Superior IO-360 SERIES Installation & Operation Manual Download

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O-360 & IO-360 SERIES ENGINES

INSTALLATION & OPERATION MANUAL

621 South Royal Lane, Suite 100 / Coppell, TX 75019 / 800-277-5168

www.superior-air-parts.com

P/N SVIOM01 Revision A, March, 2004

FAA Approved

Summary of Contents for IO-360 SERIES

Page 1: ...O 360 IO 360 SERIES ENGINES INSTALLATION OPERATION MANUAL 621 South Royal Lane Suite 100 Coppell TX 75019 800 277 5168 www superior air parts com P N SVIOM01 Revision A March 2004 FAA Approved ...

Page 2: ...XCHANGE BASIS AND EXCLUDE LIABILITY FOR INCIDENTAL SPECIAL CONSEQUENTIAL OR ANY OTHER DAMAGES INCLUDING WITHOUT LIMITATION ANY LIABILITY OF CUSTOMER TO A THIRD PARTY OR FOR ECONOMIC LOSS REPLACEMENT COST COST OF CAPITAL LOST REVENUE LOST PROFITS OR LOSS OF USE OF OR DAMAGE TO AN AIRCRAFT ENGINE COMPONENT OR OTHER PROPERTY AND IN NO EVENT WILL SUPERIOR S LIABILITY EXCEED THE ORIGINAL COST OF THE EN...

Page 3: ...ss Limitations Chapter 3 Aircraft Engine Integration Considerations 1 General 2 Induction System 3 Fuel System 4 Engine Cooling 5 Exhaust 6 Lubrication System 7 Propeller Attachment 8 Electrical System 9 Engine Controls 10 Engine Accessories 11 Engine Mounting 1 1 4 7 9 12 15 16 18 20 22 Chapter 4 Engine Installation 1 General Instructions 2 Preparing Engine For Service 3 Installation of Engine 4 ...

Page 4: ...tion 6 Low Power and Engine Runs Rough 7 Low Oil Pressure On Engine Gage 8 High Oil Temperature 9 Excessive Oil Consumption 1 2 2 3 3 3 4 4 4 Chapter 8 Servicing Requirements 1 General 2 Lubricants 3 Fuels 4 Consumables 1 1 2 2 Chapter 9 Engine Preservation And Storage 1 Temporary Storage 2 Indefinite Storage 3 Inspection Procedures 4 Returning An Engine To Service After Storage Appendix A O 360 M...

Page 5: ...01 Revision History Revision Letter Effectiv e Date Description Pages Revised A 03 29 04 Initial Release All WARNING It is the users responsibility to insure that this is the current revision of this manual Do not perform any operation installation maintenance or other procedure until confirming this manual is current ...

Page 6: ...8 1 6 IO 360 Engine Front View 1 9 1 7 IO 360 Engine Left Side View 1 10 1 8 IO 360 Engine Top View 1 11 1 9 IO 360 Engine Rear View 1 12 3 1 Oil System Schematic 3 14 3 2 Ignition Wiring Diagram 3 17 3 3 Alternator Mounting Pad 3 21 3 4 1 Dynafocal Mount Dimensions 3 23 3 5 2 Dynafocal Mount Dimensions 3 23 3 6 Conical Mount Dimensions 3 24 3 7 Limit and Ultimate Engine Forces 3 26 3 8 Engine Mou...

Page 7: ... Wing Warm Up 6 5 6 4 Ground Running Rotorcraft Warm Up 6 5 6 5 Fixed Wing Pre Takeoff Ground Check 6 6 6 6 Rotorcraft Pre Takeoff Ground Check 6 7 6 7 Fuel Mixture Leaning General Rules 6 8 6 8 Leaning with Exhaust Gas Temperature Gage 7 9 6 9 Leaning with Flowmeter 6 9 6 10 Leaning with Manual Mixture Control 6 9 6 11 Shut Down Procedure 6 9 7 1 Abnormal Operating Procedures 7 1 7 2 Engine Will ...

Page 8: ...pproval of Superior Upon approval of an installation design Superior will provide a letter that states in part that the installation design is acceptable and does not adversely effect the function of the engine with respect to engine longevity while the engine is operated in accordance with recommended procedures Superior requires certain technical data regarding the installation in order to deter...

Page 9: ... be downloaded at www superior air parts com All Vantage Series Engine manuals and service information may also be purchased by contacting Superior Air Parts 621 South Royal Lane Suite 100 Coppell Texas 75019 Accessory Information may be obtained at www championaerospace com www unisonindustries com www skytecair com www precisionairmotive com www aeroaccessories com or call 972 829 4600 ...

Page 10: ...g toward the front Cylinder numbering is from the front to the rear with odd numbered cylinders on the right side of the engine The direction of crankshaft rotation is clockwise as viewed from the rear of the engine looking forward unless otherwise specified Accessory drive rotation direction is defined as viewed from the rear of the engine looking forward 2 CONTINUED AIRWORTHINESS Vantage Engines...

Page 11: ...der 361 cubic inches Model Suffix Denotes detail engine configuration 1st Digit Crankshaft Propeller Type A Fixed Pitch Thin wall front main B Constant Speed Thin wall front main 2nd Digit Crankcase Engine Mount Type 1 1 Dynafocal Mount 2 2 Dynafocal Mount 3 Conical Mount 3rd Digit Accessory Package 4th Digit Power Rating Piston Compression Ratio Fuel System Ignition System Carbureted Fuel Injecte...

