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MAINTENANCE MANUAL

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1. enun HUS OM Teraperature 22 crise zeit Cylinder Head Magneto System Grounding CAUTION The magneto system grounding check must be accomplished at idle RPM only Damage to the engine may result at engine speeds above idle RPM WARNING Absence of RPM drop when checking magnetos is an indication of a malfunction in the ignition system resulting in a hot magneto This type of malfunction must be corrected prior to continued operation of the engine The engine may inadvertently experience ignition or start up anytime the propeller is moved Damage injury or death may result If engine continues to run when magnetos are switched Off a malfunction is occurring in the ignition system Slowly move mixture control to IDLE CUT OFF and record Mixture RPM Rise 25 to 50 RPM acis arcte ce Positive ea cete eme de ied event When propeller stops rotating place ignition switch master switch and fuel selector in off position TABLE 23 1 OPERATING LIMITS ENGINE MODEL L TSIO 360 RB Full Throttle Speed RPM Idle Speed RPM Fuel Grade Octane Fuel Flow at Full Throttle Lbs Hr Oil Temperature Limit Oil Pressure Max Oil Cold Minimum at Idle Magneto Drop Max Magneto Spread Cylinder Head Temperature with Bayone
2. 21 4 21 1 21 2 21 2 CRANKCASE DESCRIPTION The crankcase provides a tight enclosure and oil galleries for lubrication The crankcase is sufficiently rigid to provide support for the crankshaft camshaft and bearings CRANKCASE DETAILED DESCRIPTION Two aluminum alloy castings are joined along the vertical center plane to form the complete crankcase The individual castings with studs and inserts will be referred to as the left crankcase and right crankcase throughout this section Bosses molded in the crankcase castings are line bored in the assembled castings to form bearings for the camshaft and saddles for precision crankshaft main bearing inserts A needle bearing is installed between the left and right rear upper crankcase halves to support the front end of the starter adapter shaft gear Guides are bored through lateral bosses for hydraulic tappets Cylinder mounting pads on the left crankcase are farther forward than the corresponding pads on the right crankcase to permit each connecting rod to work on a separate crankpin There are six studs and two through bolts for attaching cylinder base flanges The propeller governor mount pad is located on the left hand lower front corner of the of the left case half A fuel pump mounting pad is located on the front lower right crankcase The crankcase interior is vented by a breather assembly consisting of a tube and baffle assembly with a side ex
3. 20 19 20 13 Maintenance Cylinder Dimensions eee 20 20 20 14 Cylinder Flange Torque Sequence For Single Cylinder Installation 20 21 20 1 20 1 20 2 CYLINDER COOLING Cylinder cooling is accomplished by transferring heat from the cylinder barrel and cylinder head cooling fins to the surrounding airflow The engine cowling inner cylinder baffles peripheral baffles and baffle seals direct cooling airflow evenly around the cylinders providing uniform cylinder temperatures Ram air induced by the aircrafts forward speed provides the source of cooling air Airflow is regulated by the size of the cooling air inlets and outlets Increasing or decreasing outlet size with the use of airframe cowl flaps changes airflow and is used as an aid in controlling engine operating temperatures Below is a general illustration showing engine cooling airflow COOLING AIRFLOW INLET CYLINDER BAFFLES lt gt AMBIENT AIR FIGURE 20 1 GENERAL ENGINE COOLING AIRFLOW DIAGRAM continued on next page 20 2 CYLINDERS PISTONS AND VALVE DRIVE TRAIN The cylinders pistons and valve train are the portion of the engine that develop power The cylinder combustion chamber provides a controlled area for burning fuel air mixture and converting that heat energy into mechanical energy Aviation fuel and air is drawn into a cylinder during the intake stroke compressed by the pisto
4. M 1 2 Related rrr romanae nin dn nnne ran 1 2 Manual Revisions 1 3 Service Reports and 1 3 Description of Engine Model Code 1 4 Definition of Terms re corren entrer eter re eroe encore 1 4 Engine Design Features eee eterne 1 4 J 1 9 Engine Specifications eese eene 1 9 Operating 1 9 Engine Description 5 0360 1 5 Engine Description L TSIO360RB 1 6 1 1 1 1 SCOPE This publication contains information on maintenance and installation of Teledyne Continental Motors TCM L TSIO 360 RB RELATED PUBLICATIONS The following are related engine and accessory manuals 1 o Overhaul Manual for L TSIO 360 RB Series Aircraft engine Form X30596A Supplement No Illustrated Parts Catalog for L TSIO 360 RB Series Aircraft Engine Form XX30597A Supplement No 1 Operators and Installation Manual for L TSIO 360 RB Series Air
5. eaten 20 2 20 2 Cylinders Pistons And Valve 20 4 20 3 Cylinder Assembly Detailed Description 20 4 20 4 Cylinder Assembly Inspection 50 100 20 7 20 5 Cylinder Assembly Troubleshooting 20 13 20 6 Cylinder Assembly Maintenance 20 15 FIGURE PAGE 20 1 Engine Cooling Airflow 20 2 20 2 Cylinder Piston And Valve 2 2 244 1 421 1 2 enne 20 3 20 3 Cylinder Assembly Description eere nenne 20 4 20 4 Piston Assembly Description 20 5 20 5 Valve Train Description 4 4 4 410 2 0 4 000000000 nt iieiea 20 6 20 6 Hydraulic Tappet Description ttnn tnea EEEn n eenn 20 7 20 7 Master Onfice TOOL die et ARE te cct 20 8 20 8 Static sutra 20 9 20 9 BAADE AAS Te E T TOT M 20 9 20 10 Differential Pressure Tester 20 10 20 11 Ring p 20 12 20 12 Cylinder Assembly Service Limits
6. 1 4 1 1 1 1 1 11 5 11 5 Variable Absolute Pressure Controller 11 6 Slipjoirit Assembly cicer croi ast anas cde ac xau rode kei oon E SR grae 11 8 Multi Segment V Band 11 8 11 2 EXHAUST SYSTEM DESCRIPTION The L TSIO 360 RB exhaust system contains the following engine components rear mounted turbocharger hydraulic wastegate lubrication plumbing exhaust collector assembly and turbocharger tailpipe assembly During normal engine operation exhaust gases exiting the cylinder combustion chambers flow through the exhaust collector to the turbocharger turbine housing inlets The exhaust gas flow provides turbine wheel rotation and exits through the turbine housing discharge port and tailpipe assembly The turbine wheel drives the compressor wheel which is connected by a common shaft Engine manifold pressure is maintained within the specified limits by controlling the turbocharger compressor discharge pressure Compressor discharge pressure deck pressure is regulated by controlling the flow of exhaust gas through the turbocharger turbine This is accomplished by installing a hydraulically controlled butterfly type exhaust by pass valve wastegate in the exhaust system pr
7. PISTON PRESSED BEAD SPRING WASHER s Q CYLINDER WASHER g BARREL HYDRAULIC TAPPET y CRANKCASE CRANKSHAFT CAMSHAFT FIGURE 20 5 VALVE TRAIN DESCRIPTION 20 3 20 4 CYLINDER ASSEMBLY DETAILED DESCRIPTION continued Hydraulic Tappet See Figure 20 6 The barrel type hydraulic valve tappet consists of a steel body 1 an expanding spring 2 a check valve assembly 3 4 and 5 a plunger 6 a socket 7 and a retaining ring 8 A groove 9 around outside of the body picks up oil from the crankcase oil gallery From the exterior groove oil is directed to the interior body groove 11 through hole 10 and from the interior groove through the hole to the reservoir 12 Oil is withheld from reservoir 14 by check valve ball 5 which is supported by a spring 4 in the housing 3 The check valve is opened by outward motion of the plunger under pressure of the expanding spring whenever a clearance occurs in the valve train The reservoir is kept full of oil which transmits lifting force from the body of the plunger The plunger and socket are selectively fitted to the body to permit a calibrated leakage so the lifter will readjust its effective length after each cycle while the cylinder valve is closed to return lash in valve train to zero The barrel type hydraulic tappets may be removed and replaced without complete disassembly of the engine 8 1 Body 2 Spring Plunger 3 Check Ball Retainer
8. 12 626 Tm 1 4 fh AS eX o La CM NR i e PR p MANIFOLD PRESSURE id Ml 1 4375 200 2 THDS P LE male PER MS33656G4 063 065 IL Yaa ORIFICE 45 ELBOW 12 MAX 3 00 PAD 3 00 TO GOV PAD FIGURE 1 1 Engine Description L TSIO 360 RB VENT FOR 250 1 0 HOSE OVERBOARD DRAIN PER 533658 4 2255 CRANKCASE Pu 7 Ld BREATHER PI p Ig 9557 m W x 0 2 Se cel 7 E QE Sm Il a E d lt gt baa 5 D bonn NNNM A gt CUSTOMER SUPPLIED ALTERNATOR DRIVE SHEAVE 1 09 MAGNETO REMOVAL CLEARANCE 10 19 FOCAL POINT INTERSECTION OF MOUNTS EYE VALVE POINT MouNTS 12 50 62 DIA IN By OIL TEMP CONN 1625 18UNF 3B THDS IP nb ld V vu PAD AND20010 ENGINE MOUNTS SUMP SIL PRESSURE 4X 0 4688 1 75 CAPACITY CONNECTION OUTSIDE DIAMETER SQUARTS n E se cauc THREADS PER SIDE OIL FILTER REMOVAL MS33656G4 j 6 20 4 60 0 060 065 8 25 47 30 ORIFICE FITTING TO COMPRESSOR INLET 31 18 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d 1 6 1 38 ACROSS CAST AL C
9. 9 5 General Cotter Pin 9 6 9 1 9 1 9 2 GENERAL To facilitate and insure proper reinstallation tag or mark all parts and hardware as they are removed or disassembled Tag any unserviceable parts or units for investigation and possible repair Take extreme care to prevent foreign matter lockwire nuts washers dirt etc from entering the engine on or off the aircraft Make use of protective caps plugs and covers to insure openings are unexposed WARNING Dust caps used to protect open lines must be installed OVER the tube ends and NOT IN the tube ends Flow through the lines will be blocked if lines are inadvertently installed with the dust caps in the tube ends If anything is dropped into the engine work must be stopped immediately and the item removed Insure all parts are thoroughly cleaned properly protected from dust and corrosion and properly stored until assembly Make sure replacement nonmetallic and metallic parts show no sign of storage deterioration Parts exceeding specified shelf life limitations must not be used 9 2 LOCKWIRE PROCEDURE Lockwiring is the securing together of two or more parts with lockwire which shall be installed in such a manner that any tendency for a part to loosen will be counteracted by additional tightening of the wire Wire shall be pulled taut while being twisted and caution must be exer
10. FIGURE 9 3 TAB WASHER INSTALLATION PROCEDURE COTTER PIN PROCEDURE Cotter pins are installed by inserting the cotter pin through a hole in one part and slots in the other part and spreading the exposed ends Cotter pins are not reusable and must be replaced with a new cotter pin after removal 1 Torque the nut to the lower limit of the torque specification If the slots in the nut do not line up with one of the holes in the bolt continue torquing until one does but do not exceed the upper limit of the torque specification Change the nut if necessary 2 Insert the cotter pin with the head seated firmly in the slot of the nut Bend the ends over the flat on the nut and the end of the bolt trimming the prong lengths as necessary 3 Seat the prongs firmly against the bolt and nut See Figure 9 4 General Cotter Pin Installation CAUTION Do not use side cutting type pliers to bend the ends over since the resulting nick could weaken the pin and allow a portion to become detached 9 5 9 7 9 6 FIGURE 9 4 GENERAL COTTER PIN INSTALLATION APPLICATION OF ADHESIVES Adhesives and sealants will be used as specified in this manual WARNING The improper use of sealants and adhesives will cause engine malfunction or failure Gasket Maker P N 646942 must be applied in a thin even coat Gasket Maker surfaces must be clean and free of oil and grit NOTE TCM general purpose primer 653160 must be used for surf
11. 11 4 Spring Check Ball 5 Check Ball 6 Plunger 10 7 Socket 8 8 Ring retaining Be 1 9 Oil groove exterior 12 10 Oil inlet body 11 groove interior 12 Oil reservoir plunger 43 2 13 Hole oil discharge 14 5 14 reservoir body 15 Hole Oil Outlet 3 FIGURE 20 6 HYDRAULIC TAPPET DESCRIPTION CYLINDER ASSEMBLY INSPECTION 50 HOUR Visually inspect cylinder to engine attaching hardware for security Inspect exhaust and intake flange areas for leaks Inspect induction and exhaust tube attaching hardware for security Inspect rocker box cover hardware for security and safetying Inspect rocker cover to cylinder gasket area for evidence of oil leakage Inspect pushrod housings at both ends for evidence of oil leakage Visually inspect fuel injection and cylinder drain plumbing connections for security and evidence of leakage Check spark plug and ignition connections for security Check cylinder baffling for security cracks dents and wear from chafing Inspect the steel barrel fins for rust pitting or any other damage Inspect the cylinder barrel flange and flange radius for rust and pitting Inspect the cylinder barrel for cracks Discard cylinders exhibiting any of the above indications Discard any cylinders that have been involved in an overheating or high temperature operation event such as detonation severe piston scoring or piston pin damage to the cylinder bore 20 7
12. The following procedure if properly utilized will aid in reducing the severity of corrosive attack TEMPORARY STORAGE Preparation for storage 1 Remove oil sump drain plug and drain oil Replace drain plug torque and safety Remove oil filter Install new oil filter torque and safety Service engine to proper sump capacity with oil conforming to MIL C6529 Type Il 2 Perform a ground run up Perform a pre flight inspection and correct any discrepancies Fly the aircraft for one hour at normal operation temperatures WARNING To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open g Do not stand within the arc of the propeller blades while turning the propeller 3 After flight remove all spark plug leads and remove the top spark plugs Protect the ignition lead ends with AN 4060 Protectors Using a common garden sprayer or equivalent spray atomized preservative oil that meets MIL P 46002 Grade 1 at room temperature through upper spark plug hole of each cylinder with the piston at bottom dead center position Rotate
13. b Verify the recorded parameters meet the published specifications for the engine as provided in the aircraft or engine manufacturer s Maintenance Operator s and Overhaul Manuals WARNING Operation of a malfunctioning engine can result in additional engine damage engine failure bodily injury or death After the operational inspection inspect isolate and repair any leaks found 3 Reference the applicable Airplane Flight Manual for operational values 4 Remove and inspect induction air filter Clean or replace as instructed by the filter manufacturer Inspect induction system ducts seals and gaskets for condition and deterioration in accordance with the aircraft manufacturer s instructions With induction air filter installed a Verify the induction air filter retainer is properly installed and the attaching hardware is secure in accordance with the aircraft manufacturer s instructions b Replace any questionable components as required in accordance with the aircraft manufacturer s instructions c Inspect all engine controls for proper travel freedom of movement wear correct rigging and correct attachment in accordance with the aircraft manufacturer s instructions 10 11 12 13 14 15 16 CAUTION Failure to properly install the induction air filter will result in unfiltered air being ingested into the engine which will accelerate engine wear and reduce engine service life Inspect induction
14. Alternator drive belt inspection removal installation alignment and tensioning must be performed in accordance with the airframe manufacturer s instructions 16 3 INTENTIONALLY LEFT BLANK 16 4 SECTION 17 1 17 2 17 3 17 4 17 5 FIGURE 17 1 17 2 17 3 17 4 CHAPTER 17 STARTING SYSTEM Starter And Starter Adapter Starting System Component Detail Description Starter And Starter Adapter Inspection Starting System Troubleshooting Starting System Maintenance Starter And Starter Drive Adapter Description Starter Adapter Description Starter Adapter Fits And Limits L TSI0 360 RB and Optional TSIO 360 RB Starter Adapter Fits And Limits TSI0 360 RB 17 1 17 1 17 2 STARTER AND STARTER ADAPTER DESCRIPTION The L TSIO 360 RB engines utilize a starting system that employs an electric starter motor mounted on a right angle drive adapter As the starter motor is electrically energized the adapter worm shaft and gear engage the starter shaftgear by means of a spring and clutch assembly As the shaftgear rotates it in turn rotates the crankshaft gear and crankshaft After engine start the clutch spring
15. PAGE Lubrication System DescriptiOn aacra i rode to pide x Dae genae 19 2 Lubrication System Component Detailed Description 19 4 Oil Cooler and Oil Temperature Control Valve 19 6 19 7 S ction ee T ero p Het ed ten e eer 19 7 Lubrication System Inspection 19 7 Lubrication System Troubleshooting 19 9 Lubrication System Maintenance eese seien 19 10 PAGE Lubrication System Schematic eese nennen 19 3 Oil Pump Description 360 19 5 Oil Pump Description 5 360 19 5 Oil Cooler and Oil Temperature Control Valve Description 19 6 Oil Sump and Suction Tube 19 7 Stud Identification crie ree et eR 19 8 Oil Filter Stud 1 19 8 Lubrication System Service Limits 19 12 19 1 19 1 19 2 LUBRICATION SYSTEM DESCRIPTION The engine oil supply is contained in the oil sump Oil is drawn from the sump through the oil suction tube to the intake side of the engine driven gear type oil pump From the outlet side of the pump oil passes to
16. This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms ltems are presented in sequence of the approximate ease of checking not in order of probability TROUBLE PROBABLE CAUSE CORRECTION Oil Loss Loose accessories or deteriorated See Section 18 5 Accessory Case gaskets Loose or stripped studs Insufficient torque Cracked accessory case See the L TSIO 360 Series Overhaul Manual Form X30596A for accessory case replacement Loose Accessories Loose or stripped studs Insufficient See the L TSIO 360 Series Overhaul torque Manual Form X30596A for stud replacement and torque values 18 5 ACCESSORY CASE MAINTENANCE Accessories If oil leaks are found remove applicable component replace gasket and re install component in accordance with the applicable system or component Disassembly Reassembly portions of the L TSIO 360 Series Overhaul Manual Form X30596A Insure re installed component is properly torqued and safetied Studs The replacement of studs may require component removal and replacement in accordance with the applicable component system Disassembly Reassembly portions of the L TSIO 360 Series Overhaul Manual Form X30596A When re installing components insure they are properly torqued and safetied 18 4 SECTION 19 1 19 2 19 3 19 4 19 5 FIGURE 19 1 19 2 19 2 19 3 19 4 19 5 19 6 19 7 CHAPTER 19 LUBRICATION SYSTEM
17. 100 90 APPROXIMATE BEST APPROXIMATE BEST ECONOMY 70 4 BRAKE HORSEPOWER BREAN ttt tty TINA 8 FUEL FLOW VS BRAKE HORSEPOWER FIGURE 23 23 11 23 3 23 12 TEST FLIGHT Ambient air and engine operating temperatures are of major concern during this test flight Do a normal pre flight run up in accordance with the Airplane Flight Manual Conduct a normal take off with full power and monitor the fuel flow RPM oil pressure cylinder head temperatures and oil temperatures Reduce to climb power in accordance with the Airplane Flight Manual The manual mixture control should be set in the full rich position for all operations except leaning for field elevation and leaning to maintain smoothness during climb and leaning for cruise economy Leaning operations must be performed accordance with the Airplane Flight Manual NOTE New rebuilt and overhauled engines or engines that have had new or repaired cylinders installed must be flown in accordance with the following procedure for the first two hours of operation Level flight cruise should be at 7596 power with best power or richer mixture for the first hour of operation The second hour power settings should alternate between 65 and 75 power with the appropriate best power mixture settings The best power mixture setting is 100 to 125 rich of peak turbine inlet temperature Engine controls or aircr
18. 1700 F Ignition Timing Compression stroke breaker opens Right Magneto degrees eie teet tepore 22 1 Magneto degrees BTC tela 22 1 The following spark plugs are approved for use in engine models according to the following listing L TSIO 360 RB Use TCM 630049 Champion RHM38E Spark Plug Gap Use spark plug manufacturer s specified gap ACCESSORY DRIVE RATIOS TO CRANKSHAFT meme dP WARNING Oil pressure is applied to the face of accessory drive pads If gaskets accessory or cover is not properly installed and hardware is not properly torqued oil leakage will occur CAUTION A removable oil transfer plug conducts oil under pressure from the propeller governor through the crankshaft to the propeller hub When a test club or fixed pitch propeller is used for testing purposes the governor pad cover must have an internal grooved surface to allow the circulating oil to lubricate the front main bearings The governor pad cover is not needed if a propeller governor is installed CW Clockwise CCW Counterclockwise facing drive pad This drive is a modified AND 20010 and is supplied with cover plate This drive is a modified AND 20000 and is supplied with cover plate Ratio is for 6 0 diameter driven sheave Section 2 1 2 2 2 3 CHAPTER 2 TOOLS AND EQUIPMENT Page General Information oet corr dete
19. 8 6 8 4 INDEFINITE STORAGE INSPECTION PROCEDURES 1 Aircraft prepared for indefinite storage must have the cylinder dehydrator plugs visually inspected every 15 days The plugs must be changed as soon as they indicate other than a dark blue color If the dehydrator plugs have changed color in one half or more of the cylinders all desiccant material on the engine must be replaced The cylinder bores of all engines prepared for indefinite storage must be re sprayed with corrosion preventive mixture every 90 days RETURNING AN ENGINE TO SERVICE AFTER STORAGE 1 2 Remove seals and all desiccant bags Remove cylinder dehydrators and plugs or spark plugs from upper and lower spark plug holes Remove oil sump drain plug and drain the corrosion preventive mixture Replace drain plug torque and safety Remove oil filter Install new oil filter torque and safety Service the engine with oil in accordance with the manufacturer s instructions WARNING To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open g Do not stand within
20. UC eto d eres 7 2 Approved Engine Lubricating Oils eec 7 3 i e MC I DNE 7 3 Oil Filter Element Inspection 7 4 spectrographic Oil Analysis 7 4 PAGE Oil Servicing e ocn eee 7 2 7 1 7 1 SERVICING OIL CAUTION Some funnel type quart oil containers incorporate a styrofoam or aluminum seal Remove this seal from the container and discard it before adding oil to the engine If the seal falls into the engine engine damage and possible failure can result The oil system must be serviced to capacity with the oil grades specified A certain amount of oil consumption is normal If excessive consumption or any abrupt change in rate of consumption is detected this condition must be corrected before further flight Maintain the engine compartment nacelle and the fuselage adjacent to the nacelle in a clean condition in order that an oil leak can be detected and corrected before further flight WARNING Engine operation with no oil or severely reduced oil levels will cause engine malfunction or failure CAUTION Petroleum base aviation engine oil is flammable and must be stored in well ventilated area away from any heat source OIL GAGE ROD OIL FILLER TUBE OIL FILTER FIGURE 7 1 OIL SERVICING POINTS 7 3 APPROVED ASHLESS DISPE
21. 13 1 13 2 13 2 ENGINE FUEL SYSTEM DESCRIPTION Fuel System L TSIO 360 RB The fuel injection system composed of a TCM fuel pump manifold valve nozzles and a Precision Airmotive fuel servo Fuel flows from the fuel pump to the fuel servo unit The fuel then flows from the fuel servo unit to the fuel manifold valve where it is distributed to the six fuel injector nozzles Fuel flows through the fuel nozzles to the intake valve ports A detailed description of the fuel pump fuel manifold and nozzles are given in the following sections See the Precision Airmotive Corporation RSA 5 Operating and Service Manual for a schematic of the fuel sustem and a detailed description of the fuel servo unit See Related Publications Section 1 4 for ordering information FUEL INJECTION SYSTEM COMPONENT DETAILED DESCRIPTION cont d Fuel Pump L TSIO 360 RB See Figure 13 1 Fuel enters the fuel pump inlet where it is directed to the fuel pump blades The fuel pump blades create fuel flow and the fuel is directed to the fuel pump outlet Fuel leaving the fuel outlet is directed through various fittings and fuel line to fuel servo assembly The use of a positive displacement engine driven pump means that changes in engine speed affect pump flow and pressure proportionally The fuel pump provides greater capacity than is required by the engine An adjustable relief valve maintains pump flow and pressure proportional to engine speed This provision insure
22. 17 72 8 64 3 09 MAGNETO 16 91 6 30 REMOVAL CLEARANCE 10 19 FOCAL POINT INTERSECTION OF MOUNTS OIL GAGE ROD LIFTING MANIFOLD 2 368 FOCAL LIFTING EYE VALVE POINT MOUNTS OIL TEMP CONN 626 18UNF 3B THDS 10 00 CRANKSMAET GOV DRIVE PAD AND20010 ENGINE MOUNTS OIL SUMP SIL PRESSURE 4688 X1 75 ONNECTION c OUTSIDE DIAMETER QUARTS E 5 CLEARANCE SIDE OIL FILTER REMOVAL 20 4 50 0 060 065 8 25 17 30 ORIFICE FITTING TO COMPRESSOR INLET 31 18 31 38 ACROSS CAST AL COVER 31 30 ROSS SHEET METAL COVERS 16 66 18 89 ACCESSORY DRIVE FOCAL POINT OF AND20000 TYPE X 1 545 X ENGINE SPEED C C W ZONI MOUNT LEGS ROTATION CAD 1 eu VES 72 8 30 5 8 18 af R 17 30 CRANKSHAFT 1 38 T i mE 4 S 4x 6 89 i 6 36 oiL COOLER 1 E ST NET TER na 0 4 2 75 COMPRESSOR it INLET 1 CYLINDER DRAIN 2 438 20 UNF 3A CONTROL VALVE 1375 18 NPTF FILTER 57 44 4 56 14 63 OIL PUMP 274 7 44 4 56 16 24 RELIEF VALVE TURBINE OIL RETURN FROM OPPOSITE SIDE INLET AIR OIL SEPARATOR FOR LTSIO 360 RB 5828 18UNJF 3A PER M 33656G6 OPPOSITE SIDE WASTEGATE ens vs FOR LTSI0 360 RB SEAL DRAIN PER AND 10050 4 FIGURE 6 1 INSTA
23. 2 2 1 149 004 0 404440 6 22 6 Engine Drive Train Descriplion rr rede tete 22 2 Crankshaft Description eene nnns 22 3 Connecting Rod Descrpli nk oae e tet rip eerte 22 4 Camshaft Description 22 5 Helix Pattern 22 6 Siu cS 22 7 22 1 22 1 22 2 ENGINE DRIVE TRAIN DESCRIPTION When starting engine torque is transmitted from the starter 12 through adapter components 13 14 15 amp 16 to crankshaft gear 1 As worm wheel 15 is turned the spring mounted on its hub is tightened to grip drum of shaftgear 16 After engine is started the spring returns to its normal position releasing the shaftgear and disengaging the starter Torque from the crankshaft 2 is transmitted by the crankshaft gear 1 directly to the camshaft gear 3 The camshaft gear rotating in a counterclockwise direction drives the magneto drive gears 10 11 The fuel pump is driven by a shaft 19 connected to the prop governor driven bevel gear 7 The governor drive bevel gear 6 is keyed to the camshaft 4 and meshes with and drives the governor drive bevel gear 7 The oil pump drive gear 8 mates with the internal teeth of the camsh
24. 20 4 CYLINDER ASSEMBLY INSPECTION cont d 20 8 Inspect for corrosion and pitting on the cylinder head the head fins and fin roots Inspect the cylinder head for cracks A radial fin crack extending to the root of a fin may have penetrated the dome wall Discard cylinders exhibiting any of the above indications CAUTION Corrosion pits reduce wall thickness and will cause stress concentrations and subsequent fracture Discard cylinders that have been allowed to become pitted in the areas mentioned in cylinder barrel and head inspections above Inspect for evidence of cylinder head to barrel leakage Inspect for possible turning of the cylinder head in relation to the barrel flange Cylinders with this indication must be discarded and replaced with a serviceable cylinder assembly Visually inspect pushrod housings for cracks and dents Discard cracked or dented pushrod housings WARNING Welding of the cylinder head structure can destroy the assembly preloads and casting strength resulting in cylinder assembly failure 100 HOUR Perform all visual inspection requirements of 50 hour inspection Perform the following cylinder compression test which is to be done soon after the operational engine test in Section 5 4 Cylinder Compression Test The differential pressure test is an accepted method of determining cylinder condition by measuring air pressure loss past the pistons rings and valves The operation of the equipment is based
25. CAUTION When performing dimensional inspection the following Service Limits may be used However they are only intended as a guide for re use when performing maintenance of the engine prior to major overhaul Parts with dimensions or fits that exceed service limits must not be re used Parts with values up to and including service limits may be re used however judgment should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See the current L TSIO 360 Overhaul Manual for minimum and limits If starter adapter is disassembled the following components must be dimensionally inspected 17 4 Limit Starter shaftgear in bearing Starter shaftgear front bearing journal Starter shaftgear in needle bearing Bushing in adapter cover Adapter cover oil seal bore Starter adapter Cover Pilot In Adapter Housing 0 003L Worm wheel gear 0 015 Clutch spring on Starter Shaftgear drum 50 56 from drum end 0 004T Clutch spring on clutch drum 0 008L From center line of worm gearshaft to starter adapter thrust pads 0 252 Needle bearing bore 7485 7495 Ball bearing in starter adapter Worm gearshaft in needle bearing area Worm gearshaft in ball bearing Starter pilot to starter drive adapter Starter drive tongue to worm shaft drive slot Needle bearing to worm gear shaft Starter gear to crankshaft gear Starter worm wheel gear and worm gea
26. Service Phone 1 800 992 2424 Adhesives SUGGESTED SOURCES APPLICATION 646941 High Strength Adhesive May be purchased through Cylinder deck studs squirt Sealant or Loctite 271 your local TCM Distributor nozzles fuel manifold valve diaphragm and plunger assembly 653696 Primer or Loctite LocQuic For Distributor information Primer 7471 Loctite Customer Service Phone 1 800 243 4874 649306 Sealant optional 646940 May be purchased through Through stud holes on accessory or Loctite Adhesive Sealant 222 your local TCM Distributor end of crankcase manifold valve optional Loctite Hydraulic For Distributor information to bracket screws Sealant Loctite Customer Service 569 Phone 1 800 243 4874 3M Brand EC1252 White Spot 3M Cylinder deck studs magneto Putty flanges throttle body and fuel metering unit 3 5 Miscellaneous SUGGESTED SOURCES APPLICATION TCM P N 626531 1 May be purchased through High temp paint for cosmetic and Enamel Gold 1qt your local TCM Distributor corrosion protection TCM P N 626531 2 Enamel Gold 1 gal TCM P N 535001S May be purchased through Where applicable for lockwiring Lockwire 032 in dia Steel your local TCM Distributor Corrosion Resistant ACCELAGOLD For sales and service Elf Atochem Corrosion protection interior and Turco Products N A Turco Products Div exterior aluminum parts Tucker GA 30084 P O Box 195 Accelagold is manufactured by State Route 95 West
27. applicable portion of Ignition System Disassembly Reassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A Any magneto maintenance such as point replacement condenser replacement impulse coupling replacement or internal magneto 12 5 12 5 12 6 timing must be performed in accordance with the magneto manufacturer s instructions See Slick Order Form F 1100 See Section 1 4 Related Publications for ordering information Magneto Drive Assemblies Remove the magneto drive assemblies for repair or replacement in accordance with the applicable portion of the Magneto and Accessory Drive disassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A CAUTION When performing dimensional inspection the following Service Limits be used However they are only intended as a guide for re use when performing maintenance of the engine prior to major overhaul Parts with dimensions or fits that exceed service limits must not be re used Parts with values up to and including service limits may be re used however judgment should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See the current L TSIO 360 Overhaul Manual for minimum fits and limits IGNITION SYSTEM MAINTENANCE cont d FITS amp LIMITS LEFT AND RIGHT MAGNETO ACCESSORY SERVICE Magneto gear Support Shaft to Bearing Diameter 0 0002L Sleeve in magneto
28. clamps and hardware Visually inspect turbocharger and associated turbocharger system components for evidence of oil or exhaust leakage Correct all discrepancies noted WARNING Operation of a malfunctioning engine can result in additional engine damage bodily injury or death At the completion of any maintenance event the engine must be given a complete and thorough operational run up A test flight will be required if any engine adjustments have been made which affect flight characteristics or operation This test flight is require by FAR 91 407 Record all engine parameters Verify recorded parameters are within the specifications published for the engine and aircraft Correct any discrepancies noted during operational run up prior to returning engine to service 100 HOUR INSPECTION NOTE Research and comply with the Service Publications and Airworthiness Directives In addition to the items listed in 50 Hour the following inspections and maintenance must be performed 1 10 11 Drain engine oil Reinstall oil drain plug with new gasket torque to 190 210 Ibs and safety Perform a cylinder compression test Inspect the entire engine accessory section and nacelle for indications of fuel oil or hydraulic leaks Inspect all wiring flammable fluid lines and hoses and electrical connections for proper routing support and evidence of deterioration Inspect the induction and exhaust system for leak
