Textron Lycoming IO-360, Operator'S Manual

Page 1: ...reduce to only the IO 360 AIA that is in the club aircraft If you want the full manual for all 360 models try https www lycoming com sites default files O HO IO HIO AIO 20 26 20TIO 360 20Oper 20Manual...

Page 2: ...Operator s Manual Lycoming O 360 HO 360 IO 360 AIO 360 HIO 360 TIO 360 Series Approved by FAA 8th Edition Part No 60297 12 652 Oliver Street Williamsport PA 17701 U S A October 2005 570 323 6181...

Page 3: ...s publication are trademarks or registered trademarks of their respective companies For additional information Mailing address Lycoming Engines 652 Oliver Street Williamsport PA 17701 U S A Phone Fact...

Page 4: ...ES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER LOSS ALSO IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED FOR ANY REASON DAMAGE TO THE ENGINE AND PERSONAL INJURY CAN HAPPEN CON...

Page 5: ...CTION 1 DESCRIPTION 1 1 SECTION 2 SPECIFICATIONS 2 1 SECTION 3 OPERATING INSTRUCTIONS 3 1 SECTION 4 PERIODIC INSPECTIONS 4 1 SECTION 5 MAINTENANCE PROCEDURES 5 1 SECTION 6 TROUBLE SHOOTING 6 1 SECTION...

Page 6: ...Valve Operating Mechanism 1 1 Crankcase 1 1 Crankshaft 1 1 Connecting Rods 1 2 Pistons 1 2 Accessory Housing 1 2 Oil Sump 1 2 Cooling System 1 2 Induction System 1 2 Lubrication System 1 3 Priming Sys...

Page 7: ...dual magnetos housed in a single housing Example All information pertinent to the O 360 A1F6 will apply to the O 360 A1F6D Operational aspects of engines are the same and performance curves and specif...

Page 8: ...r of the cowling Induction System Lycoming O 360 and HO 360 series engines are equipped with either a float type or pressure type carburetor See Table 1 for model application Particularly good distrib...

Page 9: ...to the engine Lubrication System All models except AIO 360 series An impeller type pump contained within the accessory housing actuates the full pressure wet sump lubrication system AIO 360 Series Th...

Page 10: ...1A A2A A1B A2B B1B S4LN 1208 S4LN 1227 S4LN 1209 S4LN 1209 RSA 5AD1 RSA 5AD1 TIO 360 A1A A1B A3B6 S4LN 1208 S4LN 1209 RSA 5AD1 TIO 360 Dual Magneto C1A6D D4LN 3021 RSA 5AD1 Models with counterclockwis...

Page 11: ...6 M1B 2 3 IO 360 A C D J K 2 3 IO 360 B E F 2 4 AIO 360 A B 2 4 HIO 360 A B 2 4 HIO 360 C 2 5 HIO 360 D 2 5 HIO 360 E 2 5 HIO 360 F1AD 2 6 HIO 360 G1A 2 6 TIO 360 A 2 6 TIO 360 C 2 7 Accessory Drives...

Page 12: ...eries FAA Type Certificate 1E10 Rated horsepower 200 Rated speed RPM 2700 Bore inches 5 125 Stroke inches 4 375 Displacement cubic inches 361 0 Compression ratio 8 7 1 Firing order 1 3 2 4 Spark occur...

Page 13: ...ropeller Governor Rear Mounted 0 866 1 Clockwise Propeller Governor Front Mounted 0 895 1 Clockwise Fuel Pump AN20010 0 866 1 Counterclockwise Fuel Pump AN20003 1 000 1 Counterclockwise Fuel Pump Plun...

Page 14: ...335 C1E6 337 AIO 360 Series A1A A2A 331 A1B A2B B1B 332 HIO 360 Series G1A 283 B1A B1B 290 A1A 311 A1B 312 D1A E1AD E1BD 321 C1A 322 C1B 323 F1AD 324 TIO 360 Series C1A6D 379 A1A A1B 386 A3B6 407 DIM...

Page 15: ...3 37 33 37 33 37 33 37 33 37 33 37 33 37 32 24 33 38 33 37 31 81 29 56 29 81 31 82 31 82 29 05 31 33 31 33 29 56 29 81 29 56 29 81 29 05 30 67 29 56 29 81 29 81 31 81 31 83 HO 360 Series A1A B1A B1B C...

Page 16: ...eral 3 1 Prestarting Items of Maintenance 3 1 Starting Procedures 3 1 Cold Weather Starting 3 3 Ground Running and Warm Up 3 3 Ground Check 3 4 Operation in Flight 3 5 Engine Flight Chart 3 10 Operati...