Page 12: ...tion System includes spark plugs 13 Fuel System 14 Starter Support Assembly 15 Oil Gage 16 Induction System 17 Accessories Note Complete engine does not include outer cylinder baffles propeller governor and airframe to engine control cables attaching hardware hose clamps vacuum pump exhaust system fittings or alternator B Specifications The manufacturer s physical specifications are listed in Tabl...

Page 13: ...3 4 32 8 See MSD IO 360 24 0 33 4 32 8 See MSD Table 1 3 Views of the Engine Engine View Figure Number Location O 360 Engine Front View Figure 1 2 p 5 O 360 Engine Left Side View Figure 1 3 p 6 O 360 Engine Top View Figure 1 4 p 7 O 360 Engine Rear View Figure 1 5 p 8 IO 360 Engine Front View Figure 1 6 p 9 IO 360 Engine Left Side View Figure 1 7 p 10 IO 360 Engine Top View Figure 1 8 p 11 IO 360 ...

Page 14: ...es March 2004 Superior Air Parts Inc Chapter 1 Engine Description 5 Figure 1 2 O 360 Engine Front View SPARK PLUG PRIMING SYSTEM SPARK PLUG CARBURETOR STARTER FUEL LINE THROTTLE LEVER CHT PROBE LOCATION TYPICAL EACH HEAD ALTERNATOR BELT NOT PROVIDED WITH ENGINE ...

Page 15: ...Inc Chapter 1 Engine Description 6 Figure 1 3 O 360 Engine Left Side View OIL FILTER HARNESS MAGNETO ACCESSORY HOUSING CYLINDER ASSEMBLY CRANKCASE ASSEMBLY STARTER SUPPORT ASSEMBLY PRIMING SYSTEM FUEL PUMP STARTER SPARK PLUG INDUCTION SYSTEM OIL SUMP ASSEMBLY FUEL LINE MIXTURE LEVER CARBURETOR ...

Page 16: ...ion Operation Manual O 360 and IO 360 Series Engines March 2004 Superior Air Parts Inc Chapter 1 Engine Description 7 Figure 1 4 O 360 Engine Top View OIL FILTER MAGNETO SPARK PLUG MAGNETO INTER CYLINDER BAFFLE ...

Page 17: ...ATE OIL TO COOLER OIL TEMP CONNECTION EYE BRACKET TACHOMETER CONNECTION VACUUM PUMP ACCESSORY PAD OIL PRESSURE GAGE CONNECTION OIL LEVEL TUBE GAGE GROUND OR P LEAD TERMINAL OIL SUPPLY TO COOLER OIL LINE TO PROPELLER COMMON PRIMER LINE SOURCE FUEL PUMP INLET OIL SUCTION SCREEN THROTTLE LEVER FUEL MIXTURE LEVER FUEL LINE VENT LINE CONNECTION DIAPHRAGM FUEL PUMP GROUND OR P LEAD TERMINAL OIL RETURN F...

Page 18: ...rch 2004 Superior Air Parts Inc Chapter 1 Engine Description 9 Figure 1 6 IO 360 Engine Front View SPARK PLUG FUEL INJECTOR STARTER FUEL INJECTION SERVO SPARK PLUG FUEL INJECTION MANIFOLD ALTERNATOR BELT NOT PROVIDED WITH ENGINE CHT PROBE LOCATION TYPICAL EACH HEAD ...

Page 19: ...Parts Inc Chapter 1 Engine Description 10 Figure 1 7 IO 360 Engine Left Side View FUEL INJECTION MANIFOLD FUEL INJECTION SERVO FUEL LINE FUEL PUMP MAGNETO WIRING HARNESS OIL FILTER ACCESSORY HOUSING CYLINDER ASSEMBLY CRANKCASE ASSEMBLY STARTER SUPPORT ASSEMBLY STARTER SPARK PLUG OIL SUMP ...

Page 20: ...Installation Operation Manual O 360 and IO 360 Series Engines March 2004 Superior Air Parts Inc Chapter 1 Engine Description 11 Figure 1 8 IO 360 Engine Top View FUEL INJECTION MANIFOLD FUEL INJECTIOR ...

Page 21: ...D PRESSURE CONNECTION GROUND OR P LEAD TERMINAL OIL SUPPLY TO COOLER OIL LINE TO PROPELLER FUEL PUMP INLET OIL DRAIN PLUG OIL SUCTION SCREEN THROTTLE CONTROL LEVER OIL DRAIN PLUG VENT LINE CONNECTION DIAPHRAGM FUEL PUMP GROUND OR P LEAD TERMINAL OIL FILTER OIL RETURN FROM COOLER FUEL INJECTION MANIFOLD BREATHER FITTING ALTERNATE OIL TO COOLER OIL TEMP CONNECTION EYE BRACKET MIXTURE CONTROL LEVER F...

Page 22: ...fications They are internally choked and honed to allow optimal operating conditions for the rings and pistons at operating temperatures Pistons The pistons are made from an aluminum alloy The piston pin is a full floating type with a plug located in each end of the pin The piston is a 3 ring type with 2 compression rings and 1 oil control ring Cooling System Superior Vantage Engines are designed ...

Page 23: ...ect to additional information contained in F A A Approved Mandatory Service Bulletins issued after the date of certification the O 360 and IO 360 engine series do not contain any components having mandatory inspection intervals 3 OTHER MANDATORY INTERVALS OR PROCEDURES Subject to additional information contained in F A A Approved Mandatory Service Bulletins issued after the date of certification t...

