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Teledyne TSIO-360 Series, Руководство по капитальному ремонту


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Содержание TSIO-360 Series

Страница 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 ...

Страница 2: ...S NOVEMBER 9988 INSERT LATEST PAGES DESTROY SUPERSEDED PAGES WRNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 18: ......

Страница 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...

Страница 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 ...

Страница 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...

Страница 22: ......

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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 ...

Страница 32: ...INTENTIONALLY LEFT BLANK ...

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

Страница 34: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

Страница 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 ...

Страница 78: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

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

Страница 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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Страница 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 ...

Страница 84: ...INTENTIONALLY LEFT BLANK ...

Страница 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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Страница 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...

Страница 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...

Страница 89: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 91: ...INTENTIONALLY LEFT BLANK ...

Страница 92: ......

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 103: ...INTENTIONALLY LEFT BLANK ...

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

Страница 105: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 119: ...INTENTIONALLY LEFl BLANK ...

Страница 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 ...

Страница 121: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

Страница 130: ......

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 146: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 155: ......

Страница 156: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 171: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 173: ...INTENTIONALLY LEFT BLANK ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 177: ......

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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 ...

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Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

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

Страница 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 ...

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

Страница 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...

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

Страница 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 ...

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

Страница 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...

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

Страница 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 ...

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

Страница 216: ...INTENTIONALLY LEFT BLANK ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

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Страница 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 ...

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Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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Страница 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 ...

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Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

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

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Страница 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 ...

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Страница 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 ...

Страница 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 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

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Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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Страница 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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Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 301: ...INTENTIONALLY LEFT BLANK ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 311: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 313: ...INTENTIONALLY LEFT BLANK ...

Страница 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 ...

Страница 315: ...INTENTIONALLY LEFT BLANK ...

Страница 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 ...

Страница 317: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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 ...

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

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

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

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

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

Страница 325: ...SEA LEV PERFORMANCE ALTITUDE PERFORMANCE ...

Страница 326: ...BRAKE HORSEPOWER ...

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

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

Страница 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 ...

Страница 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 ...

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

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

Страница 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 ...

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

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

Страница 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 ...

Страница 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 ...

Страница 338: ......

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

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

Страница 341: ......

Страница 342: ......

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

Страница 344: ......

Страница 345: ......

Страница 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 ...

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

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

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

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

Страница 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 ...

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

Страница 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 ...

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

Страница 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 ...

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

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

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

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

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

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

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

Страница 363: ......

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

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

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

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

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

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

Страница 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 ...

Страница 371: ......

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

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

Страница 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 ...

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

Страница 376: ...ALTITUDE X 1000 FEET ...

Страница 377: ......

Страница 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 ...

Страница 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 ...

Страница 380: ......

Страница 381: ......

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

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

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

Страница 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 ...

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

Страница 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 ...

Страница 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 ...

Страница 393: ...Power ManagementOperatingRecommendationsTSIO 360 LB ...

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

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

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

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

Страница 398: ......

Страница 399: ......

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

Страница 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 ...

Страница 402: ......

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

Страница 404: ......

Страница 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 ...

Страница 406: ......

Страница 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 ...

Страница 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 ...

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

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

Страница 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 ...

Страница 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 ...

Страница 413: ...100 Pump PressureLimitsTSle360 NIB ...

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

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

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

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

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

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

Страница 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 ...

Страница 421: ......

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

Страница 423: ...INTENTIONALLY LEFT BLANK ...

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

Страница 425: ...INTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 436: ......

Страница 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...

Страница 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...

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

Страница 440: ...lNTENTIONALLY LEFT BLANK ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 444: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 454: ......

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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