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Teledyne TSIO-360-RB User Manual

Teledyne TSIO-360-RB
206 pages
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Courtesy of Bomar Flying Service
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MAINTENANCE
MANUAL
TSIO-360-RB
PART NO. X30645A FAA APPROVED
1996 TELEDYNE INDUSTRIES, INC. OCTOBER 1996

Table of Contents

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Teledyne TSIO-360-RB Specifications

General IconGeneral
Bore5.125 in (130.2 mm)
Compression Ratio8.5:1
Oil SystemWet sump
Cooling SystemAir cooled
Displacement5.9 L
Fuel Type100LL Avgas

Summary

Definitions of Notes, Cautions, and Warnings

Notice to All Users

Chapter 1: Introduction

Scope

Defines the manual's coverage of maintenance and installation for the L/TSIO-360-RB engine.

Related Publications

Lists essential related engine and accessory manuals for comprehensive information.

Manual Revisions

Explains the process for receiving and incorporating manual updates to ensure currency.

Service Documents

Categorizes and defines various types of service documents issued by TCM.

Description of Engine Model Code

Breaks down the engine model designation to explain its components.

Definition of Terms

Clarifies terminology such as front, rear, and cylinder numbering for engine orientation.

Engine Design Features

Details key design characteristics of the L/TSIO-360-RB engine and its components.

General

States that operating limits and specifications apply to L/TSIO-360-RB engines and refers to other manuals.

Engine Specifications

Provides detailed technical specifications for the engine's cylinders, bore, stroke, and horsepower.

Operating Limits

Lists critical operating parameters like RPM, manifold pressure, fuel, and oil limits for safe engine operation.

Chapter 2: Tools and Equipment

General Information

Specifies the essential tools and equipment a mechanic should have for engine servicing.

Possible Special Tool Procurement Sources

Lists companies that supply specialized tools, aiding in procurement.

Special Tools

Details specific tools or their equivalents required for engine overhaul and maintenance.

Chapter 3: Sealants and Lubricants

Sealants and Lubricants

Provides a comprehensive list of aviation engine oils, including manufacturer and brand names.

Preservative Oil

Details preservative oils for temporary and indefinite storage applications.

Lubricants

Lists various lubricants and their suggested sources and applications on engine components.

Lubricants

Continues the list of lubricants, covering approved dispersant oils and specific thread lubricants.

Sealants

Details sealants for engine components like crankcase parting faces and oil seals.

Sealants

Lists sealants for pipe threads, ignition harness terminals, and stud holes.

Adhesives

Lists adhesives and primers for securing engine components like studs and flanges.

Miscellaneous

Covers miscellaneous items like high-temperature paint and lockwire for engine maintenance.

Chapter 4: Airworthiness Limitations

Mandatory Replacement Times

States that the engine does not contain components with mandatory replacement times per type certification.

Mandatory Inspection Intervals

Clarifies that specific inspection intervals are not required by type certification for this engine.

Other Related Procedures

Mentions that ADs may specify other procedures not covered here.

Distribution of Changes to Airworthiness Limitations

Explains that changes to limitations require FAA approval and will be published in ADs.

Chapter 5: Time Limits/Operational Inspection/Engine Troubleshooting

General

Emphasizes compliance with manual requirements and aircraft/accessory manufacturer's needs for safety.

Overhaul Periods

Specifies the engine overhaul period and notes it includes all accessories.

Operational Inspection

Outlines the requirement for an operational inspection before 50/100-hour inspections and starting procedures.

Operational Check List

Provides a checklist for recording system data during operational inspections.

Test Operating Limits

Lists critical operating parameters like RPM, manifold pressure, fuel, and oil limits for safe engine operation.

Time Interval Inspections

Details inspection procedures and maintenance information based on time intervals.

Scheduled Maintenance

Covers 50-hour inspection procedures, including thorough inspection and operational run-up.

Unscheduled Maintenance

Addresses unscheduled maintenance events, including propeller strikes and foreign object damage.

General Information

Introduces the troubleshooting chart, explaining its purpose and structure.

