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IO-360-N1A Engine Installation and Operation Manual

Record of Revisions

February 2016

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RECORD OF REVISIONS

Revision

Date

Revised

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Original

Original Release of Installation and Operation Manual - Part No.
IOM-IO-360-N1A

Summary of Contents for IO-360-N1A

Page 2: ...t Us Mailing Address Lycoming Engines 652 Oliver Street Williamsport PA 17701 USA Phone Factory U S and Canada Toll Free Direct 1 800 258 3279 1 570 323 6181 Lycoming s regular business hours are Monday through Friday from 8 00AM through 5 00PM Eastern Time 5 GMT Visit us Online www Lycoming com ...

Page 3: ...nual 2016 Avco Corporation All Rights Reserved Record of Revisions February 2016 Page i RECORD OF REVISIONS Revision Revision Date Revised By Revision Description Original Original Release of Installation and Operation Manual Part No IOM IO 360 N1A ...

Page 5: ... Between Overhaul Periods S I 1014 02 16 Lubricating Oil Recommendations S I 1070 02 16 Specified Fuels S I 1098 02 16 Propeller Flange Bushing Location S I 1132 02 16 Magneto Drop off S I 1154 02 16 FAA Approved Starter and Alternators S I 1241 02 16 Pre oil the Engine Prior to Initial Start S I 1409 02 16 Lycoming Engines P N LW 16702 Oil Additive S I 1427 02 16 Lycoming Reciprocating Engine Run...

Page 7: ...em Description 1 Cylinders 1 Crankcase 2 Ignition System 2 Starter 3 Fuel Injection System 4 Lubrication System 4 Cylinder Number Designations 5 Engine Reception and Lift__________________________________________________________ Uncrate Procedure for a New Rebuilt or Overhauled Engine 7 Acceptance Check 7 Engine Preservative Oil Removal 8 Lift the Engine 8 Requirements for Engine Installation ____...

Page 8: ...7 Install the Propeller 18 Step 8 Connect Fuel Lines 19 Step 9 Connect Oil Lines 19 Step 10 Install Components That Had Been Removed Before Engine Installation 20 Step 11 Add Oil 20 Step 12 Add Fuel 21 Step 13 Engine Pre Oil Procedure 21 Engine Start and Operation ________________________________________________________ Warranty Requirement 23 Before Engine Start 23 Engine Run In Engine Break In 2...

Page 9: ...____________________________________________________________ Flight Test 37 Engine Preservation and Storage ____________________________________________________ Engine Corrosion and Prevention 39 Engine Preservation 30 to 60 Days 40 Fuel Injector Preservation 42 Engine Preservation 61 to 180 Days 42 Engine Preservation 181 Days or More 43 Cold Weather Storage 43 Long Term Storage of Engines that U...

Page 11: ...rankshaft 2 5 Ignition System 3 6 Starter 3 7 Fuel Injection System 4 8 Lubrication System 4 9 Cylinder Number Designation 5 Engine Reception and Lift Section 1 Engine Data Plate 7 2 Engine Lift 8 Engine Installation 1 Oil Fill Tube and Oil Level Gage Dipstick 20 Appendix C Performance Data C 1 Sea Level and Altitude Performance 51 C 2 Minimum Fuel Flow vs Nozzle Pressure 52 C 3 Fuel Consumption v...

Page 13: ...tallation 14 Engine Installation Section 1 Aircraft Where IO 360 N1A Engines Can Be Installed 17 2 Aircraft Where IO 360 N1A Engines Cannot be Installed 17 3 Engine Installation Steps and References 17 Engine Start and Operation Section 1 Prerequisite Requirements for Engine Operation 23 Engine Conditions Section 1 Action for Engine Conditions 31 Appendix A Engine Specifications and Operating Limi...

Page 15: ...lsius CHT Cylinder Head Temperature cm Centimeter E EGT Exhaust Gas Temperature EPA Environmental Protection Agency F F Fahrenheit FAA Federal Aviation Administration FAR Federal Aviation and Space Regulation FOD Foreign Object Debris Ft lb Foot Pound torque G G Force of Gravity H HET Hartzell Engine Technologies Hg Mercury HP Horsepower I ICA Instructions for Continued Airworthiness in lb Inch Po...

