Textron Lycoming IO-360 Operator's Manual
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Textron Lycoming IO-360 Operator's Manual

Textron Lycoming IO-360 Operator's Manual

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This manual has 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%2060297-12.pdf

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Summary of Contents for Textron Lycoming IO-360

  • Page 1 This manual has 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%2060297-12.pdf...
  • Page 2 Operator’s Manual Lycoming O-360, HO-360, IO-360, AIO-360, HIO-360 & TIO-360 Series Approved by FAA Edition Part No. 60297-12 October 2005 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
  • Page 3 O, HO, IO, AIO, HIO, TIO-360 Series Operator’s Manual Lycoming Part Number: 60297-12 ©2005 by Lycoming. All rights reserved. Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of Lycoming. All brand and product names referenced in this publication are trademarks or registered trademarks of their respective companies.
  • Page 4 LYCOMING OPERATOR’S MANUAL ATTENTION OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL SAFETY WARNING NEGLECTING TO FOLLOW THE OPERATING INSTRUCTIONS AND TO CARRY OUT PERIODIC MAINTENANCE PROCEDURES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER LOSS. ALSO, IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED, FOR ANY REASON;...
  • Page 5 LYCOMING OPERATOR’S MANUAL TABLE OF CONTENTS...

  • Page 6: Table Of Contents

    LYCOMING OPERATOR’S MANUAL SECTION 1 DESCRIPTION Page General................................1-1 Cylinders............................... 1-1 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............................

  • Page 7: Cylinders

    LYCOMING OPERATOR’S MANUAL SECTION 1 O-360 AND ASSOCIATED MODELS DESCRIPTION SECTION 1 DESCRIPTION NOTE The letter “L” in the model prefix denotes the reverse rotation of the basic model. Example: model IO-360-C has clockwise rotation of the crankshaft. Therefore, LIO-360-C has counterclockwise rotation of the crankshaft.

  • Page 8: Connecting Rods

    SECTION 1 LYCOMING OPERATOR’S MANUAL DESCRIPTION O-360 AND ASSOCIATED MODELS Connecting Rods – Pistons – Accessory Housing – Oil Sump (Except AIO Series) – Crankcase Covers (AIO Series) – Cooling System – Induction System –...

  • Page 9: Lubrication System

    LYCOMING OPERATOR’S MANUAL SECTION 1 O-360 AND ASSOCIATED MODELS DESCRIPTION Lubrication System – (All models except AIO-360 series AIO-360 Series – Priming System – Ignition System – Counterweight System –...
  • Page 13 LYCOMING OPERATOR’S MANUAL SECTION 2 O-360 AND ASSOCIATED MODELS SPECIFICATIONS NOTE Engines with letter “L” in prefix will have opposite rotation to the above. DETAIL WEIGHTS 1. ENGINE, STANDARD, DRY WEIGHT.
  • Page 14 LYCOMING OPERATOR’S MANUAL SECTION 2 O-360 AND ASSOCIATED MODELS SPECIFICATIONS DETAIL WEIGHTS (CONT.) DIMENSIONS, INCHES...
  • Page 15 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-360 AND ASSOCIATED MODELS DIMENSIONS, INCHES (CONT.)
  • Page 16 LYCOMING OPERATOR’S MANUAL SECTION 3 OPERATING INSTRUCTIONS Page General................................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 ...........................

  • Page 17: General

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS SECTION 3 OPERATING INSTRUCTIONS 1. GENERAL. NOTE YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THE FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED FUELS AND LUBRICANTS, REPAIR AND ALTERATIONS.
  • Page 18 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS b. Engines Equipped with Pressure Carburetors or Bendix Fuel Injectors.

  • Page 19: Cold Weather Starting

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS c. Engines Equipped with Simmonds Type 530 Fuel Injector. 4. COLD WEATHER STARTING. 5. GROUND RUNNING AND WARM-UP. NOTE Any ground check that requires full throttle operation must be limited to three minutes, or less if the cylinder head temperature should exceed the maximum as stated in this manual.

  • Page 20: Ground Check

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS a. Fixed Wing. (1) Head the aircraft into the wind. (2) Leave mixture in “Full Rich”. (3) Operate only with the propeller in minimum blade angle setting. (4) Warm-up to approximately 1000-1200 RPM. Avoid prolonged idling and do not exceed 2200 RPM on the ground.