Engine Troubleshooting Chart

Provides a guide for diagnosing engine problems, listing probable causes and corrective actions.

Chapter 6: Unpacking, Installation and Testing

General

Emphasizes the need for technicians to have knowledge of safe procedures for engine installation.

Unpacking

Provides step-by-step instructions for unpacking the engine from both cardboard and wooden containers.

Ground Handling

Details procedures for safely handling the engine after unpacking, emphasizing care due to its weight.

Crating and Shipping

Outlines procedures for crating and shipping the engine in both cardboard and wooden containers.

Preparation for Service

Details steps for preparing the engine for service if installation is delayed after unpacking.

Engine Installation Instructions

Provides instructions for installing the engine into the airframe and making necessary connections.

Engine Pre-oiling

Describes the critical procedure for pre-lubricating engine parts before initial operation.

Preflight and Run-Up

Covers preflight checks and run-up procedures, especially for new or overhauled engines.

Flight Testing

Outlines procedures and considerations for conducting test flights after maintenance.

Chapter 7: Servicing Fluids

Servicing Oil

Provides instructions and cautions for servicing the engine oil system to maintain proper levels.

Approved Ashless Dispersant Oils

Lists approved ashless dispersant oils and approved mineral oil conforming to MIL-C-6529 Type II.

Fuel

Specifies the minimum aviation fuel grade and warns against using incorrect fuel types.

Oil Filter Element Inspection

Details how to inspect the oil filter element for signs of internal engine wear.

Spectrographic Oil Analysis

Explains the process and benefits of spectrographic oil analysis for monitoring engine wear.

Chapter 8: Engine Preservation and Storage

General

Discusses the susceptibility of aircraft engines to corrosion and the owner's responsibility for precautions.

Engine Preservation

Explains how corrosive attack affects engines and the primary method to reduce it.

Temporary Storage

Provides detailed procedures for preparing the engine for temporary storage, including pre-flight and post-flight steps.

Indefinite Storage

Details the preparation procedures for storing the engine indefinitely to prevent degradation.

Indefinite Storage Inspection Procedures

Outlines the inspection schedule for cylinder dehydrator plugs and corrosion preventive mixture.

Returning an Engine to Service After Storage

Provides comprehensive steps for returning a stored engine to service, including checks and test flights.

Chapter 9: Standard Practices

General

Emphasizes proper reinstallation, tagging of parts, and preventing foreign matter entry into the engine.

Lockwire Procedure

Explains the purpose and technique of lockwiring for securing parts and preventing loosening.

Tab Washer Procedure

Details the installation and use of tab washers for securing bolts and nuts in TCM engines.

Cotter Pin Procedure

Describes the correct procedure for installing cotter pins to secure fasteners.

Application of Adhesives

Provides guidance on the proper use of adhesives and sealants to prevent engine malfunction.

Installation of Gaskets

Outlines procedures for inspecting, preparing, and installing gaskets to prevent leaks.

Chapter 10: Engine Maintenance

General

Directs users to overhaul manuals for component removal and replacement, and to other sections for inspections.

Chapter 11: Exhaust System

Exhaust System Description

Describes the components of the exhaust system and how they function during engine operation.

Turbocharger Detailed Description

Provides a detailed explanation of the turbocharger's construction, lubrication, and operation.

Exhaust By-Pass Valve (Wastegate) Detailed Description

Explains the function and operation of the exhaust by-pass valve (wastegate) in controlling turbocharger speed.

Variable Absolute Pressure Controller (VAPC) Detailed Description

Details the VAPC's role in maintaining deck pressures for altitude compensation and its connection to the wastegate.

Turbocharger Lubrication System

Describes how pressurized oil is supplied to and returned from the turbocharger.

Exhaust System Inspection

Outlines 50-hour and 100-hour inspection procedures for the exhaust system and its components.

Exhaust System Troubleshooting

Provides a chart for diagnosing common exhaust system problems, their causes, and corrections.

Exhaust System Maintenance

Covers maintenance for exhaust system components, including collector, turbochargers, and wastegate.