Page 24: ...nes such as the Superior Vantage Series be capable of supplying clean filtered cool intake air to the engine at the maximum required flowrate and with maximum attainable pressure The term maximum attainable pressure as used here refers to an air source that provides maximum intake air pressure including ram air effects while minimizing restrictions and flow losses A reduction in flowrate or total ...

Page 25: ...the maximum air velocity requirements of the filter In general filters are more effective for lower air velocities but practical considerations must be made based on space available Intake air flow requirements of a Superior Vantage Engine are defined in Figure 1 of the Model Specification Data It is recommended that the filter be sized to provide a minimum of 150 of this flow to minimize pressure...

Page 26: ...carbureted systems However provisions are required to provide an alternate induction air source for fuel injected systems to prevent engine stoppage in the event of filter blockage due to ice or debris As with the design of the carb heat mechanism this is conventionally done by drawing air from the heated lower cowl area and introducing this air downstream from the intake air filter Although it is...

Page 27: ...ns or engine detonation under certain conditions Note When running fuel lines for use with unleaded fuel do not use 90 fittings Instead use large radius bends to reduce the likelihood of vapor lock Also try to locate the fuel boost pump as close to the fuel tank as possible Periodically inspect non metallic fuel system components for degradation Aircraft boost pumps non engine driven may be used t...

Page 28: ... by Superior Proper functioning and mixture settings of the carburetor system must be made in flight and ground idle tests These tests should include all envisioned flight attitudes and conditions as well as ground idle temperature variations In addition to performance characteristics exhaust gas and cylinder head temperatures must be monitored during these tests as a means of verifying the correc...

Page 29: ...blends or reformulated gasoline are typically most available during the colder months for smog reduction Ethanol alcohol mixed with unleaded fuel can cause vapor lock carburetor ice reduction in range carburetor problems and damage to the fuel system The use of an alcohol and water tester is recommended Acceptable gasoline is specified per ASTM D 4814 European EN228 again without alcohol When runn...

Page 30: ...rovide a seal to the interior of the cowl thus creating a separation between the upper and lower cowl volumes This is typically done primarily with metal components for stiffness against the ram air pressure with flexible rubber seals to conform to the contours of the upper cowl and to allow for relative movement between the engine and cowl The lubricating oil for Superior Vantage Engines must be ...

Page 31: ...erence between the hot oil and the cooling air the reduced air density is generally a larger consideration and will result in an overall reduction in cooler efficiency at higher altitudes Therefore cooler sizing calculations should be made with the air density appropriate for the maximum intended altitudes of the installation D Accessory Cooling Typically engine cowl baffles effectively separate t...

Page 32: ... style is to connect 2 or 4 of the exhaust tubes together before exiting the aircraft Commonly referred to as 2 into 1 or 4 into 1 systems these designs feature a space efficient way to transport the exhaust gas safely overboard Although these systems are not designed to add substantial performance benefits to the engine they can rob power and efficiency if not properly designed The intersections ...

Page 33: ...e this problem Also abrupt increases or decreases in piping size such as in a collector can increase flow losses and should be avoided 3 Shrouds and Thermal Protection Exhaust gas temperatures can be as high as 1600 F Therefore it is sometimes necessary to shield thermally sensitive components Control cables hoses engine isolator components nose gear tires etc should be either located far enough f...

Page 34: ...ult in carbide precipitation and early fatigue failure Wall thickness should be large enough to provide structural integrity yet thin enough to maintain reduced weight Historically some exhaust systems have been made with thicker material to withstand material loss due to scaling and oxidation Proper material selection however has been shown to be a more effective solution allowing for lighter wei...

Page 35: ...sure of the oil exceeds the ambient pressure Severe aeration within the anticipated flight altitudes of a Superior Vantage normally aspirated engine but must be verified through flight testing B Lubricating System Components The lubricating system of Superior Vantage Engines is composed in general of an oil sump or reservoir an oil cooler circuit an internal pressurized circuit and for installatio...

Page 36: ...ve couplings whenever possible Flow and pressure losses in the oil system not only cause inefficiencies in the overall engine system but also add to the potential for aeration during high altitude flight C Crankcase Ventilation Pressure is generated within the crankcase during normal engine operation primarily as a result of piston ring blow by If the crankcase pressure were not controlled nose se...

Page 37: ... Tach Drive No 3 Main Bearing No 2 Main Bearing Right Crankcase Oil Galley Lifters Right Side Rocker Arm Bushings Oil Pump Oil Sump Suction Screen Vacuum Pump Vacuum Pump Drive Oil Pressure Relief Valve Drain To Sump Vernatherm Valve Oil Filter Splash Oil To Rocker Arms Valves Etc To Prop Governor Thrust Face From Oil Cooler Camshaft Journal No 2 Camshaft Journal No 3 Camshaft Journal No 1 Cyl 2 3...

Page 38: ...ts Inc Integration Considerations 7 PROPELLER ATTACHMENT The flange for attaching the propeller to the crankshaft is a modified SAE Type 2 Propeller Flange per AS127 with bolts The nut and bolt specifications torque specs and methodology size and use of safety wire etc are to be specified by the propeller manufacturer ...