29. manufacturer s instructions Install all airframe manufacturer required components including cooling baffles hoses fittings brackets and ground straps in accordance with the airframe manufacturer s installation instructions WARNING Do not connect the ignition harness to the spark plugs until the propeller installation is completed Failure to comply could result in bodily injury when the propeller is rotated during installation 12X 2 40 21 i EXHAUST BY PASS VALVE ACTUATOR P EQ6939 FREON FN SEE AFTERCOOLER A i DETAIL 4 q COMPRESSOR KIT 5 12X 190 32 UNJF 3B rae CX SN 19 54 A NN NS ER 25 2PLACES m iai EE mn D M ac Ei ACCESSORY CASE N i Y v d i elis ow LU KN 4 MANIFOLD PRESSURE MINE 00 008 4375 20UNF 2A THDS pem IUU PER MS33656G4 063 065 ORIFICE 4 amp ELBOW R 12 MAX 3 00 TO 3 00 TO GOV PAD a CRANKCASE VENT FOR 260 1 0 BREATHER a EE seu HOSE OVERBOARD PER MS33660 12 Me A lt yl wil Wr Y Y UN xdi m IN SEO CUSTOMER SUPPLIED ALTERNATOR DRIVE SHEAVE FIGURE 6 1 INSTALLATION DRAWING 6 6 ACC CASE 24 28 END 18 99 NO
30. 1 Remove engine and clearly identify Removal For Overspeed 2 Engine and accessories must be completely overhauled in accordance with the respective manufacturers current overhaul instructions or replaced with certified airworthy components LIGHTNING STRIKE It is impossible to assess internal damage that may result from a lightning strike A complete disassembly and inspection of the engine must be accomplished in accordance with the manufacturer s current overhaul manual CONTAMINATED FUEL INCORRECT FUEL GRADE If the aircraft is inadvertently serviced with the wrong grade of fuel or jet fuel the fuel must be completely drained and the tank properly serviced Any engine operated on fuel of lower grade than approved for the engine or jet fuel must be completely disassembled cleaned inspected repaired reassembled and tested in accordance with the manufacturer s current overhaul manual 5 8 GENERAL INFORMATION The troubleshooting chart which follows discusses symptoms which can be diagnosed and interprets the probable causes and the appropriate corrective actions to be taken Troubleshooting for individual systems will be found in that particular section of Chapters 11 through 22 Any attempt by unqualified personnel to adjust repair or replace any parts may result in engine malfunction or failure WARNING Operation of a malfunctioning engine can cause further damage to a disabled component and possible injury to person
31. 15 FUEL LINE 1 637 R 4 613 INDUCTION TUBE MEN INJECTOR 22 59 PATUM FULL RICH VIEW A A SECTION K K TYPICAL 6 PLACES FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d FUEL OUTLET 4375 20UNJF 3A THDS PER MS33656G4 GROUND TERMINAL 190 32 UNC 2A TORQUE TO 15 17 INCH POUNDS ACCESSORY DRIVE PAD t AND20000 TYPE X m 1 545 X ENGINE SPEED C C W ROTATION TACH SENSOR ONE MAGNETO VIEW E E SCAVENGE PUMP AND ACCESSORY DRIVE LTSI0 360 RB ONLY GROUND TERMINAL 190 24 UNC 2A BATTERY TERMINAL 25 20 UNF 2A TORQUE TO 75 85 7 INCH POUNDS 313 18 UNC 2A STARTER TERMINAL TORQUE TO 180 220 INCH POUNDS FIELD TERMINAL 190 24 UNC 2A TORQUE TO 21 25 AUX TERMINAL INCH POUNDS 190 24 UNC 2A 3 TORQUE TO 21 25 500 521 VIEW G G INCH POUNDS 12 90 13 23 P ALTERNATOR 6 HOLES MARKED X 6 4 000 101 60 AIR INLET 25 HOSE ENGINE 4880 123 98 5625 18UNJF 3A 4 870 123 70 THDS PER SECTION C C MS33656G6 ARP 502 MODIFIED PROP FLANGE FUEL PUMP DRAIN 4375 20UNJF 3A THDS PER MS33656G4 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d GENERAL The operating limits and specifications listed in this section are applicable to the L TSIO 360 RB series aircraft engines Consult the L TSIO 360 RB Operator amp Installation Manual Form X30644 for additional operating procedures For time between overhaul TBO for
32. 5 4 Time Interval 5 5 Scheduled 5 6 Unscheduled 5 11 5 14 Engine Troubleshooting Chart cesses 5 14 5 1 5 1 5 3 5 2 GENERAL The scheduled inspection and maintenance described in this section must be complied with in addition to all aircraft manufacturer and accessory manufacturer inspection and maintenance requirements This manual does not contain inspection or maintenance requirements for supplemental type certificated components or systems Such information must be obtained from the supplemental type certificate holder Safety efficiency and engine service life is predicated on compliance with the aircraft and engine manufacturer s required instructions inspections and maintenance schedule The owner operator is primarily responsible for maintaining the engine in an airworthy condition including compliance with applicable Airworthiness Directives as specified in Part 39 of the Federal Aviation Regulations FAR reference FAR 91 163 NOTE Engine operational inspection must be performed before and after any 50 or 100 hour inspections or maintenance in accordance with Operational Inspection requireme
33. ENRICH IDLE VALVE LEVER FIGURE 23 3 FUEL MIXTURE ADJUSTMENT 23 6 Idle Speed Check and adjust idle speed as follows a Operate the engine at 1500 to 1800 rpm until cylinder head temperatures are 250 F to 350 F and the oil temperature is 160 F to 180 F b Reduce engine speed and stabilize it at 700 25 rpm c Adjust the idle speed screw that is located on the aft side of the throttle lever until contact is made with the throttle arm stop Full Power Performance Check and adjust full power performance as follows a Orient the aircraft so that it is pointed into the prevailing wind and run engine at 1500 to 1800 rpm until the oil temperature is 160 F to 180 F b Using a handheld digital tachometer adjust the propeller controls to 2600 With the throttle in the full forward position set the intake manifold pressure to the value shown in Figure 23 5 0 5 In Hg by adjusting the screw on the top of the controller Turning the screw clockwise decreases manifold pressure and turning the screw counterclockwise increases manifold pressure One complete 360 turn of the screw changes the manifold pressure approximately 1 0 inch HIGH SETTING ADJUSTMENT CW TO DECREASE MANIFOLD PRESSURE INLET PORT FROM BYPASS VALVE ACTUATOR NT LANE Me 55577 LOW SETTING ADJUSTMENT CAM FOLLOWER ANEROID BELLOWS OI
34. Overhaul Manual Form X30596A If nozzles are obstructed and ccanot be cleaned by soaking in lacquer thinner methyl ethyl keytone or acetone for several hours and blown dry with compressed air they must be replaced with new FUEL Pump For replacement of fuel pump see the applicable portion of disassembly and reassembly procedure in the L TSIO 360 RB Overhaul Manual Form X30596A The fuel pump may be replaced with new or it must be repaired and calibrated in accordance with the applicable instructions in the Fuel Injection System Parts And Overhaul Manual Form X30593A NOTE The appropriate test calibration equipment must be available for overhaul of any TCM fuel injection component continued on next page 13 9 Whenever the fuel pump is removed from the engine the following Fits and Limits must be checked CAUTION When performing dimensional inspection the following Service Limits may be used However they are only intended as a guide for re use when performing maintenance of the engine prior to values up to and including service limits may be re used however judgment should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See current L TSIO 360RB Overhaul manual for minimum fits and limits REF NO FITS amp LIMITS SERVICABLE LIMIT MAX FUEL PUMP DRIVE 1 Fuel pump adapter pilot in crank
35. Service Phone 1 800 243 4874 653692 Primer May be purchased through Crankcase crankshaft nose oil your local TCM Distributor seal area or Loctite LocQuic Primer 7649 For Distributor information Loctite Customer Service Phone 1 800 243 4874 646942 Gasket Maker May be purchased through your Engine seal outside local TCM Distributor diameter of all uncoated oil seals or non beaded oil sump gaskets Loctite Gasket Eliminator For Distributor information 515 Sealant Loctite Customer Service Phone 1 800 243 4874 642188 Gasket Sealant May be purchased through Cam bore cover gasket idler pin TCM 1 5 oz tube your local TCM Distributor gasket oil filler neck gasket and or holes pressed in plugs SUGGESTED SOURCES APPLICATION K amp W Copper Coat For Distributor information call K amp W Products Customer Phone 1 800 423 9446 Loctite Teflon PS T Pipe Sealant For Distributor information Pipe threads pressure relief Loctite Customer Service valve housing threads tach drive Phone 1 800 243 4874 threads oil temperature control valve studs that are exposed to oil 646940 Sealant May be purchased through All pipe thread fittings in fuel your local TCM Distributor injection system or Loctite Hydraulic Sealant 569 For Distributor information Loctite Customer Service Phone 1 800 243 4874 For Distributor information Ignition harness terminals at Miller Stephenson Customer magneto block end
36. System Disassembly Reassembly in the L TSIO 360 RB Overhaul Manual Form X30596A Turbochargers Wastegate Controller For replacement of these components see the applicable portion of exhaust system disassembly reassembly in the L TSIO 360 Series Overhaul Manual X30596A For maintenance of these components refer to the component manufacturer s instructions Airesearch 3201 Lomita Blvd Torrance California 90505 Lubrication Plumbing Turbocharger lubrication plumbing must be replaced if deteriorated or leaking in accordance with the applicable Disassembly Reassembly portions in the L TSIO 360 RB Overhaul Manual Form X30596A 11 11 INTENTIONALLY LEFT BLANK 11 12 SECTION 12 1 12 2 12 3 12 4 12 5 FIGURE 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 12 10 CHAPTER 12 IGNITION SYSTEM PAGE Slick Ignition System 12 2 Ignition System Component Detailed Description 12 2 Ignition System Inspection 50 100 500 12 2 Ignition Troubleshooting mt PS 12 4 Ignition System Maintenance 12 5 PAGE Magneto Accessory Drive 12 6 Reverse Spark Plug Installation Procedure 12 8 Spark Plug 12 8 Timing Posit
37. Tools open filter can and inspect filter element for debris If no foreign particles are present insure oil filter adapter is clean lubricate oil filter seal using Dow Corning DC 4 compound and install new oil filter Torque oil filter to 192 216 inch pounds Safety as required in accordance with Section 9 2 Lockwire Procedure If debris is detected on filter element see Section 19 5 Oil Filter NOTE Oil and filter change intervals may vary depending on the type of oil filter used See Section 5 2 Oil And Filter Change Interval If the aircraft is exposed to severe conditions such as training extreme weather or infrequent operation oil change hourly intervals should be decreased Install oil sump plug torque to 190 210 inch pounds Safety wire in accordance with Section 9 2 Lockwire Procedure Refill engine with clean aviation engine oil of the proper grade and weight to the correct engine oil quantity in accordance with Chapter 7 Servicing Oil CAUTION Use only TCM approved oils after break in period See chapter 7 for TCM approved oils Visually inspect oil sump to crankcase attaching hardware and oil sump drain plug for security and safetying Visually inspect all lubrication system component gasket areas for oil leaks Visually inspect all lubrication system components for cracks dents stripped threads punctures and abnormal wear Visually inspect oil pressure gauge plumbing for oil leaks
38. Turco Products Inc Marion Ohio 43302 215 419 5376 3 6 CHAPTER 4 AIRWORTHINESS LIMITATIONS This Airworthiness Limitations section has been FAA approved and specifies maintenance required under 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved Federal Aviation Regulations 43 16 and 91 403 require owner operator compliance with all maintenance limitations in this section concerning mandatory replacement times inspection intervals and other related procedures that are specific to this engine Any such limitations listed below are part of the design limits of the engine and the engine was type certificated based upon required owner operator compliance with the limitations 1 Mandatory Replacement Times Subject to additional information contained in FAA Airworthiness Directives AD issued after the date of certification the engines covered in this manual do not contain any components having mandatory replacement times required by type certification 2 Mandatory Inspection Intervals Subject to additional information contained in FAA Airworthiness Directives AD issued after the date of certification the engine does not require specific intervals of inspection pursuant to type certification 3 Other Related Procedures Subject to additional information contained in the Airworthiness Directives AD issued after the date of certification there are no other
39. a 6th order counterweight Similarly if a vibration occurs five times per revolution the counteracting counterweight is designated a 5th order counterweight One sixth order counterweight is installed on one 2 cheek hanger A four and one half order counterweight is installed on the opposite hanger It does not matter on which side of a cheek a particular counterweight is installed The crankshaft gear is heated to facilitate installation The gear is indexed on the crankshaft by a dowel and secured by machined bolts A neoprene oil seal is seated in a machined bore in the crankcase assembly in the shaft exit area and is sealed to the crankshaft by a helical spring inside the seal s cavity COUNTERWEIGHT HANGAR BLADE CC Crankshaft Cheek RJ Rod Journal MJ Main Journal FIGURE 22 2 CRANKSHAFT DESCRIPTION 22 3 Connecting Rod The connecting rods are made of aircraft quality steel The connecting rod large diameter end which attaches to the crankshaft crankpin or rod journal is fitted with a cap and two 2 piece bearing The bearing cap is held to the main rod by special bolts and nuts A split steel backed bronze bushing is pressed into the piston pin end and machined for a precision fit Weight variation of connecting rods in opposing bays Example 1 and 2 connecting rods is limited to 1 2 ounce 14 grams BEAM OR SHANK amp BOLTS FIGURE 22 3 CONNECTING ROD DESCRIPTION Camshaft The forging is mach
40. air and delivers it to the engine intake manifold As engine power is increased the flow of exhaust gases increase which increases the speed of the turbine compressor assembly and the output of the turbocharger The flow of exhaust gases through the turbocharger is controlled by the Exhaust By pass Valve or wastegate WHEEL SHROUD CENTER HOUSING SEAL RING PISTON RING COMPRESSOR RETAINER THRUST BACK PLATE y AS COMPRESSOR WHEEL BAND CLAMP SHAFT TURBINE COMPRESSOR HOUSING HOUSING TURBINE WHEEL AND SHAFT PISTON RING TURBINE FIGURE 11 2 BASIC TURBOCHARGER 11 4 COMPRESSOR MAIN DRIVE HOUSING HOUSING qu S S iss Sum TURBINE WHEEL COMPRESSOR WHEEL AIR INLET EXHAUST DISCHARGE EXHAUST COMPRESSED NGET AIR DISCHARGE FIGURE 11 3 TURBOCHARGER SECTIONAL VIEW 11 3 EXHAUST BY PASS VALVE WASTEGATE DETAILED DESCRIPTION The Exhaust By pass Valve or wastegate used on the L TSIO 360 RB engine is an oil actuated butterfly type valve The exhaust by pass valve butterfly valve is connected to the actuator by mechanical linkage The exhaust by pass valve is installed in the engines exhaust system near the turbocharger in an exhaust by pass pipe that allows some of the exhaust gases to by pass the turbocharger turbine The exhaust by pass valve butterfly valve is spring loaded to the open position Pressurized oil from the engine is directed
41. air box for security and deterioration in accordance with the aircraft manufacturer s instructions WARNING Insure the fuel selector is in the off position prior to servicing fuel filters Drain the fuel filter and service as required and reinstall in accordance with the aircraft manufacturer s instructions Visually inspect engine and nacelle for fuel oil leaks and other discrepancies WARNING Failure to identify and correct fuel or oil leaks can result in engine nacelle fire loss of engine power engine failure bodily injury or death Drain engine oil small full flow filter During engine oil change oil must be drained into an appropriate container and disposed of properly Reinstall oil drain plug with new gasket torque to 190 210 in lbs and safety Remove oil filter Inspect filter element See Oil Filter Element Inspection Oil Analysis and Spectrographic Oil Analysis at the end of this chapter Place a thin film of Dow Corning DC 4 compound on new oil filter gasket Install new oil filter Torque filter to 192 216 and safety wire Inspect all induction system or cylinder drain s for clogging or restriction Inspect ignition leads for chafing deterioration and proper routing Visually inspect magnetos for condition Inspect repair and adjust as required if magneto drop or spread was not within published limits Inspect exhaust system for cracks excessive leakage deterioration loose and missing brackets
42. as being of aircraft quality when actually the quality and origin of these units are unknown Users of such units are usually unaware of potential hazards involved with replacement parts not eligible for use on certificated aircraft Units may be deceptively advertised as unused like new or remanufactured This implies the quality of such units is equal to an original repaired or overhauled unit Federal Aviation Regulations FAR 43 13 and FAR 145 57 specify performance rules for replacement of parts and materials used in maintenance and alteration of United States US certificated aircraft As outlined in FAR 91 403 FAR 121 363 FAR 123 45 and FAR 135 143 a the owner operator is responsible for continued airworthiness of the aircraft which includes parts replacement IDENTIFICATION OF THE APPROVED PARTS Approved serviceable replacement parts are identified by a A Federal Aviation Administration FAA Form 8130 3 Airworthiness Approval Tag An Airworthiness Approval Tag identifies a part or group of parts approved by authorized FAA representatives b An FAA Technical Standard Order TSO number and identification mark that indicates the part or appliance has been manufactured under the requirements of FAR 21 Subpart O c An FAA Parts Manufacturer Approval PMA symbol together with the manufacturer s name part number and make and model of the type certified product on which the part might be installed stamped on the part
43. circuit continuity Refer to the airframe manufacturer s instructions Starter motor malfunctioning See Section 17 5 Starter Starter Motor Runs But Starter adapter drive train or See Section 17 5 Starter Does Not Turn Crankshaft clutch malfunctioning Adapter Starter Motor Dragging Improperly charged battery Refer to airframe manufacturer s instructions Starter switch contacts Refer to airframe burned or dirty manufacturer s instructions Malfunctioning Starter See Section 17 5 Starter 17 5 STARTING SYSTEM MAINTENANCE Starter The starter motor may be removed for repair or maintenance in accordance with applicable portions of starter and starter adapter disassembly reassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A Supplement 1 Disassembly maintenance and reassembly of the starter motor must be performed in accordance with the starter manufacturer s instructions Starter Adapter The starter adapter may be removed from the engine and disassembled in accordance with the applicable portions of starter and starter adapter disassembly reassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A Supplement 1 Whenever the starter adapter is removed from the engine because of malfunction it must be disassembled cleaned inspected and repaired in accordance with the L TSIO 360 Overhaul Manual FormX30596A Supplement 1 During maintenance the service limits on the next page can be used
44. cloth must not be used on the piston skirts because the diameters and cam ground contour must not be altered Scored or burned pistons must be discarded After cleaning thoroughly rinse pistons using a stoddard solvent to remove all debris Rings Piston rings must be replaced 100 20 15 Cylinder Baffling Refer to the airframe manufacturer s instructions Before any repair procedures are performed after cleaning the cylinder and it s related components must be visually fluorescent penetrant and magnetic particle Inspected as applicable in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A CAUTION When performing dimensional inspection the following Service Limits may be used However they are intended as a guide for performing maintenance of the engine prior to major overhaul Parts with dimensions or fits that exceed service limits must not be re used Parts with values up to and including service limits may be re used Judgement should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See the current L TSIO 360 Series Overhaul Manual for minimum fits and limits If the cylinder and it s components meet the required visual fluorescent penetrant and magnetic particle inspections the cylinder and its components must be dimensionally inspected CYLINDER ASSEMBLY SERVICE LIMITS No Limit Max CYLINDER AND HEAD
45. crankshaft as opposite cylinders are sprayed Stop crankshaft with none of the pistons at top dead center 4 Re spray each cylinder To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder 5 Install top spark plugs but do not install spark plug leads Seal all engine openings exposed to the atmosphere using suitable plugs and covers Tag each propeller in a conspicuous place with the following notation on the tag DO NOT TURN PROPELLER ENGINE PRESERVED PRESERVATION DATE NOTE If the engine is not returned to flyable status on or before the 90 day expiration it must be preserved in accordance with Indefinite Storage procedures in this chapter 8 4 INDEFINITE STORAGE PREPARATION FOR STORAGE 1 Remove oil sump drain plug and drain oil Replace drain plug torque and safety Remove oil filter Install new oil filter torque and safety Service engine to proper sump capacity with oil conforming to MIL C6529 Type Il Perform a ground run up Perform a pre flight inspection and correct any discrepancies Fly the aircraft for one hour at normal operation temperatures WARNING To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle
46. engine damage or failure MAGNETO TO ENGINE TIMING WARNING To prevent injury or death before beginning maintenance on the ignition system insure that the magneto switches and master switches are in the off position the aircraft battery is disconnected and all ignition leads are disconnected and removed from the spark plugs Attach a sign stating Hot Magneto Do Not Turn on each propeller blade In conducting magneto timing check use a top dead center locator protractor and pointer such as the Eastern Electronics Model E25 Timing Indicator or equivalent Use the following basic timing procedure to insure that timing is accomplished in accordance with the required specifications 1 Remove all top spark plugs Rotate the crankshaft to the start of the compression stroke on the number one cylinder Install the top dead center locator in the number one cylinder spark plug hole 2 Install timing disk of indicator on the crankshaft flange propeller spinner or propeller hub 3 Turn propeller slowly in direction of normal rotation until the piston lightly touches the top dead center locator 4 Rotate the disc of the timing indicator until the 0 mark aligns with the pointer POSITIVE DEAD CENTER LOCATOR INSTALLED A ADJUST THE PROTRACTOR TIMING INDICATOR DIAL TO THE 0 TDC INDICATION 1 CYLINDER PISTON LIGHTLY TOUCHING NORMAL DIRECTION OF ROTATION NOTE THE PROTRACTOR TIMING IND
47. ignition lead coupling nuts to 110 120 inch pounds E 12 14 Consult service bulletins issued by the ignition harness manufacturer regarding tips for increased service life ENGINE FIRING ORDER 1 6 3 2 5 4 MAGNETO FIRING ORDER 1 2 3 4 5 6 FIGURE 12 10 IGNITION WIRING DIAGRAM 12 15 INTENTIONALLY LEFT BLANK 12 16 SECTION 13 1 13 2 13 3 13 4 13 5 FIGURE 13 1 13 2 13 3 13 4 13 5 13 6 13 1 CHAPTER 13 FUEL SYSTEM PAGE Engine Fuel System Description 13 2 Fuel Injection System Component Detailed Description 13 2 Fuel Injection System Inspection 50 100 13 4 Fuel Injection System 13 6 Fuel System Maintenance 13 7 Fuel Pump Description 5 360 13 2 General Fuel Manifold Valve Description 13 3 General Fuel Nozzle Description 13 3 General Sealant Application 13 4 General Control Linkage Lubrication Points 13 5 Fuel Pump Drive Fits and 13 8
48. in the adapter housing and does not continue into the housing below the minimum 500 extension See Figure 19 7 Oil Filter Adapter Stud Inspection Replace the adapter housing if the extension is less than the specified 500 minimum STAMP THE LETTER S IN THIS LOCATION OIL FILTER STUD OIL FILTER ADAPTER ASSEMBLY FIGURE 19 6 STUD IDENTIFICATION D After extension height inspection remove the stud from the adapter Clean the threads of the adapter housing and stud with Loctite Primer T TCM P N 646944 and allow to dry E Apply a line of Loctite 271 TCM P N 646941 along the large threads 8125 16 end of the stud and install into the adapter finger tight to 30 inch pounds torque Check for proper stud extension height in accordance with Figure 19 7 Oil Filter Adapter Stud Inspection F Allow the parts to cure for a minimum of thirty minutes prior to installation of the oil filter CAUTION Curing times may vary depending on ambient temperature Consult Loctite instructions After installation of a new oil filter adapter stud stamp a 125 high letter s in the location shown in Figure 19 6 Stud Identification OIL FILTER STUD APPLY LINE OF LOCTITE HERE INCOMPLETE THREAD ENGAGEMENT LOCATION OIL FILTER ADAPTER ASSEMBLY STUD LARGE END FIGURE 19 7 OIL FILTER ADAPTER STUD INSPECTION continued on next page 19 9 19 4 Using an oil filler can cutter See Chapter 2
49. make certain that all fuel has drained from the intake manifold and or cylinder prior to attempting engine starting INSPECTION PROCEDURES FOR SUSPECTED HYDRAULIC LOCK In the event of a suspected hydraulic lock perform the following inspection 1 Remove all cylinders and connecting rods in accordance with the applicable TCM Overhaul Manual Inspect the connecting rods in accordance with applicable TCM Overhaul Manual If all rods meet the criteria specified by TCM reassemble the engine in accordance with the overhaul manual If any connecting rod does not meet TCM acceptance criteria remove and disassemble the engine to allow inspection of the crankcase and crankshaft in accordance with the applicable TCM Overhaul Manual Replace any part that does not meet Overhaul Manual inspection criteria Replace each non conforming connecting rod and its associated piston piston pin and cylinder assembly Any parts that require replacement must be destroyed to prevent future installation Reassemble the engine in accordance with the applicable TCM Overhaul Manual and return the aircraft to service ENGINE OVERSPEED INSPECTION Engine operation at speeds in excess of rated RPM limitations can cause damage to the engine and can result in subsequent engine failure If an engine overspeed occurs determine the cause for overspeed and correct it The airframe manufacturer s instructions on engine and propeller overspeed must also be refere
50. on the principle that for any given airflow through a fixed orifice a constant pressure drop across that orifice will result The compression testing equipment must be calibrated and used in the proper manner to insure accurate results To accurately accomplish a leakage check use the following information on leakage and use the Master Orifice tool to calibrate the leakage checking equipment used on Teledyne Continental engines FACTORY CALIBRATED ORIFICE CLEAN With Soft Brush Do Not Alter Size DUST CAP a lt DUST CAP SPARK PLUG THREADS 18mm FIGURE 20 7 MASTER ORIFICE TOOL For procurement see chapter 2 EXHAUST VALVE SPARK INTAKE VALVE CYLINDER WALL CYLINDER DIMENSION HEAD amp amp CHOKE BARREL SEAL 1ST amp 2ND COMPRESSION RING GAP PISTON DIMENSION FIGURE 20 8 STATIC SEAL FIGURE 20 9 DYNAMIC SEAL LEAKAGE CHECKS Cylinder leakage is broken down into two areas of concern the Static Seal and the Dynamic Seal Static Seal The static seal consists of the valve to valve seat seals spark plug to spark plug port seals and cylinder head to barrel seal No leakage of the static seal is permissible Dynamic Seal The dynamic seal consists of the piston rings to the cylinder wall seal This seal leakage can vary from cylinder to cylinder ring gap position wear or the amount of engine oil on the cylinder wall EQUIPMENT Testing equipment must be kept clean and checked peri
51. one end to wind into the other end Lubricate the oil seal lips using Shell 2 Twist the seal and slide over crankshaft with the recessed side toward the engine Bring the ends of the seal back together With the spring ends opposite the seal split carefully work the spring into it s recess in the seal 4 Apply a thin coat of Permatex to outside diameter of seal Using thumb pressure work seal into counterbore with the oil seal split at the 10 o clock or 2 o clock position After seal is in place wipe oil from seal and shaft Spray exposed portion from which plating has been removed with aluminum primer After installation re install oil seal retainer plates Torque retainer plate hardware 4 each 10 24 screws to 21 0 25 0 inch pounds SEAL SPRING 753 FREE LENGTH 753 INSIDE HCOKS CARE ACTUAL SIZE FIGURE 22 6 CRANKSHAFT OIL SEAL Engine Drive Train Component Removal If all other probabilities have been evaluated and it is determined a malfunction is occurring with internal engine components the engine must be removed from the airframe in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A and the airframe manufacturer s instructions CAUTION When relieving engine weight from the airframe the engine hoist must be attached to the engine lifting eyes only NOTE Place a support at the load bearing area of airframe tail to prevent damage to the airframe NOTE Exer
52. operated in excess of 25 hours or 6 months whichever occurs first If oil consumption has not stabilized within the first 25 hours of engine operation drain and replenish the oil and replace the filter Approved Oil Grade All Temperatures TCM Approved Multi Viscosity Below 40 F Ambient Air Sea Level TCM Approved SAE 30 or Multi Viscosity Above 40 F Ambient Air Sea Level TCM Approved SAE 50 or Multi Viscosity 2 Visually inspect the engine and nacelle for fuel oil leaks and other discrepancies 3 Correct any discrepancies noted during this inspection prior to returning the engine to service 5 6 SCHEDULED MAINTENANCE 50 HOUR INSPECTION NOTE Research and comply with the Service Publications and Airworthiness Directives 1 Thoroughly inspect the engine for any signs of leakage Clean engine exterior by spraying or brushing with a flame resistant solvent used for general cleaning of engine parts NOTE Any environmentally hazardous materials used in cleaning must be collected and disposed of in accordance with Environmental Protection Agency regulations CAUTION Do not use any alkaline cleaning solutions for external engine cleaning these solutions will remove the alodized finish of aluminum parts CAUTION Do not use Kerosene or Gasoline for cleaning 2 A pre inspection operational run up must be performed See Operational Inspection of this chapter a Record the engine operating parameters
53. security and deterioration Any components exhibiting cracks dents punctures or that are worn beyond serviceable limits must be discarded and replaced with new 100 HOUR Perform all inspection requirements of 50 hour inspection and the following If oil pressure does not conform with 10 psi minimum 30 to 60 psi normal operation and 100 psi maximum oil cold pressure determine the cause and adjust or repair as required LUBRICATION SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Excessive Oil Consumption Oil leakage Replace leaking oil lines torque loose See Excessive Crankcase connections see Section 19 5 Gasket or seal leakage Replace gasket or oil seals see Section 19 5 Improper seasonal weight or grade oil Service engine with proper oil see Chapter 7 Servicing Oil Worn piston rings or valve guides See Section 19 6 Pistons High Oil Temperature Indication Low oil supply Replenish See Chapter 7 Servicing Oil Cooler air passages clogged Clean thoroughly see Section 19 5 Oil Cooler Cooler core plugged Remove cooler and flush thoroughly see Section 19 5 Oil Cooler Thermostat damaged or held open by Remove clean valve and seat If still
54. solid matter inoperative replace See Section 19 5 Oil Temperature Control Valve 19 10 TROUBLE PROBABLE CAUSE CORRECTION High Oil Temperature Indication Oil viscosity too high Drain and refill with correct seasonal cont d weight See Chapter 7 Servicing Oil Prolonged ground operation Limit ground operation to a minimum refer to airframe manufacturer s operating instructions Malfunctioning gauge or bulb unit Check wiring Check bulb unit Check gage Refer to airframe manufacturer s instructions Low Oil Pressure Indication Low oil supply Oil viscosity too low Replenish Drain and refill with correct 19 5 seasonal weight See Chapter 7 Servicing Oil Malfunctioning pressure pump Replace pump See Section 19 5 Oil Pump Malfunctioning pressure gauge Check gauge Clean plumbing Replace if required in accordance with airframe manufacturer s instructions Weak or broken oil pressure relief Replace spring Adjust oil pressure in valve spring accordance with Section 23 2 Oil Pressure Adjustment Clogged Oil Filter See Section 19 5 Oil Filter Oil Pressure Maladjusted Adjust oil pressure in accordance with Section 23 2 Oil Pressure Adjustment LUBRICATION SYSTEM MAINTENANCE Oil Pump The accessory case may be removed in accordance with applicable portions of accessory case disassembly reassembly instructions in L TSIO 360 Series Overhaul Manual Form X30596A See Section 23 4 for
