• Author / Uploaded
• Keith Koppelman

Citation preview

OVERHAUL MANUAL MODELS TSIO-360-A,AB -B,BB -C,CB -D,DB -E,EB -F,FB -GB -H,HB -JB K,KB -LB -MB -SB

FORM NO. X30596A

FAAAPPROVED

O 1997 TELEDVNE INDUSTRIES, INC.

OCTOBER 1997

CURRENT STATUS OF PAGES AS OF: OCTOBER 1997 See "Manual Revisions," inrthe introduction section for distribution procedure. THE ORIGINAL DATE OF THIS PUBLICATION IS NOVEMBER 9988. INSERT LATEST PAGES; DESTROY SUPERSEDED PAGES.

WRNING If the user of this manual is uncertain whether all current revisions have been incorporated into the manual, contact Teledyne Continental Motors. Do not perform any operation, maintenance, installation or other operation until the manual is confirmed current.

1997 are for the

ii REVISED OCT 97

(Please note the following statements from FAA Advisory Circular 20-62C entitled "ELIGIBILITY, QUALITY, AND IDENTIFICATION OF APPROVED REPLACEMENT PARTS"):

3.

BACKGROUND. An increasingamount of replacement parts (including standard parts), materials, appliances, and instruments are offered for sale as being of aircraft quality when actually the quality and origin of these units are unknown. Users of such units are usually not aware of the potential hazards involved with replacement parts that are not eligible for use on certificated aircraft. Frequently such units are deceptively advertised or presented as "unused," "like new," or "remanufactured!' This implies that the quality of such units is equal to an original or appropriately repaired or overhauled unit. The performance rules for replacement of parts and materials used in the maintenance and alteration of U.S. certificated aircraft are specified in Federal Aviation Regulations (FAR) 43.13 and FAR 145.57. The responsibility for the continued airworthiness of the aircraft, which includes the replacement of parts, is the responsibility of the ownerioperator as outlined in FAR 91.163, FAR 121.363, FAR 123.45, FAR 127.131 and FAR 135.143 (a).

4.

IDENTIFICATION OF THE APPROVED PARTS.

Approved serviceable replacement

parts are identified as follows: a.

By an FAA Form 8130-3 (Formerly FAA Form 186), Airworthiness Approval Tag. An Airworthiness Approval Tag identifies a part or group of parts that have been approved by authorized FAA representatives.

b.

) number and identificationmark that indicates the part or By an FAATechnical Standard Order 0 appliance has been manufactured under the requirements of FAR 37.

c.

By an FWPMA symbol, together with the manufacturer's name, trademark or symbol, part number, and the make and model of the type certificated product on which the part is eligible for installation, stamped on the part. An FAA Parts Manufacturer Approval (FWPMA) is issued under FAR 21.305. The make and model information may be on a tag attached to the part.

d.

By shipping ticket, invoice, or other document which provides evidence that the part was produced by a manufacturer holding an FAA Approved Production Inspection System issued utlder FAA 21, Subpart F, or by a manufacturer holding an FAA Production Certificate issued under FAA 21, Subpart G.

e.

By a certificate of airworthiness for export issued by a foreign government under the provisions of FAR 21, Subpart N.

I I.

KNOW YOUR SUPPLIER. It has come to our attention that many reproduced parts and components, particularly instruments which have been manufactured by persons other than the original manufacturer, are available for purchase and installationon U.S. certificatedaircraft. Often, an original part is used as a sample to produceduplicates. The reproduced parts appear to be as good as the original part; however, there are many unknown factors to be considered that may not be readily apparent to the purchaser, i.e., heat treating, plating, inspections, tests and calibrations. All too often the faulty part is not discovered until a malfunction or an accident occurs.

I 2.

SUMMARY. in accordance with FAR'S, certification of materials, parts, and appliances for return to service, for use on aircraft, is the responsibility of the person or agency who signs the approval. The ownerloperator, as denoted in paragraph 3 of this advisory circular, is responsible for the continued airworthiness of the aircraft. To assure continued safety in aircraft operation, it is essential that great care be used when inspecting, testing, and determining the acceptability of all parts and materials. Particular caution should be exercised when the identity of materials, parts, and appliances cannot be established or when their origin is in doubt.