Page 39: ... requires connection of the P lead or grounding lead to the left and right magnetos per the following procedure Attach the ignition P lead terminal to the condenser stud using the lock washer and nut on the magneto Torque the P lead terminal nut to 13 15 inch pounds Attach the P lead ground shield if applicable to the ground screw on the side of the magneto Torque the P lead ground shield screw to...

Page 40: ...l O 360 and IO 360 Series Engines 17 Chapter 3 Aircraft Engine March 2004 Superior Air Parts Inc Integration Considerations Figure 3 2 Ignition Wiring Diagram 1 3 2 4 Firing Order Clockwise Rotation 1 3 2 4 Ignition Wiring Diagram ...

Page 41: ...n the control itself should the lever hit its stop before the control hits it full forward potential 7 Superior recommends a vernier style mixture control for improved control during leaning 8 The control does not bind or have slack so as to cause delays in response during actuation 9 Control cables should be the minimum possible length avoiding loops or S turns 10 Control cables should be securel...

Page 42: ...he common primer line source at the rear of the engine Figure 1 5 illustrates the common primer line source for a typical Superior Vantage carbureted engine Note Manual primer pumps should include a positive lock feature to prevent the pump from inadvertently actuating during flight E Carburetor Heat Control A mechanical control to actuate the carburetor heat mechanism is required for carbureted S...

Page 43: ...x 0 7 tapped holes as shown in Figure 3 3 This mounting pad and the V belt drive pulley on the flywheel are designed to accept standard front pulley general aviation alternators The V belt and pulley are SAE Size 0 380 in accordance with SAE J636 Typically these alternators include a fan to cool the internal components of the alternator However depending upon the power output of the alternator and...

Page 44: ...tion Operation Manual O 360 and IO 360 Series Engines 21 Chapter 3 Aircraft Engine March 2004 Superior Air Parts Inc Integration Considerations Figure 3 3 Alternator Mounting Pad MOUNTING PAD CRANKCASE SIDEVIEW ...

Page 45: ...th minimum obstruction to cooling airflow weight the location and method of installing the oil cooler accessories and accessory cooling and obstruction of intake and exhaust systems Superior Vantage Engines are designed to accommodate modern isolation systems to minimize the vibration levels transmitted to the airframe Both conical and Dynafocal suspension systems are available as identified in th...

Page 46: ...eration Manual O 360 and IO 360 Series Engines 23 Chapter 3 Aircraft Engine March 2004 Superior Air Parts Inc Integration Considerations Figure 3 4 1 Dynafocal Mount Dimensions Figure 3 5 2 Dynafocal Mount Dimensions ...

Page 47: ...ongitudinal dimension This data together with the appropriate data for additional components such as propeller assembly oil cooler and other engine and engine mount supported items provide sufficient information to locate the center of gravity with respect to the airframe C Engine Mount Design Loads Superior Vantage Engines are certified to meet the requirements of FAR 23 Acrobatic Category load f...

Page 48: ...in terms of vertical forces as a function of the longitudinal center of gravity The term engine torque in Table 3 3 relates to the average output torque of the engine at maximum rated speed plus design factors as required by 14CFR Part 33 When performing the engine installation design for a Superior Vantage Engine it is required that the average output torque at maximum rated speed and power be be...

Page 49: ...irframe do not match these forcing functions during prolonged operation Although these loads will vary depending upon choices of mount style propeller and accessories Superior has measured the transmitted vibratory loads for a typical installation Figures 3 8 and 3 9 illustrate forcing functions produced by the engine on the engine on a typical engine mount design Data is presented for startup and...

Page 50: ...or Vantage O IO 360 0 5000 10000 15000 20000 25000 Frequency Hz Torsional Bending Horizontal Bending Vertical Engine Forcing Functions on Firewall Steady State Operation Superior Vantage O IO 360 0 5000 10000 15000 20000 25000 Frequency Hz Torsion Bending Horizontal Bending Vertical Figure 3 8 Engine Mount Forcing Function for Engine Startup and Shutdown Figure 3 9 Engine Mount Forcing Function fo...

Page 51: ...holes and turn the crankshaft through at least twice in order to remove the cylinder preservation oil from the cylinders Remove the shipping plugs installed in the upper spark plug holes and inspect the cylinder bores for rust or contamination Contact Superior if any abnormal condition is noted Engines that have been subjected to a cold environment for long periods of time should be placed into at...

Page 52: ...roved propeller in accordance with the manufacturer s instructions Outline Drawings for the installation design are located in the Model Specification Data These illustrations are provided by engine series and therefore include reference dimensions only Full size detailed installation drawings may be obtained from Superior Air Parts Engineering 4 INSTRUMENTATION CONNECTIONS Superior Vantage Engine...

Page 53: ...SSIBLE INJURY TO PERSONNEL MAKE SURE THOROUGH INSPECTION AND TROUBLESHOOTING PROCEDURES ARE ACCOMPLISHED THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL AND OR DAMAGE TO THE EQUIPMENT A Prior to Break In Start Up 1 Engine oil sump should be filled with 100 straight weight mineral oil Use MIL L 6082 grade 100 Refer to chapter seven for fluid requirements 2 Engine must be pre oiled and oil pressure ...

Page 54: ...nd weather conditions eg high density altitudes Full Rich operation may not be practical In this event substitute the requirement of Full Rich as discussed in this chapter with the richest practical setting 3 Lean fuel mixture and maintain shallow climb Use caution to not overheat the cylinders Should overheating occur reduce power and or enrichen mixture 4 Monitor RPM oil pressure oil temperature...