55. system or component section of this manual CAUTION Dimensional inspection of the crankcase and crankcase internal components must be performed in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Prior to dimensional inspection insure that the part conforms with all visual fluorescent penetrant magnetic particle or ultrasonic inspection requirements All crankcase repairs must be performed in accordance with the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A Any non TCM supplied accessory that was disassembled for maintenance must be re assembled in accordance with the applicable accessory manufacturer s instructions Any maintenance involving crankcase separation will require an acceptance test oil consumption determination reinstallation in airframe and test flight in accordance with the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A 21 7 INTENTIONALLY LEFT BLANK SECTION 22 1 22 2 22 3 22 4 22 5 FIGURE 22 1 22 2 22 3 22 4 22 5 22 6 CHAPTER 22 ENGINE DRIVE TRAIN PAGE Engine Drive Train Descripllon 22 2 Engine Drive Train Component Detailed Description 22 3 Engine Drive Train Trspectloni snae ee ro e decet 22 5 Engine Drive Train 22 5 Engine Drive Train 2
56. ten micron in size or smaller Since engine oil analysis is used as a tool to establish engine wear trends and deviations from the established norm either method is acceptable however it is important to realize the oil analysis program must utilize the same laboratory for all sample analysis Comparing an oil analysis report from a separate laboratory will have little meaning if each laboratory uses a different analysis method 7 5 SPECTROGRAPHIC OIL ANALYSIS continued A proper spectrographic oil analysis program should begin with the first engine oil change Establishing a wear trend data base for an engine will require analysis of at least three oil samples As the engine accumulates operating time and additional oil samples are analyzed a definitive wear trend can be identified Unexplained deviations from normal wear trend patterns should be investigated using accepted conventional inspection methods Spectrographic oil analysis must be accomplished according to a set protocol to provide any useful information Even if done properly spectrographic oil analysis will rarely provide any prior indication of a fatigue type failure A single spectrographic oil sample will usually not provide a high level of useful information since there is no established wear trend data on that specific engine for comparison Spectrographic oil analysis will assist in the identification of an internal engine problem If samples are properly taken at regul
57. the shipping plugs installed in the lower spark plug holes and turn the crankshaft through at least two complete revolutions in order to remove the cylinder preservation oil from the cylinder Remove the shipping plugs installed in the upper spark plug holes and inspect the cylinder bore with a borescope for rust or contamination Contact your Teledyne Continental Motors Distributor if any abnormal condition is noted Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Install the spark plugs and torque to 300 360 in Ibs Install the upper spark plugs finger tight CAUTION During installation of propeller governor in accordance with the airframe manufacturer s instructions insure that the governor gear splines align properly with the camshaft governor drive gear and that the governor is fully seated to the crankcase prior to installing the attaching hardware This will eliminate the possibility of misalignment forcing the governor bevel gear over the camshaft governor drive gear Also insure that the proper gasket is used and lubrication holes are properly aligned WARNING Oil pressure is applied to the face of the accessory drive pads If gasket accessory or cover is not properly installed and hardware is not properly torqued oil leakage will occur CAUTION When a test club or fixed pitch propeller is used for testing purposes the governor pad cover must have an inte
58. 12 13 3 To prevent sticking of sleeves and to minimize twisting of ferrule coat insulating sleeves use MS122N C02 Spray Miller Stephenson Chemical Co Inc 16 Sugar Hollow Road Danbury Connecticut 06810 See Figure 12 9 Coating Insulating Sleeve Hold ferrules while torquing or loosening spark plug coupling nuts to protect against twisting conduit or cable 4 Clamp harness leads as required COAT FIGURE 12 9 COATING INSULATING SLEEVE IGNITION HARNESS INSTALLATION A B C D The high tension cable outlet plates can be attached to either magneto in only one position Attach cable outlet plate to magneto Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Install all spark plugs and torque to 300 360 inch pounds Secure the ignition leads to the cylinder rocker covers using the ignition lead clamps and rocker cover screws Use caution routing and attaching leads Keep leads away from high heat sources such as the exhaust manifold Keep the leads away from any engine component that may cause chafing CHAFING A condition caused by a rubbing action between adjacent or contacting parts under light pressure which results in wear NOTE An ignition system wiring diagram is located on next page see figure 12 10 NOTE The cylinder firing order is 1 6 3 2 5 4 Install the ignition leads on the proper plugs and screw on Torque
59. 2 CLUTCH SPRING WORM WHEEL SCAVENGE PUMP SHAFT GEAR CRANKCASE BUSHING SCAVENGE PUMP NEEDLE GEAR BEARING ROLLER BEARING STANDARD STARTER ADAPTER L TSIO 360 RB WORM DRIVE GEAR AND SHAFT BALL BEARING NEEDLE BEARING STARTER MOTOR ADAPTER HOUSING CLUTCH SPRING SCAVENGE PUMP SHAFT NEEDLE BEARING BEARING NEEDLE BEARING DRIVE SHEAVE SCAVENGE PUMP WORM WHEEL GEAR STANDARD ADAPTER TSIO 360 RB FIGURE 17 2 STARTER ADAPTER DESCRIPTION 17 3 STARTER AND STARTER ADAPTER INSPECTION 50 Hour Visually inspect starter drive adapter to engine starter adapter cover to adapter housing and starter to adapter attaching hardware for security Visually inspect for oil leakage at cover oil seal area cover to adapter and starter adapter to engine area BEVEL GEARS 100 Hour Perform all visual inspection requirements of 50 hour inspection Starter motor electrical connections must be inspected for security and corrosion 17 3 17 4 STARTING SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not in order of probability TROUBLE PROBABLE CAUSE CORRECTION Starter Will Not Operate Master switch circuit Refer to the airframe continuity manufacturer s instructions Master
60. 2 inches in length the crack should be scribe marked at its extremities and re inspected for crack progression at the next 50 hours of operation If no progression is observed and no additional cracks are found continue to inspect at regular intervals not to exceed 100 hours duration If a crack is observed in any non critical dark gray areas that is more than two 2 inches in length or if a previously observed crack has progressed to two 2 or more inches in length repair or replace the crankcase prior to further flight If any crack is observed in a critical gray area repair or replace the crankcase or engine prior to further flight Reasons for crankcase replacement A Anycrackin the critical gray areas B Anycrack two 2 inches or more in length in the non critical dark gray area C Any crack that is leaking oil not seeping Cracks less than two inches in length and located in shaded areas as illustrated in Figure 21 3 FIGURE 21 2 INSPECTION OF CRANKCASE NON CRITICAL AREA FIGURE 21 3 INSPECTION OF CRANKCASE CRITICAL GRAY AND NON CRITICAL DARK GRAY AREAS 21 3 CRANKCASE INSPECTION continued CAUTION Repair of the crankcase must be performed by FAA approved repair facilities only TCM has established that welding of the crankcase is an acceptable repair process The weld procedure must conform with approved FAA repair standards and the dimensional integrity of the crankcase must be maintained Refer to
61. 2 2 Possible Special Tool Procurement 5 2 3 opecial Tools ee decet dte m nth ec dedi 2 4 2 1 2 1 GENERAL INFORMATION The mechanic should be equipped with a complete set of the necessary tools that include the following 1 a Wrenches 1 4 through 1 1 4 Common and Philips Head Screwdrivers Pliers Common Diagonal Cutters Needle Nose Duck Bill Snap Ring Ratchets 1 4 3 8 amp 1 2 Drive Sockets 1 4 Drive 5 32 through 1 2 3 8 Drive 3 8 through 1 1 2 Drive 7 16 through 1 1 4 Sockets Deepwell 1 2 Drive 7 16 through 1 Feeler Gauges Leather or Soft Plastic Mallet Torque Wrenches 0 500 In Lbs 0 100 Ft Lbs Micrometers Slide Hammer Pullers Thickness Gauges Vernier Calipers Small Hole Gauges 16 Ford Wrench Must be currently calibrated and the calibration must be traceable to the National Bureau of Standards 2 2 POSSIBLE SPECIAL TOOL PROCUREMENT SOURCES All tools in the Special Tool list are for reference only and not for the purpose of promoting or suggesting tools to be purchased from the indicated sources The following information is given as an aid for special tool procurement purposes COMPANY GENERAL PRODUCT SUMMARY ALCOR Box 32516 10130 Jones Maltsberger Rd San Antonio TX 78284 512 349 3771 KENT MOORE 29784 L
62. 47 2 3 SPECIAL TOOLS Specific tools listed or equivalent tools marketed by other manufacturers are necessary for overhaul and maintenance of the aircraft engine ITEM TOOL See NO Section GENERAL ENGINE RECIPROCATING 646953 Master Orifice Tool for cylinder compression test available from Kent Moore 5 4 2 7251 Differential Pressure Cylinder Checker available from Kent Moore 5 4 IGNITION SYSTEM 3 Borrough s 3608A Protractor Timing Indicator Disc or equivalent for setting engine timing 12 6 4 Model E25 Timing Indicator available from Eastern Electronics Inc 12 7 5 11 9110 1 Magneto Timing Light available from KELL STROM Tool Company Inc 12 7 FUEL INJECTION 6 Borrough s 8165 Injector Nozzle Remover and Installer or equivalent 13 3 CHARGING SYSTEM 7 Borrough s 7726 Torch Band Tension Adjuster or equivalent for Gen Alt Belt 16 5 Tensioning 8 BTU 33 73F Belt Tension Gage available from Kent Moore 16 5 9 Borrough s 4973 Generator Drive Holders or equivalent 16 5 10 Borrough s 61 5 Pulley Pulled or equivalent for gen alt sheave removal 16 5 11 Borrough s 8091 GEN ALT Output Tester or equivalent 16 5 12 647 Alternator Analyzer Voltage Regulator Tester available from Eastern Electronics 16 5 Inc 13 E100 Alternator Regulator Battery Tester available from Eastern Electronics Inc 16 5 14 Model 29 Voltage amp Circuit Tester available from Eastern Electronics Inc 16 5 STARTING SYSTEM 15 Borrough s 8093C Bearing Pul
63. 5 18UNJF 3A 4 870 123 70 THDS PER SECTION C C MS33656G6 ARP 502 MODIFIED PROP FLANGE DRAIN 4375 20UNJF 3A THDS PER MS33656G4 FUEL PUMP FIGURE 6 1 INSTALLATION DRAWING cont d 6 7 ENGINE PRE OILING It is important that all engine internal moving parts be properly lubricated before initial running of engine Pre oil engine prior to initial engine operation according to the following procedure 1 Pre oiling may be accomplished using a bladder type pressure pot capable of holding at least 1 gallon of clean aviation engine oil with an output pressure of 50 not to exceed 60 psi See Section 7 2 Approved Ashless Dispersant Oils for proper type of oil to use See Section 1 10 Operating Limits for proper seasonal oil grade 2 Remove rocker box covers from cylinders Connect pre oiler supply hose to engine oil pressure gage line connection fitting Open pre oiler valve and watch cylinder rocker areas for indication of oil flow Some engines may take as long as twenty 20 minutes for oil indication depending on oil temperature 3 After oil flow has been confirmed re install rocker covers using new gaskets torque rocker cover screws to limit specified in the L TSIO 360 Overhaul Manual Form OH 08 Close valve on pre oiler Disconnect pre oiler supply hose and cap or re install engine oil pressure gage line on pressure gage line connection fitting as applicable 4 Check engine oil gage rod dipstick and service t
64. 8 3 8 4 8 5 8 6 CHAPTER 8 ENGINE PRESERVATION AND STORAGE Page M 8 2 Engine Preservation oett ta ata ini 8 2 Temporary StOrage csvo gie 8 2 c S 8 3 Indefinite Storage Inspection 8 4 Returning An Engine To 2 2 2 2 2 44 144 nennen 8 4 8 1 8 1 8 3 8 2 GENERAL There is no practical procedure that will insure corrosion prevention on installed aircraft engines Susceptibility to corrosion is influenced by geographical location season and usage The owner operator is responsible to recognize the conditions that are conducive to corrosion and take appropriate precautions ENGINE PRESERVATION Corrosive attack can occur in engines that are flown only occasionally regardless of geographical location In coastal areas and areas of high humidity corrosive attack can occur in as little as two days The best method of reducing the likelihood of corrosive attack is to fly the aircraft at least once every week for a minimum of one hour NOTE Corrosive attack may reduce engine service life Of primary concern are cylinders piston rings valves valve guides camshaft and lifters NOTE See Precision Airmotive Corporation instructions for preservation of the fuel servo unit
65. ASSEMBLY 1 See Note 1 See 2 0 0020 47 Cylinder bore surface roughness Nitride Barrels using 180 grit stone cross hatch 22 32 Microfinish measured in direction of piston travel 25 29 3 Cylinder bore surface roughness Channeled Chrome using 180 grit stone cross hatch 22 32 Finish all area within ring travel Must show evidence of contact with honing stone Partially honed areas shall not exceed 10 of bore surface and no area shall exceed one inch in any direction Finish pitting is undesirable if present it is subject to the following limits Pits No more than two pits in any 1 4 inch Diameter circle Not more than 25 pits of any one size in entire cylinder bore is acceptable Pit Size Diameter 031 5 Cylinder bore surface roughness Cermicrome Finish pitting is undesirable if present it is subject to the following limits Pits No more than two pits in 1 4 inch Diameter circle Not more than 25 pits of any one size in entire cylinder bore is acceptable Pit Size Diameter 031 8 25024 idth idth ROCKERARMSANDSHAFTS 13 0 0150 0 020 Description Servicable Limit Max CYLINDER AND HEAD ASSEMBLY 100 0 2000 Hed Piston pin Diameter Piston pin 0 005 oversize Diameter 1 0034 SPRING TEST DATA Lc c Inner valve spring 625957 c
66. Adjustment and Test At the completion of all 50 100 hour inspection procedures see Chapter 23 and perform the post maintenance operational test WARNING The figures depicted in this publication are for illustration purposes only They are not intended to be accurate detailed illustrations of any specific engine model part or equipment 10 1 INTENTIONALLY LEFT BLANK 10 2 SECTION 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 FIGURE 11 1 11 2 11 3 11 4 11 5 11 6 11 6 CHAPTER 11 EXHAUST SYSTEM PAGE Exhaust System Description sees 11 2 Turbocharger Detailed Description 11 4 Exhaust By pass Valve Wastegate Detailed Description 11 5 Variable Absolute Pressure Controller Detailed Description 11 6 Turbocharger Lubrication System 11 7 Exhaust System Inspection eese ennt nnns 11 7 Exhaust System Troubleshooting eene 11 9 Exhaust System 11 11 PAGE Induction and Exhaust System Schematic 11 3 Basic Turbocharger enia naa a Rd 11 4 Turbocharger Sectional
67. An FAA PMA is issued under FAR 21 305 The make and model information may be on a tag attached to the part d Shipping ticket invoice or other document which verifies the part was manufactured by a facility holding an FAA Approved Production Inspection System issued under FAR 21 Subpart F or by a manufacturer holding an FAA Production Certificate issued under FAR 21 Subpart G e Certificate of airworthiness for export issued by a foreign government under the provisions of FAR 21 Subpart N KNOW YOUR SUPPLIER Many reproduced parts and components are available for purchase and installation on US certified aircraft Often an original part is used as a sample to produce duplicates The reproduced parts appear to be as good as the original part however many unknown factors are not readily apparent to the purchaser such as degree of heat treating plating inspections tests and calibrations Often the faulty part is not discovered until a malfunction or an accident occurs SUMMARY In accordance with FAR certification of materials parts and appliances for return to service for use on aircraft is the responsibility of the person agency who signs the approval The owner operator is responsible for the continued airworthiness of the aircraft To assure continued safety in aircraft operation great care must be used when inspecting testing and determining the acceptability of all parts and materials Exercise extreme discretion to identify and esta
68. BLE CAUSE CORRECTION Exhaust system gas leakage Locate and correct in accordance with the airframe manufacturer s instructions Repair or replace in accordance with the airframe manufacturer s instructions Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Replace See Section 22 5 Engine Drive Train Maintenance Crankshaft Nose Oil Seal Torque or replace See the applicable disassembly reassembly portions of the L TSIO 360 Series Overhaul Manual Form X30596A for correct torque values Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Replace cylinder amp piston rings See Section 20 6 Cylinder Assembly Maintenance Slow Engine Acceleration Mixture too rich Momentarily pull mixture control back On A Hot Day until engine acceleration picks up Engine Will Not Stop At Idle Cut Off Fuel manifold valve not seating properly Climbing to Altitude Fuel Flow Fluctuates Fuel Vaporization Fuel mixture too rich Low Fuel Pressure Incorrect fuel pump adjustment and operation Malfunctioning fuel pump relief valve High Fuel Pressure Malfunctioning relief valve operation in fuel pump Restricted re circulation passage in fuel pump Repair or replace fuel manifold valve See Section 13 5 Fuel System Maintenance Fuel Manifold Valve Operate fuel boost pump in accordance with the air
69. CT FOR BULGES OR HOT SPOTS FIGURE 11 6 SLIP JOINT ASSEMBLY T BOLT FASTENER INNER SEGMENT INNER SEGMENT OUTER RADII BAND CONTACT 100 LESS THAN 062 INCH CLEARANCE OUTER BAND UE INNER SEGMENT NORMALLY FLAT FIGURE 11 7 MULTI SEGMENT V BAND CLAMP 11 7 EXHAUST SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given check other listings of troubles with similar symptoms ltems are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Lacks Power Improperly adjusted controller To adjust the controller see Reduction In Maximum Chapter 23 Manifold Pressure or Critical Altitude Loose or damaged exhaust Inspect entire exhaust system to system turbocharger for cracks and leaking connections Torque connections and replace damaged parts Malfunctioning turbocharger Check for unusual noise in turbocharger If malfunction is suspected remove exhaust and or air inlet connections and check rotor assembly for possible rubbing in housing damaged rotor or damaged bearings Per component manufacturer s instructions replace if turbocharger damage is noted Exhaust system gas leakage Inspect exhaust system for gas leakage gaskets at cylinder exhaust ports gaskets at turbine inlet flanges etc and correct White Smoke Exhaust Turbo coking oil forced through Cl
70. ELETE TNT TA TELT ETALE ELLE L Hts fib tT TEER EET E tt SO eA tt tet amp 82r09 OIS 1 1 1313 gassia SA Tans E ITI TET ttt PET LLLLLELELELLLECLLEELEEELLELLEEEINLLLEEL LLLLLCLLLELEEEEELLEEELLCELEELLEINNL tN LLLLLLELLLELELLELLI pt TT ee LLILLELEEELLELLTLELET ELE ELELLLTT LLLLLLLLCLLLLLLLELETEELTEEEEETELLLLEN thet ttt A E RRR REA NAR LEE TET TTT TT Ne LLITTTTTTEEETLLLLLLELELLLELELLELELELELELELEENCL LL ELE EE 1 PTET LALAT PET NT LEP TTT TTT ee TTT TAT FIGURE 23 7 FUEL FLOW VS METERED FUEL PRESSURE FUEL FLOW FUEL FLOW vs BRAKE HORSEPOWER L TSIO 360 RB 150 1 Continuous operation at Turbine Inlet Temperature T i T 140 1 in excess of 1650 F is prohibited 2 Manual leaning permitted to minimum SFC approx 42 LBS BHP HR as long as 1650 F is not exceeded at 75 power and below 130 3 Manual leaning to T I T 1550 F maximum permitted as long FULL RICH as cylinder head temperature remains below 420 F and oil 120 temperature does not exceed 200 F at 80 power and below
71. EX Installation Drawing 5 360 6 6 Installation Drawing L TSIO 360 RB 6 7 Installation Drawing L TSIO 360 RB 6 8 Installation Drawing L TSIO 360 RB 6 9 6 1 INTENTIONALLY LEFT BLANK 6 1 6 3 GENERAL Technicians involved with engine preparation and installation into the airframe must possess a detailed knowledge of safe procedures used in engine servicing and the operation of ground support equipment The engine must have a detailed visual inspection prior to installation in the airframe UNPACKING Packaging Category A Cardboard Container 1 Cut steel banding straps securing the container Use caution as straps may spring loose when cut Remove the staples from the base of the cardboard cover Lift cardboard cover vertically and remove Attach a hoist to the engine lifting eye located at the top of the crankcase backbone Take up slack on the hoist then cut the steel banding straps holding the engine to the base Use caution as straps may spring loose when cut Lift the engine vertically and install on a transportation stand or dolly CAUTION Do not allow chains to become entangled on engine or its hardware Packaging Category B Wooden Container 1 Remove the 4 fo
72. F or equivalent For Temporary storage up to 90 days MIL P 46002 Grade 1 oil NOX RUST VCI 105 For Indefinite storage or equivalent May be purchased through Rock Island Lubricant amp Chemical Co P O Box 5015 1320 1st Street Rock Island Illinois 61204 Phone 1 800 522 1150 TYPE SUGGESTED SOURCES APPLICATION Molyshield Grease May be purchased through Needle bearings and ball bearings American Lubricants Valve stems 1227 Deeds All ACC drive splines Dayton Ohio 45401 couplings Phone 513 222 2851 Idler gear and pin Fuel injection controls o rings springs shafts and bushings Magneto rubber drive bushings Dow Corning G N Paste For Distributor information call Camshaft lobes and lifter faces Dow Corning amp G N Paste is a 1 800 248 2481 have state amp city registered trademark of Dow information available Corning Corporation Alvania Shell 2 For Distributor information Shell Front crankshaft oil seal Product Information Center Phone 1 800 231 6950 MIL S 3545C Grease Shell 5 Shell Product Information Center Fuel injection linkage pivot points Phone 1 800 231 6950 throttle shaft bushings lever bushings Permatex Maintain Lubricant For Distributor information call Fuel injection linkage pivot points Permatex Customer Service throttle shaft bushings Phone 1 800 641 7376 bushings 646943 Anti Seize Lubricant May be purchased through All fuel injector
73. Figure 22 5 Helix Pattern Application Remove plating by working a piece of very fine emery cloth back and forth around the shaft This should blend the finish uniformly without leaving any lines scratches 22 5 DIRECTION OF PATTERN MARKS 30 THIS DISTANCE lt 1 D FIGURE 22 5 HELIX PATTERN APPLICATION TSIO 360 4 See Figure 22 5 Helix Pattern Application Apply helix using a strip of 180 grit emery cloth approximately one half inch wide Do approximately one quarter of the surface indicated at a time stroking the cloth outward toward the propeller flange in the direction of rotation CCW towards you using maximum hand pressure Reverse direction for left hand rotating engines This should result in a 30 pattern similar to that illustrated in Figure 22 5 Helix Pattern Application After doing the first portion rotate crankshaft by hand to make next portion available Apply the same pattern again and continue completely around the crankshaft in this manner 22 6 Repeat cleaning operation INSTALLATION 1 Use only oil seal assembly P N 530917 which consists of an oil seal and spring P N 530974 Check the spring length It should be 7 9 16 1 32 in length See Figure 22 6 Crankshaft Oil Seal Remove spring from new oil seal Unhook the spring ends using an unwinding motion Wrap spring around shaft in seal area Turn spring ends in unwinding direction then join and allow
74. ICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 12 4 TIMING POSITION STEP 1 12 9 5 Slowly rotate the crankshaft in the opposite direction of normal rotation until the piston lightly touches the dead center locator Observe reading on the disk under the pointer NOTE DIAL INDICATOR POSITIONS SHWON ARE EXAMPLES ONLY POSITIONS ON THE PROTRACTOR TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE POSITIVE DEAD CENTER LOCATOR INSTALLED 1 CYLINDER PISTON LIGHTLY TOUCHING OPPOSITE NORMAL DIRECTION OF ROTATION NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 12 5 TIMING POSITION STEP 2 6 Move the disk to exactly one half of the number of degrees observed toward the top center mark NOTE DIAL INDICATOR POSITIONS SHWON ARE EXAMPLES ONLY POSITIONS ON THE PROTRACTOR TIMING INDICATOR DISC WILL DIFFER FROM ENGINE TO ENGINE POSITIVE DEAD CENTER LOCATOR INSTALLED 1 CYLINDER PISTON LIGHTLY TOUCHING NORMAL DIRECTION OF ROTATION NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 12 5 TIMING POSITION STEP 3 7 This will be approximately one half the number of degrees remaining of 360 degrees of crankshaft rotation You have now located top dead center 12 10 8 Remove the top dead center locator from the number 1 cylinder and find the com
75. ING Liquid cooled cylinders In addition to 5 6 and 7 above as applicable inspect cylinder head cooling jacket for leaks Thoroughly wash the entire engine with an approved cleaning solution and repeat the visual inspection outlined above CAUTION Failure to properly install and maintain engine baffles and baffle seals will adversely affect cylinder service life Insure magneto to engine timing is within specifications CAUTION Magnetos using riveted type impulse coupling require repetitive 100 hour inspection Clean inspect gap test and rotate all spark plugs WARNING Worn spark plugs that are continued in service may cause internal arcing in the magnetos 12 Check all engine controls control cables control rod ends and levers for security wear improper assembly routing and freedom of movement throughout the entire range of travel WARNING Insure fuel selector is in the off position prior to removing the fuel metering unit inlet screen 13 14 Inspect fuel nozzles upper deck and fuel injection nozzle reference lines hoses manifolds and fittings for proper routing support and signs of fuel stains Inspect manifold valve for security of installation proper venting and signs of fuel stains At the first 100 hour inspection on new rebuilt or overhauled engines remove fuel injection nozzles Clean nozzles by soaking in lacquer thinner acetone or methyl ethyl ketone MEK Fu
76. L OUTLET PORT ASSEMBLY TO ENGINE SUMP POPPET SEAT FIGURE 23 4 CONTROLLER ADJUSTMENT 23 7 39 T 38 a lt 37 100 120 140 160 180 200 220 240 OIL TEMPERATURE DEGREES FAHRENHEIT FIGURE 23 5 ADMP VS OIL TEMPERATURE c Adjust fuel flow rates Set the engines to 2600 rpm the manifold pressure to 38 0 Hg And the mixture controls to full rich Adjust fuel flow rates to the range of 24 0 to 25 0 gallons per hour with the fuel flow adjustment knob that is located on the top left side of the FSA 5 fuel servo Turn the knob clockwise to decrease the fuel flow or counter clockwise to reduce it Turning the knob seven clicks in either direction reduces or increases fuel flow approximately 1 gallon per hour The final fuel flow setting shall not exceed 15 clicks in the counter clockwise LEAN direction Recheck a Recheck idle settings 700 25 RPM and adjust as required b Recheck full power settings as specified above and adjust as required c Remove test equipment in accordance with the manufacturer s instructions d After all ground checks and adjustments are completed check to insure that all lines that 23 8 were disconnected during setup have been reconnected and torqued to specified values Safety wire mixture adjustment knob Torque jam nut on the controller adjustment screw to the limit specified in the L TSIO 360 Series Overhaul Manual Form X30596A to prevent
77. L TSIO 360 RB series engines see section 5 2 and the latest TBO Service Bulletin Overhaul Periods For All Teledyne Continental Aircraft Engines Accessories supplied with engine by TCM have the same TBO with criteria for service and longevity outlined in current TCM TBO Service Bulletins unless otherwise specified ENGINE SPECIFICATIONS Manufacturer Teledyne Continental Motors Model L TSIO 360 RB Cylinders Arrangement Individual cylinders in a horizontally opposed position Compression etm b e a E RERO Urge da 7 5 1 Firing Order TS10 360 RB 1 6 3 2 5 4 Firing Order ETSIO 300 RB 1 4 5 2 3 6 66 ET A 6 Bore 5 4 438 Stroke 5 3 875 Piston Displacement in cus ease 360 Brake Horsepower Rated Maximum Continuous Operation L TSIO 360 RB 220 BHP OPERATING LIMITS NOTE The following specifications apply to all L TSIO 360 RB engines unless otherwise specified Crankshaft Speed RPM L TSIO 360 RB Rated Maximum Continuous Operation 2600 RPM t s DS icr 700 RPM 25 Manifold Pressure Limit In H
78. LACE THE CYLINDER See Section 20 6 Cylinder Maintenance Dynamic Seal Check See Figure 20 9 Dynamic Seal 9 To check the dynamic seal of a cylinder proceed with the leakage test and observe the pressure indication of the cylinder pressure gauge The difference between this pressure and the pressure shown by the regulator gauge is the amount of leakage at the dynamic seal 20 11 10 If the leakage is below the previously determined low cylinder gauge reading loss past the 20 12 dynamic seal may be due to piston ring end gap alignment or by the piston and piston rings angular direction in the cylinder bore see Figure 20 11 Ring Positioning First insure that the piston and piston rings are centered This can be accomplished by reducing regulator pressure to 20 pounds per square inch and working piston through top dead center several times bringing the piston to top dead center in the normal direction of engine rotation Adjust regulated pressure to 80 pounds per square inch and determine amount of loss If the gauge reading is higher than the previously determined master orifice calibrated reading proceed to next cylinder to be tested NOTE Piston ring rotation within the ring land is a normal design characteristic As illustrated in Figure 20 11 Ring Positioning the compression ring location may have a direct bearing on the dynamic seal pressure check Therefore complete the test in the opposite direction if readin
79. LLATION DRAWING cont d 7 7 698 lt OUTSIDE OF FLANGE AFTERCOOLER DETAIL BUSHING PROP CONTROL SUPPORT ENGINE MOUNT X p TO ACC CASE M N Y NS TRUE VIEW FOCAL SECTION D D N ANGLE 4 PLACES 2 4 6 SIDE THEORETICAL ENGINE VERTICAL IDLE CUT OFF CENTERLINE 1915 1955 DIA N EO DATUM Y 9 00 MIXTURE CONTROL LEVER MAY BE POSITIONED THROUGH 360 IN INCREMENTS OF 15 1 637 FUEL LINE 1 613 INDUCTION TUBE 5 INJECTOR 22 59 FULL RICH VIEW A A SECTION K K TYPICAL 6 PLACES FIGURE 6 1 INSTALLATION DRAWING cont d 6 8 FUEL OUTLET 4375 20UNJF 3A THDS PER MS33656G4 GROUND TERMINAL 190 32 UNC 2A TORQUE TO 15 17 INCH POUNDS ACCESSORY DRIVE PAD AND20000 TYPE X 1 545 X ENGINE SPEED C C W ROTATION TACH SENSOR ONE MAGNETO VIEW E E SCAVENGE PUMP AND ACCESSORY DRIVE LTSI0 360 RB ONLY VIEW F F GROUND TERMINAL 190 24 UNC 2A BATTERY TERMINAL 25 20 UNF 2A TORQUE TO 75 85 CI CONES di INCH POUNDS 313 18 UNC 2A STARTER TERMINAL X TORQUE TO 180 220 7 INCH POUNDS FIELD TERMINAL 190 24 UNC 2A TORQUE TO 21 25 AUX TERMINAL INCH POUNDS 190 24 UNC 2A TORQUE TO 21 25 500 521 VIEW G G INCH POUNDS 12 90 13 23 PM ALTERNATOR 6 HOLES MARKED X 4 000 101 60 AIR INLET 25 HOSE ENGINE 4 880 123 95 562
80. MAINTENANCE MANUAL TSIO 360 RB Courtesy of Bomar Flying Service www bomar biz PART NO X30645A FAA APPROVED 01996 TELEDYNE INDUSTRIES INC OCTOBER 1996 DEFINITIONS OF NOTES CAUTIONS and WARNINGS NOTES CAUTIONS and WARNINGS are defined for the use in this manual as follows NOTE Special interest information which may facilitate performance of a procedure or operation of equipment CAUTION Used to emphasize certain information or instructions which if disregarded may result in damage to engine or accessories WARNING Used to provide warning with respect to information and or instructions which if disregarded will endanger personnel and or severely damage the engine resulting in subsequent engine malfunction or failure Notes cautions and warnings do not impose undue restrictions They are inserted to obtain maximum safety efficiency and performance Abuse misuse or neglect of equipment can cause eventual engine malfunction or failure CFC WARNING STATEMENT The United States Environmental Protection Agency EPA has adopted regulations under the Clean Air Act which require warning statements accompany all products manufactured with or which contain a Class 1 ozone depleting substance as defined in EPA regulation 58 Federal Regulation 8136 February 11 1993 Teledyne Continental Motors is pursuing alternatives to these substances to eliminate their use as soon as possible WARNING Manufactured with 1 1 1 tri
81. Manifold Valve TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Run At Idling Speed Rough Idling Engine Runs Too Lean At Cruising Power Engine Runs Too Rich At Cruising Power Engine Runs Too Lean Or Too Rich At Throttle Setting Other Than Cruise Continuous Fouling Of Spark Plugs Fuel injection system improperly adjusted Air leak in intake manifold Fuel injection system improperly adjusted Mixture levers set for improper mixture Fouled Spark Plugs Hydraulic lifters fouled Burned or warped exhaust valves worn seat scored valve guides Improper manual leaning procedure Fuel injection system maladjusted Restrictions in air intake passages Improper manual leaning of fuel Air mixture Fuel injection system maladjusted Piston rings excessively worn or broken Piston rings are not seated See Section 13 4 Fuel Injection System Troubleshooting Torque loose connection or replace damaged part See Section 14 5 Induction System Maintenance See Section 13 4 Fuel Injection System Troubleshooting Adjust the manual mixture control in accordance with the airframe manufacturer s Airplane Flight Manual AFM Remove clean and adjust gaps See Section 12 6 Ignition System Maintenance Spark Plugs Remove and clean lifters Inspect and clean oil filter at more frequent intervals See Section 20 6 Cylinder Assembly Maintenance Hydraulic Valve Tappets