  • Page 21: Operation In Flight

    (Fixed pitch propeller). (2) Helicopter. 7. OPERATION IN FLIGHT. Fuel Mixture Leaning Procedure.
  • Page 22 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS GENERAL RULES Never exceed the maximum red line cylinder head temperature limit. For maximum service life, cylinder head temperatures should be maintained below 435°F (224°C) during high performance cruise operation and below 400°F (205°C) for economy cruise powers. Do not manually lean engines equipped with automatically controlled fuel system.
  • Page 23 LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS...
  • Page 24 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS (b) Deduct 125°F from this temperature and thus establish the temperature reference point for use when operating at maximum power mixture. (c) Return mixture control to full rich and adjust the RPM and manifold pressure for desired performance cruise operation.
  • Page 25 LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS To avoid this, all installations are equipped with a system for preheating the incoming air supply to the carburetor. In this way sufficient heat is added to replace the heat loss of vaporization of fuel, and the mixing chamber temperature cannot drop to the freezing point of water (32°F).

  • Page 26: Engine Flight Chart

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS 8. ENGINE FLIGHT CHART. 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.

  • Page 27: Operating Conditions

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS FUEL PRESSURE, PSI (CONT.) – Model Max. Desired Max. HIO-360-E, -F Series Inlet to fuel pump Inlet to fuel injector TIO-360-A Series Inlet to fuel pump Inlet to fuel injector TIO-360-C1A6D Inlet to fuel pump Inlet to fuel injector...
  • Page 28 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS OPERATING CONDITIONS (CONT.) O-360-A, -C** Series O-360-B, -D Series O-360-A1P, -A4D, -A4P, -C4P, -F, -G Series...
  • Page 29 LYCOMING OPERATOR’S MANUAL SECTION 3 O-360 AND ASSOCIATED MODELS OPERATING INSTRUCTIONS OPERATING CONDITIONS (CONT.) O-360-J2A HO-360-A, -C Series; HIO-360-G1A HO-360-B Series IO-360-A, -C, -D, -J, -K; AIO-360 Series IO-360-B, -E, -F Series (Except -B1C); IO-360-M1A**, -M1B**...

  • Page 30: Shut Down Procedure

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS 9. SHUT DOWN PROCEDURE. a. Fixed Wing. b. Helicopters.
  • Page 31 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS...
  • Page 32 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-360 AND ASSOCIATED MODELS...
  • Page 33 LYCOMING OPERATOR’S MANUAL SECTION 4 O-360 AND ASSOCIATED MODELS PERIODIC INSPECTIONS SECTION 4 PERIODIC INSPECTIONS NOTE Perhaps no other factor is quite so important to safety and durability of the aircraft and its components are faithful and diligent attention to regular checks for minor troubles and prompt repair when they are found.
  • Page 34 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS O-360 AND ASSOCIATED MODELS 1. DAILY PRE-FLIGHT. a. Engine. b. Turbocharger. 2. 25-HOUR INSPECTION (ENGINE). 3. 50-HOUR INSPECTION (ENGINE). a. Ignition System.
  • Page 35 LYCOMING OPERATOR’S MANUAL SECTION 4 O-360 AND ASSOCIATED MODELS PERIODIC INSPECTIONS b. Fuel and Induction System – c. Lubrication System. (Engines Not Equipped with External Filter.) d. Exhaust System – e. Cooling System – f. Cylinders – g. Turbocharger –...
  • Page 36 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTION O-360 AND ASSOCIATED MODELS h. Carburetor – 4. 100-HOUR INSPECTION. a. Electrical System. b. Lubrication System – c. Magnetos – d. Engine Accessories – e. Cylinders – f. Engine Mounts – g. Fuel Injection Nozzles and Fuel Lines – h.
  • Page 37 LYCOMING OPERATOR’S MANUAL SECTION 4 O-360 AND ASSOCIATED MODELS PERIODIC INSPECTIONS 5. 400-HOUR INSPECTION. Valve Inspection – 6. NON-SCHEDULED INSPECTIONS.
  • Page 38 LYCOMING OPERATOR’S MANUAL SECTION 5 MAINTENANCE PROCEDURES Page General................................5-1 Ignition and Electrical System Ignition Harness and Wire Replacement....................5-1 Timing Magneto to Engine Single Magneto ............................5-1 Dual Magneto ............................5-1 Generator or Alternator Output ......................5-4 Fuel System Repair of Fuel Leaks..........................