Page 55: ...ion prior to the first flight of the day A proper pre flight inspection is essential for flight safety B Perform Inspection Checks as follows 1 Be sure all switches are in the Off position 2 Be sure magneto ground wires are connected 3 Visually inspect the engine and propeller for any damage oil or fuel leaks security and proper servicing 4 Check oil level in sump add oil as necessary 5 See that f...

Page 56: ...ly run in by Superior Air Parts but requires further break in until oil consumption has stabilized After this period a change to approved ashless dispersant oil should be made Refer to the Special Procedures Chapter Five Break in Instructions Superior Vantage Engines are certified for 100LL Avgas per ASTM D910 91 98 lead optional Avgas per ASTM D910 and Motor Gasoline with a minimum antiknock inde...

Page 57: ...ME HIGH POWER IS APPLIED THIS CAN POSSIBLY CAUSE ENGINE FAILURE THIS WOULD MOST LIKELY OCCUR ON TAKEOFF IF THE AIRCRAFT IS INADVERTENTLY SERVICED WITH THE WRONG GRADE OF FUEL THE FUEL MUST BE COMPLETELY DRAINED AND THE TANK PROPERLY SERVICED PRIOR TO FURTHER ENGINE OPERATION Note For added safety when using 91 Octane motor fuel the use of a Reid Vapor Pressure RVP tester such as a Hodges Volatilit...

Page 58: ...5 Turn on Master Switch 5 Turn on Boost Pump 6 Turn on Boost Pump if installed 6 Open throttle to wide open Move mixture control to Full Rich until a slight but steady fuel flow is noted approximately 3 to 5 seconds Return mixture control to Idle Cut off 7 Open throttle approximately travel Prime with 1 to 3 strokes of manual priming pump or activate electric primer for 1 to 2 seconds 7 Set magnet...

Page 59: ... to exceed 1 000 RPM Verify oil pressure which can take up to 45 seconds to rise to the minimum of 20 psi If a full minute goes by without reaching a proper oil pressure setting the engine should be shut down and inspected D Ground Run and Warm Up The engines covered in this manual are air cooled and depend on the forward speed of the aircraft to cool properly It is recommended that the following ...

Page 60: ...DO NOT OPERATE THE ENGINE AT RUN UP SPEED UNLESS OIL TEMPERATURE IS 75 F MINIMUM AND OIL PRESSURE IS WITHIN SPECIFIED LIMITS OF 50 95 PSI CAUTION OPERATION OF THE ENGINE AT HIGH RPM BEFORE REACHING MINIMUM OIL TEMPERATURE MAY CAUSE LOSS OF OIL PRESSURE AND ENGINE DAMAGE 6 Perform all ground operations with cowling flaps if installed fully open and propeller control set for maximum RPM except for b...

Page 61: ... DROP AND SLIGHT ENGINE ROUGHNESS AS EACH MAGNETO IS SWITCHED OFF AN RPM DROP IN EXCESS OF 150 RPM MAY INDICATE A FAULTY MAGNETO OR FOULED SPARK PLUGS 4A Controllable pitch propeller Check for ignition problems with propeller in Low Pitch High RPM and set the throttle to approximately 1700 RPM A Move propeller governor control toward low RPM position and observe tachometer Engine speed should decr...

Page 62: ...o Check Raise collective pitch control to obtain 15 inches of manifold pressure and 2 000 RPM Switch from both magnetos to one and observe drop off switch back to both until the engine regains its speed and then switch to the other magneto and note drop off At no time should this drop off exceed 175 RPM Difference between the drop offs of the two magnetos should never exceed 50 RPM If a smooth dro...

Page 63: ...uld be observed by the operator of Superior Air Parts aircraft engines 3 Never exceed the maximum red line cylinder head temperature limit of 500 F 4 For maximum service life cylinder head temperatures should be maintained below 430 F during high performance cruise operation and below 400 F for economy cruise powers 5 Do not lean engines with automatically controlled fuel systems 6 On engines with...

Page 64: ... by airframe manufacturer Omit step one for Rotorcraft shut down Table 6 10 Leaning with Manual Mixture Control Economy cruise 80 power or less without flowmeter or EGT gage Carbureted Engines Fuel Injected Engines Slowly lean mixture control from Full Rich position Slowly lean mixture control from Full Rich position Lean until engine roughness is noted Continue leaning until slight loss of power ...

Page 65: ...peration 5 Cruise Flight During normal cruise flight leave the carburetor air heat control in the Cold position 7 If the presence of carburetor ice is noted apply full carburetor air heat and open the throttle to limiting manifold pressure and or RPM A slight additional drop in manifold pressure which is normal will be noted This will be restored as the ice is melted The carburetor heat control sh...

Page 66: ...REVENT INJURIES TO PERSONNEL AND OR DAMAGE TO THE EQUIPMENT WARNING FUEL IS TOXIC AND FLAMMABLE DO NOT BREATHE VAPORS USE IN A WELL VENTILATED AREA FREE FROM SPARKS FLAME OR HOT SURFACES PUT ON SPLASH GOGGLES SOLVENT RESISTANT GLOVES AND OTHER PROTECTIVE GEAR IN CASE OF EYE CONTACT FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION IN CASE OF SKIN CONTACT WASH WITH SOAP AND WATER WARNING H...