82. Mobil Oil Company NYCO S A Pennzoil Company Phillips Petroleum Company Phillips Petroleum Company Quaker State Oil amp Refining Company Red Ram Limited Canada Shell Australia Shell Canada Limited Shell Oil Company Sinclair Oil Company Texaco Inc Total France Union Oil Company of California Brand Name BP Aero Oil Castrol Aero AD Oil Castrol Aero AD Oil Chevron Aero Oil Conco Aero S Delta Avoil Cil Exxon Aviation Oil EE Gulfpride Aviation AD Mobil Aero Cil TURBONYCOIL 3570 Pennzoil Aircraft Engine Oil Phillips 66 Aviation Oil Type A X C Aviation Multiviscosity Oil SAE 20W50 SAE 20W60 Quaker State AD Aviation Engine Oil Red Ram X C Aviation Oil 20W50 Aeroshell R W Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell 15W50 Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W15 Sinclair Avoil Texaco Aircraft Engine Oil Premium AD Total Aero DM 15W50 Union Aircraft Engine Oil HD Break in Oil MIL C 6529 Type Corrosion preventive mineral oil NOTE Mineral oil conforming with MIL C 6529 Type contains a corrosion preventive additive and must not be used for more than 25 hours or six months whichever occurs first oil consumption has not stabilized in this time drain and replenish the oil and replace the oil filter Preservative Oil TYPE SUGGESTED SOURCES APPLICATION MIL C 6529 Type Aeroshell Fluid 2
83. N Reface pressure relief valve seat using light finger pressure when turning refacing tool After the refacing procedure the depth from the top of the oil pump housing to the seat face must not exceed the specified limit item 2 in Figure 19 8 Lubrication System Service Limits Accessory cases with oil pressure relief valve housings that exceed specified limits must be discarded CAUTION Thoroughly clean oil pressure relief valve cavity after refacing procedure All debris from the refacing procedure must be removed Reassemble serviceable or new relief valve housing and adjusting screw Turn adjusting screw into housing about halfway Install new copper washer and nut Assemble plunger spring washer and slide into housing Coat housing threads with TCM anti seize lubricant insure relief valve components are aligned and install in oil pump housing Torque housing to 240 260 inch pounds Safety wire oil pressure relief valve housing in accordance with Section 9 2 Lockwire Procedure The engine oil pressure must be adjusted prior to release for return to service in accordance with Section 23 2 Oil Pressure Adjustment Oil Temperature Control Valve Remove the oil temperature control valve and inspect the valve seat for scoring nicks roughness or deterioration Inspect oil temperature control valve limits in accordance with Section 19 5 temperature control valves exhibiting any of the above indications or that exceed sp
84. NG Fuel injection lines must not be bent or deformed The fuel injection lines must be securely clamped to the fuel line support brackets Do not assemble in a binding configuration Single Cylinder Removal Disconnect battery in accordance with the airframe manufacturer s instructions Tag the propeller with the warning DO NOT TURN PROPELLER Remove cowling and any airframe supplied accessories in accordance with the airframe manufacturer s instructions Remove cylinder using cylinder and piston removal instructions in the L TSIO 360 Series Overhaul Manual Form X30596A When the cylinder is removed with the spark plugs installed inspection can be accomplished by filling the inverted cylinder bore with nonflammable solvent and then inspected for leaks at the static seal areas When cylinder is removed use the following information to clean pistons prior to dimensional inspection Pistons Do not use wire brushes or scrapers of any kind Soft or hard carbon deposits may yield to solvent action If deposits remain install tight fitting skirt protector sand blast the piston heads with soft grit or by the vapor grit method Do not use sand shot metal grit or glass beads Ring grooves must be cleaned by pulling lengths of binder twine or very narrow strips of crocus cloth through them Do not use automotive ring grooves scrapers since the corner radii at the bottoms of the grooves and side clearances must not be altered Abrasive
85. OIL IN FROM 2 4 6 OIL RETURN TO SIDE CRANKCASE ACCESSORY CASE OIL RETURN TO SCAVENGE PUMP OIL SUPPLY FROM OIL FILTER ADAPTER 4 AIR INLET 29 COMPRESSOR TURBINE 12 EXHAUST GAS DISCHARGE FIGURE 11 1 INDUCTION AND EXHAUST SYSTEM 11 3 11 2 TURBOCHARGER DETAILED DESCRIPTION The turbocharger consists of a radial inward flow turbine and turbine housing a centrifugal flow impeller compressor and compressor housing each bolted to a center housing The center housing incorporates bearings that support the turbine compressor shaft The shaft and bearings are lubricated with pressurized engine oil that enters the center housing through an oil inlet check valve and fitting Drilled passages direct the pressurized oil to the bearings After passing through the bearings the oil is evacuated from the center housing oil outlet and check valve by an engine driven scavenge pump Oil seals installed outboard of the turbine compressor shaft bearings retain the oil in the center housing The inlet and outlet check valves prevent oil from flooding the center housing when the engine is not operating During engine operation exhaust gases from the engine pass through the turbine housing and cause the turbine wheel to rotate Since the turbine wheel and compressor are attached to a common shaft the compressor rotates with in the compressor housing The compressor impeller draws in ambient air through the aircraft induction system compresses the
86. ORMAL ELECTRODE CONDITION Insulator tip gray tan or light brown Few combustion deposits Electrodes not burned or eroded Proper type heat range plug for engine and service Spark plug should be cleaned regapped and tested before reinstallation NORMAL WORN OUT CONDITION Electrodes eroded by high voltage sparking and by corrosive gases formed during combustion to less than 1 2 original thickness More voltage needed to fire spark plugs often more than ignition system can produce Discard and replace with new spark plugs SEVERE WORN OUT CONDITION Excessively eroded center and ground electrodes 9 trodes er due for replacement Check fuel metering and magneto timing Discard spark plugs and check heat range before installing new ones FIGURE 12 3 SPARK PLUG WEAR 12 8 12 5 IGNITION SYSTEM MAINTENANCE Continued If the engine is equipped with a right angle drive starter adapter and does not freely turn in the opposite direction of normal rotation the starter motor must be removed from the starter adapter Some right angle starter drive adapters incorporate an over riding spring clutch design that restricts engine rotation in the opposite direction of normal rotation CAUTION The importance of establishing and maintaining correct magneto to engine timing cannot be overemphasized Incorrect timing in addition to producing a rough running engine can lead to detonation pre ignition and possible internal
87. OVER 31 35 Tos SHEET METAL COVERS 16 65 18 89 ACCESSORY DRIVE PAD FOCAL POINT OF X ENGINE SPEED FILLER ROTATION P AND sA dom po et p 8 18 n CRANKSHAFT Y f NS mu 3 em 11214 qn 6 83 E ri d 49 OIL COOLER lt A ANE el ZS d D 4 2 75 COMPRESSOR 725 pers SU AM INLET a j CYLINDER DRAIN X JN e 2 CONNECTION OIL TEMPERATURE vA T oL MINIS CONTROL VALVE 376 18 NPTF p n 27 44 4 56 14 63 PUMP a 274 7 44 4 56 16 24 RELIEF VALVE TURBINE OIL RETURN FROM oro SDE INLET AIR OIL SEPARATOR 60 8028 18UNJF 3A Gprostre sive FOR LTSIO 360 RB PER AND 10050 4 FIGURE 1 2 ENGINE DESCRIPTION L TSIO 360 RB Cont d 1 7 gt lt OUTSIDE OF 3 65 3 38 6 32 6 85 od 7 7 et 696 0 2 e OUTSIDE OF FLANGE AFTERCOOLER DETAIL BUSHING PROP CONTROL SUPPORT ENGINE MOUNT 66 par TO ACC CASE lt 18 M x Y TRUE VIEW FOCAL ANGLE 4 PLACES THEORETICAL Come VERTICAL CENTERLINE N SECTION D D 2 4 6 SIDE x DATUM Y IDLE CUT OFF 1915 1965 DIA MIXTURE CONTROL LEVER MAY BE POSITIONED THROUGH 360 IN INCREMENTS OF
88. RSANT OILS BP Oil Corporation Castrol Castrol Limited Australia Chevron U S A Inc Continental Oil Delta Petroleum Company Exxon Company U S A Gulf Oil Company Mobil Oil Company NYCO S A Pennzoil Company Phillips Petroleum Company Phillips Petroleum Company Quaker State Oil amp Refining Company Red Ram Limited Canada Shell Australia Shell Canada Limited Shell Oil Company Sinclair Oil Company Texaco Inc Total France Union Oil Company of California APPROVED MINERAL OIL MIL C 6529 TYPE Il FUEL Aviation Minimum Grade BP Aero Oil Castrol Aero AD Oil Castrol Aero AD Oil Chevron Aero Oil Conco Aero S Delta Avoil Oil Exxon Aviation Oil EE Gulfpride Aviation AD Mobil Aero Oil TURBONYCOIL 3570 Pennzoil Aircraft Engine Oil Phillips 66 Aviation Oil Type A X C Aviation Multiviscosity Oil SAE 20W50 SAE 20W60 Quaker State AD Aviation Engine Oil Red Ram X C Aviation Oil 20W50 Aeroshell R W Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W50 Aeroshell Oil W Aeroshell Oil W 15W50 Anti Wear Formulation Aeroshell Oil W 15W15 Sinclair Avoil Texaco Aircraft Engine Oil Premium AD Total Aero DM 15W50 Union Aircraft Engine Oil HD 100LL Blue or 100 Green WARNING The use of lower octane rated fuel or jet fuel will result in damage or destruction of an engine the first time high power is applied This would most likely occur on takeoff If th
89. RY CASE PAGE secre ER 18 2 Accessory Case Detailed Description 18 2 Accessory Gase Inspection Iri pel dH RERO 18 4 Accessory Gase Troubleshooting 18 4 Accessory Case 18 4 Accessory Case Description nid nnne area ede 18 3 18 1 18 1 18 2 18 2 ACCESSORY CASE The aluminum alloy casting is attached to the rear of the engine crankcase Crankcase dowels align the accessory case with the crankcase The accessory case is secured to the crankcase by crankcase studs and various attaching hardware Accessory mount pads on the rear surface are machined in one plane parallel to the machined parting flange which surrounds the front side of the casting Mounting pads for the magnetos alternator cover starter tachometer drive oil filter adapter oil pressure relief valve and an oil suction screen boss are provided The oil pump housing is machined into the internal portion of the accessory case ACCESSORY CASE DETAILED DESCRIPTION See Figure 18 1 for accessory locations A machined threaded boss is located on the lower right hand side of the L TSIO 360 RB and lower left hand side of the TSIO 360 RB accessory case for installation of an oil pressure relief valve The front face of the accessory case is machined flat to mate with the crankcase Oil pump gear chambers are m
90. Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Refer to the airframe manufacturer s Airplane Flight Manual AFM for engine operating instructions See Section 13 4 Fuel Injection System Troubleshooting Check passages and remove restrictions See the airframe manufacturer s Airplane Flight Manual AFM for correct leaning procedure See Section 13 4 Fuel Injection System Troubleshooting Replace rings Replace cylinder if damaged See Section 20 6 Cylinder Assembly Maintenance Hone cylinder walls replace rings See Section 20 6 Cylinder Assembly Maintenance TROUBLE PROBABLE CAUSE CORRECTION Engine Runs Rough At Loose mounting bolts or Torque mounting bolts Replace High Speed damaged mount pads mount pads See Section 21 5 Crankcase Maintenance Engine Mounts Plugged fuel nozzle jet Clean See Section 13 5 Fuel System Maintenance Fuel Nozzles Propeller out of balance Remove and repair in accordance with airframe manufacturer s instructions Ignition system malfunction See Section 12 5 Ignition Troubleshooting Continuous Missing At Broken valve spring Replace See Section 20 6 High Speed Cylinder Assembly Maintenance Continuous Missing At Plugged fuel nozzle jet Clean See Section 13 5 Fuel High Speed Cont d System Maintenance Fuel Nozzles Burned or warped valve Repair cylinder See Section 20 6 Cylinder Assembly Maintenance Hydraulic
91. SIO 360 Overhaul manual Form X30596A 13 10 SECTION 14 1 14 2 14 3 14 4 14 5 FIGURE 14 2 CHAPTER 14 INDUCTION SYSTEM PAGE Induction System Descriptloh eene itn e tee rn nee ee 14 3 Overboost Valve Detailed Description 14 3 Induction System Inspection 50 100 Hour ess 14 4 Induction System 14 4 Induction System Maintenance 14 5 ssim me 14 3 14 1 14 1 14 2 14 2 INDUCTION SYSTEM DESCRIPTION See Figure 11 1 Induction and Exhaust System Schematic for induction system components and induction air flow The induction system is mounted above the engine It serves to carry induction air to the individual cylinder intake ports Engine components through which air flows following the aircraft air inlet filter alternate air door are turbocharger compressor aftercooler overboost controller adapter fuel servo unit throttle area balanced manifold induction tubes and cylinder intake ports Air flows through these components in the order they are listed As the compressor wheel rotates high volume compressed intake air is discharged from the compressor housing outlet The compressed air flows through induction tubing to the aftercooler The cooled compressed air flows from the aftercooler through induction tubes to the throttle assembly Installed on the con
92. T Check and record the following system data SLALOM PEE Record RPM Drop for each magneto at 1700 150 RPM MAXIMUM AND 50 RPM SPREAD MAXIMUM Propeller Operation at 1700 Or as specified in aircraft manufacturer s instructions Increase engine to full power and record Manifold eene RUSH ROW E Dre aei aeree Oil Cylinder Head Temperature Alternator Output Reduce engine to idle and record Manifold OIlPEOSSUFO Oil Cylinder Head Temperature eese Magneto System Grounding CAUTION The magneto system grounding check must be accomplished at idle RPM only Damage to the engine may result at engine speeds above idle RPM WARNING Absence of RPM drop when checking magnetos is an indication of a malfunction in the ignition system resulting in a hot magneto This type of malfunction must be corrected prior to continued operation of the engine The engine may inadvertently experience ignition or start up anytime the propeller is moved Damage injury or death may resu
93. TCM Service Bulletin M90 17 or current revision as applicable continued on next page 21 5 21 4 CRANKCASE TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listing of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Cil Loss Loose accessories or deteriorated See Section 21 5 Crankcase Maintenance gaskets Cracked crankcase See Section 21 3 Crankcase Inspection Insufficient torque Torque hardware to proper value in accordance with the TSI0 360 Series Overhaul Manual Form X30596A Loose Accessories Loose or stripped studs See Section 21 5 Studs Insufficient torque Torque hardware to proper value in accordance with Most current version of the L TSIO 360 Series Overhaul Manual X30596A Engine Runs Rough Cracked engine mount See Section 21 5 Engine Mounts Excessive Crankcase Pressure Cylinder blow by See Section 20 4 Cylinder Compression Test 21 5 CRANKCASE MAINTENANCE Crankcase Leaking gaskets must be replaced Remove component replace gasket and re install component in accordance with applicable system or component section in the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A Exercise judgment as to the extent of disassembly required During reassembly insure that all reinstal
94. TEM COMPONENT DETAILED DESCRIPTION Alternator For a detailed description of TCM alternators see TCM Form No X30531 3 Alternator Service Instructions See Section 1 4 Related Publications for ordering information CHARGING SYSTEM INSPECTION 50 Hour Visually inspect the alternator mounting hardware for security and corrosion Inspect the alternator and mounts for cracks The drive belt belt and electrical connections must be inspected in accordance with the airframe manufacturer s instructions 100 Hour Perform all requirements of 50 hour inspection Compare findings of engine operational inspection with Airframe Manufacturer s Alternator Output And Load Specifications During inspection of charging system any indication of an alternator malfunction will require alternator removal The alternator may be removed for repair or replacement in accordance with the applicable portions of the L TSIO 360 Overhaul Manual Form X30596A alternator disassembly reassembly CHARGING SYSTEM TROUBLESHOOTING Refer to the airframe manufacturers applicable charging system troubleshooting information CHARGING SYSTEM MAINTENANCE Alternator For maintenance or repair of TCM alternators See TCM Form No X30531 3 Alternator Service Instructions The alternator and mounting bracket may be removed for repair or replacement in accordance with the applicable portions of the L TSIO 360 Overhaul Manual Form X30596A alternator disassembly reassembly
95. ace preparation before applying gasket maker at the engine nose seal area INSTALLATION OF GASKETS All gaskets must be new and visually inspected prior to installation If the gasket shows any indication of gouges nicks cuts or bends discard it and obtain an undamaged gasket Gasket surfaces must be clean and free of oils and grit Apply a thin coat of TCM Gasket Sealant 642188 to both sides of gasket where specified Once gasket sealant has been applied install gasket Install assembly and evenly torque hardware WARNING Gaskets and components must be properly positioned hardware torqued and safetied as required during assembly to prevent oil loss 10 1 CHAPTER 10 ENGINE MAINTENANCE GENERAL During engine 50 and 100 hour inspections if engine components must be remove and replaced refer to the applicable disassembly reassembly instructions found in the TSIO 360 Series Overhaul Manual Form OH 08 as outlined in Maintenance Section of each system NOTE Engine operational inspection must be performed prior to any 50 100 hour static inspections See Section 5 3 Operational Inspection Compare recorded findings of operational inspection to Operating Limits Section 1 10 and information listed under applicable system 50 and 100 hour inspection of the following chapters Corrections and adjustments will be found in the individual system chapters of this manual under Maintenance and Chapter 23 Post Maintenance
96. achined in the interior of the accessory case The oil pump is driven by the cam gear Passages are cast into the accessory case to allow oil to flow from the oil sump through the suction tube to the oil pump gears pressure relief valve and main oil gallery The accessory case is sealed to the crankcase and oil sump by a gasket Oil Suction Screen Boss A threaded oil screen boss is located on the bottom left hand side of the accessory case LTSIO 360 RB EXTERNAL VIEW OF ACCESSORY CASE STARTER ADAPTER MOUNT FLANGE MAGNETO MOUNT FLANGES ACCESSORY CASE INTERNAL VIEW ALTERNATOR COVER FLANGE OIL PRESSURE RELIEF VALVE Boss Oll SUCTION OIL FILTER ADAPTER SCREEN Boss MOUNT FLANGE fi DIL FILLER NECK STARTER ADAPTER MOUNT FLANGE HOUSING TSI0 360 RB EXTERNAL VIEW OF ACCESSORY CASE TACH DRIVE MOUNT FLANGE OIL PRESSURE RELIEF VALVE BOSS OIL SUCTION OIL FILTER ADAPTER SCREEN BOSS MOUNT FLANGE FIGURE 18 1 ACCESSORY CASE DESCRIPTION 18 3 ACCESSORY CASE INSPECTION 50 Hour Visually inspect accessories for security and all gasket areas for oil leaks All accessory studs must be visually inspected and checked for security Safety mechanisms such as lockwire and locking tab washers must be inspected for proper installation and security Inspect all areas of the accessory case for cracks 100 Hour Perform all inspection requirements of 50 hour inspection 18 4 ACCESSORY CASE TROUBLESHOOTING
97. aft attitude should be adjusted as required to maintain engine temperatures and pressures within specifications Descent from high altitude should be accomplished at low cruise power settings During descent engine pressures and temperatures must be carefully monitored Avoid long descents with cruise RPM and manifold pressure below 18 Hg CAUTION Rapid descents at high RPM and low manifold pressure are to be avoided During descent monitor cylinder head and oil temperatures maintaining above the minimum recommended operating range NOTE Avoid long descents at low manifold pressure which can result in excessive engine cooling Satisfactory engine acceleration may not occur when power is applied Any discrepancies detected during test flight must be corrected and the aircraft again test flown prior to approval of engine for return to service The appropriate logbook entries must be made in accordance with Part 43 of the Federal Aviation Regulations FAR before the engine can be returned to service
98. aft gear 3 The scavenge pump is part of the starter adapter assembly and is driven by the starter shaft gear 16 which drives gear 17 and 18 OPTIONAL ACCESSORY FIGURE 22 1 ENGINE DRIVE TRAIN DESCRIPTION Crankshafts Gears 11 Right Magneto Drive Gear Crankshaft 12 Starter Camshaft Gear 13 Starter Coupling Camshaft 14 Worm Drive Shaft Hydraulic Tappet 15 Starter Worm Wheel Governor Drive Bevel Gear 16 Starter Shaftgear Governor Driven Bevel Gear 17 Scavenge Pump Drive Gear Oil Pump Drive Shaftgear 18 Scavenge Pump Driven Gear Oil Pump Driven Gear 19 Fuel Pump Drive Shaft Left Magneto Drive Gear continued on next page 22 2 ENGINE DRIVE TRAIN COMPONENT DETAILED DESCRIPTION Crankshaft The crankshaft has four machined main journals which are supported by precision bearing inserts in each of the four bearing saddles machined in the crankcase Six machined rod journals provide attachment of the connecting rod assemblies Figure 22 2 shows the method of numbering the crankshaft main journals connecting rod journals and crankshaft cheeks which are identified by letters and location numbers Counterweights assemblies are supplied in matched pairs with the bushings installed Maximum weight difference not to exceed 2 grams The counterweight order number designates the vibration frequency the counterweight is absorbing If a vibration frequency occurs six times per revolution the counterweight is designated
99. aft if the piston is not at top dead center The propeller must be secured during check to prevent rotation Open the cylinder pressure valve completely Check the regulator pressure gauge and adjust if necessary to 80 pounds per square inch Observe the pressure indication on the cylinder pressure gage The difference between this pressure and the pressure shown by the regulator pressure gauge is the amount of leakage through the cylinder If the cylinder pressure gauge reading is higher than the previously determined master orifice calibrated pressure reading proceed to the next cylinder and perform leak check If the cylinder pressure gauge reading is lower proceed with the following Document cylinder compression pressure Static Seal Check See Figure 20 8 Static Seal 6 First check the static seal for leakage Positive identification of static seal leakage is possible by listening for air flow sound at the exhaust or induction system port When checking for cylinder head to barrel leakage use a soapy solution between the fins and watch for bubbles Use a soapy solution around both spark plug seals for leakage NO LEAKAGE IS ALLOWED IN STATIC SEALS If leakage is occurring in the intake or exhaust valve areas See Section 20 6 Cylinder Maintenance for staking valves Leakage by the valves must be eliminated before a dynamic seal check can be performed If leakage is noted between the cylinder head and barrel REP
100. agneto timing can be expected during normal engine service The time and effort required to check and adjust the magnetos to specifications is slight and the operator will be rewarded with longer contact point life smoother engine operation and less corrective maintenance between routine inspections See Section 12 5 for ignition system maintenance of the harness magneto spark plugs and timing procedure WARNING Spark plug and spark plug lead maintenance is necessary to insure proper magneto operation Failure to maintain the spark plugs and ignition harness leads will result in ignition system malfunction and subsequent engine malfunction Spark Plug Inspection Disconnect ignition leads and remove spark plugs Spark plug inspection must be performed in accordance with Section 12 5 Spark Plugs 500 HOUR INSPECTION At each 500 hour interval the magnetos must be disassembled and inspected in accordance with the applicable magneto service manual Magnetos require overhaul at engine TBO every 4 years or as specified by the manufacturer See Chapter 1 Related Publications for manual ordering information 12 4 IGNITION TROUBLESHOOTING The following troubleshooting chart is provided as a guide Review all probable causes given check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Fa
101. aintenance Cylinders Valve seats worn and leaking piston See Section 20 6 Cylinder Assembly rings worn or stuck in ring lands Maintenance Cylinders Continuous Fouling Of Piston rings excessively worn or See Section 20 6 Cylinder Assembly Spark Plugs broken Maintenance Cylinders Piston rings not seated See Section 20 6 Cylinder Assembly Maintenance Cylinders Cylinder has been overheated See Section 20 6 Cylinder Assembly Maintenance Cylinders Cylinder bore out of round See Section 20 6 Cylinder Assembly Maintenance Cylinders Valve seats worn and leaking piston See Section 20 6 Cylinder Assembly rings worn or stuck in ring lands Maintenance Cylinder Sluggish Operation and Valve seats worn and leaking piston See Section 20 6 Cylinder Assembly Low Power Output rings worn or stuck in ring lands Maintenance Cylinder 20 14 Excessive Crankcase Pressures The following troubleshooting test is recommended when excessive crankcase pressures are suspected An airspeed indicator may be used as a substitute for a water manometer The indicator can be plumbed into a field modified oil cap dipstick housing or timing plug depending on engine model to determine excessive crankcase pressure Engines with timing plugs can be modified or use P N 630415 plug which is already drilled for attachment of the fitting for the airspeed indicator On engines that incorporate a separate dip stick tube the rubber hose to the airs
102. alfunction accordance with the airframe manufacturer s instructions Engine oil pressure Adjust oil pressure in accordance with maladjusted Chapter 23 Oil Pressure Adjustment Low oil supply Oil viscosity Replenish Drain and refill with too low correct seasonal weight See Chapter 7 Servicing Fluids TROUBLE PROBABLE CAUSE CORRECTION Malfunctioning oil pump Replace oil pump See Section 18 5 Oil Pump Weak or broken oil pressure Replace spring Adjust pressure to relief valve spring 30 60 pounds per square inch in accordance with Chapter 23 Oil Pressure Adjustment High Oil Temperature Prolonged ground operation Limit ground operation to a minimum Indication Malfunctioning gage or bulb Check wiring Check bulb unit Check unit gage Replace malfunctioning parts in accordance with the airframe manufacturer s instructions 5 20 SECTION 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 FIGURE 6 1 CHAPTER 6 Unpacking Deinhibiting Installation and Testing PAGE GOS A m 6 2 eS 6 2 6 2 Grating and ede ih e ete Ha 6 2 Preparation for 6 3 Engine Installation 6 4 Engine 6 12 Preflightand Tm 6 12 gendum 6 13 IND
103. all fuel injection system components plumbing and connections for security deterioration leaks and chafing WARNING Fuel injection lines must not be bent or deformed The fuel injection lines must be securely clamped to the fuel line support brackets Do not assemble in a binding configuration 13 5 WARNING Never clean nozzles with wire or other similar object If nozzle jet is plugged and obstruction cannot be removed by solvent action REPLACE THE NOZZLE 100 Hour Perform all requirements under 50 hour inspection The fuel nozzles must be removed cleaned and visually inspected every three hundred hours of operation The nozzles must be cleaned by soaking in lacquer thinner methyl ethyl keytone or acetone for several hours Blow dry with compressed air Apply 646943 anti seize lubricant to fuel nozzle threads cylinder end in accordance with Figure 13 4 General Sealant Application Install fuel nozzles in cylinders 1 through 6 Torque fuel nozzles to 55 65 inch pounds Re install fuel lines on fuel nozzles Torque fuel line B nuts to 40 45 inch pounds CAUTION Never use Teflon tape on fuel injection system fittings FLARED END APPLY F I SEALANT SPARINGLY HERE a TAPERED END DO NOT APPLY Fil SEALANT TO THE FIRST TWO THREADS FIGURE 13 4 GENERAL SEALANT APPLICATION continued on next page FUEL INJECTION SYSTEM INSPECTION 13 6 WARNING Failure to comply with the fo
104. an oil pressure relief valve installed in the oil gallery in the accessory case The valve opens when the pump pressures exceed the adjusted limit and oil is directed back to the oil sump From the pressure relief valve the oil flows to a full flow oil filter From the oil filter oil is directed through a gallery to the oil cooler The oil cooler incorporates an oil temperature control valve Oil passing through the oil temperature control valve cavity is directed either through the oil cooler core or by passes the oil cooler core depending on the oil temperature to the left crankcase gallery In this manner engine oil temperature is maintained within the normal operating range Oil passages off the left main gallery direct oil flow to the camshaft journals the right main gallery and hydraulic valve tappet bosses Oil flow is also directed upward to each of the crankshaft main bearings and forward to the propeller governor pad Oil from the rear crankshaft main bearing is directed upward to the starter shaft gear bushing Oil flow is tapped off the left main oil gallery and directed to the turbocharger through various hoses fittings and a check valve to the turbocharger bearings The oil from the turbocharger is collected through various hoses fittings and a check valve by the oil scavenge pump where it is returned to the engine oil sump From the propeller governor lubricating oil is directed through a crankcase gallery to the front main bearing wh
105. and accessory drive gear Diameter 0 0036T Washer in Drive Gear Diameter 0 0021T Magneto coupling retainer on magneto 0 0550L and accessory drive gear sleeve Diameter Magneto coupling retainer in magneto drive gear slot Side Clearance Magneto coupling rubber bushings on magneto drive lugs Side Clearance 1 3 2 FIGURE 12 1 MAGNETO ACCESSORY DRIVE ADAPTER Spark Plugs Remove the spark plugs for cleaning or replacement in accordance with applicable portions of Ignition System Disassembly Reassembly instructions in the TSIO 360 MB amp SB Overhaul Manual Form After spark plugs are removed clean and gap the spark plugs in accordance with the spark plug manufacturer s instructions and test Replace any spark plug that does not meet the manufacturer s specifications Insure that each spark plug is free of any residue from cleaning process all requirements of cylinder compression test in Section 20 4 have been accomplished apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Re install spark plugs using the reverse spark plug installation order Torque spark plugs to 300 360 inch pounds CAUTION Never install a spark plug that has been dropped Discard them For determination of spark plug re use see Spark Plug Wear Figure 12 3 12 7 CYLINDER ROTATION CYLINDER CYLINDER NUMBER NUMBER FIGURE 12 2 SPARK PLUG ROTATION PROCEDURE N
106. ander is installed in the third groove which has six oil drain holes to the interior Weight differences are limited to 1 2 ounce or 14 175 grams in opposing bays Piston pins are full floating with permanently pressed in aluminum end plugs PISTON STEEL INSERT RINGS TOP COMPRESSION SECOND COMPRESSION THIRD OIL CONTROL PISTON PIN END PLUG OIL SCRAPER PISTON SKIRT FIGURE 20 4 PISTON ASSEMBLY DISCRIPTION 20 5 20 3 20 6 CYLINDER ASSEMBLY DETAILED DESCRIPTION continued Valve Rocker arms Shafts Pushrods And Housings Valve Train Valve rocker arms are steel forgings with hardened pushrod sockets and rocker faces The rocker arm has a precision bronze bushing that accommodates the rocker shaft The rocker arm shaft is secured to the rocker boss studs using retainers lock tabs and nuts They have a drilled oil passage for lubrication Pushrods are steel tubes with forged steel ball ends which are center drilled for oil passages The pushrod housings are beaded steel tubes The bead at the cylinder end retains an o ring The bead at the crankcase end retains a heavy spring washer packing ring and second washer RETAINING BOLT ROCKER SHAFT TAB WASHER ROCKER ROTOCOIL ON EXHAUST VALVE RETAINER ON INTAKE VALVE PRESSED IN OUTER VALVE BALL END SPRING O RING INNER VALVE PRESSED BEAD SPRING PUSHROD VALVE LUBRICATION PASSAGE PUSHROD HOUSING B CYLINDER
107. ar intervals it should provide the owner operator and oil analysis technician with information relative to normal or abnormal wear that occurs during the course of engine operation Deviations from an established wear trend pattern should alert the owner operator and oil analysis technician to further investigate Limitations Variations in operation use and maintenance may be reflected in the parts per million content reported Deviations from standard or previously used sampling procedures may result in variations to the parts per million content in the sample report General Procedures To establish a data base for comparison and analysis oil samples must be taken on a regular schedule using the same sampling techniques and laboratory The engine must have been operated long enough to obtain normal operational temperatures and the oil sample taken within 30 minutes after engine shut down The tube or funnels used to drain the oil from the sump must be clean and free of any foreign material or residue If the oil sample is taken from the oil as it drains from the sump allow approximately 1 3 of the oil drain prior to taking the sample If the sample is taken via the oil filler or other location using a sampling tube it is critical the sample be taken from two or three inches above the bottom of the oil sump not from the bottom Do not take an oil sample from the oil filter canister 7 6 INTENTIONALLY LEFT BLANK Section 8 1 8 2