Page 16: ...meter MSB Mandatory Service Bulletin N Nm Newton Meter P P N Part Number POH Pilot s Operating Handbook ppm Particles per Million psi Pounds per Square Inch R rpm Revolutions per Minute S SAE Society of Automotive Engineers oil viscosity SB Service Bulletin SI Service Instruction STC Supplemental Type Certificate T TCM Teledyne Continental Motors TR Temporary Revision V V Volt Voltage ...

Page 17: ...he Service Table of Limits SSP 1776 for dimensions clearances measurements and torque values Service Bulletins Service Instructions and Service Letters As advancements in technological applications on this engine continue Lycoming will make future revisions to this manual However if more timely distribution is necessary Lycoming supplies subscribers with up to date Service Bulletins SBs Service In...

Page 18: ...ible guidance and recommended practices for safe operation of its engines The table below defines the four types of safety advisory messages used in this manual per the American National Standard and ANSI Z535 6 2006 Safety Advisory Conventions Advisory Word Definition DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury This signal word is to be limit...

Page 19: ...vice Supplemental Service Information Refer to the latest revision of Service Letter No L114 for a list of Lycoming publications available for purchase Feedback To supply comments suggestions or corrections to this manual either make a call to customer service or use the Lycoming com website Customer Service Lycoming has a Customer Service Hot Line to supply information and assistance to owners op...

Page 21: ...uned induction and a down exhaust NOTICE Refer to Appendix C for engine performance data Figure 1 IO 360 N1A Cylinders There are four cylinders on this engine Each cylinder Figure 2 contains a cylinder head barrel piston parallel intake and exhaust valve guides and valve seats rocker shafts rocker covers and fins Fuel and air enter the cylinder through the cylinder head for mixing and combustion w...

Page 22: ...erts The crankshaft main bearings are pairs of inserts installed in the crankcase at each journal The crankshaft Figure 4 is within the crankcase The crankshaft has journals to attach connecting rods and pistons Oil is supplied through the propeller flange for a single acting controllable pitch propeller Four oil nozzles supply oil for internal piston cooling Figure 3 Crankcase Figure 4 Crankshaft...

Page 23: ...n and Operation Manual 2016 Avco Corporation All Rights Reserved System Description February 2016 Page 3 Figure 5 Ignition System Starter The engine can have either a 12V or 24V starter Figure 6 Refer to Appendix A Figure 6 Starter ...

Page 24: ...p and fuel lines which connect the fuel injectors to the fuel manifold Refer to the fuel flow and consumption curves in Appendix C Figure 7 Fuel Injection System Lubrication System The lubrication system Figure 8 includes a wet sump oil pump oil fill dipstick oil suction screen full flow oil filter and oil lines Two filler extensions are available There are two drain plugs on the oil sump Another ...

Page 25: ... front of the engine and the accessories are at the rear of the engine When viewed from the top of the engine the left side cylinders are 2 4 Cylinder 2 is at the front of the engine Figure 9 When viewed from the top of the engine the cylinders on the right are 1 3 Cylinder 1 is at the front of the engine The firing order of the cylinders is 1 3 2 4 Figure 9 Cylinder Number Designation ...

Page 27: ...ter of the box cut the tape at the top of the box with a knife and open the box C Remove a few top slats of the crate and then remove the top pillow D Look for any fluid oil or fuel on the skid or below the engine If fluid is found identify the source E If the leaked fluid is preservative oil examine each engine cylinder per the Engine Preservation 61 to 180 Days section in the Engine Preservation...

Page 28: ...O PREVENT THE PRESERVATIVE OIL FROM SPLASHING ON OTHER ENGINE PARTS 1 Connect the hoist and chains to the lifting lug on the engine as shown in Figure 2 Figure 2 Engine Lift MAKE SURE THE AREA IS CLEAR WHEN LIFTING THE ENGINE DO NOT LIFT FROM THE FRONT REAR SIDES OR BOTTOM OF THE ENGINE DO NOT LET THE ENGINE HIT ANY OBJECTS TO PREVENT DAMAGE TO THE ENGINE OR ITS COMPONENTS 2 Lift the engine slowly...