Page 17: ...should be operated on straight mineral oil for a minimum of 50 hours or until oil consumption has stabilized After this period a change to an approved additive oil may be made if so desired NOTE Crui...

Page 18: ...Both 12 Check oil pressure gage If minimum oil pressure is not indicated within thirty seconds stop engine and determine trouble b Engines Equipped with Pressure Carburetors or Bendix Fuel Injectors 1...

Page 19: ...8 Open throttle travel 9 Move combination magneto switch to Start using accelerator pump as a primer while cranking engine 10 When engine fires allow the switch to return to Both 11 Check oil pressure...

Page 20: ...return to full low pitch position Full feathering check twin engine on the ground is not recommended but the feathering action can be checked by running the engine between 1000 1500 RPM then momentar...

Page 21: ...drop off past normal is usually a sign of a too lean or too rich mixture f Do not operate on a single magneto for too long a period a few seconds is usually sufficient to check drop off and to minimiz...

Page 22: ...ings Operate the engine at maximum power mixture for performance cruise powers and at best economy mixture for economy cruise power unless otherwise specified in the airplane owner s manual During let...

Page 23: ...O 360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS Figure 3 1 Representative Effect of Fuel Air Ratio on Cylinder Head Temperature Power and Specific Fuel Consumption at Constant RPM and Manifold Pre...

Page 24: ...othly and power is regained WARNING REFER TO THE PILOT S OPERATING HANDBOOK OR AIRFRAME MANUFACTURER S MANUAL FOR ADDITIONAL INSTRUCTIONS ON THE USE OF CARBURETOR HEAT CONTROL INSTRUCTIONS FOUND IN EI...

Page 25: ...ssible for engine roughness to occur due to the over rich fuel air mixture produced by the additional carburetor heat When this happens lean the mixture with the mixture control only enough to produce...

Page 26: ...0 A C D E F 100 130 TIO 360 A 100 130 NOTE Aviation grade 100LL fuels in which the lead content is limited to 2 c c per gal are approved for continuous use in the above listed engines Refer to latest...

Page 27: ...50 30 to 90 F SAE 40 SAE 40 0 to 70 F SAE 30 SAE 40 30 or 20W40 Below 10 F SAE 20 SAE 30 or 20W30 Refer to latest revision of Service Instruction No 1014 OIL SUMP CAPACITY All Models Except AIO 360 Se...

Page 28: ...ormance Cruise 75 Rated 2450 135 10 5 45 500 F 260 C Economy Cruise 65 Rated 2350 117 9 5 39 500 F 260 C O 360 B D Series Normal Rated 2700 168 75 500 F 260 C Performance Cruise 75 Rated 2450 126 11 6...

Page 29: ...0 B Series Normal Rated 2900 180 80 500 F 260 C Performance Cruise 75 Rated 2700 135 10 5 45 500 F 260 C Economy Cruise 65 Rated 2700 117 9 0 39 500 F 260 C IO 360 A C D J K AIO 360 Series Normal Rate...

Page 30: ...gle when applicable 2 Idle until there is a decided drop in cylinder head temperature 3 Move mixture control to Idle Cut Off 4 When engine stops turn off switches b Helicopters 1 Idle as directed in t...

Page 31: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS O 360 AND ASSOCIATED MODELS Figure 3 5 Part Throttle Fuel Consumption IO 360 A C D J K AIO 360 Series 3 20...

Page 32: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS O 360 AND ASSOCIATED MODELS Figure 3 21 Sea Level and Altitude Performance IO 360 A C D J K AIO 360 Series 3 36...

Page 33: ...but are meant for the engine only Consult the airframe manufacturer s handbookfor additional instructions Pre Starting Items of Maintenance The daily pre flight inspection is a checkof the aircraft p...

Page 34: ...security lubricant or air leak age 2 Checkengine crank case breather for restrictions to breather 2 25 HOUR INSPECTION ENGINE After the first twenty five hours operation time new rebuilt or newly over...

Page 35: ...ose they must be removed and machined flat before they are reassembled and tightened Ex amine ex haust manifolds for general condition e Cooling System Check cowling and baffle for damage and secure a...

Page 36: ...instructions Checkmagneto to engine timing Timing procedure is described in Section 5 1 b of this manual d Engine Accessories Engine mounted accessories such as pumps temperature and pressure sensing...

Page 37: ...the piston and connecting rod assembly and inspected for further damage Replace any parts that do not conform with limits shown in the latest revision of Special Service Publication No SSP1776 6 NON...

Page 38: ...Alternator Output 5 4 Fuel System Repair of Fuel Leaks 5 4 Carburetor or Fuel Injector Inlet Screen Assembly 5 4 Fuel Grades and Limitations 5 4 Air Intake Ducts and Filter 5 4 Idle Speed and Mixture...