OVERHAUL FOR TSIO-360 SERIES AIRCRAFT ENGINE

- NOTICE The overhauler must comply with all instructions contained in this manual in order to assure safe and reliable engine performance. Failure to comply will be deemed misuse, thereby relieving the engine manufacturer of responsibility under its warranty. This manual contains no warranties, either expressed or implied. The information and procedures contained herein provide the overhauler with technical information and instructions applicable to proper overhaul procedures. Prior to overhaul, the mechanic must meet requirements of Federal Aviation Regulation 65 and must follow FAR parts 43, 91, and 145, as applicable. This manual must be used in conjunction with the FAA Advisory circular 43.13-1A, Acceptable Methods, Techniques and Practices Aircraft Inspection and Repair, as well as Teledyne Continental Motors' TSIO-360 - Series Parts Catalog X30597A.

-

CHAPTER I

-

Introduction

4

-

Airworthiness Limitations

5

-

Time Limits/Maintenance Checks

70

-

Standard Practices

72

-

Engine, Reciprocating

79

-

80

-

Starting

81

-

Turbines

73 74

75

76 77 78

Engine Fuel System Ignition Air Engine Controls Engine Indicating Exhaust Oil

INTRODUCTION This Teledyne Continental Motors Overhaul Manual is prepared in accordance with the GAMA (General Aviation Manufacturers Association) format. The manual is divided into groups which enable a broad separation of contents, (Chapters) within each group. The chapters are broken down into major systems, Engine - Reciprocating, Exhaust, Starting, etc. The System Chapters are arranged alphabetically. All System Chapters are assigned a number which becomes the first element of a standardized numbering system. The element "72" of the number series 72-00-00 refers to the System Chapter on "Engine Reciprocating." All information pertaining to the engine will be covered in this System Chapter. The major System Chapters are then broken down into Sub-system Sections. These sections are identified by the second element of the standardized numbering system. The number "10" of the basic number series "72-10-00" is for the "disassembly" of the engine. The Subsection is the third element of the standardized numbering system "72-10-12." This number is the final breakdown of the Chapter. Number "12" is for "Oil Pump Assembly," that is "Disassembled" from the "Engine." EXAMPLE:

- Chader "Engine F3eciprocating"

-

- Section "Disassembly"

- Subsection "Oil Pump Assembly"

In producing this publication, considerable effort has been put forth to provide grammatically clear and accurate information. Teledyne Continental Motors solicits the users assistance in providing information for review on changes that the user may suggest.

TABLE OF CONTENTS SECTION

PAGE

...The following Section and Grid Numbers are located on Fiche 1 of 2.

NOTE

ii iii iv v vi xii

xvi

Current Status of Pages . Warning . . . . . . . . Notice. . . . . . . . . Introduction . . . . . . Table of Contents. . . . List of lllustrations . . . List of Charts. . . . . .

. . . . . . . . . . . . . . .............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. ..............

ii iii iv

v vi xii xvi

CHAPTER f INTRODUCTION 1-00M) 1-00-01 1-00-02 1-00-03 1-00-04

SCOPE Related Publications . . . . Service Bulletins . . . . . . Service Reports and Inquiries 100% Replacement Parts . .

. . . .

. . . .

. . . .

....... . . . . . . . . . . . . . . . . . . . . .

1-00-03 1-00-04 1-00-04 1-00-05

1-10-00 1-10-01 1-10-02 1-10-03 1-10-04

DEFINITIONS & ABBREVIATIONS Abbreviations / Symbols . . . . . Definitions . . . . . . . . . . . . Description of Engine Model Code . Basic Design Features . . . . . .

. . . .

. . . .

. . . .

. . . .

1-10-01 1-10-02 1-10-06 1-10-07

1-20-00 1-20-01

TOOLS Special Tools

...................

1-20-01

1-30-00 1-30-01

PRODUCTS Product List

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

......

CHAPTER 4 AIRWORTHINESS LIMITATIONS 4-00-00

Airworthiness Limitations

..............

4-00-01

CHAPTER 5 TlME LIMITS/MAINTENANCE CHECKS 5-00-00 5-10-00 5-20-00 5-20-01 5-20-02 5-20-03 5-50-00

GENERAL . . . . . . . . . . . . . . TIME LIMITS/INSPECTION PROGRAM . SCHEDULED MAINTENANCE . . . . . Preflight Inspection . . . . . . . . . . 50 Hour Inspection . . . . . . . . . . 100 Hour Inspection . . . . . . . . . UNSCHEDULED MAINTENANCE . . .

....... ....... ....... ....... ....... . . . . . . . .......