108. arness accordance with ignition harness manufacturer s instructions Weak or burned out condenser Replace points and condenser in as evidenced by burned or accordance with magneto pitted breaker points manufacturer s instructions Sluggish Operation and or Fouled or dead spark plugs Clean spark plugs Replace dead Excessive RPM Drop spark plugs See Section 12 6 Spark Plugs Improperly gaped spark plugs Adjust to proper gap accordance with spark plug manufacturer s specifications Magnetos out of time Inspect internal timing magnetos in accordance with magneto manufacturer s instructions See Section 12 5 Placing The Crankshaft In Timing Position and Magneto Timing And Installation On Engine Damaged magneto breaker Replace points and condenser in points or condenser accordance with magneto manufacturer s instructions 12 5 IGNITION SYSTEM MAINTENANCE Harness Assemblies Remove the harness assemblies for repair or replacement in accordance with the applicable portion of Ignition System Disassembly Reassembly instructions in the L TSIO 360 Overhaul Manual Form X30596A See Chapters 8 and 18 Any harness assembly maintenance such as single lead replacement must be performed in accordance with the Harness Manufacturer s Instructions See Slick Order Form F 1100 See Section 1 4 Related Publications for ordering information Magnetos Remove the magnetos for repair or replacement in accordance with the
109. ations Section 1 4 for ordering information Poor Acceleration Idle mixture incorrect Adjust fuel mixture in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for ordering information Poor Acceleration cont d Unmetered fuel pressure too high Lower unmetered fuel pressure Adjust in accordance with Section 23 2 Fuel System Adjustment Worn linkage Replace worn elements of linkage in accordance with airframe manufacturer s instructions Engine Runs Rough Restricted nozzle jet Remove and clean all nozzles See Section 13 5 Fuel Nozzles Improper mixture Adjust engine driven fuel pump in accordance with Section 23 2 Fuel System Adjustments Low Fuel Flow Gauge Restricted flow to metering unit Check for restriction between fuel pump and metering Indication unit Inadequate flow from fuel pump Adjust engine driven fuel pump in accordance with section 23 2 Fuel System Adjustments High Fuel Flow Gauge Restricted flow beyond metering Check for restricted nozzles or fuel manifold valve Indication valve Clean or replace as required See Section 13 5 Fuel Nozzles amp Fuel Manifold Valve Restricted recirculation passage in Replace engine driven fuel pump See Section 13 5 fuel pump Fuel Pump 13 8 13 5 TROUBLE PROBABLE CAUSE CORRECTION Fluctuating or Erroneous Fuel Fuel vapor as a result of high ambient If not cleared with auxiliary pump chec
110. blish the origin of materials parts and accessories NOTICE TO ALL USERS This manual does not contain maintenance or installation information for supplemental type certificated components or systems This manual contains information on engines components and systems designed tested and certified by TCM in accordance with the pertinent type design data The following publication contains information applicable to each engine maintenance requirement It is important all personnel involved with these functions thoroughly read and understand the information provided these instructions inform of the procedures necessary to maintain continued airworthiness and they must be followed carefully Prior to performing maintenance the mechanic must meet requirements of FAR 65 and must follow FAR Parts 43 91 and 145 as applicable Use this manual in conjunction with Teledyne Continental Motors TCM service documents related publications accessory manufacturers instructions FAR and FAA Advisory Circulars This manual contains no warranties either expressed or implied Publication Format This publication is formatted for practical use and ease of reference Chapter and page numbering are independent so that revisions can be made without affecting the entire publication Due to the large volume of information necessary for maintenance maintenance chapters are independently numbered For example chapter 1 begins on page 1 chapter 2 begins again wit
111. bushings Install holding washers lock washers and nuts Snug nuts but do not torque This will allow turning of the magnetos for final timing Remove the T118 timing pins from Slick magnetos WARNING Any debris that falls into the engine interior must be removed prior to engine operation E Using the above procedure paragraphs A through D install the remaining magneto F The magneto timing light breaker point leads are connected to the ground terminals of the magnetos The timing light breaker point leads are connected so that the light on the right side of the timing light box represents the right magneto and the light on the left side of the timing light box represents the left magneto The timing lights should indicate that the points in both magnetos are closed Tap the right magneto up with a non marring hammer until the light indicates points just opening Tap the left magneto down until the light indicates points just opening Secure magnetos G Watch the lights on the magneto timing light Turn the crankshaft a few degrees counterclockwise then clockwise until the timing indicators pointer is pointing to the correct degree As the pointer aligns with the correct degree both lights on the magneto timing light must indicate that the points just open within one half degree of crankshaft rotation If timing light does not indicate the above re adjust the magnetos NOTE Point opening is indicated by light illumination on some timi
112. case diameter 0 005L 2 Fuel pump body pilot in adapter diameter 0 0045L 3 Oil seal in adapter diameter 0 002T 4 Fuel pump drive shaft in impeller shaft diameter 0 011L 5 Fuel pump drive shaft in governor gear diameter 0 055L 6 Governor driven gear in crankcase diameter 0 005 7 Governor driven gear bore in crankcase diameter 0 876 8 Governor drive gear to camshaft gear diameter 0 012 FIGURE 13 6 FUEL PUMP DRIVE FITS AND LIMITS FUEL SYSTEM MAINTENANCE cont d Fuel Servo Unit For removal and replacement of the fuel servo unit see the applicable portion of disassembly and reassembly procedure in the L TSIO 360 RB Overhaul Manual Form X30596A The fuel servo unit may be replaced with new or it must be repaired and calibrated in accordance with the applicable instructions in the Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for ordering information Fuel Injection System Plumbing Any fuel injection system plumbing or attaching hardware found to be loose deteriorated leaking chafed broken bent or dirty must torqued replaced or cleaned in accordance with the applicable portion of the L T
113. chloroethane and or CFC 113 substances which harm public health and the environment by destroying ozone in the upper atmosphere This warning applies to all Teledyne Continental Motors fuel injection assemblies manifold valve assemblies regulator assemblies magneto assemblies starter adapters oil pumps oil coolers accessory cases crankcases cylinder and valve assemblies cylinder kits bearings turbochargers turbocharger bearings and thrust collars tubes hoses and exhaust systems and components WARNING Manufactured with 1 1 1 trichloroethane CFC 12 and or CFC 113 substances which harm public health and the environment by destroying ozone in the upper atmosphere This warning applies to all Teledyne Continental Motors new and rebuilt engines CURRENT STATUS OF PAGES AS OF OCTOBER 1996 See Manual Revisions in the introduction section for distribution procedure THE ORIGINAL DATE OF THIS PUBLICATION IS OCTOBER 1996 INSERT LATEST PAGES DESTROY SUPERSEDED PAGES WARNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact Teledyne Continental Motors Do not perform any operation maintenance installation or other operation until the manual is confirmed current MODEL TSIO 360 MB amp SB FORM X30645A STATUS PAGE STATUS PAGE STATUS PAGE STATUS ORIGINAL WARNING BACKGROUND Replacement parts materials and accessories may be sold
114. cise judgment in determining the extent of disassembly Maintenance of removed engine systems and components must be performed in accordance with that particular system or component section of this manual CAUTION Dimensional inspection of the crankcase and crankcase internal components must be performed in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Prior to dimensional inspection insure that the part conforms with all visual fluorescent penetrant magnetic particle or ultrasonic inspection requirements NOTE When the engine has been disassembled a complete visual dimensional and non destructive test inspection must be performed on all components prior to re assembly Engine disassembly cleaning inspection repair replacement assembly and test must be accomplished in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A 22 7 INTENTIONALLY LEFT BLANK 22 8 CHAPTER 23 POST MAINTENANCE ADJUSTMENT AND TEST SECTION PAGE 23 1 Post Maintenance Operational 23 2 23 2 Engine Adjustment And Setup 23 4 23 3 GP ao ese asd Ole 23 12 FIGURE PAGE 23 1 General Oil Pressure 23 4 23 2 Fuel Pump Adjustment Idle 23 5 23 3 Fuel Servo Adjustments rtu pde cop eb 23 6 23 6 C
115. cised during the twisting operation to keep the wire tight without over stressing See Figure 9 1 General Lockwire Procedure for steps in applying lockwire All lockwire utilized on TCM engines must conform to MS 20995 Condition A Most bolts utilized in TCM engines that require lockwiring will use 032 lock wire and require twisting at a rate of 7 to 10 twists per inch Lockwire shall be new at each application 1 LOCKWIRE 2 INSERTING 3 BENDING WIRE 4 TWISTING WIRE 5 PULLING HOLES WIRE AROUND BOLT WIRE PARALLEL 6 BENDING WIRE 7 TWISTING WIRE 8 BENDING 9 CUTTING AROUND BOLT TWISTED WIRE EXCESS WIRE FIGURE 1 STEPS IN APPLYING SAFETY WIRE FIGURE 9 1 GENERAL LOCKWIRE PROCEDURE 9 3 9 4 LOCKWIRE PROCEDURE cont d Various examples of lockwiring are shown in Figure 9 2 General Lockwire Patterns 1 All items to be lockwired must be properly torqued Applying torque that is above or below specified limits to obtain alignment of the holes is not permitted Lockwire shall be installed in such a manner that the strand through the hole will have a tendency to pull the in the tightening direction Insert half of the required length of lockwire through the first unit and bend around the head of the unit The direction of wraps and twist of strands shall be such that the loop around the unit comes under the strand protruding from the hole so that the loop will stay down and will not tend to s
116. craft Engine Form X30644 Teledyne Continental Motors Aircraft Engine Service Documents including service bulletins Fuel Injection Manual Form 30593A Starter Service Instructions Form X30592 TCM Ignition Systems Master Service Manual Form No X40000 Alternator Maintenance and Parts Catalog Form No X30631A The above publications can be ordered through your Teledyne Continental Motors Distributor or ordered directly if prepaid from Teledyne Continental Motors P O Box 90 Mobile Alabama 36601 ATTN Publications Sales Department Telephone 334 438 3411 For price information on the above publications see TCM Publications Index Form X 94 Current Publications and Form X 3 94 Optional Publications Slick Ignition Systems Master Service Manual Form No F 1100 Order through Slick Aircraft Products Unison Industries 530 Blackhawk Park Avenue Rockford Illinois 61104 ATTN Subscription Department Telephone 815 965 4700 MANUAL REVISIONS Revisions to this manual will be furnished to purchasers who complete and retum the registration post card in the front of this manual Page iii Current Status of Pages is updated at each revision Remove and discard the old page iii Insert the new page iii as a record of which revisions have been incorporated into the manual WARNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual contact TCM Do n
117. ctrode gaps and cracked porcelains Test plugs for regular firing under pressure Replace damaged or misfiring plugs Gap spark plugs to spark plug manufacturer s specifications See Section 12 6 Ignition System Maintenance Spark Plugs Loose or damaged intake Inspect entire manifold system for manifold possible leakage at connections Replace damaged components torque all connections and clamps See Section 14 5 Induction System Maintenance Fuel nozzles malfunctioning Check for restricted nozzle jets lines and clean or replace as necessary See Section 13 5 Fuel System Maintenance Fuel Nozzles Malfunctioning Turbocharger See Section 11 8 Exhaust System wastegate or exhaust system Troubleshooting Insufficient oil in oil sump oil Add oil or change oil to proper dilution or using improper viscosity See Chapter 7 Servicing grade oil for prevailing Fluids ambient temperature High oil temperature Malfunctioning oil temperature control valve in oil cooler oil cooler restriction Replace valve or clean oil cooler See Section 18 5 Oil Cooler Leaking damaged orloose Check for restricted lines loose oil line connections connections and for partially plugged Restricted screen or filter oil filter or screens Clean parts torque connections and replace malfunctioning parts See Section 18 5 Oil Pump for filter replacement Oil pressure gage Check oil pressure gage calibration in m
118. d for 19 11 19 5 19 12 maintenance the oil suction tube screen must be cleaned and all lower internal hardware inspected for security and safetying Oil sumps that are warped or cracked must be discarded LUBRICATION SYSTEM MAINTENANCE continued Oil Suction Tube The oil sump and accessory case must be removed to gain access to the oil suction tube If oil suction tube access is required see the applicable portions of oil sump accessory case in accordance with the applicable disassembly reassembly in the L TSIO 360 Series Overhaul Manual Form X30596A Oil Cooler The oil cooler or its components may be removed for replacement and repair in accordance with the applicable portions of oil cooler disassembly reassembly instructions in the L TSIO 360 Series Overhaul Manual Form 08 Oil Pressure Relief Valve Cut safety wire remove the oil pressure relief valve and inspect the plunger for scoring nicks and the conical face for roughening Inspect oil pressure relief valve limits in accordance with Section 19 5 Oil pressure relief valves with scoring nicks roughening of the conical face or that exceed the specified limits must be discarded and replaced with new Inspect the oil pressure relief valve seat for scoring nicks or roughening Seats with these indications must be refaced Using an Oil Pressure Relief Spot Facer as shown in Chapter 2 Tools reface the pressure relief valve seat in the oil pump housing CAUTIO
119. disengages from the shaftgear The TSIO 360 RB engines utilize an accessory drive adapter and freon compressor mounting brackets The accessory drive adapter has provisions for installing a sheave on an extended shaft Accessories may be mounted on either of the drive pads provided See Chapter 15 ACCESSORY DRIVE ADAPTER CRANKSHAFT scAVENGE PUMP GEARS WORM WHEEL FIGURE 17 1 STARTER AND STARTER ADAPTER DESCRIPTION STARTING SYSTEM COMPONENT DETAIL DESCRIPTION Starter For a detailed description of TCM electric starter motors see TCM Form X30592 Starter Service Instructions See Section 1 4 Related Publications for ordering information Starter Adapter The starter adapter assembly uses a worm drive gear shaft and worm gear to transfer torque from the starter motor to the clutch assembly The shaft is supported in the housing at the starter end by a ball bearing and retaining ring the opposite end is supported by a needle bearing pressed into the adapter housing As the worm gear rotates the worm wheel and clutch spring the clutch spring is tightened around the drum of the starter shaftgear As the shaftgear turns its torque is transmitted directly to the crankshaft gear The starter shaftgear is supported at the adapter cover by a pressed in ball bearing and is supported at the opposite end by a needle bearing in the crankcase The L TSIO 360 RB starter adapter rotates the crankshaft in a clockwise direction 17
120. e the engine driven fuel pump discharge pressure is set to 35 45 psig If the engine driven fuel pump pressure does not fall within this range the fuel pressure may be adjusted by the following method a Loosen jam nut on the fuel pressure adjustment b Adjust screw clockwise to increase fuel pressure or counter clockwise to decrease fuel pressure FUEL PRESSURE ADJUSTMENT CLOCKWISE TO INCREASE FIGURE 23 2 FUEL PUMP ADJUSTMENT continued on next page 23 5 c Repeat static runup and readjust pressure as required to obtain fuel pump pressure of 35 to 45 psig Idle Mixture Check and adjust idle mixture as follows Idle Performance a Operate the engine at 1500 to 1800 rpm until cylinder head temperatures are 250 F to 350 F and the oil temperature is 160 F to 180 F b Reduce the engine speed and stabilize it at 700 25 RPM c Slowly but positively move the mixture control from FULL RICH toward IDLE CUTOFF The engine speed should increase 25 to 50 rpm before beginning to drop toward zero d If the engine speed increase is less that 25 rpm the mixture is too lean and you will need to adjust the idle mixture set screw to enrich the mixture If the engine speed increase is more that 50 rpm the mixture is too rich and you will need to adjust the idle mixture set screw to lean the mixture FUEL FLOW ADJUSTMENT KNOB CCW TO ENRICH IDLE SPEED ADJUSTMENT CW TO INCREASE IDLE MIXTURE ADJUSTMENT LENGTHEN TO
121. e aircraft is inadvertently serviced with the wrong grade of fuel or jet fuel the fuel must be completely drained and the tank properly serviced For aircraft fueling procedure see the airframe manufacturer s instructions 7 3 7 5 7 4 OIL FILTER ELEMENT INSPECTION Inspect oil filter element at each oil and filter change even if oil analysis is being used Filter element inspection may identify internal engine wear that will not be identified through oil analysis New rebuilt overhauled engines or engines that have had cylinders replaced will generally exhibit noticeable amounts of normal wear material at the first and second oil and filter change The amount of material present should significantly decrease between the first and second oil and filter change if the engine and or cylinders have been properly operated during the break in period As with oil analysis oil filter element inspection provides maintenance personnel with additional information on the wear characteristics of a specific engine Sudden unexplained increases in concentration of wear material in a filter element should alert maintenance personnel to investigate the source and cause of the material Material Identification Ferrous attracts to magnet Aluminum will sizz or bubble when placed in a 50 solution of muriatic acid Bronze or Copper will turn bright green when placed in nitric acid Carbon will disintegrate when rubbed between index finge
122. ean or change turbocharger turbine housing seal Low Manifold Pressure Improperly adjusted controller Adjust according to Chapter 23 or replace if adjustment cannot be made Induction or exhaust manifold Repair or replace as required leaks Manifold Pressure Higher Binding wastegate Replace wastegate Than Normal Manifold Pressure Higher Improperly adjusted controller Adjust see Chapter 23 Than Normal con t Loss of Aircrafts Critical Improperly adjusted controller Adjust see Chapter 23 Altitude Induction or exhaust manifold Repair or replace as required 11 9 TROUBLE PROBABLE CAUSE CORRECTION Loss of Aircraft s Critical Aftercooler plugged or damaged Repair or replace as required Altitude cont d Turbocharger Seals Worn or damaged seals Refer Turbocharger Leaking Instructions Engine Oil Level Frequently Leaking Turbocharger check Replace check valves Refer to Low After Servicing Prior to valves and seals Turbocharger Manufacturer s Operation Instructions for turbocharger maintenance Lack of Oil to Turbocharger Damaged check valve Replace check valve 11 10 11 8 EXHAUST SYSTEM MAINTENANCE Exhaust System Collector Component maintenance is limited to torquing loose connections and replacement of components Under no circumstance shall any exhaust system component be welded For replacement of exhaust system collector component see the applicable portion of Exhaust
123. ears regardless of total operating hours since last overhaul or replacement Engine mounted accessories not supplied by TCM such as alternators stand by generators etc may require servicing at specific intervals Refer to the instructions provided by the aircraft manufacturer accessory manufacturer or STC holder for detailed information TCM gear driven alternators require inspection and testing at 500 hour intervals Refer to the applicable alternator manufacturer s instructions See Related Publications in the Introduction section of this manual 5 7 UNSCHEDULED MAINTENANCE Unscheduled maintenance events include but are not limited to PROPELLER STRIKES A propeller strike is 1 any incident whether or not the engine is operating that requires repair to the propeller other than minor dressing of the blades or 2 any incident while the engine is operating in which the propeller makes contact with any object that results in a loss of engine RPM Propeller strikes against the ground or any object can cause engine and component damage even though the propeller may continue to rotate This damage can result in catastrophic engine failure A PROPELLER STRIKE INSPECTIONS Following any propeller strike a complete engine disassembly and inspection is mandatory and must be accomplished prior to further operation Inspect all engine accessories in accordance with the manufacturer s instructions In addition to the engine component insp
124. ecified limits must be discarded and replaced with new Reinstall serviceable or new oil temperature control valve using new gasket and torque to 440 460 inch pounds Safety wire oil temperature control valve housing in accordance with Section 9 2 Lockwire Procedure CAUTION When performing dimensional inspection the following Service Limits may be used However they are only intended as a guide for re use when performing maintenance of the engine prior to major overhaul Parts with dimensions or fits that exceed service limits must not be re used Parts with values up to and including service limits may be re used however judgment should be exercised considering the PROXIMITY of the engine to its recommended overhaul time Service limits must NOT be used when overhauling an engine See the current L TSIO 360 Series Overhaul Manual Form X30596A for minimum fits and limits 19 5 LUBRICATION SYSTEM MAINTENANCE continued If the accessory case is removed from the engine the following components must be dimensionally inspected DESCRIPTION SERVICEABLE LIMIT Oil temperature control valve 0 090 inch minimum travel at Oil Temperature ENGINE AND OIL COOLER MOUNT BRACKET 11 22 FIGURE 19 7 LUBRICATION SYSTEM SERVICE LIMITS 10 19 13 INTENTIONALLY LEFT BLANK 19 14 CHAPTER 20 CYLINDER ASSEMBLY SECTION PAGE 20 1 Cylinder COO ITIg iuto
125. ecorded close regulator pressure valve and remove Master Orifice Tool from the cylinder adapter See the schematic diagram of a typical differential pressure tester shown below CYLINDER ADAPTER CYLINDER PRESSURE VALVE CYLINDER CYLINDER PRESSURE ADAPTER VALVE CYLINDER PRESSURE GAUGE CYLINDER PRESSURE GAUGE RESTRICTOR ORIFICE REGULATOR MASTER ORIFICE PRESSURE HAND TIGHT GAUGE REGULATOR 4H PRESSURE VALVE RESTRICTOR ORIFICE REGULATOR PRESSURE GAUGE CYLINDER REGULATOR PRESSURE VALVE COMPRESSED COMPRESSED n AIR SOURCE AIR SOURCE FIGURE 20 10 DIFFERENTIAL PRESSURE TESTER CALIBRATION PERFORMING THE CHECK The following procedures are listed to outline the principles involved and are intended to supplement the manufacturer s instructions for the particular tester being utilized WARNING To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and
126. ection requirements set forth in the appropriate overhaul manual pay particular attention to the following areas while performing the specified non destructive testing 1 Crankshaft surfaces forward of the front main bearing journal These surfaces must be free of sludge paint or any other substance that could mask reliable magnetic particle inspection indications 2 Forward crankcase bearing support and adjacent structure NOTE In addition to any part that is damaged TCM recommends for counterweight equipped engines replacement of all counterweight pins bushings end plates and snap rings regardless of their condition B MINOR FOREIGN OBJECT DAMAGE FOD INSPECTION For instances where the propeller is damaged by a small foreign object during operation such as a small stone inspection and repair must be accomplished in accordance with the propeller manufacturer s published instructions Any time foreign object damage requires propeller removal for repairs other than minor dressing of the blades the incident is considered a propeller strike and must be inspected as outlined in paragraph A above HYDRAULIC LOCK GENERAL INFORMATION Hydraulic lock is defined as a condition in which a volume of liquid equal to or greater than the clearance volume of the combustion chamber is drawn into the cylinder during starting This liquid being incompressible restricts piston travel during the compression stroke Damage only occurs aft
127. edure for correction 13 7 continued on next page 13 4 FUEL INJECTION SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start And No No fuel to engine Check tank fuel level See the airframe manufacturer s Fuel Flow Gage Indication instructions Mixture control improperly rigged Check mixture control for proper rigging See the airframe manufacturer s instructions Engine not primed Prime in accordance with the airframe manufacturer s instructions Selector valve in wrong position Position selector valve to MAIN TANK position Engine Will Not Start With Fuel Engine flooded Allow all fuel to drain from intake system Flow Gauge Indication WARNING Starting an engine with a flooded intake system will result in hydrostatic lock and subsequent engine malfunction or failure No fuel to engine Loosen one line at nozzle If no fuel shows with fuel flow on gage replace fuel manifold valve See Section 13 5 Manifold Valve Rough Idle Nozzle jet restricted Remove nozzles and clean See Section 13 5 Fuel Nozzles Improper idle mixture Adjust fuel mixture in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Public
128. el nozzles must be cleaned every 300 hours or annual inspection Any environmentally hazardous materials used in cleaning must be contained and disposed of in accordance with Environmental Protection Agency regulations CAUTION Never clean nozzles with wire or other similar object If nozzle jet is plugged and obstruction cannot be removed by solvent action REPLACE THE NOZZLE 19 16 17 18 19 20 21 22 23 24 25 Inspect all accessories for condition security of mounting and proper operation Refer to aircraft or component manufacturer s Maintenance Manual for specifics Inspect engine mount legs for cracks Check engine mount isolators for signs of deterioration proper assembly and security Check all fasteners for integrity and security Visually inspect the turbocharger center housing for general condition Inspect the compressor housing V band clamp for security Inspect the exhaust housing bolts and lock tabs for security Inspect the oil inlet and outlet fittings and surrounding area for evidence of oil leakage Remove the induction air supply duct to the turbocharger compressor and inspect the compressor blades for evidence of foreign object damage Turn compressor wheel by hand check for freedom of rotation Inspect the interior of the air supply duct for general condition Remove the turbocharger exhaust stack and inspect the turbine wheel for damage freedom of rotation and ev
129. er the preceding cylinder or cylinders in the firing order have fired thereby providing the required force to drive the piston of the fluid filled cylinder through the compression stroke Most hydraulic lock events in horizontally opposed aircraft engines are due to fuel accumulation in the induction system and or cylinder assembly Over priming prior to or during engine starting will allow fuel to accumulate in the induction system or cylinder faster than the system drains can evacuate it Other causes of hydraulic lock can be attributed to 1 Restricted or clogged induction system or cylinder drain s 2 Extended operation of the electric boost pump a During failed engine start NOTE 4 b Following loss of power during ground operation c Following momentary engine shutdown d During single engine operation for training purposes on twin engine aircraft Over priming and attempting engine start with the aircraft parked on an incline that negates the effective operation of the drain system A failure to drain oil from cylinders that have been preserved Damage from a hydraulic lock can be extensive Engine components such as connecting rods cylinder assemblies pistons piston pins crankcase and crankshaft can be damaged due to the extreme stress WARNING Over priming can cause a flooded intake resulting in a hydraulic lock event and subsequent engine malfunction or failure If you over prime or flood your engine
130. ere it is directed to the interior of the crankshaft Oil then travels through a transfer plug installed in the crankshaft to the variable pitch propeller Hydraulic valve tappets transfer oil from the main oil galleries to the cylinder overhead through the hollow pushrods to a drilled oil passage in the rocker arms Oil exiting the rocker arms lubricates the valve stems springs and rotocoils The oil then falls to the lower rocker cavity and returns to the crankcase and sump through the pushrod housings TO PROPELLER CAMSHAFT BEARING gt gt 4 Pos BEARING SS gt STARTER BUSHING IDLER SHAFT GOVERNOR i LER PAD g CCESSORY DRIVE TAPPETS BUSHINGS N SCAVENGE iud d CHECK OIL COOLER OIL TEMPERATURE CONTROL VALVE OIL SUMP PICK UP OIL FILTER TURBOCHARGER OIL PRESSURE RELIEF VALVE BY PASS TO SUMP OIL SUCTION OIL UNDER PRESSURE wee mE RE BY PASS OIL OIL TEMPERATURE CONTROL VALVE GOVERNOR OIL SCAVENGE OIL FIGURE 19 1 LUBRICATION SYSTEM SCHEMATIC 19 3 19 2 19 4 LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION Oil Pump The oil pump is a positive displacement pump that consists of two meshed steel gears that revolve inside the oil pump cavity machined in the accessory case The camshaft drives the oil pump drive gear which drives the oil pump driven gear The oil pump driven gear is supported by a shaft pressed into
131. essory case oil suction screen cavity CRANKCASE TO SUMP ACCESSORY ATTACHING HARDWARE CASE GASKET WE OIL SCREEN OIL SUMP PLUG SAFETY WIRE SAFETY WIRE OIL PICK UP TUBE OIL DRAIN PLUG FIGURE 19 5 OIL SUMP AND SUCTION TUBE DESCRIPTION LUBRICATION SYSTEM INSPECTION 50 HOUR Remove oil drain plug drain oil into approved container oil warm and replace plug Torque oil sump plug to 190 210 inch pounds and safety as required Oil must be properly disposed of Cut safety wire and remove oil filter Oil Filter Adapter Inspection A new stud P N 653489 must be installed if the old stud is a plain steel color with a length of 1 440 inch if it is found to be loose or it is installed beyond the stud setting height specified in Figure 19 7 Oil Filter Adapter Stud Inspection Install new stud in accordance with the following procedure A Remove old stud P N 632373 and inspect the threads in the adapter housing for damage Replace the adapter housing if any thread damage is evident Note Oil filter adapters that incorporate this modification from the factory can be determined by the letter S stamped into the adapter housing See Figure 19 6 Stud Identification B Clean the adapter housing threads thoroughly to remove any remaining thread adhesive and oil C Install the applicable new stud P N 653489 and confirm that the incomplete thread on the stud stops at the first thread
132. frame manufacturer s Airplane Flight Manual AFM Check and adjust in accordance with Chapter 23 Replace malfunctioning pumps See Section 13 5 Fuel System Maintenance Fuel Pump Replace fuel pump See Section 13 5 Fuel System Maintenance Fuel Pump Replace fuel pump See Section 13 5 Fuel System Maintenance Fuel Pump Replace fuel pump See Section 13 5 Fuel System Maintenance Fuel Pump TROUBLE Fluctuating Fuel Pressure Engine Has Poor Acceleration Engine Runs Rough At Speeds Above Idle Engine Lacks Power Reduction in Maximum Manifold Pressure PROBABLE CAUSE CORRECTION Incorrect fuel pump adjustment and operation Fuel gage line leak or air in gage line Vapor in fuel system excessive fuel temperature Idle mixture too lean Incorrect fuel air mixture worn control linkage or restricted air cleaner Malfunctioning ignition system Improper fuel air mixture Restricted fuel nozzle jet Ignition system and spark plugs malfunctioning Incorrectly adjusted throttle control sticky linkage or dirty air cleaner Check and adjust in accordance with Chapter 23 Replace malfunctioning pumps See Section 13 5 Fuel System Maintenance Fuel Pump Drain gage line and torque connections in accordance with the airframe manufacturer s instructions Normally operating the auxiliary pump will clear system Operate boost pump in accordance with the airframe manufac
133. g Absolute 38 0 Fuel Control SySterr aote arp Precision RSA 5 Fuel Injection SUMERET rs eT For fuel grade see Chapter 7 Servicing e For Oil grade amp capacity see Chapter 7 Servicing Oil Pressure MINIMUM 10 Normal Operation 30 to 60 Oil Sump Capacity U S Quarts i 8 0 Oil Consumption Lb BHP Hr 006 X Power 100 1 10 OPERATING LIMITS Cont d Oil Temperature Specifications All Temperatures Approved Multi Viscosity Below 40 F Ambient Sea Level TCM Approved SAE 30 or Multi Viscosity Above 40 F Ambient Sea Level TCM Approved SAE 50 or Multi Viscosity Oil Temperature Limits Minimum for 100 F Maximum AllOWaDIe 0cccccccccceecessssseaeeecececcsseseseeeseecesssesessseeseeceseseseeaees 240 F Recommended Operational Range eese 160 180 F Cylinder Head Temperature TSIO 360 RB Recommended maximum at 420 F Mum c 460 F Turbine Inlet Temperature Maximum Continuous 1650 F Maximum 60 seconds