Page 29: ...e section Prepare a Stored Engine for Installation in this chapter Prepare a New Rebuilt or Overhauled Engine for Installation NOTICE The engine is sent from the factory with preservative oil in the cylinders and in the crankcase A preservation date stamp usually on the engine box identifies the date this oil was added and preservation is good for 60 days afterward If an intake valve was open the ...

Page 30: ... are found speak to Lycoming Engine s Service Department 5 Drain preservative oil from the oil sump A Put a 15 quart 14 liter capacity container under the oil sump B Remove the safety wire from both oil sump drain plugs Discard the safety wire C Remove the oil sump drain plugs D Drain the remaining preservative oil from the oil sump into the container NOTICE If some preservative oil stays in the e...

Page 31: ...of expansion plug falls off 10 Remove the fuel inlet strainer and clean it with a hydrocarbon based solvent such as mineral spirits or equivalent 11 Examine the fuel supply lines fuel manifold and throttle body to make sure they are clean and dry NOTICE During the first 50 hours of engine operation of new rebuilt or overhauled engines it is recommended that this engine by operated with mineral oil...

Page 32: ...servative oil removal procedure as follows A If any of the dehydrator plugs which contain crystals of silica gel break and the crystals fall into the engine complete the following procedure per the IO 360 N1A Engine Maintenance Manual Disassemble the engine Clean the engine B Put a container under the engine to collect the cylinder preservative oil C Turn the crankshaft through three or four revol...

Page 33: ...If a constant speed propeller is to be used A Use a pointed punch tool to make a 1 8 in 3 18 mm to 3 16 in 4 76 mm hole in the center of the front crankshaft plug B Remove and discard the expansion plug from the crankshaft C Look for and remove any foreign object contamination sometimes a little piece of expansion plug falls off 14 Refer to Chapter 74 20 in the IO 360 N1A Engine Service Manual to ...

Page 34: ... through the cooler system will be approximately 7 5 gallons per minute 28 4 liters minute and heat rejection will not exceed 820 Btu per minute The oil cooler must withstand continuous pressure of 150 psi 1034 kPa and have a minimum proof pressure of 400 psi 2758 kPa A thermostatic bypass valve and pressure relief valve are optional The pressure relief valve limits the pressure drop between coole...

Page 35: ...nt to the Type 1 Dynafocal engine mounts There are four mounting bosses integral to the crankcase Refer to the respective Installation Drawing identified in Appendix B for the IO 360 N1A engine Maximum Allowable Load for the Mounting Attachment and Structure The Type 1 Dynafocal mounts can withstand a 10 G load per FAA FAR requirements Step 5 Prepare the Aircraft Engine Harness Lycoming Engines ca...

Page 36: ...IO 360 N1A Engine Installation and Operation Manual Requirements for Engine Installation 2016 Avco Corporation All Rights Reserved Page 16 February 2016 This page intentionally left blank ...

Page 37: ...e cannot be installed in aircraft in Table 2 Table 2 Aircraft Where IO 360 N1A Engines Cannot Be Installed Any FAR Part 25 aircraft Any FAR Part 29 rotorcraft NOTICE Installation drawings for this engine are available for purchase from Lycoming Engines Refer to Appendix B for ordering information To install the engine refer to the section reference in this chapter for each step in Table 3 Table 3 ...

Page 38: ...age and propeller if constant speed as necessary in accordance with the aircraft manufacturer s specifications and drawings Step 4 Install External Accessories as necessary 1 Remove the accessory drive cover plate and gasket 2 Install the accessory on the supplied pad in accordance with the aircraft manufacturer s instructions Refer to Table A 3 in Appendix A 3 If necessary install the propeller g...

Page 39: ...ams for fuel lines on this engine The fuel line configuration diagram is conceptual and for reference only Fuel line routing on you engine could have slightly different configurations Fuel lines must be examined every 100 hours per the IO 360 N1A Engine Service Manual B Make sure that the fuel lines are securely connected to dampen vibration during flight with the necessary cushioned clamps and ha...