5-00-03 5-10-01 5-20-01 5-20-01 5-20-01 5-20-02 5-50-01

CHAPTER 70 STANDARD PRACTICES 70-00-00 70-10-00 70-20-00 70-30-00 70-40-00 70-50-00

vi

March 1989

GENERAL . . . . . . . . . . . . . . . LOCKWIRE PROCEDURE . . . . . . . . CRANKCASETHREADING PROCEDURE . APPLICATION OF ADHESIVES . . . . . INSTALMTION OF GASKETS . . . . . . CYLINDER LEAKAGE CHECK . . . . . .

......

...... ...... ......

...... ......

70-00-02 70-00-03 70-00-04 70-00-05 70-00-05 70-00-05

AEROflCHE GRID NO.

SECTION Leakagechecks . . . Equipment. . . . . . Performing The Check

................ . . . . . . . . . . . . . . .

...............

70-00-07 70-00-07 70-00-08

CHAPTER 72-00 ENGINE RECIPROCATING GENERAL . . . . . Introduction . . . . Crankcase . . . . . Crankshaft . . . . . Connecting Rods. . Camshaft . . . . . Pistons . . . . . . Liers . . . . . . . Cylinders . . . . . Gear Train . . . . . Lubrication System . Valve Mechanism. . Induction System. . Exhaust System . . Ignition System. . .

................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................

CHAPTER 72-10 DISASSEMBLY General . . . . . . . . . . . . . . . . . . . . . . 72-10-03 Extent of Disassembly. . . . . . . . . . . . . . . . 72-10-04 Parts to be Discarded . . . . . . . . . . . . . . . . 72-10-04 Preliminary Cleaning . . . . . . . . . . . . . . . . . 72-60-04 Ignition System . . . . . . . . . . . . . . . . . . 72-10-04 Fuel InjectionSystem . . . . . . . . . . . . . .72.1 0-06 thru 08 Accessory Case . . . . . . . . . . . . . . . . . . 72-10-10 Induction System. . . . . . . . . . . . . . . 72-10-12 thru 22 Oil Sump . . . . . . . . . . . . . . . . . . . . . 72-10-24 Oil Cooler . . . . . . . . . . . . . . . . . . . . . 72-10-25 Alternator Assembly . . . . . . . . . . . . . . . . 72-10-26 Starter and Starter Drive Adapter . . . . . . . . 72-10-28 thru 32 Oil Pump Assembly . . . . . . . . . . . . . . . . . 72-10-34 Cylinders and Pistons. . . . . . . . . . . . . 72-10-37thru 39 Crankcase. . . . . . . . . . . . . . . . . . . . . 72-10-40 Camshaft Assembly. . . . . . . . . . . . . . . . . 92-10-42 Crankshaft Group . . . . . . . . . . . . . . . . . 72-10-42 Exhaust System . . . . . . . . . . . . . . . .72.1 0.44 thru 51 CHAPTER 72-20 CLEANING. REPAIR AND REPUCEMENT General . . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . Valves . . . . . . . . . . . . . . . . . . . Rocker Shafts . . . . . . . . . . . . . . . Pushrods. Valve Rockers and Small Steel Pasts Camshaft and Crankshaft . . . . . . . . . . Crankcase. . . . . . . . . . . . . . . . . March 1989 Vii

AEROFICHE GRID NO.

Gears . . . . . . . . . . . . . . . . . . . . . . . Sheet Metal Parts and Intake Manifold . . . . . . . . Castings. . . . . . . . . . . . . . . . . . . . . . Stud Replacement . . . . . . . . . . . . . . . . . Helical Coil Insert Installation . . . . . . . . . . . . Spark Plug Hole Helical Coil Inserts . . . . . . . . . Fin Repairs . . . . . . . . . . . . . . . . . . . . Valve Guides. . . . . . . . . . . . . . . . . . . . Valve Rockers . . . . . . . . . . . . . . . . . . . Hydraulic Valve t i e r s . . . . . . . . . . . . . . . Connecting Rods. . . . . . . . . . . . . . . . . . Piston Pin Bushing Replacement . . . . . . . . . . . Crankshaft Assembly . . . . . . . . . . . . . . . . Magneto Gear Support Shaft . . . . . . . . . . . . Magneto and Alternator Drive Coupling . . . . . . . . Tachometer Drive Housing . . . . . . . . . . . . . Starter Drive Adapter . . . . . . . . . . . . . . . . Oil Pump Assembly . . . . . . . . . . . . . . . . . Ignition Cables . . . . . . . . . . . . . . . . . . . CHAPTER 72-30 INSPECTION General . . . . . . . . . . . . Visual Inspection . . . . . . . . Magnetic Particle Inspection. . . Crankshaft Ultrasonic Inspection. Flourescent Particle Inspection . Dimensional Inspection . . . . . Dimensional Limits . . . . . . . TaMe of Limits . . . . . . . . . Critical New Part Dimension . . . Protective Coating . . . . . . . Application of Alodizing . . . . . Repair of Alodized Surfaces . . . Enamel Coatings . . . . . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