134. gs are below prescribed limits TOP COMPRESSION RING GAP 1 T D C DIRECTION MOVEMENT TOP COMPRESSION zm d e e mmm DIRECTION FIGURE 20 11 RING POSITIONING 11 If recheck of cylinder pressure gauge reading indication remains below allowable loss engine may be run up to operating temperature and rechecked prior to cylinder being removed and repaired Rework of cylinders must be accomplished in accordance with Cylinder Assembly Repair And Replacement in the L TSIO 360 Series Overhaul Manual Form X30596A COMPRESSION TEST TROUBLESHOOTING FIRST CHECK CHECK FOR METHOD CONDITIONS CORRECTIVE STATIC SEAL Intake Valve Listen for air flow NO LEAKAGE seat seal in intake port PERMISSABLE Exhaust valve to Listen for air flow seat seal in exhaust port Spark plug 2 to Apply soapy port seal spark plug Cylinder head to Apply soapy Bubbles Replace cylinder barrel seal solution between head and barrel Cylinder head Apply soapy Bubbles Replace cylinder cracks solution around cylinder head area DYNAMIC SEAL Leakage by piston Test gauge below Piston cracked or out Replace Piston rings remove oil tolerance of limits filler cap listen Cylinder wall Replace Cylinder dimensions out of limits above tolerance NOTE Perform all co
135. h page 1 etc To locate information easily use the Publication Table of Contents and the Chapter Contents provided at each division WARNING This manual the Service Documents the Overhaul Manual and the Parts Catalog constitute the instructions for Continued Airworthiness prepared by TCM as approved by the FAA pursuant to FAR Part 33 As required by FAR S 43 13 each person performing maintenance alteration or preventive maintenance on the engine or accessories must use the methods techniques and practices prescribed in the Instructions for Continued Airworthiness Failure to comply with the Instructions for Continued Airworthiness may result in engine malfunction engine failure injury or death Publication Table of Contents COVER PAGES PAGE Definition of Notes Cautions and Warnings ii Warning Statement sd eom eto datu ii NUS iii Replacement Parts Warning rh CR nas iv Notice to all sers oerte eerte Pr ERR PARTO del NOTE Contents of each chapter listed in chapter Chapter Contents before each division Chapter Index CHAPTER PAGE 1 Introduction C T 1 2 2 Tools Mainteriarice eret 2 1 3 Approved Products ccrte hier eb eve a tse e d ce tet puse 3 1 4 Airworthiness Limitations c
136. idence of oil Visually inspect exhaust system transition unit at the turbocharger for general condition and evidence of exhaust leaks cracks and distortion Verify operation and accuracy of EGT TIT system Note The aircraft manufacturer may require the EGT TIT system to be operational for all categories of flight Check the limitations section of the Airplane Flight Manual for specific requirements Calibration of the EGT TIT system may be mandatory at 100 hour intervals Consult the aircraft manufacturer s Maintenance Manual for specific instructions Remove the turbocharger compressor discharge duct and inspect the interior for evidence of oil If there is evidence of oil in the duct further inspection of the turbocharger is required to determine cause and source of oil Refer to the turbocharger manufacturer s information for specific instructions Inspect all turbocharger control system linkage for correct rigging looseness and lubricate link rod pins with Permatex Maintain Lubricant Inspect waste gate actuator and butterfly valve for general condition and freedom of movement Check link rod pins and levers for wear Lubricate waste gate butterfly valve with Mouse Milk 5 9 26 Visually inspect magneto pressurization filter for contamination If filter element is white it may be continued in service If filter element has turned to yellow or red element is contaminated and must be replaced there is visible moisture present
137. ils To Start Due Ignition switch OFF or grounded switch ON Check for To Ignition Troubles switch wires grounded wires Spark plugs fouled improperly Remove and clean Adjust to gapped or loose proper gap in accordance with Spark Plug Manufacturer s Specifications Re install and torque to 300 360 inch pounds Magnetos improperly timed to See Section 12 5 Ignition System engine Maintenance Placing Crankshaft In Timing Position and Magneto Timing Installation Engine Shorted condenser Replace condenser in accordance with magneto manufacturer s instructions Magneto internal timing incorrect Inspect internal timing or timed for opposite rotation magnetos in accordance with the magneto manufacturer s instructions See Section 12 5 Ignition System Placing Crankshaft In Timing Position and Magneto Timing And Installation On Engine 12 4 TROUBLE PROBABLE CAUSE CORRECTION Rough Idling Spark plugs fouled or improperly Clean spark plugs Adjust spark plug gap in accordance with spark plug manufacturer s specifications Weak condenser Replace condenser in accordance with magneto manufacturer s instructions Rough At Speeds Above Loose or improperly gaped Torque to 300 360 inch pounds Idle spark plugs torque Adjust to proper gap in accordance with spark plug manufacturer s specifications High tension leak in ignition Inspect ignition harness h
138. iming at 20 BTC 1 If magneto drop is out of tolerance proceed to Ignition System Maintenance Section 12 6 ignition timing for the applicable ignition system During magneto off check if the engine continues to run then see Slick service instructions Visually inspect high tension ignition leads for chafing deterioration and other requirements in accordance with Ignition System Manufacturer s instructions Inspect magneto accessory drive adapters for secureness and oil leaks 12 3 IGNITION SYSTEM INSPECTION continued 100 HOUR INSPECTION Perform all requirements of 50 hour inspection and the following WARNING Magneto to engine timing maintenance does not insure magneto harness and spark plug performance Failure to properly maintain the magneto harness and spark plugs will lead to internal engine damage and failure Magneto ignition harness and spark plugs must be maintained in accordance with the manufacturer s instructions NOTE A single severe kick back while cranking the engine can cause failure of components in the cranking system Kick back can be caused by intermittent operation of the impulse couplings Perform the following operational tests at the specified intervals to insure that these systems are functioning properly Magneto Inspection See the magneto manufacturer s instructions for magneto 100 hour inspection procedures 12 3 12 3 IGNITION SYSTEM INSPECTION continued NOTE Minor changes in m
139. in the filter canister the magnetos must be removed from the engine disassembled and inspected for possible internal contamination and corrosion 27 Correct any discrepancies noted 28 Perform post inspection operational run up Visually inspect engine and nacelle for fuel and oil leaks 29 Correct any discrepancies noted during this inspection prior to returning engine to service SYSTEM DRAIN INSPECTION At each scheduled maintenance interval perform the following inspection to ensure that the drain s function properly WARNING Do not rotate the propeller or allow any personnel to stand in the area of the propeller arc while performing the following inspection 1 Perform a normal engine start priming sequence in accordance with the Aircraft Manufacturer or STC holder s instructions 2 Observe the drain location s in the engine cowling and make certain that fuel drains from each 3 Remove clean or replace any drain that does not function properly 500 HOUR INSPECTION 3 In addition to the items listed for 100 hour inspections perform the following inspections and maintenance every 500 hours of engine operation Magnetos require a thorough detailed inspection Refer to the applicable service and overhaul information published by the manufacturer of the magneto Magnetos must be overhauled or replaced at the same intervals as the engine TCM magnetos formerly Bendix must be overhauled or replaced every four y
140. ine operating temperatures are of major concern during this test flight Accomplish a normal pre flight run up in accordance with the airframe manufacturer s Pilot s Operating Handbook Airplane Flight Manual Conduct a normal take off with full power and monitor the fuel flow RPM oil pressure cylinder head temperatures and oil temperatures Reduce to climb power in accordance with the flight manual and maintain a shallow climb attitude to gain optimum airspeed and cooling Rich mixture should be used for all operations except leaning for cruise economy Leaning operations must be performed in accordance with the airframe manufacturer s Pilot s Operating Handbook Airplane Flight Manual Level flight cruise should be at 75 power with best power or richer mixture for the first hour of operation During the second hour alternate power settings between 65 and 75 power with the appropriate best power mixture settings The best power mixture setting is 100 F to 150 F rich of peak exhaust gas temperature The descent should be made at low cruise power settings with careful monitoring of engine pressures and temperatures Any abnormal conditions detected during test flight must be corrected and any final adjustments must be accomplished prior to releasing the aircraft for normal service 6 12 INTENTIONALLY LEFT BLANK SECTION 7 1 7 2 7 3 7 4 7 5 FIGURE 7 1 CHAPTER 7 SERVICING FLUIDS PAGE Servicing ce tiere ee
141. ined on four main journals nine cam lobes and the gear mount flange at the rear of the camshaft The main journals are supported in the crankcase by machined bearing saddles The hydraulic tappets move inward and outward in their bores by the eccentric shape of the cam lobes The lobes and journals are ground and hardened Movement of the tappets open and close the intake and exhaust valves within the cylinder by mechanical linkage of the pushrods and rocker arms Valve opening and closing is synchronized with piston position by timing the camshaft and crankshaft gears Four unequally spaced bolts secure the gear to the camshaft and insure proper positioning locating the gears timing mark in relation to the cam lobes The camshaft gear has internal teeth for driving the oil pump gear and if installed a gear driven alternator or generator A front mounted keyed bevel gear drives the governor driven bevel gear which drives the fuel pump through a common shaft OIL PUMP DRIVE GOVERNOR BEVEL SHAFT PROVISIONS DRIVE GEAR WOODRUFF KEY M J CAMSHAFT GEAR FIGURE 22 4 CAMSHAFT DESCRIPTION 22 4 22 3 22 4 22 5 ENGINE DRIVE TRAIN INSPECTION 50 Hour Visually inspect the front crankshaft exit area for evidence of oil leakage corrosion or pitting and any obvious over stressing of the crankshaft and flange Visually inspect propeller installation in accordance with the airframe manufacturer s Instructions 100 Hour Perform
142. ing Tools for Crankshaft Bearings or equivalent 3604 8068 Crankshaft Blade and Damper Bushing Remover Replacer available from Kent Moore Borrough s 8077C Bushing Remover amp Replacer Counterweight or equivalent Borrough s 8111A Connecting Rod Fixture or equivalent Borrough s 8072C Adapter Kit or equivalent for connecting rod inspection 8071 Reamers for connecting rod bushing available from Kent Moore D 4000 Federal Dimension Air Gage for connecting rod bushing inspection available from Federal Tool Supply Co Inc 1 00025 Setting Ring for checking 1 0000 to 1 0005 tolerance available from Federal Tool Supply Co Inc 1 00025 Air Plug for checking 1 0000 to 1 0005 tolerance available from Federal Tool Supply Co Inc 5209 Propeller Shaft Oil Seal Installer available from Kent Moore OPERATIONAL INSPECTION 85328 Alcor Portable Digital EGT Unit available from Alcor Inc 85329 Alcor Portable Digital CHT available from Alcor Inc Model 20 ATM C Porta Test Unit available from Approved Aircraft Accessories Inc See Section Sealants Lubricants CHAPTER 3 SEALANTS AND LUBRICANTS 3 1 SEALANTS AND LUBRICANTS Recommended Grade Above 40 F ambient air sea level Below 40 F ambient air sea level SAE 50 or Multi Viscosity SAE 30 or Multi Viscosit BP Oil Corporation Castrol Castrol Limited Australia Chevron U S A Inc Continental Oil Delta Petroleum Company Exxon Company U S A Gulf Oil Company
143. ion Step T cuin tarte tege cese tosta e Hetero 12 9 Timing io iiio qii em 12 10 Timing Position Step 3 eo tr rd emet 12 10 Timing Position Step inira ee i s e p ef bs etia las Tea 12 11 Timing 12 12 Coating Insulating SIBeve 12 13 Ignition Wiring Diagram cet a neon 12 14 12 1 12 1 12 2 12 3 12 2 SLICK IGNITION SYSTEM DESCRIPTION The L TSIO 360 engines utilize two Slick Unison 6224 Series pressurized magnetos The left magneto fires the 1 3 5 lower and the 2 4 6 upper spark plugs while the right magneto fires the 1 3 5 upper and 2 4 6 lower spark plugs The Slick 6224 Series pressurized magnetos manufactured by Slick Electro Incorporated 530 Blackhawk Park Avenue Rockford Illinois 61101 are designed to provide ignition for six cylinder light aircraft engines The magnetos generate and distribute high tension current through high tension leads to the spark plugs To obtain the retard spark necessary for starting the magnetos employ an impulse coupling The impulse coupling rotates the magneto between impulse trips faster than engine cranking speed thus generating a better spark for starting the engine The impulse coupling automatically retards the spark during engine cranking and drives the magneto The Slick 6224 magnetos are pressurized by engine deck pressure piped from the 2 4 6 side of the contr
144. ior to the inlet of the turbine housing The wastegate butterfly valve is spring loaded to the open position and closed by pressurized oil from the engine Oil flow through the wastegate actuator is controlled by a variable absolute pressure controller VAPC that is mounted to the induction system after the turbocharger compressor but before the throttle butterfly valve sensing compressor discharge pressure The controller is mechanically linked to the throttle and using a system of cams followers and poppet valves controls oil flow from the wastegate actuator to the engine On engine start the controller senses insufficient compressor discharge pressure deck pressure and restricts the flow of oil from the wastegate actuator to the engine This causes the wastegate butterfly valve to close As the throttle is advanced exhaust gas flow across the turbine increases increasing turbine compressor shaft speed and compressor discharge pressure The VAPC senses compressor discharge pressure and as pressure increases to the selected setting the controller poppet valve begins to open relieving oil pressure to the wastegate actuator This allows the butterfly valve to move toward the open position Exhaust gases by pass the turbine and the turbine compressor shaft speed stabilizes and compressor discharge pressure stabilizes maintaining selected manifold pressure 2 4 6 CYLINDERS 1 3 5 CYLINDERS VARIABLE PRESSURE CONTROLLER AFTERCOOLER
145. ith the procedures in the airframe manufacturer s Airplane Flight Manual AFM High power ground operation resulting in cylinder and oil temperatures exceeding normal operating limits can be detrimental to cylinders pistons valves and rings The fuel system must be adjusted prior to flight in accordance with this manual See Chapter 23 Fuel System Adjustment An operational inspection in accordance with section 5 3 of this manual must be performed prior to releasing the aircraft for test flight The operational inspection must be performed to insure that no induction system exhaust system oil system fuel system leaks or any other discrepancies exist After the operational inspection a test flight is required to insure that the engine and aircraft meet all of the manufacturer s performance and operational specifications prior to releasing the aircraft for normal service WARNING Although the engine fuel system was adjusted at engine test the fuel system must be checked and adjusted in accordance with Chapter 23 Fuel System Adjustment of this manual and current TCM service documents when the engine is first installed into the airframe and at 100 hour intervals to insure proper operation All discrepancies must be corrected prior to test flight FLIGHT TESTING CAUTION Adhere to engine operating limits published in this Manual and the Pilot s Operating Handbook Airplane Flight Manual during test flight Ambient air and eng
146. itt iter tete heir ume a ee epa Rap 4 1 5 Time Limits Operational Insp Troubleshooting 5 1 6 Unpacking De Inhibiting Installation amp 6 1 7 Servicing FIUlds rr E a ERE 7 1 8 Engine Preservation and Storage oie nda te ti edunt 8 1 9 Standard Practices 2 9 1 10 E gine osa eta ro reddes ebd tutta 10 1 11 Exha st ates rela hore Ba dtd t d Mes mer eas sated 11 1 12 caves 12 1 13 Fuel Injection SyS e 13 1 14 Ind tion SY SUSI Rc 14 1 15 Air Conditioning System ice et RI ER OR oS declare 15 1 16 Electrical Sy Stemi p 16 1 17 Starter Starter AdapteT inise eodeni a eene enne eene 17 1 MEE Soc d 18 1 19 Lubrication Syste M quaa ee ene poit co tulo dcdit ado babel ema 19 1 20 Cylinder Assembly iere oen 20 1 21 I A 21 1 22 Engine Drive 22 1 23 Post Maintenance Adjustment amp 23 1 vi SECTION 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 FIGURE 1 1 1 2 CHAPTER 1 PAGE
147. ittle Mack Roseville MI 48066 2298 800 253 0138 CHAMPION SPARK PLUG CO Box 910 900 Upton Ave Toledo OH 43661 419 535 2461 EASTERN ELECTRONICS INC 180 Roberts St East Hartford CT 06108 203 528 9821 FEDERAL TOOL SUPPLY CO INC 1144 Eddy St Providence Rhode Island 02940 800 343 2050 AIRCRAFT TOOL SUPPLY P O Box 4525 2840 Breard St Monroe LA 71201 507 451 5310 McMASTER CARR SUPPLY CO P O Box 4355 Chicago Illinois 60680 312 833 0300 SNAP ON TOOLS 2611 Commerce Blvd Birmingham Alabama 35210 205 956 1722 Kell Strom Tool Company Inc 214 Church St Wethersfield CT 06109 Krautkramer Branson P O Box 350 Lewiston PA 17044 717 242 0327 Merrit Products 201 W Mansville Compton California 90224 310 639 4242 Instruments for Light Powered Aircraft Special Tools Precision Instruments Measuring Instruments Precision Tools Special Tools Spark Plugs Ignitors Oil Filters Special Tools Fuel Pressure Test Equipment Measuring Instruments Precision Tools Piston Position Indicators Precision Inspection Instruments Special Tools Precision Tools Special Tools Precision Tools Special Tools Precision Tools Special Tools Ignition Test Equipment Ultrasonic Test Equipment Special Tools COMPANY GENERAL PRODUCT SUMMARY APPROVED AIRCRAFT ACCESSORIES INC Model 20 ATM C Porta Test Unit 29300 Goddard Road Romulus Michigan 48174 313 946 55
148. k for clogged Flow Indications temperatures vapor vent in fuel pump vapor separator cover Clean only with solvent no wires See Section 13 5 Fuel Pump Air in fuel flow gauge line Leak at Repair leak and purge line Refer to airframe gage connection manufacturer s instruction Poor Idle Cut Off Engine getting fuel Check mixture controls in full idle cut off Check auxiliary pump is OFF If neither replace manifold valve See Section 13 5 Manifold Valve FUEL SYSTEM MAINTENCE WARNING Anytime the fuel pump fuel servo unit fuel manifold valve or fuel injection nozzles are removed and replaced the fuel system must be checked adjusted and tested in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for ordering information Fuel Manifold Valve For replacement of fuel manifold valve see the applicable portion of disassembly and reassembly procedure in the L TSIO 360 RB Overhaul Manual Form X30596A The manifold valve may be replaced with new or it must be repaired and calibrated in accordance with the applicable instructions in the Fuel Injection Systems Parts and Overhaul Manual Form X30593A NOTE The appropriate test calibration equipment must be available for the overhaul of any TCM fuel injection system component Fuel Nozzles For replacement of fuel nozzles see the applicable portion of disassembly and reassembly procedure in the L TSIO 360 RB
149. lation alignment and tensioning must be performed in accordance with airframe manufacturers instructions Customer supplied air conditioning components plumbing and connections must be repaired in accordance with airframe manufacturers instructions 15 3 INTENTIONALLY LEFT BLANK 15 4 SECTION 16 1 16 2 16 3 16 4 16 5 CHAPTER 16 ELECTRICAL SYSTEM PAGE Electrical Charging System 16 2 Electrical Charging System Component Detailed Description 16 2 Charging System Inspection 50 100 HOUT 16 2 Charging System Troubleshooting eese 16 2 Charging System 16 2 16 1 16 1 ELECTRICAL CHARGING SYSTEM DESCRIPTION The L TSIO 360 RB engines incorporate provisions on the right front crankcase half for mounting a belt driven alternator The alternator generates electrical current for powering the aircraft electrical system For description of the aircraft electrical and charging system see the applicable Airframe manufacturer s Instructions CRANKCASE THROUGH BOLTS SHIM WASHER BOLT SLIDE ADJUSTMENT BOLT WASHER NUT CUSTOMER SUPPLIED DRIVE SHEAVE FIGURE 16 1 BELT DRIVEN ALTERNATOR 16 2 16 2 16 3 16 4 16 5 ELECTRICAL CHARGING SYS
150. led components are properly torqued and safetied Studs The replacement of crankcase studs or helical coils will require component removal and replacement in accordance with the applicable component system section in the L TSIO 360 Series Overhaul Manual Form X30596A Replace studs or helical coils in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A During reassembly insure that all reinstalled components are properly torqued and saftied Engine Mounts Replace engine shock mounts in accordance with the airframe manufacturer s instructions CAUTION When relieving engine weight from the airframe the engine hoist must be attached to the engine lifting eyes only Place a support at the load bearing area of aircraft tail to prevent damage to the airframe Crankcase Separation If the crankcase halves must be separated remove the engine from airframe in accordance with the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A and the airframe manufacturer s instructions Engine disassembly cleaning inspection repair replacement and assembly must be accomplished in accordance with the most current version of the L TSIO 360 Series Overhaul Manual Form X30596A NOTE Exercise judgment in determining how far systems and components should be disassembled Any maintenance of engine systems and components removed from engine must be performed in accordance with that particular
151. ler or equivalent for needle bearing removal 17 5 16 Borroughs 23 1 Needle Bearing Installer or equivalent 17 5 LUBRICATION SYSTEM 17 8048 Oil Pressure Relief Spot Facer available from Kent Moore 19 3 CYLINDERS 18 68 3 Push Rod Spring Compressor available from Kent Moore 20 6 19 3882 Cylinder Base Nut Wrenches available from Kent Moore 20 6 20 Borrough s 8079 Cylinder Base Nut Wrenches or equivalent 20 6 21 3882 3882 2 Cylinder Base Nut Wrenches available from Kent Moore 20 6 22 3601 Ring Compressor for cylinder installation available from Kent Moore 20 6 23 8121 Piston Pin Removers available from Kent Moore 20 6 24 3602 Valve Spring Compressor available from Kent Moore 20 6 ITEM TOOL Courtesy of Bomar Flying Service See NO www bomar biz Section 25 545 116 Dial Bore Gages available from Federal Tool Supply Co Inc 20 6 26 CFL10 Cylinder Hone available from Snap On Tools 20 6 27 No 1675 Valve Seat Grinder Set Sioux Brand available from Aircraft Tool Supply 20 6 28 AEX 375 Valve Seat Grinder Pilot 437 Dia available from Aircraft Tool Supply 29 K28 Intake Valve Seat Grinding Stone Roughening 45 available from Aircraft Tool Supply 30 K98 Intake Valve Seat Grinding Stone Finishing 45 available from Aircraft Tool Supply 31 K428 Exhaust Valve Seat Grinding Stone Roughening 45 available from Aircraft Tool Supply 32 K498 Exhaust Valve Seat Grinding Stone Finishing 45 available from Aircraft Tool Supply 33 Borr
152. lifter dirty or worn Remove and clean or replace See Section 20 6 Cylinder Assembly Maintenance Hydraulic Valve Tappets Sluggish Operation And Throttle not full open Check and adjust linkage See Low Power Rigging of Mixture and Throttle Controls in the applicable airframe manufacturer s instructions Restrictions in air intake Inspect air intake and remove passages restrictions Ignition system malfunction See Section 12 5 Ignition Troubleshooting Fuel injection system See Section 13 4 Fuel Injection maladjusted System Troubleshooting Exhaust system gas leakage See the airframe manufacturer s instructions High Cylinder Head Lean fuel air mixture due to See the airframe manufacturer s Temperature improper manual leaning Airplane Flight Manual AFM for procedure correct leaning procedure Dirt between cylinder fins Clean thoroughly Magnetos out of time No Re time Check internal magneto appreciable drop detected timing and magnetos timing to engine during pre flight check See Section 12 6 Ignition System Maintenance TROUBLE High Cylinder Head Temperature Cont d Engine compartment cooling baffles in poor condition Exhaust valve leaking At front of engine damaged Oil Leaks crankshaft oil seal Around plugs fittings and gaskets due to looseness or damage Low Compression Excessively worn cylinder walls Piston rings excessively worn Valve faces and seats worn PROBA
153. lip up and leave a slack loop Twist the strands while taut until the twisted part is just short of a hole in the next unit The twisted portion should be within one eighth 1 8 inch from the hole in either unit Insert the uppermost strand through the hole in the second unit and follow the rules in paragraph three After lockwiring the last unit continue twisting the wire to form a pigtail providing a minimum of four twists to insure that the pigtail will not unravel Cut off the excess lockwire and bend the pigtail toward the part and against the bolt head flats DO NOT ALLOW THE PIGTAIL TO EXTEND ABOVE THE BOLT HEAD FIGURE 9 2 GENERAL LOCKWIRE PATTERNS 9 5 TAB WASHER PROCEDURE Tab washers are installed by fitting a tab in a tab slot and bending the remaining tabs firmly against the bolt or nut flat Tab washers are used in various locations in TCM engines and must not be reused after removal The tabs that are provided to be bent up against the head flats must be seated firmly with no scarring of the tabs This provides proper locking of the unit and prevents tabs from breaking off 1 Make certain that the holding tab is located in the tab hole or slot 2 Check the units to be secured and verify that they have been correctly torqued in accordance with the applicable overhaul manual 3 Bend tabs against the head flats firmly by tapping them into place with a soft drift See Figure 9 3 Tab Washer Installation Procedure
154. llowing instructions can result in fuel system linkage and or related component damage and subsequent loss of engine power Inspect the operation of each engine related control including the throttle mixture propeller and alternate air controls Make certain that each control has full limit of travel and that no binding or excessive play caused by worn parts or improper installation is evident Inspect the fuel servo levers in accordance with the manufacturer s instructions See Related Publications Section 1 4 for ordering information CLEAN INSPECT AND LUBRICATE IN ACCORDANCE WITH THE PROCEDURE SPECIFIED IN SECTION 13 3 100 HOUR CLEAN INSPECT AND LUBRICATE IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS CLEAN INSPECT AND LUBRICATE IN ACCORDANCE WITH THE AIRFRAME MANUFACTURER S INSTRUCTIONS FIGURE 13 5 GENERAL CONTROL LINKAGE LUBRICATION POINTS WARNING Connections requiring torqued fasteners must not exhibit any movement or motion between components Such movement may cause abnormal wear resulting in component malfunction or failure and subsequent loss of power Inspect all engine control cables for proper routing and security in accordance with the airframe manufacturers instructions Inspect all engine control cables for signs of damage or wear caused by chafing and heat distress in accordance with the airframe manufacturer s instructions See Figure 13 5 To insure proper operation and to pr3event accelerated water
155. lt If engine continues to run when magnetos are switched Off a malfunction is occurring in the ignition system Slowly move mixture control to IDLE CUT OFF and record Mixture RPM Rise 25 to 50 RPM Positive Fuel When propeller stops rotating place ignition switch master switch and fuel selector in off position 5 4 TEST OPERATING LIMITS ENGINE MODEL ENGINE MODEL TSIO 360 RB LTSIO 360 RB Full Throttle Speed RPM 2600 2600 Manifold Pressure In hg Absolute 38 0 38 0 Idle Speed RPM 700425 7004 25 Fuel Grade Octane 100LL 100 100LL 100 Fuel Flow at 140 150 140 150 Full Throttle Lbs Hr Oil Temperature Limit 240 F 240 F Oil Pressure Max Oil Cold 100 100 Minimum at Idle 10 10 Oil Pressure Operational Range 30 80 30 80 Magneto Drop Max 150 RPM 150 RPM Magneto Spread 50 RPM 50 RPM Cylinder Head Temperature 460 F 460 F with Bayonet Thermocouple Max Maximum RPM may not be attainable at static run up depending on setting of propeller low pitch stops 5 5 TIME INTERVAL INSPECTIONS Inspection procedures and maintenance information are provided in the individual system chapters Engine mounted accessories not supplied by TCM may require servicing at specific intervals some of these are alternators pneumatic pumps air oil separators and stand by generators Refer to the instructions provided by the airc
156. me manufacturer s instructions INDUCTION SYSTEM MAINTENANCE Induction System Induction system maintenance is limited to removal and replacement of malfunctioning components and torquing loose connections in accordance with the applicable portions of the L TSIO 360 Series Overhaul Manual Form X30596A Induction System disassembly and reassembly procedures Lubrication Fuel and controller linkage levers and bushings must be cleaned inspected and lubricated in accordance with the instructions in Section 13 3 Fuel Injection System Inspection 100 Hour 14 3 INTENTIONALLY LEFT BLANK 14 4 CHAPTER 15 AIR CONDITIONING SECTION PAGE 15 1 Air Conditioning System 15 2 15 2 Air Conditioning System Component Detailed Detail Description 15 2 15 3 Compressor Bracket 15 3 15 4 Air Conditioning Troubleshooting 15 3 15 5 Compressor Bracket 15 3 FIGURE PAGE 15 2 Compressor Drive 510 360 15 2 15 1 15 1 AIR CONDITIONING SYSTEM DESCRIPTION Air Conditioning The TSIO 360 RB engine utilizes a compressor mounting kit for the addition of a customer supplied belt driven compressor and air conditioning system For a description of the complete air conditioning system refer to the airframe manufacturer s informati
157. n Sub Assembly of the L TSIO 360 Series Overhaul Manual Form X30596A Single Cylinder Reinstallation Reinstall repaired or new cylinder in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Loosely install spark plugs and gaskets in cylinder Have an assistant hold nuts on opposite end of cylinder through bolts when torquing cylinder attaching hardware Hydraulic Valve Tappets Malfunctioning hydraulic valve tappets must be removed discarded and replaced with new Remove and replace tappets in accordance with the applicable instructions in the L TSIO 360 Series Overhaul Manual Form X30596A Reinstall all valve train components that were removed using new o rings seals and gaskets in accordance with in the L TSIO 360 Overhaul Manual Form X30596A Rocker cover screws must be torqued to 45 55 inch pounds and safetied as required SECTION 21 1 21 2 21 3 21 4 21 5 FIGURE 21 1 21 2 21 3 CHAPTER 21 CRANKCASE ASSEMBLY PAGE Crankcase Description Astea a a a E 21 2 Crankcase Detailed Description 21 2 Crankcase Inspection 50 100 21 3 Crankcase Troubleshooting tbe 21 5 Crankcase enne nnns 21 5 PAGE Crankcase Description a eene nnne 21 2 Inspection of Crankcase Non Critical Area 21 3 Inspection of Crankcase Critical and Non Critical Areas
158. n during the compression stroke and then ignited by a high intensity spark from the spark plug As the mixture is ignited the expanding gases force the piston to move inward toward the crankshaft This inward motion acting on the connecting rod and crankshaft throw is converted into rotary motion by the crankshaft As the crankshaft throw rotates past half of one revolution the connecting rod and piston start moving outward on the exhaust stroke toward the cylinder head During this movement the exhaust valve begins to open allowing the burned mixture exhaust to escape Momentum from the crankshaft forces the piston toward the cylinder head in preparation of the next intake stroke event Proper mechanical timing between the crankshaft and camshaft allows the intake and exhaust valves to open and close in synchronization with piston position in all six cylinders Proper magneto internal timing and magneto to engine mechanical timing allow precise spark plug ignition at 20 1 before top dead center during the piston s compression stroke PISTONS CRANKSHAFT AND RINGS CYLINDER HEAD AND BARREL VALVES CONNECTING 4 lw gt PUSHROD ROCKER ARM HYDRAULIC TAPPET OIL SUMP CAMSHAFT FIGURE 20 2 CYLINDER PISTON AND VALVE TRAIN 20 3 CYLINDER ASSEMBLY DETAILED DESCRIPTION Cylinder Valve Guides Valves Rotocoils The externally finned aluminum alloy head castings are heated and valve seat inser
159. n the L TSIO 360 Series Overhaul Manual Form X30596A 100 HOUR Perform all inspection procedures listed under 50 hour inspection and inspect alternate air door operation air filter and control connections for freedom of movement and or lost motion due to wear in accordance with the airframe manufacturer s instructions Fuel control unit to controller linkage levers and bushings must be cleaned inspected and lubricated in accordance with the instructions in Section 13 3 Fuel Injection System Inspection 100 Hour Inspect manifold drain lines and check valves for leaks chafing and function At each scheduled maintenance interval perform the following inspection to ensure that the drain s function properly INDUCTION SYSTEM TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms Items are presented in sequence of approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start Induction system intake Locate and remove obstruction obstructed Engine Will Not Run At Idling Induction system leakage See Section 14 5 Speed Engine Runs Too Rich At Restrictions in air intake Check air passages remove Cruise Power passages restriction Sluggish Operation And Low Throttle not opening wide Check and adjust control Power 14 5 connections in accordance with the airfra