  • Page 39: Ignition And Electrical System

    LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES SECTION 5 MAINTENANCE PROCEDURES 1. IGNITION AND ELECTRICAL SYSTEM. a. Ignition Harness and Wire Replacement – b. Timing Magnetos to Engine. Single Magneto – Dual Magnetos –...
  • Page 40 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS...
  • Page 41 LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES NOTE Some timing lights operate in the reverse manner as described. The light comes on when the breaker points open. Check your timing light instructions. c. Internal Timing – Dual Magneto – Main Breakers –...

  • Page 42: Generator Or Alternator Output

    SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS d. Generator or Alternator Output – 2. FUEL SYSTEM. a. Repair of Fuel Leaks – b. Carburetor or Fuel Injector (Except Simmonds Injectors) Fuel Inlet Screen Assembly – c. Fuel Grade and Limitations – NOTE It is recommended that personnel be familiar with latest revision of Service Instruction No.

  • Page 43: Lubrication System

    LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES 3. LUBRICATION SYSTEM. a. Oil Grades and Limitations – b. Oil Suction and Oil Pressure Screens – c. Oil Pressure Relief Valve – Non-Adjustable Oil Pressure Relief Valve – Oil Pressure Relief Valve (Adjustable) –...
  • Page 44 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS a. Removal of Cylinder Assembly. NOTE The hydraulic tappets, push rods, rocker arms and valves must be assembled in the same location from which they were removed. b. Removal of Piston from Connecting Rod – c.
  • Page 45 LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES CAUTION NEVER USE A MAGNET TO REMOVE HYDRAULIC PLUNGER ASSEMBLIES FROM THE CRANKCASE. THIS CAN CAUSE THE CHECK BALL TO REMAIN OFF ITS SEAT, RENDERING THE UNIT INOPERATIVE. d. Assembly of Hydraulic Tappet Plunger Assemblies – e.
  • Page 46 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS NOTE Cylinder assemblies not using hold-down plate are tightened in the same manner as above omitting the shims.

  • Page 47: Generator Or Alternator Drive Belt Tension

    LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES CAUTION AFTER ALL CYLINDER BASE NUTS HAVE BEEN TIGHTENED, REMOVE ANY NICKS IN THE CYLINDER FINS BY FILING OR BURRING. NOTE Inserting a longer push rod will decrease the valve clearance. 5.
  • Page 48 SECTON 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS Exhaust Bypass Valve (TIO-360-A Series). Exhaust Bypass Valve (TIO-360-C1A6D).
  • Page 49 LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES...
  • Page 50 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-360 AND ASSOCIATED MODELS...
  • Page 51 LYCOMING OPERATOR’S MANUAL SECTION 5 O-360 AND ASSOCIATED MODELS MAINTENANCE PROCEDURES...
  • Page 52 LYCOMING OPERATOR’S MANUAL SECTION 6 TROUBLE-SHOOTING – ENGINE Page Failure of Engine to Start..........................6-1 Failure of Engine to Idle Properly......................6-2 Low Power and Uneven Running....................... 6-2 Failure of Engine to Develop Full Power....................6-3 Rough Engine ............................... 6-3 Low Oil Pressure............................
  • Page 53 LYCOMING OPERATOR’S MANUAL SECTION 6 O-360 AND ASSOCIATED MODELS TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING 1. TROUBLE-SHOOTING – ENGINE.
  • Page 54 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-360 AND ASSOCIATED MODELS...
  • Page 55 LYCOMING OPERATOR’S MANUAL SECTION 6 O-360 AND ASSOCIATED MODELS TROUBLE-SHOOTING...
  • Page 56 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-360 AND ASSOCIATED MODELS 2. TROUBLE-SHOOTING – TURBOCHARGER.
  • Page 57 LYCOMING OPERATOR’S MANUAL SECTION 6 O-360 AND ASSOCIATED MODELS TROUBLE-SHOOTING...
  • Page 58 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-360 AND ASSOCIATED MODELS NOTE Smoke would be normal if engine has idled for a prolonged period.
  • Page 59 LYCOMING OPERATOR’S MANUAL SECTION 7 O-360 AND ASSOCIATED MODELS INSTALLATION AND STORAGE...
  • Page 60 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-360 AND ASSOCIATED MODELS...

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