......

......

......

...... ...... ...... ...... ......

.... .... .... .... ....

72-30-03 72-30-04 72-30-05 72-30-06 72-30-08 . . . . 72-30-08 . . . . 7230-08 . 72-30-09 thru 16 . . . .7230.1 7-18 . . . . 72-30-18 . . . . 72-30-18 . . . . 72-30-18 . . . . 72-30-19

CHAPTER 72-40 SPECIFIC lNSPECTlONS Crankcase. . . . . . . . . . . . . . . . . . . . . Crankshaft. . . . . . . . . . . . . . . . . . . . . Crankshaft and Counterweight Pins and Bushings . . . Camshaft . . . . . . . . . . . . . . . . . . . . . Connecting Rods. . . . . . . . . . . . . . . . . . Gears . . . . . . . . . . . . . . . . . . . . . . . Pistons and Rings . . . . . . . . . . . . . . . . . Cylinders . . . . . . . . . . . . . . . . . . . . . Hydraulic Valve t i e r s . . . . . . . . . . . . . . . Intake Tubes . . . . . . . . . . . . . . . . . . . . Lubrication System . . . . . . . . . . . . . . . . . Fuel Injection System . . . . . . . . . . . . . . . .

viii March 1989

AERORC1-1E GRID NO.

SECTION Ignition System. Exhaust System Inspection Chart

. . . . . . . . . . . . . . . . . . 72-40-07 . . . . . . . . . . . . . . . . . . 72-40-09 . . . . . . . . . . . . . . . 7 2 4 - 11 thru 19

CHAPTER 72-50 ASSEMBLY OF SUBASSEMBLIES General . . . . . . . . . . . . . . . Oil Pump Assembly. . . . . . . . . . Starter and Starter Adapter . . . . . . Cylinder Assembly . . . . . . . . . . Piston and Ring Assemblies . . . . . . Pushrod Housing. . . . . . . . . . . Crankshaft and Connecting Rods . . . Camshaft . . . . . . . . . . . . . . Crankcase. . . . . . . . . . . . . . Fuel Injection. Air Throttle and Metering Assembly . . . . . . . . . . . . .

....... ....... ....... ....... ....... ....... ....... ....... ....... ....

72-50-03 72-50-05 72-50-06 72-50-07 72-50-07 72-50-07 72-50-08 72-50-08 72-50-08

72-50-09 thru 13

CHAPTER 72-60 FINAL ASSEMBLY General . . . . . . . Crankcase. . . . . . Cylinders and Pistons. Accessory Case . . . Fuel Pump. . . . . . Starter Drive Adapter . Alternator Assembly . Oil Coder . . . . . . Valve Mechanism. . . Intercylinder Air Baffles Oil Sump . . . . . . Induction System. . . FuetlnjectionSystem. Ignition System . . . Exhaust Systems. . .

...............

72-60-03 72-60-03 . . . . . . . 72-60-08 . . . . . . . 72-60-09 . . . . . . . 72-60-10 . . . . . . . 72-60-10 . . . . . . . 72-60-10 . . . . . . . 72-60-11 . . . . . . . 72-60-11 . . . . . . . 72-60-11 . . . . . . . 72-60-13 . . . . 7240-13 thru 15 . . . . . . . 72-60-15 . . . . . . . 72-60-15 . . . . . . . 72-60-17

...............

. . . . . . . .

....... ....... ....... ....... . . . . . . . ....... ....... .......

........ ........ ........ ........ ........

CHAPTER 72-70 TESTING AFTER OVERHAUL Test Stand . . . . . Test Club . . . . . Cooling Air Scoop . Induction Air Intake . Exhaust System . . Controls . . . . . . Electrical Wiring . . Instruments . . . . Breather. . . . . . Fuel System . . . . Governor Pad Cover Engine Test . . . . Starting Procedure . Overhaul Test Run . Test Flight . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

......