160. nced and followed If an engine overspeed occurs comply with the following procedures RPM TO 3000 1 2 Less than one minute No action required More than one minute Proceed as follows a Drain oil through a fine mesh screen and inspect for debris b Remove oil filter and inspect filter element for debris c Remove and inspect inside of rocker covers for debris Inspect valve stem Keeper grooves and valve keepers for condition security and proper installation Inspect valve springs rocker arms spring retainers rotocoils pushrods etc d Perform a borescope inspection on all cylinders e If no discrepancies are noted re service engine perform operational inspection and correct any discrepancies noted prior to returning the engine to service f If discrepancies are found a decision must be made based on the evidence as to the extent of the corrective action required RPM TO 3300 1 In addition to action required for B above proceed as follows a Remove all cylinder assemblies including rods and pistons b Clean inspect repair or replace all components removed from the engine in accordance with the manufacturer s current overhaul manual Using new connecting rod bolts and nuts reassemble service and test the engine in accordance with the manufacturer s current overhaul manual c After five and ten hours of engine operation remove oil filter and inspect filter element for debris RPM EXCEEDING 3300
161. nel By careful inspection and troubleshooting such damage and injury can be avoided ENGINE TROUBLESHOOTING CHART This troubleshooting chart is provided as a guide Review all probable causes given check other listings of troubles with similar symptoms ltems are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Engine Will Not Start Fuel Tank Empty Service aircraft fuel system in accordance with the airframe manufacturer s instructions See Chapter 7 Servicing Fluids for correct fuel grade Improper starting procedure Refer to the airframe manufacturer s Airplane Flight Manual AFM for engine starting procedures Check for performance of each item Cylinder overprimed Engine Allow fuel to drain from intake system 159866 WARNING Starting an engine with a flooded intake system will result in hydraulic lock and subsequent engine malfunction Induction system leak Torque or replace loose or damaged hose connection See Section 14 5 Induction System maintenance Excessive Starter slippage Replace starter adapter See Section 17 5 Fuel system malfunction Isolate cause and correct See Section 13 4 Fuel Injection System Troubleshooting Ignition system malfunction See Section 12 5 Ignition Troubleshooting Manifold valve vent Repair or replace manifold valve See obstruction Section 13 5 Fuel System Maintenance
162. ng lights while other timing lights operate in the reverse manner i e the light goes out when the points open CAUTION When installing the magneto on the engine using the specified nuts and clamps take the following precautions Tighten both nuts by hand to finger tightness Torque each nut alternately to 8 3 to 10 0 ft lbs Exceeding 10 0 ft Ibs torque may cause the mounting flange to crack H Torque the magneto attaching hardware to 8 3 10 0 foot pounds Disconnect timing light from magnetos Insure that connections between magneto and ignition switch are secure If the ignition harness was removed during ignition system maintenance it must be reinstalled in accordance with the following instructions IGNITION HARNESS PRE INSTALLATION INSTRUCTIONS A Clean the mating surfaces before installing harness on magneto Install and tighten nuts around plate alternately to seat cover squarely on magneto Torque screws according to the Magneto Manufacturer s Instructions B The harness assemblies are constructed of a lightweight flexible silicone coated cable Because the harness assemblies are lightweight and flexible the following must be observed when installing the harness on an engine 1 Support leads with the necessary clamps and cable ties to prevent any whipping or chafing action 2 Route leads as far away as possible from exhaust manifold to insure they are not exposed to temperatures in excess of 400 F
163. ng temperature the oil temperature control valve vernatherm is open allowing oil to flow through the by pass portion of the oil cooler adapter Oil flowing through the by pass flows past the oil temperature control valve and out to the crankcase left main oil gallery When oil temperature reaches 168 F 172 F the oil temperature control valve closes and the oil flows through the cooler core As the oil flows through the cooler core cooling air fins between the core oil passages dissipate heat from the oil maintaining normal operational oil temperatures OIL COOLER ADAPTER PLATE OIL FLOW TO LEFT MAIN OIL GALLERY OIL IN FROM QUE C OIL FILTER OIL FLOW OIL BELOW NORMAL OPERATING TEMPERATURE COOLING FINS OIL TEMPERATURE CONTROL VALVE OIL FLOW OIL AT NORMAL OPERATING TEMPERATURE 19 4 OIL COOLER AND OIL TEMPERATURE CONTROL VALVE DESCRIPTION continued on next page 19 7 19 2LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION continued 19 3 19 8 Oil Sump The oil sump is cast aluminum The sump is attached to the crankcase flange with 14 nuts washers and lock washers The oil sump assembly incorporates a tapped drain plug boss The drain plug boss has provisions for safety wiring of the oil drain plug Oil Suction Tube The oil suction tube is threaded into the oil sump and sealed to the accessory case by the accessory case gasket Oil flows from the sump through the oil suction tube to the acc
164. nozzles at or your local TCM Distributor cylinder head Loctite Anti Seize Lubricant 767 or For Distributor information Loctite Exhaust studs nut end before Customer Service torquing Phone 1 800 243 4874 All class 4 studs All mechanical tach drive housing threads 3 3 SUGGESTED SOURCES APPLICATION Approved Ashless Dispersant Oil See Aviation Engine Oil Ashless Cylinder studs and through bolts Dispersant Table crankcase studs connecting rod bolts and nuts engine accessory studs unless otherwise specified CHAMPION Spark Plug For Champion Products Spark plugs Thread Lubricant No 2612 Distributor information Phone CHAMPION is a registered 803 843 5400 trademark of Cooper Industries Chesterton No 4 Chesterton Technical Product Induction system hose Information connections Phone 508 469 6783 Dow Corning No 4 For Distributor information call Spin on oil filter rubber seals 1 800 248 2481 have state amp city information available SUGGESTED SOURCES APPLICATION Permatex Aviation Grade 3D For Distributor information call Crankcase parting face oil pump Permatex Customer Service covers scavenge pump covers Phone 1 800 641 7376 and 641543 Silk Thread May be purchased through and your local TCM Distributor 646942 Gasket Maker May be purchased through your local TCM Distributor or Loctite Gasket Eliminator For Distributor information call 515 Sealant Loctite Customer
165. nt of the gear coupling slot and impulse coupling lugs If not aligned pull the magneto drive gear out of mesh and turn to position needed Push gear back into mesh WARNING Prior to any engine or magneto timing procedure disconnect all ignition harness spark plug leads from the spark plugs Do not attach any ignition harness spark plug leads to the spark plugs until all magneto engine timing procedures and magneto to switch connections have been entirely completed The magneto is in a SWITCH ON condition when the switch wire is disconnected To prevent possibility of serious bodily injury or death before moving the propeller accomplish the following 12 12 a b e Disconnect all spark plug leads Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open Do not stand within the arc of the propeller blades while turning the propeller C Insure that the crankshaft is positioned in accordance with Section 12 6 Placing Crankshaft In Timing Position D Insure that the magneto drive coupling bushings and retainers are properly installed Place a new gasket on the magneto flange and install magneto carefully so that the drive coupling lugs mate with the slots of the drive
166. ntenance Cylinder Dimensions see next page 20 18 5 363 80200 3745 eee WSS SHH GON WES iba 4 4 875 25 STRAIGHT a rap D DIA 5 FROM BOTTOM OF SKIRT NEW PART SERVICE LIMITS STANDARD 4437 4 439 4442 005 4442 SERVICE LIMITS FOR MINIMUM aa MAXIMUM X DIA IS ACTUAL ANDARD 4 434 4 436 MEASURED D DIA 4 439 4 441 ZEE GERMEN ZW DAE PLUS 001 In NEW PART STANDARD 491 443 44 448 pone TSIO 360 SERIES CAUTION Cylinder assemblies exceeding new parts dimension shown are acceptable when performing maintenance before engine overhaul However piston ring gaps given in the table of limits must be maintained When engine is being overhauled TCM requires that all Parts be brought back to new parts limits by rework or replacement See New Parts and Service Limits in L TSIO 360 Series Overhaul Manual Form X30596A NOTE DIMENSIONS SHOWN ARE FINISHED AFTER HONING FIGURE 20 13 MAINTENANCE CYLINDER DIMENSIONS 20 19 20 6 20 20 CYLINDER ASSEMBLY MAINTENANCE continued Single Cylinder Reassembly After all cylinder components have been cleaned inspected and repaired in accordance with TCM specifications reassemble cylinder in accordance with Cylinder and Pisto
167. nts described in this manual See Chapter Contents During engine 50 and 100 hour inspections if engine components must be replaced refer to the applicable system maintenance chapter Adjustment information will be found in the individual system chapters of this section NOTE The figures depicted in this section are for illustration purpose only They are not intended to be accurate detailed illustrations of any specific engine model part or equipment WARNING When performing any inspection or maintenance always treat the engine as if the ignition switch was on Do not stand or allow anyone else to stand within the arc of the propeller A loose or broken wire or a component malfunction could cause the engine and propeller to rotate and or the engine to start Engines operated in extremely humid locations or in exceptionally cold damp climates or coastal areas may require more frequent inspections If the engine is operated in excess of 100 hours per year the engine must be inspected at each 100 hour interval in addition to an annual inspection OVERHAUL PERIODS Engine Model Overhaul Period L TSI0 360 RB 1800 HOURS NOTE Overhaul periods for the engine include all engine accessories OPERATIONAL INSPECTION An operational inspection must be performed prior to 50 100 hour inspections STARTING Start engine using the starting procedure given in the airframe manufacturers Airplane Flight Manual AFM OPERATIONAL CHECK LIS
168. o correct capacity Engine is now ready for initial run up and test CAUTION Recheck the oil level in the sump Do not operate the engine with more or less than the oil sump capacity See Sections 1 10 Operating Limits and 7 1 Servicing Oil for correct grade oil sump capacity and servicing points If the magneto attaching nuts were loosened or the magnetos rotated during engine installation magneto to engine timing must be adjusted to specification prior to starting See Section 12 5 Ignition System Maintenance of this manual Apply Champion thread lubricant to spark plugs in accordance with the manufacturer s instructions see Chapter 3 Install the upper spark plugs and torque to 300 360 inch pounds Install the ignition harness B nuts on the spark plugs The nuts are stamped with a position identifier which means the top spark plug of the number one cylinder PREFLIGHT AND RUN UP Engines that have a complete set of overhauled or new cylinders and new piston rings installed must be serviced with Engine Break In and Preservation oil conforming with MIL C 6529 TYPE until it has been determined that the engine oil consumption has stabilized approximately 25 hours of operation Thereafter the engine must be serviced with the appropriate grade depending on ambient temperature of ashless dispersant oil See Section 7 2 Approved Ashless Dispersant Oils Start the engine in accordance w
169. ocuments determined by the manufacturer to enhance safety maintenance or economy CATEGORY 5 SERVICE INFORMATION LETTER SIL This category provides general information that may be useful to the owner operator or aircraft maintenance technician AMT SPECIAL SERVICE NOTICE SSN TCM may issue a Special Service Notice when a product condition can be rectified by direct contact with each customer to whom the product was delivered Special service notices will be upgraded to Service Bulletins if confirmation of compliance with the Special Service Notice cannot be verified by TCM SERVICE REPORTS AND INQUIRIES you have an inquiry or require technical assistance contact a TCM distributor field representative or customer service 1 3 1 5 DESCRIPTION OF ENGINE MODEL CODE Example code L TSIO 360 RB 1 COELO Left hand Turbo super Fuel injection Horizontally Displacement model specification rotation charged opposed 360 cubic inch number 1 6 DEFINITION OF TERMS Front rear left and right refer to the engine view facing the accessory end The accessory end is referred to as the rear and propeller flange the front of the engine Cylinders are numbered starting from the rear with odd numbers on the right and even numbers on the left 1 7 ENGINE DESIGN FEATURES The L TSIO 360 RB series The L TSIO 360 RB series engines are air cooled having six horizontally opposed ove
170. odically for accuracy as follows using a line pressure of 100 to 120 pounds per square inch close the cylinder pressure valve then set the regulator pressure valve to 80 pounds per square inch The pressure in both gages should stabilize with no leakage The restrictor orifice dimension in the Master Orifice Tool for Teledyne Continental aircraft engines must be 0 040 inch orifice diameter 0 250 inch long with 60 approach angle and must flow 120 5 cubic feet per hour at 30 pounds per square inch differential pressure 20 9 20 4 cont d 20 10 Master Orifice Tool For conformity in testing equipment a Master Orifice Tool Part Number 646953 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 pounds per square inch to the tester with cylinder pressure valve closed Turn the regulator pressure valve on adjusting pressure to indicate 80 pounds per square inch Remove the dust caps from both ends of the Master Orifice Tool and install onto a cylinder spark plug adapter Turn the cylinder pressure valve on and readjust regulator pressure gauge to read 80 pounds per square inch At this time the cylinder pressure gauge indication will be the low allowable limit for cylinder leak checks The low allowable limit is referred to as the master orifice calibrated pressure reading After the master orifice calibrated pressure reading has been r
171. of the wastegate increases causing the wastegate butterfly valve to close increasing exhaust gas flow to the turbocharger turbine The Variable Absolute Pressure Controller consists of a poppet valve controlling oil flow referenced to a pressure sensitive bellows on one side and a mechanically actuated spring loaded plunger on the other The mechanical actuated plunger is connected through a series of cams levers and link rods to the throttle plate The VAPC is installed on the engine intake manifold prior to the throttle plate and in such a way that the pressure sensitive bellows is in the intake manifold and senses turbocharger compressor discharge pressure deck pressure During engine operation compressor discharge pressure is referenced by the VAPC s bellows while the mechanically linked plunger is positioned according to throttle plate position When ever the compressor discharger pressure sensed by the bellows is less than the mechanical and spring pressure acting on the plunger the poppet valve is positioned to restrict oil flow from the wastegate actuator to the engine and the wastegate butterfly valve goes closed If the compressor discharge pressure sensed by the bellows is greater than the mechanical and spring pressure acting on the plunger the poppet valve moves to a position that increase oil flow from the wastegate actuator to the engine and the wastegate butterfly valve opens During cruise operation the forces acting on
172. oil pressure adjustment NOTE Repairs other than stoning nicks on parting flanges replacement of studs worn parts and refacing the oil pressure relief valve seat on the oil pump housing are not possible The oil pump driven gear shaft is pressed into the accessory case pump housing and cannot be replaced The pump gear chamber must not be enlarged If it is scored the accessory case must be discarded Heavy scoring on the gear contact area of the oil pump cover renders it unserviceable See Section 19 3 100 Hour Inspection for oil pressure relief valve seat refacing Discard accessory cases with oil pump housing that exhibit cracks or that are worn beyond specified limits Oil Filter Adapter Repairs other than stud replacement worn parts replacement and stoning nicks on parting flanges are not possible Discard oil filter adapters that exhibit cracks The oil filter adapter stud must be inspected and replaced if necessary in accordance with Section 19 3 Oil Filter Adapter Inspection Oil Filter Cut safety wire and remove the filter Using an oil filter can cutter open can and inspect the oil filter element Oil Sump If repair or replacement is required the oil sump assembly may be removed from the engine in the aircraft provided clearance is available After clearance has been gained the oil sump may be removed and reinstalled in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Whenever oil sump is remove
173. oller and overboost valve adapter IGNITION SYSTEM COMPONENT DETAILED DESCRIPTION For a detailed description of magnetos and harnesses see Slick Ignition Systems Master Service Manual Order Form F 1100 as applicable See Related Publications Section 1 4 for ordering information Magneto Drive Assembly Each magneto is driven by a magneto drive gear retainer and bushings housed inside the accessory case Two rubber bushings per magneto are installed within a retainer on the drive gear The rubber bushings provide a shock absorbing engagement between magneto and engine drive train The magnetos are attached to the upper rear portion of the accessory case and secured by retainers lockwashers and nuts The magneto drive gear assemblies are driven by the camshaft gear IGNITION SYSTEM INSPECTION WARNING Absence of any RPM drop when checking magnetos may indicate improper grounding in the ignition circuit Should the propeller be moved by hand as during pre flight the engine may fire and cause injury to personnel This type of malfunction must be corrected prior to continued operation of the engine Continued operation of the engine at idle RPM with the ignition switch in the OFF position will verify this malfunction 50 HOUR INSPECTION Compare recorded findings of operational inspection with the following The magneto drop for left or right magneto must be no greater than 150 RPM and magneto spread no greater than 50 RPM with ignition t
174. ompressed to 1 100 in length 62LBS Inner valve spring 625957 compressed to 1 500 in length j 33 LBS Outer valve spring 625958 compressed to 1 168 in length 77 LBS Outer valve spring 625958 compressed to 1 159 in length 43 LBS 1 559 PISTONS RINGS AND PINS Cermicrome is a registered trademark of Engine Components Inc Use 005 oversize rings See Figure 20 13 Maintenance Cylinder Dimensions Intake valves may be reworked in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A Exhaust valves MUST NOT be reworked worn exhaust valves must be replaced 100 See TCM Service Bulletin M90 13 or current revision as applicable Intake and exhaust valve seats may be reworked in accordance with the TSIO 360 Series Overhaul Manual Form X30596A Valve guides may be replaced in accordance with the L TSIO 360 Series Overhaul Manual Form X30596A If the required rocker arm to roto coil clearance cannot be obtained without exceeding 0 34 11 32 grind width the rocker must be replaced See illustration on next page 20 17 SECTION A A 20 8 187 JD 27A 4 40 12 21 19 9 2 3 4 41 42 NS ay s Peau AA 11 28 29 38 27 7 2 32 33 34 35 FIGURE 20 12 CYLINDER ASSEMBLY SERVICE LIMITS For Mai
175. on 15 2 AIR CONDITIONING SYSTEM COMPONENT DETAIL DESCRIPTION Compressor Mounting Kit The accessory drive adapter and compressor mounting brackets are attached to the rear of the starter adapter assembly The accessory drive adapter houses the scavenge pump gears and gearing for two right angle drive adapter pads and a shaftgear for the compressor drive sheave Two compressor mounting brackets are attached to the adapter by the adapter cover attaching hardware ENGINE TOP VIEW ACCESSORY di 4 ZA 1 2 x CUSTOMER SUPPLIED STARTER COMPRESSOR ADAPTER FREON COMPRESSOR ACCESSORY DRIVE MOUNT BRACKETS ADAPTER COMPRESSOR DRIVE SHEAVE ENGINE REAR VIEW FIGURE 15 1 COMPRESSOR DRIVE TSIO 360 RB 15 2 15 3 15 4 15 5 COMPRESSOR BRACKET INSPECTION 50 Hour Visually inspect the compressor bracket assembly for security and cracks The drive belt customer supplied air conditioning components plumbing and connections must be inspected in accordance with the airframe manufacturer s instructions AIR CONDITIONING SYSTEM TROUBLESHOOTING See the Airframe Manufacturer s Instructions COMPRESSOR MOUNTING KIT MAINTENANCE Remove and replace worn or malfunctioning compressor mounting kit components in accordance with applicable portions of disassembly reassembly in the L TSIO 360 Overhaul Manual Form X30596A Supplement 1 Freon compressor drive belt inspection removal instal
176. ontain proper type of fuel 100LL blue or 100 green The aircraft fuel system must be serviced in accordance with the airframe manufacturer s instructions Check engine oil sump for proper servicing See Chapter 7 for oil type specification and servicing point Start engine using the starting procedure given in the airframe manufacturers Airplane Flight Manual AFM Oil Pressure Check If no oil pressure is noted within 30 seconds shut engine down and investigate CAUTION Operation of engine without oil pressure may result in engine malfunction or stoppage OPERATIONAL INSPECTION An operational inspection must be performed prior to 50 100 hour inspections OPERATIONAL CHECK LIST Check and record the following system data Record RPM Drop for each magneto at 1700 150 RPM MAXIMUM AND 50 RPM SPREAD MAXIMUM Propeller Operation at 1700 Or as specified in aircraft manufacturer s instructions Increase engine to full power and record Manifold 4 8480 Eel EloWi oc E A t As Oll PRESSURE i t een reet eet eerte ete diras Oil Cylinder Head Temperature esee Alternator mee oreet ae Reduce engine to idle and record Manifold Pressure c tb Rr e rM rrt
177. ontroller AdjuStMeEnt ooi e fe t diee 23 7 23 7 ADMP VS Oil 23 8 23 8 Constant Speed Sea Level Performance 23 9 23 10 Fuel Flow Vs Metered Fuel 23 10 23 13 Fuel Flow Vs Brake 23 11 TABLE PAGE 23 1 Fuel System Pressure and Flow Value 23 3 23 1 23 1 23 2 POST MAINTENANCE OPERATIONAL TEST STARTING WARNING Over priming can cause hydrostatic lock and subsequent engine malfunction CAUTION Insure propeller area is clear before initiating starting sequence NOTE If engine has had a new cylinder or cylinders and piston rings installed start the engine in accordance with the airframe manufacturer s Airplane Flight Manual AFM Operate the engine at 750 RPM for one minute gradually increasing RPM to 1000 RPM in three minutes Check the magneto circuit for proper grounding prior to a normal shut down Allow the engine to cool adequately and make a visual inspection for any discrepancies If engine exhibits any discrepancies return to the applicable chapter to correct the discrepancy discrepancies must be corrected prior to operational test and engine adjustment NOTE Before starting engine insure that fuel tanks c
178. ot perform any operation maintenance installation or other operations until the manual has been confirmed to be current SERVICE DOCUMENTS TCM service documents include categories for Mandatory Service Bulletins Critical Service Bulletins Service Bulletins Service Information Directives Service Information Letters and Special Service Notices Category Definitions CATEGORY 1 MANDATORY SERVICE BULLETIN MSB Service documents relating to known or suspected hazards to safety that have been incorporated in whole or in part in an Airworthiness Directive AD issued by the FAA or have been issued at the direction of FAA by the manufacturer to require compliance with an already issued AD or an equivalent issued by another country s airworthiness authority CATEGORY 2 CRITICAL SERVICE BULLETIN CSB Service documents determined by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to persons or property on the ground unless some specific action inspection repair replacement etc is taken by the product owner or operator Documents in this category may be candidates for incorporation in an Airworthiness Directive issued by the FAA CATEGORY 3 SERVICE BULLETIN SB Service documents considered by the product manufacturer to constitute a substantial improvement to the inherent safety of an aircraft or component of an aircraft CATEGORY 4 SERVICE INFORMATION DIRECTIVE SID Service d
179. ough s 5221A Holding Fixture Adapters or equivalent 34 Borrough s 5221B Cylinder Holding Fixture or equivalent 35 Borrough s 8156 Cylinder Heating Stand or equivalent 36 Borrough s 8086 Valve Seat Insert Remover amp Replacer or equivalent 37 Borrough s 4910 Installer Valve Seat Insert or equivalent 38 Borrough s 4956 Installer Valve Seat Insert or equivalent 39 Borrough s 8116 Common Parts Kit or equivalent 40 Borrough s 8116 1B through 15B Boring Bars or equivalent 41 Borrough s 8116 1R through 15R Reamers or equivalent 42 Borrough s 8116 1 through 16 Expanding Guide Bodies or equivalent 43 4909 Valve Seat Straight Side Insert Cutters available from Kent Moore 4954 Valve Seat Straight Side Insert Cutters available from Kent Moore 4985 Valve Seat Straight Side Insert Cutters available from Kent Moore 5224 Valve Seat Straight Side Insert Cutters available from Kent Moore 5225 Valve Seat Straight Side Insert Cutters available from Kent Moore 44 8135 Valve Seat Step Side Insert Cutters available from Kent Moore 8136 Valve Seat Step Side Insert Cutters available from Kent Moore 8138 Valve Seat Step Side Insert Cutters available from Kent Moore 45 Borrough s 8122A Common Drive Handle or equivalent 46 122 Valve Guide Cleaner available from Kent Moore 47 2873 Valve Guide Remover available from Kent Moore 48 3619 Valve Guide Replacer available from Kent Moore 49 Borrough s 3170 Floating Holder or equivalent 50 4981 Val
180. peed indicator can be connected directly to this tube and secured with a clamp By the use of the following table it will be possible to obtain actual water pressure in H2O when checking a suspect engine Run engine on the ground at full power to check for excessive pressure If the pressures are excessive check the system with crankcase breather system disconnected from the engine vent standpipe If the pressure then drops appreciably the breather system should be checked for possible blockage caused by but not limited to the air oil separator collapsed lines sludge build up wet vacuum pump etc After disconnecting the breather system if the pressure is still high the cylinders must be checked for blow by If the aircraft has an air oil separator installed in the breather system it will cause a higher airspeed reading when connected because of the back pressure When the ground run has been finished the breather system must be reinstalled 20 6 NOTE Excessive crankcase pressure in flight can be caused by ram air entering the engine interior through an improper fitting oil cap seal and or damaged crankshaft nose seal AIRSPEED VERSUS WATER PRESSURE Inches H O 1 23 H20 Limits for TSIO 360 60 1 77 0 70 2 42 H20 80 MPH 3 16 H20 90 MPH 4 00 H20 100 MPH 4 94 Reference 1 PSI 2 Hg 120 MPH 7 131 1 Hg 13 6 H20 140 MPH 9 729 150 MPH 11 18 CYLINDER ASSEMBLY MAINTENANCE WARNI
181. position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open g Do not stand within the arc of the propeller blades while turning the propeller After flight remove spark plug leads and remove spark plugs Protect the ignition lead ends with AN 4060 Protectors Install protective plugs P N 22671 in bottom spark plug holes Using a common garden sprayer or equivalent spray atomized preservative oil that meets MIL P 46002 Grade 1 at room temperature through upper spark plug hole of each cylinder with the piston at bottom dead center position Rotate crankshaft as opposite cylinders are sprayed Stop crankshaft with none of the pistons at top dead center Re spray each cylinder To thoroughly cover all surfaces of the cylinder interior move the nozzle or spray gun from the top to the bottom of the cylinder Install dehydrator plugs MS 27215 1 or 2 in each of the upper spark plug holes Make sure each plug is blue in color when installed Attach a red REMOVE BEFORE FLIGHT streamer to each bag of desiccant Place a bag of desiccant in the exhaust pipes and seal the openings Seal all engine openings exposed to the atmosphere using suitable plugs and covers Tag propeller in a conspicuous place with the following notation on the tag DO NOT TURN PROPELLER ENGINE PRESERVED PRESERVATION DATE 8 5
182. pression stroke on the number 1 cylinder by placing a finger over the spark plug hole as the crankshaft is rotated Continue rotating crankshaft on the compression stroke until the 0 mark is under the pointer On engines equipped with impulse couplings continue turning the crankshaft in the normal direction of rotation until each impulse coupling trips Couplings may trip a few degrees on either side of top dead center If one or both impulse couplings trip after top dead center turn the propeller back to a few degrees before top dead center and approach the top dead center position from the normal direction of rotation POSITIVE DEAD CENTER LOCATOR REMOVED 0 TDC POSITION 1 CYLINDER NORMAL DIRECTION OF ROTATION NOTE THE PROTRACTOR TIMING INDICATOR SHOWN IS USED WITH THE PROPELLER AND SPINNER INSTALLED FIGURE 12 5 TIMING POSITION STEP 4 9 To check either the magneto timing or to time the magneto to the engine move the propeller in the opposite direction of normal rotation past the specified magneto timing setting and then back in the direction of normal rotation until the desired setting before top dead center is under the pointer to remove the gear backlash Disconnect the ground switch leads from the magnetos Place a Bendix 11 851 timing light or equivalent on the engine and connect the right lead to the right magneto ground terminal and connect the left lead to the left magneto ground terminal Connect
183. r Scavenge pump driven gear on shaft Scavenge pump drive gear in adapter Scavenge pump gears in adapter Scavenge pump drive gears in adapter Scavenge pump drive gear in starter shaftgear Starter shaftgear in scavenge pump cover Scavenge pump driven gear to drive gear NS SS S gt 5 Pir B N 62 VSN SSN C M M f EA RIN SREY REA 1 2 FIGURE 17 3 STARTER ADAPTER FITS AND LIMITS LTSIO 360 RB and OPTIONAL TSIO 360 RB 17 5 17 5 STARTING SYSTEM MAINTENANCE cont d Limit Diameter Diameter 0 002L 0 003T 1 574 1 576 Diameter End Clearance Diameter Diameter Diameter Diameter Diameter Diameter Side Clearance Diameter Diameter Backlash Backlash Diameter Diameter Diameter Backlash Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter Backlash Diameter Diameter 17 6 21 24 D UL em E 4 Ge 40 E m 4 g A 5 gt a 2 2 NARA SSRN TREE em B SSS LI 112 UZ 7 Ray A gt gt m 37 3 6 1 2 11 Pa 22 30 31 32 FIGURE 17 4 STARTER ADAPTER FITS amp LIMITS 17 7 INTENTIONALLY LEFT BLANK 17 8 SECTION 18 1 18 2 18 3 18 4 18 5 FIGURE 18 1 CHAPTER 18 ACCESSO
184. r and thumb Sand will not disintegrate when rubbed between two hard surfaces and will scratch glass when pressure is applied Nickel will not be magnetically attracted but looks similar to ferrous material Tin will not be attracted magnetically It looks similar to nickel but is soft and malleable SPECTROGRAPHIC OIL ANALYSIS Spectrographic oil analysis has become popular with the owners and operators of general aviation piston powered aircraft This process was developed more than 35 years ago by the railroads as a method of identifying wear characteristics in large diesel engines Eventually oil analysis was adopted by the military and then by commercial and general aviation Engines are designed and manufactured using various materials and alloys The engine lubrication system is designed to provide either pressure or splash oil to areas of the engine subjected to frictional loading During normal operation these areas undergo minute continuous wear sub micronscopic material is released from these contact surfaces and are suspended in the lubricating oil Spectrographic oil analysis identifies these materials and their level of concentration in parts per million PPM There are two accepted methods of performing oil analysis atomic absorption and atomic emissions Atomic absorption will identify suspended wear material that is five micron in size or smaller while atomic emissions will identify suspended wear material that is
185. raft manufacturer accessory manufacturer or STC holder for detailed information CAUTION New rebuilt and overhauled engines or engines that have had overhauled or new cylinders and new piston rings installed must be given a 100 hour inspection after 25 hours of operation Oil Change Interval With small full flow filter 50 hours With large full flow filter 100 hours Oil Filter Change Interval With large or small full flow filter 50 hours Hours stated or six months whichever comes first CAUTION Use only TCM approved oils See TCM approved oils in Operation Section Normal Operating Procedures 25 HOUR INSPECTION NOTE Research and comply with all applicable Service Publications and Airworthiness Directives 1 After the first 25 hours of operation on new rebuilt or overhauled engines perform a complete 100 hour inspection Drain the oil used for engine break in If engine oil consumption has stabilized service the engine with TCM approved oil oil consumption has not stabilized service engine with a mineral oil conforming to MIL C 6529 Type Il First 25 hours of operation Mineral non detergent oil or Corrosion Preventive oil corresponding to MIL C 6529 Type NOTE Mineral oil conforming to MIL C 6529 Type Il is a straight mineral oil with a corrosion preventive additive This oil must not be
