean parts tighten connections replace malfunctioningparts TROUBLE Low Fuel Pressure Cont d High Fuel Pressure Fluctuating Fuel Pressure Low Oil Pressure On Engine Gage PROBABLE CAUSE Fuel control lever in...

Page 434: ...r proper pump pressure and replacepump if malfunctioning Removeand clean all nozzles Cleanand regap spark plugs Check ignitioncablesfor wear Replace malfunctioningcomponents Check movement of linkage by control from idleto full throttle Make proper adjustments and replaceworn components Serviceair cleaner lnspectspark plugsfor fouled electrodes heavy carbondeposits erosion of electrodes improperly...

Page 435: ...CHAPTER 78 EXHAUST 78 00 00 GENERAL 78 10 00 EXHAUST SYSTEM 78 20 00 EXHAUSTSYSTEM TROUBLESHOOTINGCHART ...

Page 436: ......

Page 437: ...f incoming exhaust flow which is adjusted by the wastegate Oil pressure for the turbocharger system is engine supplied 78 10 00 EXHAUST SYSTEM The exhaust systems used on the UTSIO 360 E EB F FB GB KB LB MB SB engines consist of a left hand and right hand exhaust collector assembly which Is composed of elbow risers on cylinders 1 5 2 6 tee risers on cylinders 4 3 assorted exhaust tubes turbocharge...

Page 438: ...system gas leakage Turbo choking oil forced though seal turbine housing CORRECTION To check the adjustment of the wastegatevalve refer to the airframe service manual lnspect entire exhaust system to turbocharger for cracks and leaking connections Tighten connections and replace damaged parts Check for unusual noise in turbo charger If malfunction is suspected remove exhaust and or air inlet connec...

Page 439: ...CHAPTER 79 OIL 79 00 00 GENERAL 79 10 00 APPROVED OIL PRODUCTS 79 20 00 LUBRICATING SYSTEM TROUBLESHOOTING CHART ...

Page 440: ...lNTENTIONALLY LEFT BLANK ...

Page 441: ...l Oil Company Sinclair Oil Company Texaco Inc Total France Union Oil Company of California APPROVED MINERAL OIL MIL 6 6529 TYPE II BP Aero Oil Castrol Aero AD Oil Castrol Aero AD Oil ChevronAero Oil Conco Aero S DeltaAvoil Oil ExxonAviation Oil EE GulfprideAviation AD Mobil Aero Oil TURBONYCOIL 3570 PennzoilAircraft Engine Oil Phillips 66 Aviation Oil Type A XIC Aviation Multiviscosity Oil SAE 20W...

Page 442: ...ce of alkaline solids in system Malfunctioningpressurepump Malfunctioningpressuregage Weak or brokenoil pressure relief valve spring Clogged filter or strainer CORRECTION Replenish Cleanthoroughly Removecooler and flush thoroughly Remove cleanvalve and seat If still inoperative replace Drainand refillwith correct seasonal weight See Chapt 77 Limit ground operationto a minimum Check wiring Check bu...

Page 443: ...CHAPTER 80 STARTING GENERAL Prestarting Starting Ground Warm Up Pre takeoffCheck Flooded Engine Cold Weather Operation Preheating Hot Weather Operation Ground OperationAt HighAltitude Airports ...

Page 444: ......

Page 445: ...uld thoroughly familiari e himself with abnormal environmental conditions Wenever such abnonnal conditions are encountered or anticipated the procedures and techniques for normal operafion should be tailored accordingly For example if the aircraft is to be temporarily operated in extreme cold or hot weather consideration should be given to an early oil change and or routine inspection servicing NO...

Page 446: ...t If tlze engine does not start after tlzirty seconds of cranking allow a 3 to 5 nzinute coolingperiod before attempting to restart CAUTION I f engine kicks back wlte z stam zg DO NOT attempt to start The ignition starting system is inoperative and nzust be repaired before damaging starter adapterassenzbly 9 Throttle 1000to 1500RPM 10 Oil Pressure ABOVE 30 POUNDSWITHIN 30 SECONDS 11 Alternator Swi...

Page 447: ...ssaryfor warm up and testing 5 Increase engine speed to 1700 RPM only long enough to perform the following checks A Magnetos With both magnetos ON position the right magneto switch OFF and note engine RPM now back to both magnetos ON to clear the spark plugs Then position the left magneto switch OFF and note engine RPM Now return switch to both magnetos ON The allowable difference between the maxi...

Page 448: ...trumentindications A Oil Pressure The oil pressure relief valve will maintain pressure within the specified limits if the oil temperature is within the specified limits and if the engine is not excessively worn or dirty Fluctuating or low pressure may be due to dirt in the oil pressure relief valve or congealed oil in the system This should be corrected prior to continued operation of the engine B...

