Teledyne TSIO-360-RB User manual

Courtesy of Bomar Flying Service
www.bomar.biz
MAINTENANCE
MANUAL
TSIO-360-RB
PART NO. X30645A FAA APPROVED
1996 TELEDYNE INDUSTRIES, INC. OCTOBER 1996

ii
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 trichloroethane 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.

iii
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DESTROY SUPERSEDED PAGES.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 & -SB FORM X30645A
PAGE STATUS PAGE STATUS PAGE STATUS PAGE STATUS
ALL ORIGINAL

iv
WARNING
BACKGROUND. Replacement parts, materials and accessories may be sold 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. 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 establish the origin of materials, parts, and accessories.

v
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 manufacturer's
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 with
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 § 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.

vi
Publication Table of Contents
COVER PAGES PAGE
Definition of Notes, Cautions and Warnings........................................................................ii
CFC Warning Statement......................................................................................................ii
Status Page.........................................................................................................................iii
Replacement Parts Warning ...............................................................................................iv
Notice to all users................................................................................................................ v
NOTE ... Contents of each chapter are listed in chapter "Chapter Contents" before each division.
Chapter Index
CHAPTER PAGE
1 Introduction ...................................................................................................................1-2
2 Tools (Maintenance)..................................................................................................... 2-1
3 Approved Products ....................................................................................................... 3-1
4 Airworthiness Limitations.............................................................................................. 4-1
5 Time Limits/Operational Insp./Troubleshooting ........................................................... 5-1
6 Unpacking/De-Inhibiting/Installation & Test ................................................................. 6-1
7 Servicing, Fluids ........................................................................................................... 7-1
8 Engine Preservation and Storage ................................................................................ 8-1
9 Standard Practices ....................................................................................................... 9-1
10 Engine Maintenance................................................................................................... 10-1
11 Exhaust System.......................................................................................................... 11-1
12 Ignition System ........................................................................................................... 12-1
13 Fuel Injection System ................................................................................................. 13-1
14 Induction System ........................................................................................................ 14-1
15 Air Conditioning System ............................................................................................. 15-1
16 Electrical Charging System ........................................................................................ 16-1
17 Starter & Starter Adapter ............................................................................................ 17-1
18 Accessory Case.......................................................................................................... 18-1
19 Lubrication System ..................................................................................................... 19-1
20 Cylinder Assembly...................................................................................................... 20-1
21 Crankcase................................................................................................................... 21-1
22 Engine Drive Train...................................................................................................... 22-1
23 Post Maintenance Adjustment & Test ........................................................................ 23-1

1-1
CHAPTER 1
SECTION PAGE
1-1 Scope ...................................................................................................... 1-2
1-2 Related Publications ............................................................................. 1-2
1-3 Manual Revisions .................................................................................. 1-3
1-4 Service Reports and Inquires .............................................................. 1-3
1-5 Description of Engine Model Code ..................................................... 1-4
1-6 Definition of Terms................................................................................ 1-4
1-7 Engine Design Features ....................................................................... 1-4
1-8 General ................................................................................................... 1-9
1-9 Engine Specifications ........................................................................... 1-9
1-10 Operating Limits .................................................................................... 1-9
FIGURE PAGE
1-1 Engine Description L/TSIO360-RB ...................................................... 1-5
1-2 Engine Description L/TSIO360RB ....................................................... 1-6

1-2
1-1 SCOPE
This publication contains information on maintenance and installation of Teledyne
Continental Motors (TCM) L/TSIO-360-RB
1-2 RELATED PUBLICATIONS
The following are related engine and accessory manuals.
1. Overhaul Manual for L/TSIO-360-RB Series Aircraft engine, Form X30596A
Supplement No.
2. Illustrated Parts Catalog for L/TSIO-360-RB Series Aircraft Engine, Form XX30597A.
Supplement No. 1
3. Operators and Installation Manual for L/TSIO-360-RB Series Aircraft Engine, Form
X30644.
4. Teledyne Continental Motors Aircraft Engine Service Documents (including service
bulletins).
5. Fuel Injection Manual, Form 30593A.
6. Starter Service Instructions, Form X30592.
7. TCM Ignition Systems Master Service Manual, Form No. X40000.
8. 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: [phone]
For price information on the above publications see TCM Publications Index Form X-
-94, Current Publications and Form X-3-94, Optional Publications.
9. 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: [phone]

1-3
1-3 MANUAL REVISIONS
Revisions to this manual will be furnished to purchasers who complete and return 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 not perform any operation,
maintenance, installation or other operations until the manual has been confirmed to
be current.
1-4 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 documents
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. If you have an inquiry or require technical
assistance, contact a TCM distributor, field representative or customer service.