186. related procedures required pursuant to the type certification for this engine 4 Distribution of Changes to Airworthiness Limitations Changes to the Airworthiness Limitations section constitute changes to the type design of this engine and require FAA approval Such changes will be published in FAA Airworthiness Directives AD NOTE The limitations in this section apply only to specific limitations which are part of the engine design Under the Federal Aviation Regulations numerous other additional limitations are applicable to this engine and it s accessories For example Federal Aviation Regulation Parts 91 and 43 among other parts define inspection criteria maintenance requirements and procedures that are applicable to this engine It is the responsibility of the owner operator to maintain the engine in an airworthy condition by complying with all applicable Federal Aviation Regulations and by performing maintenance in accordance with TCM Instructions for Continued Airworthiness which consist of TCM publications and service documents INTENTIONALLY LEFT BLANK TIME LIMITS OPERATIONAL INSPECTION ENGINE SECTION 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 CHAPTER 5 TROUBLESHOOTING PAGE General teo e 5 2 Overhaul 5 2 Operational 5 3 Test Operating Limits tet
187. rhead inclined valve cylinders The cylinder displacement of 360 cubic inches is achieved with a 4 4 inch bore and a 3 875 inch stroke The L TSIO 360 RB series engines are fuel injected The crankshaft is equipped with pendulum type counterweight dampers that suppress torsional vibrations The L TSIO 360 RB series engine have a doweled six bolt hole configuration propeller flange A mounting pad is provided to utilize a hydraulic controlled governor for a constant speed propeller The L TSIO 360 RB series engines are designed with a wet sump and a positive displacement oil pump When properly adjusted under normal operating conditions the desired oil pressure is maintained by a pressure relief valve Engine cranking is accomplished by a geared right angle drive starter adapter and a direct current starter motor The L TSIO 360 RB series incorporate provisions for a belt driven alternator installed on the from 1 3 5 side of the crankcase The engine is equipped with two gear driven magnetos mounted on the accessory case The exhaust and turbocharging system is supplied with the engine 1 4 EXHAUST BY PASS VALVE m ACTUATOR ON PRA sn E SEE AFTERCOOLER i qd LI COMPRESSOR KIT 1 12X 190 32 HOSE T7 QD XS UNJF 3B M 7 19 84 Ac ZEN as x Ns A 4 4 57 T 5 2 Ted 9 1 JE
188. rnal grooved surface to allow the circulating oil to lubricate the front main bearing The governor pad cover is not needed if a propeller governor is installed WARNING Do not connect the ignition harness to the spark plugs until the propeller installation is completed Failure to comply could result in bodily injury when the propeller is rotated during installation NOTE Remove all protective plugs from the following locations exhaust outlets crankshaft flange and fuel pump fittings NOTE Drain preservative oil from sump Engines that have a complete set of overhauled or new cylinders and new piston rings installed must be serviced with clean Engine Break In and Preservation oil conforming with MIL C 6529 TYPE until it has been determined that the engine oil consumption has stabilized approximately 25 hours of operation Thereafter the engine must be serviced with clean ashless dispersant oil See Section 7 2 Approved Ashless Dispersant Oils 6 6 ENGINE INSTALLATION INSTRUCTIONS See Figures 6 1 CAUTION The engine must be hoisted using the lifting eye brackets only WARNING The aircraft fuel tanks and lines must be purged to remove all contamination prior to installation of the main fuel inlet line to the fuel pump Failure to comply can cause erratic fuel injection system operation and damage to its components Install the engine and make airframe to engine connections in accordance with the airframe
189. rned areas cracks and looseness During this inspection give special attention to the condition of welded area and seams for cracks Visually inspect exhaust elbow to manifold clamps for corrosion cracks and security Discard any clamps that exhibit corrosion or cracks and torque any loose connections Visually inspect slipjoints for bulging and cracks See figure 11 6 Continued on next page 11 7 11 6 100 HOUR INSPECTION continued Multi segment V Band Clamps Figure 11 7 Clamps located between turbocharger and tailpipe should first be cleaned using crocus cloth on the outer band of clamp assembly Inspect spot weld areas for cracks and looseness inspect the corner radii of clamp inner segments for cracks using a flashlight and mirror If clamp has been removed and reinstalled inspect inner segment spacing If inner segments contact after clamp assembly has been torqued the clamp assembly must be replaced Inspect clamp outer band flatness using a straightedge especially within two inches of spot weld tabs that retain the T bolt fastener clearance should be less than 062 of an inch Clearances in excess of 062 of an inch are cause for rejection Inner segment and outer band contact must be 100 When replacement of clamp is required install new clamp insuring V segments go over exhaust flanges using a rawhide or plastic mallet tap clamp circumferentially as clamp is torqued to 40 inch pounds INSPE
190. rrective actions in accordance with Section 20 6 Cylinder Assembly Maintenance 20 5 CYLINDER ASSEMBLY TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms Items are presented in sequence of the approximate ease of checking not necessarily in order of probability TROUBLE PROBABLE CAUSE CORRECTION Rough Idling Hydraulic tappets fouled See Section 20 6 Cylinder Assembly Maintenance Hydraulic Tappets Burned or warped exhaust valves See Section 20 6 Cylinder Assembly worn valve seats Scored valve guides Maintenance Cylinders Valve seats worn and leaking piston See Section 20 6 Cylinder Assembly rings worn or stuck in ring lands Maintenance Cylinders High Cylinder Head Exhaust valve leaking cylinder baffles See Section 20 6 Cylinder Assembly Temperature loose or bent Cooling area between Maintenance Cylinders cylinder fins obstructed Exhaust gasket leaking Replace gasket 20 13 TROUBLE PROBABLE CAUSE CORRECTION Valve seats worn and leaking piston See Section 20 6 Cylinder Assembly rings worn or stuck in ring lands Maintenance Cylinders Low Compression Piston rings excessively worn See Section 20 6 Cylinder Assembly Maintenance Cylinders Valve faces and seats worn See Section 20 6 Cylinder Assembly Maintenance Cylinders Excessively worn cylinder walls See Section 20 6 Cylinder Assembly M
191. s cracks deterioration broken missing or loose brackets clamps and hardware Cylinder Barrel Using an inspection light and mirror thoroughly inspect the cylinder barrel including the cylinder barrel fins and the areas between and adjacent to the fins for cracks sharp indentations chafing damage and pitting This visual inspection must include a detailed external inspection of the areas of the cylinder barrel which experience the highest operational stresses from the power stroke of the piston These areas are the 12 o clock area of the first six fins below the head on one side of the engine and the 6 o clock area on the other side In addition inspect for any signs of leakage of oil fuel soot or any condition that could indicate that the integrity of the cylinder or the head to barrel junction has been breached Cylinder Head Inspect the external surfaces of the cylinder head including the cylinder head fins intake and exhaust ports top and bottom spark plug bosses and fuel nozzle boss Inspect for cracks exhaust flange leakage or any signs of leakage of oil fuel soot or any conditions that could indicate that structural integrity of the cylinder or the head to barrel junction has been breached Inter cylinder and peripheral baffling Carefully inspect all inter cylinder and peripheral baffling for correct installation proper positioning deterioration chafing and missing or broken sections CORRECT OR REPLACE ANY DISCREPANT BAFFL
192. s assemblies continued on next page 13 3 A O RING COMPRESSOR DISCHARGE EAA AIR PASSAGE AMAT AIR INLET AU AG O RING 13 3 13 4 SLEEVE ASSEMBLY 4 e NOZZLE IDENTIFICATION NUMBER STAMPED ON HEX FLAT FIGURE 13 3 FUEL NOZZLE DESCRIPTION Fuel nozzle See Figure 13 3 The fuel discharge nozzle is located in the cylinder head The nozzle outlet is screwed into the tapped fuel nozzle hole in the cylinder head The nozzle body has a drilled central passage with a counterbore at each end The lower end is the fuel outlet The upper bore contains a removable jet for calibrating the nozzles Near the top radial holes connect the upper counterbore with the outside of the nozzle body for air admission A shroud is mounted on the nozzle body and extends over the nozzle body The nozzle shroud is sealed to the nozzle body using o rings The nozzle shrouds are referenced to upper deck pressure This provides a positive air pressure differential to insure proper fuel atomization at all operating parameters Nozzles are calibrated in several ranges and all nozzles furnished for one engine are of the same range identified by a letter stamped on the hex of the nozzle body FUEL INJECTION SYSTEM INSPECTION 50 Hour Inspect the fuel servo unit in accordance with the manufacturer s instructions See Related Publication Section 1 4 for ordering information Visually inspect
193. s proper pump pressure and delivery for all engine operating speeds A check valve is provided so that the aircraft boost pump pressure to the system can by pass the engine driven fuel pump during engine priming and starting This feature also aids in the suppression of vapor formation during high ambient temperature conditions The check valve also permits the use of the aircraft auxiliary fuel boost pump in the unlikely event of an engine driven fuel pump malfunctions FUEL INLET PUMP ASSEMBLY RELIEF VALVE ASSEMBLY FUEL OUTLET FUEL BY PASS FIGURE 13 1 FUEL PUMP DESCRIPTION L TSIO 360 RB DIAPHRAGM LOADING SPRING PTT UPPER CHAMBER DIAPHRA VENT FUEL INLET VALVE FUEL OUT TO NOZZLES FIGURE 13 2 GENERAL FUEL MANIFOLD VALVE DESCRIPTION Fuel manifold Valve See Figure 13 2 The fuel manifold valve body contains a fuel inlet diaphragm chamber and outlet ports for fuel lines to the individual nozzles The diaphragm is enclosed by a vented cover which retains the diaphragm loading spring When the plunger is down in the body bore fuel passages to the nozzles are closed off The plunger is drilled for passage of fuel from the fuel inlet chamber to its base As fuel flow increases pressure overcomes diaphragm spring tension causing the plunger to move to the open position and fuel flows from manifold valve outlets through fuel lines to the fuel lines to the fuel nozzle
194. t Thermocouple Max 2600 700 100LL 100 140 150 240 100 PSI 10 PSI 150 RPM 50 RPM 460 F 23 3 23 2 ENGINE ADJUSTMENT AND SETUP Oil Pressure Adjustment The adjusting screw is turned clockwise to increase oil pressure and counterclockwise to decrease oil pressure With normal operating oil temperature 180 200 F adjust oil pressure to maintain 30 80 pounds per square inch at full power RPM Torque locknut and safety as required eee ax 3 ERE 5 dii OIL PRESSURE ADJUSTMENT THIS SIDE ON 510 360 OIL PRESSURE ADJUSTMENT THIS SIDE LTSI0 360 RB FIGURE 23 1 OIL PRESSURE ADJUSTMENT 23 4 23 2 ENGINE ADJUSTMENT AND SETUP continued Fuel System Adjustment Verify that the aircraft fuel system is operating properly in accordance with the airframe manufacturer s instructions before performing any engine fuel system setup procedures Adjust the engine fuel system as follows NOTE currently calibrated Porta Test Unit Model number 20 ATM C manufactured by Approved Aircraft Accessories Inc or equivalent must be used to adjust the fuel system The Porta Test Unit must be connected and operated in accordance with the manufacturer s instructions Engine driven fuel pump With the engines operating at 2600 rpm and 38 0 inches Hg Manifold pressure mixtures to 24 0 to 25 0 gallons per hour and the emergency fuel pumps in the off position verify th
195. t system for security welded joints for cracking evidence of exhaust gas leakage and turbocharger compressor turbine for freedom of rotation Inspect turbocharger oil seals and lubrication system plumbing for evidence of oil leakage 100 HOUR INSPECTION Before proceeding with cleaning and inspection insure that the exhaust system is cool The entire exhaust should be cleaned and visually inspected for condition and leaks using the following procedure Cleaning In order to thoroughly inspect the exhaust system components must be clean and free of oil grease etc Use a suitable solvent such as Stoddard solvent and wipe away any debris Wipe any excess solvent dry with a clean cloth CAUTION Never use flammable solvents wire brushes or abrasives to clean exhaust system components Never use a lead pencil to mark any exhaust system component The turbocharger wastegate and controller assemblies must be cleaned and inspected in accordance with the component manufacturer s instructions Airesearch 3201 Lomita Blvd Torrance California 90505 Visual inspection Perform all requirements of 50 hour inspection with the addition of the following During 100 hour inspection items which might hinder inspection may be removed except multi segment V band clamps In the event that exhaust system components have to be removed see the 510 360 Overhaul Manual Form X30596A Stacks Risers Elbows Inspect these components for bu
196. tension for hose attachment The breather assembly is pressed into a boss on the upper right crankcase OIL GAGE HOUSING PROP GOVERNOR ENGINE MOUNT OIL PRESSURE ACCESSORY CASE MOUNT PAD PAD BOSS STARTER SHAFT GEAR NEEDLE BEARING BREATHER ASSEMBLY IN P ENS 3 90 OG AGNETO DRIVE GEAR BORES FUEL PUMP SUPPORT BUSHINGS MOUNT PAD CRANKSHAFT NOSE 1 3 5 OR R H CRANKCASE SEAL LAND STARTER SHAFTGEAR NEEDLE BEARING REAR CRANKSHAFT BEARING BORE MV CAMSHAFT BORE INTERMEDIATE CRANKSHAFT BEARING BORE FRONT CRANKSHAFT BEARING BORE CAMSHAFT FIGURE 21 1 CRANKCASE DESCRIPTION 21 3 21 3 21 4 CRANKCASE INSPECTION 50 HOUR Visually inspect accessories for security and all gasket areas for oil leaks All accessory and cylinder mounting studs must be visually inspected and checked for security Safety mechanisms such as lockwire and locking tab washers must be inspected for proper installation and security Inspect engine mount brackets for cracks and security Inspect all areas of crankcase for cracks 100 HOUR Perform all visual inspection requirements of 50 hour inspection Inspect crankcase for cracks in accordance with the following instructions Critical gray and non critical areas are illustrated in Figure 21 3 If a crack is observed in any of the non critical dark gray areas that is less than two
197. the accessory case and supported by the oil pump cover plate The oil pump drive gear shaft is supported by bushings pressed into the accessory case As the engine starts rotating the oil pump drive gear turns looking from the rear of the engine forward counterclockwise this drives the driven gear in a clockwise direction The two gears turning create a suction that draws oil from the sump through the oil suction tube to the oil pump gears The oil is then forced around the outside of the gears and directed through a gallery to the pressure relief valve and oil filter An adjustable oil pressure relief valve regulates oil pressure within the specified limits This insures adequate lubrication to the engine and its accessories at all speeds ACCESSORY CASE INTERNAL VIEW TSIO 360 DRIVEN GEAR OIL PUMP CAVITY DRIVE GEAR PRESSURE RELIEF VALVE OIL RETURN TO SUPPLY OIL OUT TO OIL IN FROM FILTER SUMP FIGURE 19 2 OIL PUMP DESCRIPTION TSIO 360 19 5 ACCESSORY CASE INTERNAL VIEW LTSIO 360 DRIVEN GEAR OIL PUMP CAVITY DRIVE GEAR PRESSURE RELIEF VALVE OIL RETURN TO SUPPLY OIL IN FROM OIL OUT TO SUMP FILTER FIGURE 19 3 OIL PUMP DESCRIPTION LTSIO 360 19 2 LUBRICATION SYSTEM COMPONENT DETAILED DESCRIPTION continued Oil Cooler And Oil Temperature Control Valve Oil flowing from the oil filter enters the oil cooler inlet oil temperature control valve cavity When the oil is below normal operati
198. the arc of the propeller blades while turning the propeller Rotate propeller by hand several revolutions to remove preservative oil Service and install spark plugs and ignition leads in accordance with the manufacturer s instructions Service engine and aircraft in accordance with the manufacturer s instructions Thoroughly clean the aircraft and engine Perform visual inspection Correct any discrepancies Conduct a normal engine start Perform operational test in accordance with Operational Inspection Chapter 1 Maintenance Correct any discrepancies Perform a test flight in accordance with airframe manufacturer s instructions Correct any discrepancies prior to returning aircraft to service Change oil and filter after 25 hours of operation SECTION 9 1 9 2 9 3 9 4 9 5 9 6 FIGURE 9 1 9 2 9 3 9 4 CHAPTER 9 STANDARD PRACTICES PAGE 9 2 Lockwire Procedure 9 3 Tab Washer 9 5 Cotter Pin 9 5 Application Of Adhesives iios oe rrt 9 6 Installation Of 9 6 General Lockwire 9 3 General Lockwire 9 4 Tab Washer Installation
199. the fuel servo to controller linkage must be inspected for excessive play which can cause lost motion and breakage of parts Inspect the pivot points of levers and linkages for debris old grease and oil Inspect the fuel servo levers for worn bushings which cause excessive play in accordance with the servo manufacturer s instructions Clean pivot point areas thoroughly using clean Stoddard solvent After cleaning dry each area using compressed air Unless otherwise specified by the servo or airframe manufacturer apply LPS 2 PERMATEX Maintain Lubricant or equivalent to the two pivot points shown in Figure 13 5 If lever or link rods are replaced initial lubrication must be accomplished using SHELL 5 or LUBRICATE 630AA or equivalent The other pivot points and control connections shown in Figure 13 5 must be maintained in accordance with the servo or airframe manufacturer s instructions WARNING Anytime fuel control to throttle linkage attaching hardware levers or lever bushings haven replaced or reassembled the fuel system must be checked adjusted and tested in accordance with Precision Airmotive Corporation RSA 5 Operation and Service Manual See Related Publication Section 1 4 ordering information Worn or corroded linkage or attaching hardware must be replaced in accordance with Chapters 9 and 10 of the L TSIO 360 overhaul manual Form X30596A Fuel servo levers or lever bushings must be replaced in accordance with Precision Airmoti
200. the poppet valve are stabilized Thus the oil flowing from the wastegate actuator through the VAPC is constant and the wastegate butterfly valve is positioned in a intermediate position maintaining the selected compressor discharge pressure and manifold pressure HIGH SETTING ADJUSTMENT CW TO DECREASE MANIFOLD PRESSURE oi INLET PORT FROM BYPASS VALVE ACTUATOR 2 vA N N TTE i CAM LOW SETTING ADJUSTMENT CAM FOLLOWER ANEROID BELLOWS OIL OUTLET PORT ASSEMBLY TO ENGINE SUMP POPPET SEAT FIGURE 11 5 VARIABLE ABSOULUTE PRESSURE CONTROLLER 11 5 11 6 TURBOCHARGER LUBRICATION SYSTEM Pressurized oil is supplied to the turbocharger from the engine fitting located in left crankcase half 2 4 6 cylinder side below number 2 and 4 cylinder oil gallery supplies pressurized engine oil to the turbocharger center housing oil inlet Oil is return to the engine from the turbocharger center housing is accomplished by a scavenge pump contained in the starter adapter assembly Flexible high pressure hoses connect the engines oil system to the turbocharger Since the turbocharger is mounted below the center line of the engine check valves are installed in the oil supply hose and oil return hose to prevent oil from flooding the turbocharger center housing when the engine is not operating EXHAUST SYSTEM INSPECTION 50 HOUR INSPECTION Visually inspect entire exhaus
201. the screw setting from changing Torque the jam nut on the engine driven fuel pump to the limit specified in the L TSIO 360 Series Overhaul Manual Form X30596A Du IE Of 64 C ae ON E 9 AA e wo w uA 5 S 3 amp 5 8 09 OIS1 1 VAS 44445 LNVLSNOD FIGURE 23 6 CONSTANT SPEED SEA LEVEL PERFORMANCE CURVE Oth 021 011 001 08 04 09 081 23 10 i EN EE e Rp rp METERED FUEL PRESSURE o gt o THTHEHBHHIBIHIGHHIRHGIHGED Li 445 1 pt tp td M 1 Ppp T li I ee EEN Hp bee Nen cea ee eee ERE PLEBE C H AAT TET TH HH HR dM M eH
202. the timing light ground lead to a suitable ground such as a bolt or stud With the crankshaft in the correct timing position turn the crankshaft a few degrees counterclockwise then clockwise until the timing pointer is approaching the correct degree position As the pointer aligns with the specified timing position both timing lights must indicate that both magneto points are breaking within the specified timing tolerance If the magnetos are not timed to the engine within the required specification the magneto s must be removed from the engine and inspected and repaired in accordance with the magneto manufacturer s instructions and specifications 12 11 POSITVEDE LOCATOR RE S 2 Ji ES P EXAMPIE FULLADVANCE FRNG POSTON 20 BEFORE TOP DEAD CENTER E ZS a SPNNER NSTALLED NOTE THE SHOWN 5 USED W THE PROPELLER AND FIGURE 12 5 TIMING POSITION STEP 5 MAGNETO TIMING AND INSTALLATION ON ENGINE A Insert the T118 timing pin going in L or R hole depending on magneto rotation in the distributor block Turn rotor in the opposite rotation of magneto until pin engages the gear Without turning the magneto coupling hold the magneto in the position it will occupy when installed Check the alignme
203. to the inlet of the by pass valve actuator The pressurized oil acting on the actuator plunger and against spring pressure drives the by pass valve butterfly to the closed position A Variable Absolute Pressure Controller VAPC is connected in the oil return line from the exhaust by pass valve actuator to the engine The VAPC controls the oil pressure acting on the exhaust by pass valve actuator by increasing or decreasing the restriction to return oil flow from the by pass valve actuator to the engine BUTTERFLY PISTON OIL OUTLET PORT TO AR CONTROLLER CI NS 4 i 2222222 54 L a c 4 p LIH spr H SS CEN ENS OIL INLET PORT POWER CYLINDER DRAIN PORT FIGURE 11 4 WASTEGATE Figure 11 4 WASTEGATE continued on next page 11 5 11 4 VARIABLE ABSOLUTE PRESSURE CONTROLLER VAPC DETAILED DESCRIPTION The variable absolute pressure controller is designed to maintain deck pressures to provide sea level horsepower at varying altitudes By means of a sensing port in the pneumatic section of the controller the outside of the aneroid bellows is subjected to deck pressure The aneroid bellows is linked to a poppet valve spring loaded normally closed As pressure differences occur the poppet valve readjusts changing the amount of restriction to oil flow from the wastegate As the restriction of oil flow occurs pressure in the hydraulic portion
204. troller overboost valve adapter assembly is an overboost valve that will relieve excessive deck pressure in the event of wastegate controller malfunction Air exiting the fuel metering throttle assembly flows into the balanced induction manifold and is distributed to the individual cylinder intake ports through induction tubes Induction air flows into the intake ports and is mixed with fuel from the injector nozzles where it enters the cylinder as a combustible mixture when the intake valve opens Refer to the airplane manufacturer s Airplane Flight Manual AFM for alternate air door operations OVERBOOST VALVE DETAILED DESCRIPTION The overboost valve consists of a housing spring valve head and aneroid bellows assembly The valve head is held in the closed position by the spring and aneroid bellows The overboost valve is set to open slightly above maximum deck pressure to prevent damage in the event of a system malfunction SPRING ANEROID BELLOWS ASSEMBLY mr bir VALVE HEAD FIGURE 14 2 OVERBOOST VALVE 14 3 14 4 INDUCTION SYSTEM INSPECTION 50 HOUR Visually inspect the induction manifold aftercooler and overboost valve for security safetying leaks cracks and chafing Inspect all induction tube connections for security and wear Inspect all induction tube hoses for deterioration Any attaching brackets exhibiting cracks must be replaced Torque loose hardware using the values specified i
205. ts installed before the head is screwed and shrunk onto an externally finned steel alloy barrel to make the permanent head and barrel assembly The cylinder barrel is nitrided for wear resistance Intake and exhaust valve guides are pressed into the cylinder head Special helical coil thread inserts are installed in upper and lower spark plugs holes The cylinder intake port is located on top of the cylinder and the exhaust port is located on the bottom Rotocoil assemblies retain two concentric springs surrounding each valve and are locked to the stems by tapered semi circular keys which engage grooves around the valve stems Valve rocker covers are stamped sheet steel and zinc plated ROCKER ARM ROCKER SHAFT VALVE RETAINER KEYS ROTOCOIL OUTER SPRING INNER SPRING EXHAUST SPRING RETAINER VALVE GUIDE INTAKE VALVE GUIDE EXHAUST VALVE COOLING FINS INTAKE VALVE SEAT INSERT CYLINDER HEAD INTAKE VALVE CYLINDER BARREL CYLINDER BARREL COOLING FINS CYLINDER BASE FLANGE CYLINDER SKIRT FIGURE 20 3 CYLINDER ASSEMBLY DESCRIPTION 20 4 20 3 CYLINDER ASSEMBLY DETAILED DESCRIPTION continued Piston Pistons are aluminum alloy castings with a steel insert cast into the top ring groove Pistons have three ring grooves above the pin hole and one ring groove below Compression rings are installed in the top and second grooves The groove below the pin hole contains an oil scraper A center slotted oil control ring and exp
206. turer s Airplane Flight Manual AFM Check RPM Rise Idle Cutoff Readjust idle mixture in accordance with Chapter 23 Fuel System Adjustment Torque loose connections replace worn elements of linkage Service air cleaner in accordance with airframe manufacturer s instructions Check ignition cables and connections Replace malfunctioning spark plugs See Section 12 4 Ignition System Inspection Check fuel manifold connections for leaks Torque loose connections Check fuel control and linkage for setting and adjustment Check fuel filters and screens for dirt Check for proper fuel pump pressure and replace pump if malfunctioning See Section 13 5 Fuel System Maintenance Remove and clean all nozzle jets See Section 13 5 Fuel System Maintenance Fuel Nozzles Clean and re gap spark plugs Check ignition cables for wear Replace malfunctioning components See Section 12 6 Ignition System Maintenance Check movement of linkage by moving control from idle to full throttle Make proper adjustments and replace worn components Service air cleaner in accordance with the airframe manufacturer s instructions TROUBLE Low Oil Pressure Indication On Engine Gage Low Oil Pressure Indication On Engine Gage cont d PROBABLE CAUSE CORRECTION Malfunctioning ignition Inspect spark plugs for fouled system component electrodes heavy carbon deposits erosion of electrodes improperly adjusted ele
207. ur lag screws attaching the wooden cover to the base 2 Lift the wooden cover vertically and remove 3 Open the moisture proof plastic bag 4 Attach a hoist to the engine lifting eye located at the top of the crankcase backbone Take up slack on the hoist prior to loosening the engine mount bolts then remove the bolts from the shipping shock mounts Lift the engine vertically and install on a transportation stand or dolly CAUTION Do not allow chains to become entangled on engine or its hardware GROUND HANDLING After engine is removed from container attached to hoist proceed with care Do not let engine front rear sides or bottom come in contact with any obstructions as the extreme weight may cause damage to the engine or components If contact has occurred inspect for obvious or consequential damage CRATING AND SHIPPING Category A cardboard container Lower engine onto container base and attach with metal banding straps Install and attach container cover Category B wooden container Lower engine onto container base Attach engine using shock mounts and bolts Cover engine with plastic bag Install and attach container cover to base 6 5 6 4 PREPARATION FOR SERVICE If the engine is not to be installed within five 5 days after removing shipping plugs it must be represerved in accordance with procedures listed in Chapter 8 If the engine is to be installed within five 5 days after unpacking remove
208. ve Corporation RSA 5 Operation and Service Manual See Related Publications Section 1 4 for ordering information Consult the airframe manufacturer and or their most current published instructions concerning aircraft engine control cable attach point inspection cleaning repair installation and lubrication After the preceding procedures have been accomplished verify that each control has full limit of travel the required safeties are in place that no binding of levers or linkages is occurring and that control movement is unrestricted by contact with other parts or components that are located in close proximity Compare recorded findings of operational inspection with the following data ENGINE Fuel Flow Fuel Flow RPM Unmetered or Lbs Hr Gal Hr Propeller Pump Pressure APPROX PSID L TSIO 360 RB 700 RPM IDLE 35 45 140 150 24 0 25 0 2600 RPM F T NOTE The fuel system must be adjusted using a calibrated Porta Test Unit amp connected in accordance with the manufacturer s instructions See Aircraft Specifications for other values where applicable NOTE Fuel pressures must be checked using external calibrated instrumentation connected to the fuel system as shown in Chapter 23 Fuel System Adjustment Do not use airframe cockpit gages when checking fuel pressures If the fuel system is not functioning properly proceed to fuel system troubleshooting to determine the cause and proc
209. ve Guide Remover available from Kent Moore 51 Borrough s 8116 24 through 29 Valve Stem Hole Reamers or equivalent 52 3606 CP Reamer Carbide Tipped available from Kent Moore 3606 HP Reamer High Speed Steel available from Kent Moore 53 2684 Reamer to Morse Taper Adapter Square Shank available from Kent Moore 54 2848 Plug Gage for valve guide inspection available from Kent Moore 55 4943 1HS through 5HS Reamers Valve Guide Boss available from Kent Moore 56 Borrough s 4918 Spark Plug Insert Replacer or equivalent 57 Borrough s 4919 Spark Plug Insert Remover or equivalent ITEM NO 2 6 TOOL Borrough s 445 18mm Spark Plug Tap or equivalent for straightening out damaged threads 2769A13 Rosan Stud Remover available from McMASTER CARR Supply Co Rosan Q is a registered trademark of Fairchild Aerospace Fastener Division 8074 Rosan Lock Ring Installer available from Kent Moore 8118 Rocker Arm Bushing Remover Installer available from Kent Moore 3610 Reamer Rocker Arm Bushing available from Kent Moore CRANKCASE Borrough s 8114 Crankcase Through Bolt Removers or equivalent L423 Crankcase Splitter available from Kent Moore Borrough s 505 Stud Drivers or equivalent ENGINE DRIVE TRAIN Borrough s 8117A Runout Block Set or equivalent for crankshaft inspection Krautkramer Branson Model USK 7D USL42 USL 48 USN 50 USN 52 or OR7S for Crankshaft Ultrasonic Testing available from Fax Corporation Borrough s 8087A Polish
210. verify that the cabin door latch is open g Do not stand within the arc of the propeller blades while turning the propeller Perform the test as soon as possible after the engine is shut down to insure that the piston rings cylinder walls and other engine parts are well lubricated and at operating conditions Turn the crankshaft by hand in the direction of rotation until the piston in the cylinder being checked is coming up on its compression stroke Install an adapter in the spark plug hole and connect the calibrated differential pressure tester to the adapter NOTE Cylinder pressure valve is in the Closed position Slowly open the cylinder pressure valve and pressurize the cylinder not to exceed 20 pounds per square inch Continue rotating the engine against this pressure until the piston reaches top dead center Reaching top dead center 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 least one half revolution and start over again to eliminate the effect of backlash in the valve operating mechanism and to keep the piston rings seated on the lower ring lands This is critical because the slightest movement breaks this piston ring sealing and allows the pressure to drop WARNING Care must be exercised in opening the cylinder pressure valve since sufficient air pressure will be built up in the cylinder causing it to rotate the cranksh
211. visual inspection requirements of 50 hour inspection Crankshaft Sudden Stoppage In case of prop strike sudden stoppage see Section 5 7 of this manual Engine Overspeed In case of engine overspeed see Section 5 7 of this manual ENGINE DRIVE TRAIN TROUBLESHOOTING This troubleshooting chart is provided as a guide Review all probable causes given Check other listings of troubles with similar symptoms TROUBLE 00 BLE PROBABLE CAUSE CORRECTION cM Loss Worn crankshaft nose seal Replace nose seal See Section 22 6 ENGINE DRIVE TRAIN MAINTENANCE Crankshaft Nose Oil Seal The crankshaft nose oil seal may be replaced according to the following instructions WARNING To prevent starting of engine before moving the crankshaft accomplish the following a Disconnect all spark plug leads b Verify magneto switches are connected to magnetos that they are in the OFF Position and P leads are grounded Throttle position CLOSED Mixture control IDLE CUT OFF Set brakes and block aircraft wheels Insure that aircraft tie downs are installed and verify that the cabin door latch is open g Do not stand within the arc of the propeller blades while turning the propeller A SPLIT TYPE OIL SEAL 1 Remove oil seal 2 Clean surfaces thoroughly making certain that no debris remains on shaft or in the seal counterbore Wash seal area with solvent 3 Remove any plating in the one inch area shown in

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