Page 449: ... This results in a slow cranking speed and an abnormal drain on the battery capacity At low temperatures gasoline does not vaporize readily further complicatingthe startingproblem CAUITIION During cold weather operation fuel vaporization characteristics are poor Mismanagement of the auxiliary fuel pump or overpriming of the engine could lead to cylinder hydro staticlock False starting failure to c...

Page 450: ...pply heat directly to the upper portion of the engine for approximately five minutes This will provide sufficient heating of the cylinders and fuel lines to promote better vaporization for starting If enough heater hoses are available continue heating the sump area Otherwise it will suffice to transfer the source of heat from the sump to the upper part of the engine 4 Start the engine immediately ...

Page 451: ...r than warming the engine sufficiently to maintain oil temperatureand oil pressurewithin limitswhenfull RPM isapplied NOTE Before applying power for takeoff assure that oil pressure oil temperature and cylinder head temperature are well within the normal operating range When full power is appliedfor takeoff assurethat oil pressureiswithin limitsand steady Any of the following engine conditions sho...

Page 452: ...me heat or exposure to altitude will age aviation gasoline causing the volatile ingredients to dissipate This reduces the tendency of fuel to vaporize and may induce problems with starting If the volatile condition reaches a low enough level starting may become difficult due to poor vaporization at the fuel nozzles since the fuel must vaporize in order to combinewith oxygen inthe combustionprocess...

Page 453: ...OUND OPERATIONAT HIGH ALTITUDE AIRPORTS Because of insufficient air density at altitudes oil pressure oil temperatures and cylinder headtemperature gages should be carefully observedto prevent engine overheating ...

Page 454: ......

Page 455: ...CHAPTER 81 TURBINES 81 00 00 GENERAL 81 10 00 TURBOCHARGER 81 20 00 WASTEGATES 81 30 00 CONTROLLER 81 40 00 LUBRICATIONSYSTEM 81 50 00 TROUBLESHOOTING CHART ...

Page 456: ...nders The induction system area between the turbocharger compressor and the throttle valve is referred to as upper deck The speed of the turbocharger turbine is determine by the amount of incoming exhaust gases This is controlled by the wastegate of which there are two different types that will be discussed later The variable absolute pressure controller regulates the engine oil pressure that is r...

Page 457: ...s are provided on the center housing for engine supplied lubricating oil For overhaul approval pertaining to the turbocharger referto the turbochargermanufacturer s instructions COMPRESSOR HOUSING COMPRESSOR URBINE WHEEL XHAUST DISCHARGE COMPRESSED AIR EXHAUST INLET DISCHARGE FIGURE 81 10 00 BASE TURBOCHARGER 81 20 00 WASTEGATES The wastegate is used to adjust the amount of incoming exhaust gases ...

Page 458: ...the L TSIO 360 E EB F FB G GB KB LB Current production engines usethe bypassvalve as shown in Fig 81 20 00 A Adjust the exhaust bypass valve bolt all the way in turning in a clockwise CW direction and reposition apprsximately ten 10 turns out CCW 8 10 threads showing outside locknut Lock in place with the check nut Run engine to check full throttle manifold pressure refer to Chapter 77 Make fine a...

Page 459: ...table devices and should be replacedwhen foundto be malfunctioning SPRING FIGURE 81 20 01 HYDRAULICWASTEGATE 81 30 00 CONTROLLER The variable pressure controller senses upper deck pressure and regulates the wastegate actuator Engine oil flows from the engine to the wastegate actuator and from the actuator to the absolute pressure controller An oil restrictor controls the oil flow back to the engin...

Page 460: ...rease or decrease ina direct relationshipto the throttle angle With the variable absolute pressure controller upper deck pressure is maintained at ap proximately one to two inches above manifold pressure Maintaining this relatively low differential between manifold and upper deck pressures reduces the load on the turbocharger and throttle valve NOTE Controllers are not field serviceable and should...

Page 461: ...nge pump one check valve is needed in the oil return line to prevent oil from draining back into the unit If the turbocharger is located below the engine crankcase check valves are required in both the oil supply and return lines Piston ring like oil seals are used on the compressor wheel shaft to prevent the lubricating oil from entering the turbine and compressor housings from the center housing...

Page 462: ...sted waste gate controller lnductionor exhaust manifold leaks Bindingwastegate Improperlyadjusted wastegate Intercoolerpluggedor damaged lmproperlyadjusted waste gate and controllers Inductionor exhaust manifold leaks Worn or damagedseals Leakingcheckvalve LeakingTurbocharger check valves and seals Damagedcheck valve Adjust accordingto Aircraft Manufacturer sInstructions Replacewastegate Adjust ac...

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