...... ...... ...... ......

...... ......

. . . .

. . . .

. . . .

... ... ... ...

. . . .

. . . .

. . . .

. . . .

...... ...... ...... ......

72-70-03 72-70-03 72-70-03 72-70-03 . . . . . . . . . . 72-70-03 . . . . . . . . . . 72-70-03 . . . . . . . . . . 72-70-03 . . . . . . . . . . 72-70-03 . . . . . . . . . . 72-70-04 . . . . . . . . . . 92-70-04 . . . . . . . . . . 72-70-04 . . . . . . . . . . 72-70-04 . . . . . . . . . . 72-7064 . . . . . . . 72-70-06 thru 09 . . . . . . . . . . 72-70-10 March 1989 ix

AEROFICHE GRID NO. CHAPTER 72-80 ENGINE PRESERVATION General . . . . . . Flyable Storage . . Temporary Storage . Indefinite Storage. . NOTE

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . . . . . . . . .......... . . . . . . . . . . ..........

72-80-03 72-80-03 72-80-04 72-80-05

.. .The following Section and Grid Numbers are located on Fiche 2 of 2. CHAPTER 73-00 ENGINE FUEL SYSTEM Engine Fuel Systems . . . . . . . . . . . Set-Up Procedure . . . . . . . . . . . . Turbocharged Engines . . . . . . . . . . Special Set-Up Procedures . . . . . . . . Fuel System Pressure and Flow Valve Charts Fuel System Troubleshooting Chart . . . .

. . . . . 73-00-03 . . . . . 7340-04 . . . . . 73-00-04 . . . . . 73-00-06 . . . . . 73-00-07 . . . . 73-0048-09

CHAPTER 74 IGNITION (TCM IGNITION SYSTEM) GENERAL . . . . . . . . . . Magneto Installation . . . . . Harness Assembly Installation .

........... ........... ...........

74-00-02 7440-02 7440-03

(SLICK IGNITION SYSTEM) GENERAL . . . . . . . . . . . Magneto Installation . . . . . . Harness Assembly Maintenance .

.......... .......... ..........

74-00-05 74-00-05 74-00-06

IGNITIONTROUBLESHOOTING.

..........

74-00-08

CHAPTER 75 AIR GENERAL .

....................

7575-00-03

CHAPTER 76 ENGINE CONTROLS GENERAL . . . . . . . . . . . . . . . . . . CRUISE CONTROL BY PERFORMANCE CURVE CRUISE CONTROL BY E.G.T. . . . . . . . . . PERFORMANCE CHARTS. . . . . . . . . . .

... ...

... ...

76-00-03 76-00-03 76-00-03 7640-05

CHAPTER 77 ENGINE INDICATING GENERAL . . . . . . . . . . . . . . OPERATING LIMITS . . . . . . . . . ENGINE TROUBESHOOTING CHART .

X March 1989

. . . . . . . 7740-03 . . . . . . . 7740-04 . . . . 77-00-06 thru 11

PAGE

SECTION

AEROFICHE GRID NO.

CHAPTER 78 EXHAUST GENERAL . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . Exhaust System Troubleshooting Chart .

....... . . . . . . . .......

CHAPTER 79 OIL GENERAL . . . . . . . . . . . . . . . . . . . . . APPROVED OIL PRODUCTS . . . . . . . . . . . . LUBRICATING SYSTEM TROUBLESHOOTING CHART. CHAPTER 80 STARTING GENERAL . . . . . . . . . . . . . . . . . . . . . Prestarting. . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . Ground Warm-Up . . . . . . . . . . . . . . . . . Pre-takeoff Check . . . . . . . . . . . . . . . . . Flooded Engine . . . . . . . . . . . . . . . . . . Cdd Weather Operation. . . . . . . . . . . . . . . Preheating. . . . . . . . . . . . . . . . . . . . . Hot Weather Operation . . . . . . . . . . . . . . . Ground Operating At High Altitude Airports . . . . . . CHAPTER 81 TURBINES GENERAL . . . . . . . . . . TURBOCHARGER . . . . . . WASTEGATES . . . . . . . . CONTROLLERS . . . . . . . LUBRICATION SYSTEM. . . . TROUBLESHOOTING CHART .

........... ........... ........... ........... ........... ...........

March 1989 )