Page 67: ...battery Malfunction of magneto breaker Clean points Check internal timing of magnetos Lack of sufficient fuel flow Disconnect fuel line and check fuel flow Water in fuel injector or carburetor Drain fuel injector or carburetor and fuel lines Internal failure Check oil screens for metal particles If found complete overhaul of the engine may be required Table 7 3 Rough Idling Probable Cause Correcti...

Page 68: ...pair mount Mounting bushings worn Install new mounting bushings Unstable compression Check compression Table 7 6 Low Power Engine Runs Rough Probable Cause Correction Mixture too rich indicated by sluggish engine operation red exhaust flame at night Extreme cases indicated by black smoke from exhaust Readjustment of fuel injector or carburetor may be required by authorized personnel Mixture too le...

Page 69: ...or deformation or obstruction Insufficient oil supply Fill to proper level with specified oil Low grade of oil Replace with oil conforming to specifications Clogged oil lines or strainers Remove and clean oil strainers Excessive blow by Check condition of engine rings Replace if worn or damaged Failing or failed bearing Examine sump for metal particles If found engine overhaul may be required Defe...

Page 70: ...city is listed in Table 8 2 Table 8 1 Oil Grades All Models Average Ambient Air Recommended Grade Oil All Temperatures SAE 15W50 or 20W50 Cold 30 F SAE 30 or 10W30 Standard 30 90 F SAE 40 Hot 60 F SAE 50 Notes 1 For Break In Operation see Chapter 5 3 A straight mineral oil meeting MIL L 6082 should be used After Break In Ashless Dispersant Oils meeting MIL L 22851 or SAE J 1899 are to be used 2 Se...

Page 71: ...tane rating be used B 91 Octane Motor Fuel The Vantage series engine can operate and perform at a rated power with unleaded automotive fuel without alcohol of at least 91 Octane When operating with unleaded automotive fuel use only 91 minimum octane premium grade fuel 4 CONSUMABLES The Vantage Series Engines are equipped with spark plugs and a spin on oil filter Table 8 4 specifies these consumabl...

Page 72: ...emperature 3 On test cell Perform run up to warm engine to operating temperature Run at operating temperature for a minimum of 15 minutes WARNING TO PREVENT POSSIBILITY OF SERIOUS BODILY INJURY OR DEATH BEFORE MOVING THE PROPELLER DO THE FOLLOWING A DISCONNECT ALL SPARK PLUG LEADS B VERIFY MAGNETO SWITCHES ARE CONNECTED TO MAGNETOS AND THAT THEY ARE IN THE OFF POSITION AND THE P LEADS ARE GROUNDED...

Page 73: ... and remove the top spark plugs Protect the ignition lead ends with AN 4060 Protectors Install protective plugs in bottom spark plug holes Using a common garden sprayer or equivalent spay atomized preservative oil MIL P 46002 Grade I at room temperature through the upper spark plug hole of each cylinder with the piston at bottom dead center position Rotate crankshaft as opposite cylinders are spra...

Page 74: ... GROUNDED C THROTTLE POSITIONS CLOSED D MIXTURE CONTROL IDLE CUT OFF E SET BRAKES AND BLOCK AIRCRAFT WHEELS ENSURE THAT AIRCRAFT TIE DOWNS ARE INSTALLED AND VERIFY THAT THE CABIN DOOR LATCH IS OPEN F DO NOT STAND WITHIN THE ARC OF THE PROPELLER BLADES WHILE TURNING THE PROPELLER D Rotate propeller by hand several revolutions to remove preservative oil E Service and install spark plugs and ignition...

Page 75: ...O 360 SERIES ENGINE MODEL SPECIFICATION DATA APPENDIX A ...

Page 76: ... Full Throttle Curves Altitude Performance At Best Power Cruise Performance Map 80 Power Cruise Performance Map 70 Power Cruise Performance Map 60 Power Fuel Mixture Curve 75 Power Fuel Mixture Curve 65 Power Minimum Oil Quantity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Tables 1 2 3 4 5 6 7 8 9 10 11 12 Maximum Fuel Flow Requirements Fuel Filter Requirements Fuel Pump Inlet Pressure Limits Oil Heat Rej...

Page 77: ...el March 2004 Superior Air Parts Inc Specification Data Figure 1 Induction Air Flow Requirements Induction Air Flow Superior Vantage O IO 360 Series 6 8 10 12 14 16 18 20 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Engine Speed RPM Air Flow Lb m Min WOT 20 In Hg ...

Page 78: ...2004 Superior Air Parts Inc Specification Data Figure 2 Inter Cylinder Baffle Performance Inter Cylinder Baffle Performance Superior Vantage O IO 360 Series 0 500 1000 1500 2000 2500 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 Baffle Differential Pressure In H20 Cooling Air Flow Lb min ...

Page 79: ...Model Specification Data O 360 Series Engine 3 Appendix A O 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 3a Location of Engine Center of Gravity Horizontal ...

Page 80: ...Model Specification Data O 360 Series Engine 4 Appendix A O 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 3b Location of Engine Center of Gravity Vertical ...

Page 81: ...Model Specification Data O 360 Series Engine 5 Appendix A O 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 4 O 360 Installation Drawing Front View ...

Page 82: ...Model Specification Data O 360 Series Engine 6 Appendix A O 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 5 O 360 Installation Drawing Top View ...