Page 40: ...E APPENDIX A MUST BE ADDED TO THE ENGINE FOR CORRECT LUBRICATION ESSENTIAL TO ENGINE OPERATION NOTICE On new rebuilt or overhauled engines during the first 50 hours of engine operation it is recommended that this engine be operated with mineral oil until oil consumption has stabilized Afterwards complete an oil change drain the mineral oil and add new oil identified in Appendix A OIL MUST BE FLOWI...

Page 41: ...e initial start of a new rebuilt overhauled or stored engine or After oil cooler replacement draining or After any prolonged period of inactivity or Whenever the oil lines have been disconnected Disconnect the oil inlet connection at the oil pump and drain a sufficient amount of oil from the tank to be certain there are no obstructions or air in the inlet line to the oil pump To complete the pre o...

Page 42: ...ndication of obstructed or interrupted oil flow or air in the oil lines In this case stop the pre oiling identify and correct the cause 9 If oil pressure of at least 25 psi 172 kPa was sustained in the previous step repeat the pre oil start cycle to make sure oil pressure holds stable and that there is no sudden drop in oil pressure If oil pressure is not stable or drops suddenly stop pre oiling i...

Page 43: ...tart the Engine 3 Complete the Engine Run Up 4 Operate the Engine 5 Stop the Engine Engine Run In Engine Break In Engine run in is the initial operational check usually done on a new rebuilt or overhauled engine in a test cell at the factory or authorized repair facility where operating conditions can be closely monitored The purpose of this procedure is to ensure that the engine is operating corr...

Page 44: ...il in flight Measure the engine oil level before every flight to make sure there is sufficient oil in the engine If the oil level is too low look for any oil leaks Identify and correct the cause of any oil leak There must not be any oil leaks Refer to Appendix A in this manual Add the correct specified grade of oil as necessary Refer to the IO 360 N1A Engine Service Manual NOTICE During the first ...

Page 45: ...CAUSE A LEAK WHICH COULD LEAD TO CATASTROPHIC ENGINE FAILURE Examine fuel lines A Make sure that each fuel and lubrication line is intact not bent or damaged and does not have any kinks or dents B Make sure that the fuel and lubrication lines are securely connected C Make sure the clamps are tightly attached to support the fuel and lubrication line and to prevent movement from vibration or motion ...

Page 46: ...storage make sure the pre oil procedure was done Refer to section Step 13 Engine Pre Oil Procedure in the Engine Installation chapter in this manual 2 Complete specified steps for engine start recommended by the aircraft Pilot Operating Handbook POH aircraft manufacturer or Supplemental Type Certificate STC holder s instructions EXAMINE THE ENGINE FOR HYDRAULIC LOCK REFER TO THE IO 360 N1A ENGINE ...

Page 47: ...IF THE ENGINE IS OPERATED AT LOW OR NO OIL PRESSURE THE ENGINE CAN MALFUNCTION OR STOP 14 Look at the oil pressure gage for indicated pressure If there is no oil pressure indication within 10 seconds stop the engine Identify and correct the problems NOTICE Unstable oil pressure or oil pressure less than 25 psi 172 kPa could be an indication of obstructed or interrupted oil flow or air in the oil l...

Page 48: ...turn to BOTH Drop off must not exceed 175 rpm and must not exceed 50 rpm between magnetos D If the rpm drop exceeds 175 rpm slowly lean the mixture until the rpm peaks Then retard the throttle to the specified rpm for the magneto drop off check and repeat the check If the drop off does not exceed 175 rpm and the difference between the drop off values for both magnetos does not exceed 50 rpm and th...

Page 49: ...protection Refer to the section Volcanic Ash in the Engine Conditions chapter in this manual Operation in Flight 1 See the aircraft manufacturer s instructions for recommended power settings 2 Until oil consumption has stabilized after the first 50 hours of flight cruising is to be done at 65 to 75 power to ensure correct seating of the rings Fuel Mixture Leaning 1 For maximum service life the CHT...

Page 50: ...ach power setting C Leaning with Manual Mixture economy cruise 75 power or less without flowmeter or EGT gage 1 Slowly move the mixture control from FULL RICH to LEAN 2 Continue leaning until a slight loss of power occurs engine roughness could occur 3 Enrich until the engine operates smoothly and power is restored Step 5 Stop the Engine 1 With the aircraft on the ground set the propeller at minim...