1-4
1-5 DESCRIPTION OF ENGINE MODEL CODE
Example code: L/TSIO-360-RB (1)
L TS I O 360 RB 1
Left hand
rotation
Turbo super
charged
Fuel injection Horizontally
opposed
Displacement
(360 cubic inch)
model specification
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 overhead 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.

1-5
FIGURE 1-1. Engine Description L/TSIO-360-RB

1-6
FIGURE 1-2. ENGINE DESCRIPTION L/TSIO 360-RB (Cont’d)

1-7
FIGURE 1-2. ENGINE DESCRIPTION L/TSIO 360-RB (Cont’d)

1-8
FIGURE 1-2. ENGINE DESCRIPTION L/TSIO 360-RB (Cont’d)

1-9
FIGURE 1-2. ENGINE DESCRIPTION L/TSIO 360-RB (Cont’d)

1-10
1-8 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 & Installation Manual,
Form X30644 for additional operating procedures.
For time between overhaul (TBO) for 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.
1-9 ENGINE SPECIFICATIONS
Manufacturer Teledyne Continental Motors
Model L/TSIO-360-RB.
Cylinders
Arrangement .......................... Individual cylinders in a horizontally opposed position
Compression Ratio .............................................................................................. 7.5:1
Firing Order (TSIO-360-RB) ...................................................................... 1-6-3-2-5-4
Firing Order (LTSIO-360-RB) ................................................................... 1-4-5-2-3-6
Number of cylinders................................................................................................... 6
Bore (Inches) ..................................................................................................... 4.438
Stroke (Inches)................................................................................................... 3.875
Piston Displacement (cu. in.) ................................................................................ 360
Brake Horsepower
Rated Maximum Continuous Operation L/TSIO-360-RB, .............................220 BHP
1-10 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
Idle........................................................................................................... 700 RPM±25
Manifold Pressure Limit (In. Hg.) Absolute..........................................................38.0”
Fuel Control System .................................................. Precision RSA-5 Fuel Injection
Fuel .............................................................For fuel grade , see Chapter 7, Servicing
Oil ................................................ For Oil grade & capacity, see Chapter 7, Servicing
Oil Pressure
Idle, Minimum, psi ................................................................................................... 10
Normal Operation, psi .................................................................................... 30 to 60
Oil Sump Capacity (U.S. Quarts) ........................................................................... 8.0
Oil Consumption (Lb./BHP/Hr. Max.) ............................................. .006 X % Power
100

1-11
1-10 OPERATING LIMITS (Cont’d)
Oil Temperature Specifications
All Temperatures .........................................................TCM 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 Take-Off....................................................................................... 100°F
Maximum Allowable.......................................................................................... 240°F
Recommended Operational Range ......................................................... 160 - 180°F
Cylinder Head Temperature
TSIO-360-RB
Recommended maximum at cruise....................................................................420°F
Limit ....................................................................................................................460°F
Turbine Inlet Temperature
Maximum Continuous .....................................................................................1650°F
Maximum, 60 seconds....................................................................................1700°F
Ignition Timing (Compression stroke, breaker opens)
Right Magneto, degrees BTC............................................................................22°±1°
Left Magneto, degrees BTC ..............................................................................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.

1-12
ACCESSORY DRIVE RATIOS TO CRANKSHAFT
Accessory Direction of Rotation* Drive Ratio
Tachometer -
Magneto CW 1.5:1
Starter CW 24.73:1
* ** Propeller Governor CW 1:1
Fuel Pump (Injection), CCW 1:1
Freon Compressor CW 1.545:1 * * * *
* * * Accessory Drive Pad CCW 1.545:1
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 and 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.

2-1
CHAPTER 2
TOOLS AND EQUIPMENT
Section Page
2-1 General Information................................................................................................ 2-2
2-2 Possible Special Tool Procurement Sources......................................................... 2-3
2-3 Special Tools ......................................................................................................... 2-4

2-2
2-1 GENERAL INFORMATION
The mechanic should be equipped with a complete set of the necessary tools that include
the following:
1. Wrenches - 1/4" through 1 1/4"
2. Common and Philips Head Screwdrivers
3. Pliers - Common Diagonal Cutters, Needle Nose, Duck Bill, Snap Ring
4. Ratchets 1/4”,3/8”, & 1/2” Drive
5. 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”
6. Sockets (Deepwell) - 1/2" Drive 7/16" through 1"
7. Feeler Gauges
8. Leather or Soft Plastic Mallet
9. Torque Wrenches* 0-500 In. Lbs. / 0-100 Ft. Lbs.
10. Micrometers*
11. Slide Hammer
12. Pullers
13. Thickness Gauges
14. Vernier Calipers*
15. Small Hole Gauges
16. Ford Wrench
* Must be currently calibrated, and the calibration must be traceable to the National Bureau
of Standards.