Page 83: ...ion Drawing RADIAL CLEARANCE MUST BE MAINTAINED AS SHOWN AT FULL RICH POSITION OF LEVER 3 30 255 250 THROTTLE CLOSED 2 70 ALLOWABLE LINEAR TRAVEL 66 17 2 296 2 136 172 162 R 42 IDLE CUT OFF R1 75 43 30 76 30 FUEL PRESSURE CONNECTION 125 27NPSF FUEL INLET 250 18NPSF 1 50 2 72 2 38 THROTTLE OPEN 83 REF R1 69 FULL RICH DIA Fuel Metering System Carburetor ...

Page 84: ... Throttle Curves Superior Vantage O 360 Series Full Rich 20 21 22 23 24 25 26 27 28 29 30 Absolute Dry Manifold Pressure Inches of Mercury Prop Load Full Throttle 70 80 90 100 110 120 130 140 150 160 170 180 190 Brake Horsepower Prop Load Full Throttle 0 50 0 55 0 60 0 65 0 70 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Brake Specific Fuel Consumption Lb Hp Hr Prop Load Full Throttle RPM ...

Page 85: ...peration 2700 2300 2500 Altitude Performance Superior Vantage O IO 360 Series Best Power 0 5 10 15 20 25 Pressure Altitude Ft x 1000 Altitude Performance 28 26 24 22 20 2700 2200 0 F 50 F 50 F Std Alt Temp 2400 Example Flying at 25 1 MP 2400 RPM 2200 ft and at 75 F outside air temp the engine should produce 139 Hp on a standard day HPs However the inlet air is 25 F higher than standard day 75 F vs...

Page 86: ...erformance Superior Vantage O IO 360 Series 80 Power 144 Hp Rich of Peak Operation 24 25 26 27 28 29 30 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich No Operation with Motor Gasoline Above 430 F CHT No Operation with Motor Gasoline Above 500 F CHT ...

Page 87: ...10 Cruise Performance Map 70 Power Cruise Performance Superior Vantage O IO 360 Series 70 Power 126 Hp Rich of Peak Operation 21 22 23 24 25 26 27 28 29 30 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich 2100 2000 ...

Page 88: ...e 11 Cruise Performance Map 60 Power Cruise Performance Superior Vantage O IO 360 Series 60 Power 108 Hp Rich of Peak Operation 19 20 21 22 23 24 25 26 27 28 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich 2100 2000 ...

Page 89: ...0 0 49 3 51 3 53 3 55 3 57 3 59 3 61 3 63 3 65 3 67 3 69 3 71 3 73 3 75 3 77 3 79 3 81 3 Below Peak EGT F 75 50 25 0 49 3 51 3 53 3 55 3 57 3 59 3 61 3 63 3 65 3 67 3 69 3 71 3 73 3 75 3 77 3 79 3 81 3 Below Peak CHT F 80 90 100 110 120 130 140 49 3 51 3 53 3 55 3 57 3 59 3 61 3 63 3 65 3 67 3 69 3 71 3 73 3 75 3 77 3 79 3 81 3 Corrected Power Hp 0 40 0 45 0 50 0 55 0 60 0 65 0 70 49 51 53 55 57 5...

Page 90: ...50 200 150 100 50 0 46 9 48 9 50 9 52 9 54 9 56 9 58 9 60 9 62 9 64 9 66 9 68 9 70 9 72 9 74 9 Below Peak EGT F 75 50 25 0 46 0 48 0 50 0 52 0 54 0 56 0 58 0 60 0 62 0 64 0 66 0 68 0 70 0 72 0 74 0 76 0 Below Peak CHT F 80 90 100 110 120 46 0 48 0 50 0 52 0 54 0 56 0 58 0 60 0 62 0 64 0 66 0 68 0 70 0 72 0 74 0 76 0 Corrected Power Hp 0 40 0 45 0 50 0 55 0 60 0 65 0 70 46 48 50 52 54 56 58 60 62 6...

Page 91: ...arch 2004 Superior Air Parts Inc Specification Data Figure 14 Minimum Oil Quantity Minimum Oil Quantity Superior Vantage O IO 360 Series 0 0 5 1 1 5 2 2 5 3 3 5 30 20 10 0 10 20 30 Roll Angle Deg Oil Quantity U S Quarts Pitch Angles 30 30 20 0 10 10 Engine Left Engine Right ...

Page 92: ...Pounds Per Hour O 360 108 Table 3 Fuel Pump Inlet Pressure Limits Minimum PSIG Maximum PSIG O 360 0 5 8 Table 4 Oil Heat Rejection Airside Heat Rejection Crankcase Pressure Typical 1 450 BTU Minute Oil Heat Rejection Maximum 2 1000 BTU Minute Minimum 1800 Ft3 Min Sea Level 6 3 In H2O Baffle Press Drop Cylinder Cooling Airflow Recommended 2200 Ft3 Min Sea Level 6 5 In H2O Baffle Press Drop Crankcas...

Page 93: ...n MA 4 5 Aero Acc AF15472 SkyTec 149 12LS Unison M4001 Table 5 Oil Pressure Limits Operational Pressures Max Min Idling Normal Operating 95 55 20 Cold 115 Table 7 Engine Weight Location of Center of Gravity Center of Gravity Engine Weight Lb X In Y In Z In O 360 Axxx 288 lbs 44 2 74 7 10 O 360 Bxxx 291lbs 50 2 80 7 05 Table 8 Engine Moment of Inertia Moment of Inertia About the Center of Gravity E...