Chapter 12: Ignition System

Slick Ignition System Description

Describes the Slick 6224 Series pressurized magnetos used for engine ignition.

Ignition System Component Detailed Description

Explains the magneto drive assembly and its components housed within the accessory case.

Ignition System Inspection

Outlines 50-hour and 100-hour inspection procedures for the ignition system, including magneto checks.

Ignition Troubleshooting

Provides a troubleshooting guide for ignition system failures, covering causes and corrections.

Ignition System Maintenance

Covers maintenance for harness assemblies, magnetos, and magneto drive assemblies.

Spark Plugs

Details procedures for removing, cleaning, gapping, and installing spark plugs.

Magneto to Engine Timing

Provides a step-by-step procedure for correctly timing the magnetos to the engine.

Ignition Harness Pre-Installation Instructions

Outlines instructions for preparing and installing the ignition harness assemblies.

Chapter 13: Fuel System

Engine Fuel System Description

Describes the overall fuel system, its components, and how fuel flows from the pump to the injectors.

Fuel Injection System Component Detailed Description

Details the fuel pump, its operation, relief valve, and check valve functions.

Fuel Injection System Inspection

Outlines 50-hour and 100-hour inspection procedures for the fuel servo and injection system components.

Fuel Injection System Troubleshooting

Provides a chart for diagnosing fuel system issues, including probable causes and corrective actions.

Fuel System Maintenance

Covers maintenance procedures for the fuel servo, manifold valve, and fuel injection nozzles.

Chapter 14: Induction System

Induction System Description

Explains the components of the induction system and the flow of compressed air to the cylinders.

Overboost Valve Detailed Description

Describes the overboost valve, its components, and its function in preventing excessive deck pressure.

Induction System Inspection

Outlines 50-hour and 100-hour inspection procedures for the induction manifold and related components.

Induction System Troubleshooting

Provides a chart for diagnosing induction system problems, including causes and corrections.

Induction System Maintenance

Covers maintenance for induction system components and connections.

Chapter 15: Air Conditioning

Air Conditioning System Description

Mentions the engine's use of a mounting kit for customer-supplied AC compressors.

Air Conditioning System Component Detail Description

Details the compressor mounting kit, accessory drive adapter, and mounting brackets.

Compressor Bracket Inspection

Outlines 50-hour inspection procedures for the compressor bracket assembly and drive components.

Air Conditioning System Troubleshooting

Refers users to the airframe manufacturer's instructions for troubleshooting the AC system.

Compressor Mounting Kit Maintenance

Covers maintenance for compressor mounting kit components and drive belts.

Chapter 16: Electrical System

Electrical Charging System Description

Explains the provision for mounting a belt-driven alternator and its function in powering the aircraft.

Electrical Charging System Component Detailed Description

Refers to TCM Form No. X30531-3 for detailed descriptions of TCM alternators.

Charging System Inspection

Outlines 50-hour and 100-hour inspection procedures for the alternator and its mounting hardware.

Charging System Troubleshooting

Refers users to airframe manufacturer instructions for troubleshooting the charging system.

Charging System Maintenance

Covers maintenance and repair of TCM alternators and drive belt inspection.

Chapter 17: Starting System

Starter and Starter Adapter Description

Describes the electric starter motor, right-angle drive adapter, and their components.

Starting System Component Detail Description

Explains the starter adapter assembly, worm drive, and clutch mechanism.

Starter and Starter Adapter Inspection

Outlines 50-hour and 100-hour inspection procedures for the starter and adapter.

Starting System Troubleshooting

Provides a chart for diagnosing starting system issues, including probable causes and corrections.

Starting System Maintenance

Covers maintenance and repair procedures for the starter motor and starter adapter.

Chapter 18: Accessory Case

Accessory Case

Describes the accessory case as an aluminum casting attached to the rear of the crankcase.

Accessory Case Detailed Description

Explains accessory locations, mounting bosses, and the internal machining for oil pump gears.

Accessory Case Inspection

Outlines 50-hour and 100-hour inspection procedures for accessories, gaskets, and studs on the accessory case.