Page 51: ...k to Maintenance Engine Indication not available Make a safe landing and speak to Maintenance Engines in an environment at temperatures less than 10 F 12 C for more than 2 hours Refer to the section Apply Heat to a Cold Engine in this chapter Operation in climates above 100 F Decrease climb angles to keep the engine cool Refer to the section Engine Operation in Hot Weather in this chapter Stalled ...

Page 52: ... water Examine the engine Moisture and unwanted materials can cause damage to all systems on the engine Refer to the IO 360 N1A Engine Maintenance Manual for corrective action Apply Heat to a Cold Engine If an engine is in cold weather longer than 2 hours at temperatures less than 10 F 12 C it can become cold soaked At these extremely low temperatures oil can become thicker battery capacity decrea...

Page 53: ...tes of the heat process apply heat to the top of the engine 8 Start the engine immediately after the hot air application Refer to the section Start the Engine in the Engine Start and Operation chapter of this manual Also refer to additional engine start information in the section Cold Weather Start in this chapter Cold Weather Start NOTICE The following is Lycoming Engine s recommended procedure f...

Page 54: ...stained sufficient airspeed to cool off the engine F Continue to closely monitor temperatures Volcanic Ash 1 Given the dynamic conditions of volcanic ash Lycoming s recommendation is NOT to operate the engine in areas where volcanic ash is present in the air or on the ground Refer to the latest revision of Service Instruction No SI 1530 for any new details 2 Ash on the ground and runways can cause...

Page 55: ... action for engine overspeed 3 Record all incidents of engine overspeed in the engine logbook along with the inspection and any specified corrective action taken per the IO 360 N1A Engine Maintenance Manual Low Oil Pressure During Flight Circumstances which cause loss of oil pressure are many and varied Therefore it is difficult to make a prediction of the extent of damage to the engine or its fut...

Page 56: ...o Chapter 12 10 in the IO 360 N1A Engine Service Manual 5 Examine the oil pump for malfunction Replace the oil pump if it is not operating correctly 6 If the oil pressure indication system is operating correctly and oil pressure loss oil starvation has occurred remove and disassemble the engine and do a complete inspection per the IO 360 N1A Engine Maintenance Manual NOTICE Any decision to operate...

Page 57: ...ure per the POH DURING BREAK IN MAKE SURE THE ENGINE IS ALWAYS OPERATED AT 65 OR MORE CRUISE POWER TO ENSURE CORRECT PISTON RING SEATING ENGINE OPERATION BELOW 65 CRUISE POWER AT ANY TIME CAN CAUSE POOR ENGINE PERFORMANCE G At cruise altitude decrease power to approximately 75 and continue flight for 2 hours For the second hour operate the engine at power settings alternating between 65 and 75 pow...

Page 58: ...e in Chapter 12 10 of the IO 360 N1A Engine Service Manual N Remove the oil suction screen and the oil pressure screen or oil filter to look for any blockage or contamination If blockage or contamination is found remove the blockage and contamination and change the oil O Clean the oil suction screen and if necessary replace the oil filter P Install the suction screen and oil pressure screen or new...

Page 59: ...to be in flight at least every 30 days for at least 1 continuous hour at oil temperatures between 180 F to 200 F 80 C to 93 C depending on location and storage conditions This continuous 1 hour of operation does not include taxi take off and landing time If the engine cannot be operated at the recommended oil temperatures speak with the aircraft manufacturer about the use of oil cooler winterizati...

Page 60: ...application of preservative oil to the walls of each engine cylinder The following items from industrial suppliers are necessary for the preservation procedure Preservative oil mixture with one part by volume MIL C 6529C Type I concentrated preservation compound added to three parts by volume of MIL L 6082C SAE J1966 Grade 1100 mineral aircraft engine oil conforming to MIL C 6529C Type II Refer to...

Page 61: ...er 74 20 in the IO 360 N1A Engine Service Manual 15 Put the spray gun in either of the spark plug holes Apply the preservative oil mixture to each cylinder one at a time 16 Use the spray gun to apply a coat of approximately 2 oz 60 ml of the preservative oil mixture through the spark plug hole on the interior wall of each cylinder DO NOT TURN THE CRANKSHAFT AFTER YOU SPRAY THE CYLINDERS WITH PRESE...