Page 39: ...d turn the drive shaft in direction of normal rotation until 20 and 200 series the first painted chamfered tooth on the distributor gear is aligned in the center of the inspection window 1200 series t...

Page 40: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES O 360 AND ASSOCIATED MODELS Figure 5 1 Ignition Wiring Diagram Figure 5 2 Timing Mark s 4 Cylinder 1200 Series 5 2...

Page 41: ...l and the second positive lead to the right main break er terminal 2 Backthe engine up a few degrees and again bump forward toward number one cylinder firing position while observing timing lights Bot...

Page 42: ...Fuel of a lower octane than specified is not to be used Under no circumstances should automotive fuel be used regardless of octane rating NOTE It is recommended that personnel be familiar with latest...

Page 43: ...to maintain engine oil pressure within specified limits The valve although not adj ustable may control the oil pressure with the addition of a max imum of nine 9 P N STD 425 washers between the cap an...

Page 44: ...n to drop against the crank case as the piston leaves the cylinder b Removal of Piston from Connecting Rod Remove the piston pin plugs Insert piston pin puller through piston pin assemble puller nut t...

Page 45: ...it If difficulty is ex perienced in inserting the piston pin it is probably caused by carbon or burrs in the piston pin hole During assembly always use a generous q uantity of oil both in the piston h...

Page 46: ...tighten the inch cylinder base nuts to 600 in lbs 50 ft lbs torq ue NOTE Cylinder assemblies not using hold down plate are tightened in the same manner as above omitting the shims Figure 5 3 Location...

Page 47: ...he end of the push rod and push down so as to compress the hydraulic tappet spring While holding the spring compressed the valve clearance should be between 028and 08 0 inch If clearance does not come...

Page 48: ...il pressure and is set to predetermined open and closed clearances These clearances and the procedures for setting them are shown in Figure 5 5 Exhaust Bypass Valve TIO 360 C1A6D This valve is mechani...

Page 49: ...LYCOMING OPERATOR S MANUAL SECTION 5 O 360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES Figure 5 4 Density Control Full Throttle Setting Limits 5 11...

Page 50: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES O 360 AND ASSOCIATED MODELS Figure 5 5 Ex haust Bypass Valve Open and Closed Setting Figure 5 6 Timing Mark s on Rotating Magnet 5 12...

Page 51: ...LYCOMING OPERATOR S MANUAL SECTION 5 O 360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES Figure 5 7 Ignition Wiring Diagram Dual Magneto 5 13...

Page 52: ...neven Running 6 2 Failure of Engine to Develop Full Power 6 3 Rough Engine 6 3 Low Oil Pressure 6 3 High Oil Temperature 6 3 Excessive Oil Consumption 6 4 TROUBLE SHOOTING TURBOCHARGER Excessive Noise...

Page 53: ...uel tank Clean dirty lines strainers or fuel valves Overpriming Leave ignition off and mix ture control in Idle Cut Off open throttle and unload engine by crank ing for a few seconds Turn ignition swi...

Page 54: ...tment of fuel inj ector or sluggish engine operation red carburetor by authoriz ed ex haust flame at night Ex treme personnel is indicated cases indicated by blacksmok e from ex haust Mix ture too lea...

Page 55: ...n timing Rough Engine Crack ed engine mount Replace or repair mount Defective mounting bushings Install new mounting bushings Uneven compression Checkcompression Low Oil Pressure Insufficient oil Fill...

Page 56: ...f piston Install new rings rings Failure of rings to seat new Use mineral base oil Climb to nitrided cylinders cruise altitude at full power and operate at 75 cruise power setting until oil consumptio...

Page 57: ...rifice Ex haust bypass controller Replace unit malfunction Ex haust bypass butterfly not Low pressure Clogged orifice in closing inlet to actuator Butterfly shaft binding Check bearings Turbocharger i...

Page 58: ...aneroid bellows Ex haust bypass stick ing closed Shut off valve in return line not work ing Butterfly shaft binding Check bearings Replace bypass valve or correct link age binding Controller return l...

Page 59: ...LYCOMING OPERATOR S MANUAL SECTION 7 O 360 AND ASSOCIATED MODELS INSTALLATION AND STORAGE Figure 7 8 Installation Drawing IO 360 A Series 7 11...

Page 60: ...00 58 7 22 000 44 0 4 000 8 7 5 16 000 56 5 22 500 43 3 5 000 8 4 6 17 000 54 3 23 000 42 2 6 000 8 1 7 17 500 53 1 23 500 41 4 7 000 78 9 18 000 52 1 24 000 40 3 8 000 76 2 18 500 51 4 24 500 39 5 9...