Accessory Case Troubleshooting

Provides a chart for diagnosing accessory case oil loss and loose accessory issues.

Accessory Case Maintenance

Covers maintenance for the accessory case, including gasket replacement, studs, engine mounts, and separation.

Chapter 19: Lubrication System

Lubrication System Description

Explains the engine oil supply path from the sump, through the pump, cooler, and galleries.

Lubrication System Component Detailed Description

Details the oil pump, its components, and how it regulates oil pressure.

Lubrication System Component Detailed Description (continued)

Describes the oil cooler and oil temperature control valve operation.

Lubrication System Inspection

Outlines 50-hour inspection procedures for the oil sump, drain plug, and oil filter adapter.

Lubrication System Troubleshooting

Provides a chart for diagnosing lubrication system issues like oil leaks, consumption, and temperature.

Lubrication System Maintenance

Covers maintenance for the oil pump, oil filter adapter, oil filter, oil sump, and oil cooler.

Chapter 20: Cylinder Assembly

Cylinder Cooling

Explains how cylinder cooling is achieved through airflow directed by cowling and baffles.

Cylinder Assembly Detailed Description

Describes the cylinder assembly, including the head, barrel, valves, and rocker arms.

Cylinder Assembly Detailed Description (continued)

Details the piston assembly, including rings, pin, and oil scraper.

Cylinder Assembly Detailed Description (continued)

Describes the hydraulic tappet assembly and its function in valve train operation.

Cylinder Assembly Inspection

Outlines 50-hour and 100-hour inspection procedures for cylinder heads, barrels, and related components.

Master Orifice Tool

Explains the use of the Master Orifice Tool for calibrating compression testing equipment.

Performing the Check

Provides procedures for conducting cylinder leakage tests, including static and dynamic seal checks.

Compression Test Troubleshooting

Offers a troubleshooting guide for issues identified during cylinder compression tests.

Cylinder Assembly Troubleshooting

Provides a chart for diagnosing cylinder assembly problems like rough idling and high head temperature.

Cylinder Assembly Service Limits

Lists service limits for cylinder and head assembly components, including bore, roughness, and valve seats.

Cylinder Assembly Service Limits (continued)

Continues listing service limits for pistons, rings, pins, and valve train components.

Cylinder Assembly Maintenance (continued)

Covers single cylinder reassembly, reinstallation, and hydraulic valve tappet maintenance.

Chapter 21: Crankcase Assembly

Crankcase Description

Describes the crankcase's function in providing enclosure and support for internal engine parts.

Crankcase Detailed Description

Explains the crankcase's construction from two aluminum castings and its features like bearing saddles and tappet guides.

Crankcase Inspection

Outlines 50-hour and 100-hour inspection procedures for the crankcase, focusing on cracks.

Crankcase Troubleshooting

Provides a chart for diagnosing crankcase issues like oil loss and excessive pressure.

Crankcase Maintenance

Covers maintenance for the crankcase, including gasket replacement, studs, engine mounts, and separation.

Chapter 22: Engine Drive Train

Engine Drive Train Description

Explains how torque is transmitted from the starter to the crankshaft and how other components are driven.

Engine Drive Train Inspection

Outlines 50-hour and 100-hour inspection procedures for the crankshaft exit area and propeller installation.

Engine Drive Train Troubleshooting

Provides a chart for diagnosing engine drive train issues, focusing on oil loss.

Engine Drive Train Maintenance

Covers maintenance procedures for the crankshaft nose oil seal.

Chapter 23: Post Maintenance Adjustment and Test

Post Maintenance Operational Test

Details procedures for starting the engine after maintenance and performing an operational inspection.

Engine Adjustment and Setup

Covers oil pressure adjustment and engine fuel system adjustments.

Engine Adjustment and Setup (continued)

Details fuel system adjustments, including engine-driven fuel pump and idle mixture settings.

Idle Speed: Check and Adjust Idle Speed

Provides steps for checking and adjusting engine idle speed and full power settings.

Test Flight

Outlines procedures and considerations for conducting test flights after engine adjustments.

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