Page 62: ...mplete the following inspection although this inspection does not extend the corrosion warranty 1 After the first 60 days and every 60 days thereafter up to 180 days complete a borescope inspection of each engine cylinder one at a time as follows A Remove the top and bottom spark plugs from each cylinder one cylinder at a time Refer to Chapter 74 20 in the IO 360 N1A Engine Service Manual B Turn t...

Page 63: ... chapter F Add preservative oil as necessary per the procedure Engine Preservation 30 to 60 Days in this chapter G Replace the pink moisture indicator with a fresh blue moisture indicator 4 At the end of the 180 days if the moisture indicator is still blue and the engine must stay in storage as long as the plastic is not ripped or torn continue storage with 60 day interval checks for up to 1 year ...

Page 64: ...in the fuel tanks during storage to prevent possible formation of undesirable deposits 3 Operate the engine for a minimum of 45 minutes with the oil temperature at 180ºF 80ºC to work the aviation and automotive fuel mixture through the engine and fuel lines IF THE 45 MINUTE ENGINE OPERATION IS DONE ON THE GROUND DO NOT OPERATE THE ENGINE AT FULL STATIC FOR MORE THAN 10 SECONDS 4 Add more aviation ...

Page 65: ...Clockwise Counterweight Order This engine has no counterweights Compressor Bore 5 125 in 13 018 cm Compressor Stroke 4 375 in 11 1 cm Piston Displacement 361 in 3 5916 cm3 Compression Ratio 8 5 1 Weight lb 271 5 lb 123 2 kg Dimensions Height 20 26 in 51 46 cm Width 33 38 in 84 79 cm Length 32 75 in 83 19 cm Oil Sump Capacity 8 quarts 7 6 liters Minimum quantity of oil in flight 4 quarts 3 8 liters...

Page 66: ... Fuel minimum octane refer to the latest revision of Service Instruction No SI 1070 for any new approved fuels 91 96 or 100LL Aviation Grade Fuel Injector Precision RSA 5AD1 Fuel Pump Diaphragm Starter Drive Ratio to Crankshaft at Bendix and Rotation 16 556 1 Counterclockwise Starter Sky Tec or equivalent 12 Volt Geared Optional 24 Volt Geared Optional Alternator Drive Rotation Clockwise Alternato...

Page 67: ...Pressure Limits to Fuel Injector Inlet Parallel Boost 14 to 45 psi 97 to 310 kPa Series Boost 14 to 35 psi 97 to 241kPa Fuel Pressure at inlet to the Fuel Pump 2 to 35 psi 14 to 241 kPa Maximum Cylinder Head Temperature measured at thermocouple 500 F 260ºC Cylinder Head Temperature for maximum engine life Above 75 power 475 F 246ºC Cylinder Head Temperature for maximum engine life At 75 power and ...

Page 68: ...120 175 Dual Alternators Optional SAE Clockwise 3 80 1 60 120 175 Accessory Drive 1 AND20000 Counter clockwise 1 3 1 70 450 25 Accessory Drive 2 AND20000 Clockwise 1 3 1 100 800 40 Tachometer Optional SAE Counter clockwise 0 5 1 7 50 5 Propeller Governor AND20010 Clockwise 0 895 1 125 1200 40 Freon Compressor SAR Clockwise 1 462 1 Limited by belt Except for torque limitation and rotation Except fo...

Page 69: ... All Rights Reserved Appendix B February 2016 Page 49 APPENDIX B INSTALLATION AND WIRING DIAGRAMS NOTICE Installation drawing 04C63626 is available for purchase from Lycoming Engines for the IO 360 N1A engine Contact the Publications Clerk at Lycoming Engines at 570 327 7274 ...

Page 71: ...IO 360 N1A Engine Installation and Operation Manual 2016 Avco Corporation All Rights Reserved Appendix C February 2016 Page 51 APPENDIX C PERFORMANCE DATA Figure C 1 Sea Level and Altitude Performance ...

Page 73: ...IO 360 N1A Engine Installation and Operation Manual 2016 Avco Corporation All Rights Reserved Appendix C February 2016 Page 53 Figure C 3 Fuel Consumption vs Actual Brake Horsepower ...

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