Page 94: ...ion Grade Fuel Minimum Octane Motor Fuel O 360 91 98 Lead Optional 91 Table 11 Operating Conditions Operation RPM MAP HP Fuel Cons Lbs Hr Max Oil Cons Qts Hr Max Cyl Head Temp Maximum Rated 2700 WOT 180 108 Best Pwr 75 500 F Performance Cruise 80 Rated 2500 26 144 72 Best Pwr 50 500 F Economy Cruise 60 Rated 2400 24 108 52 Peak EGT 40 500 F Table 12 Accessory Temperature Limits Magnetos 185 F Ambi...

Page 95: ...IO 360 SERIES ENGINE MODEL SPECIFICATION DATA APPENDIX B ...

Page 96: ... And Full Throttle Curves Altitude Performance At Best Power Cruise Performance Map 80 Power Cruise Performance Map 70 Power Cruise Performance Map 60 Power Fuel Mixture Curve 75 Power Fuel Mixture Curve 65 Power Minimum Oil Quantity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Tables 1 2 3 4 5 6 7 8 9 10 11 12 Maximum Fuel Flow Requirements Fuel Filter Requirements Fuel Pump Inlet Pressure Limits Oil Heat...

Page 97: ...del March 2004 Superior Air Parts Inc Specification Data Figure 1 Induction Air Flow Requirements Induction Air Flow Superior Vantage O IO 360 Series 6 8 10 12 14 16 18 20 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Engine Speed RPM Air Flow Lb m Min WOT 20 In Hg ...

Page 98: ... 2004 Superior Air Parts Inc Specification Data Figure 2 Inter Cylinder Baffle Performance Inter Cylinder Baffle Performance Superior Vantage O IO 360 Series 0 500 1000 1500 2000 2500 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 Baffle Differential Pressure In H20 Cooling Air Flow Lb min ...

Page 99: ...Model Specification Data IO 360 Series Engine 3 Appendix B IO 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 3a Location of Engine Center of Gravity Horizontal ...

Page 100: ...Model Specification Data IO 360 Series Engine 4 Appendix B IO 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 3b Location of Engine Center of Gravity Vertical ...

Page 101: ...Model Specification Data IO 360 Series Engine 5 Appendix B IO 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 4 IO 360 Installation Drawing Front View ...

Page 102: ...Model Specification Data IO 360 Series Engine 6 Appendix B IO 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 5 IO 360 Installation Drawing Top View ...

Page 103: ... 7 Appendix B IO 360 Model March 2004 Superior Air Parts Inc Specification Data Figure 6 Fuel Injection Installation Drawing 1935 DIA OPEN 1935 DIA 80 1 62 RAD 2 00 RAD MIXTURE CONTROL VALVE CLOSED 1 88 37 70 25 Fuel Metering System Fuel Injector ...

Page 104: ...l Throttle Curves Superior Vantage IO 360 Series Full Rich 20 21 22 23 24 25 26 27 28 29 30 Absolute Dry Manifold Pressure Inches of Mercury Prop Load Full Throttle 70 80 90 100 110 120 130 140 150 160 170 180 190 Brake Horsepower Prop Load Full Throttle 0 50 0 55 0 60 0 65 0 70 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Brake Specific Fuel Consumption Lb Hp Hr Prop Load Full Throttle RPM ...

Page 105: ...operation 2700 2300 2500 Altitude Performance Superior Vantage O IO 360 Series Best Power 0 5 10 15 20 25 Pressure Altitude Ft x 1000 Altitude Performance 28 26 24 22 20 2700 2200 0 F 50 F 50 F Std Alt Temp 2400 Example Flying at 25 1 MP 2400 RPM 2200 ft and at 75 F outside air temp the engine should produce 139 Hp on a standard day HPs However the inlet air is 25 F higher than standard day 75 F v...

Page 106: ...Performance Superior Vantage O IO 360 Series 80 Power 144 Hp Rich of Peak Operation 24 25 26 27 28 29 30 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich No Operation with Motor Gasoline Above 430 F CHT No Operation with Motor Gasoline Above 500 F CHT ...

Page 107: ... 10 Cruise Performance Map 70 Power Cruise Performance Superior Vantage O IO 360 Series 70 Power 126 Hp Rich of Peak Operation 21 22 23 24 25 26 27 28 29 30 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich 2100 2000 ...

Page 108: ...re 11 Cruise Performance Map 60 Power Cruise Performance Superior Vantage O IO 360 Series 60 Power 108 Hp Rich of Peak Operation 19 20 21 22 23 24 25 26 27 28 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 Fuel Flow Lb Hr Absolute Dry Manifold Pressure In Hg Peak EGT Best Power 2700 2300 2500 2400 2600 2200 Full Rich 2100 2000 ...

Page 109: ... Mixture Curve 75 Power Performance Cruise Fuel Mixture Curve Superior Vantage IO 360 Series 26 in Hg x 2400 RPM 200 150 100 50 0 Below Peak EGT F 75 50 25 0 Below Peak CHT F 80 90 100 110 120 130 140 Corrected Power Hp 0 40 0 45 0 50 0 55 0 60 0 65 0 70 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 BSFC Lb Hp hr Fuel Flow Lb Hr ...

Page 110: ...13 Fuel Mixture Curve 65 Power Economy Cruise Fuel Mixture Curve Superior Vantage IO 360 Series 24 in Hg x 2400 RPM 250 200 150 100 50 0 Below Peak EGT F 75 50 25 0 Below Peak CHT F 80 90 100 110 120 Corrected Power Hp 0 40 0 45 0 50 0 55 0 60 0 65 0 70 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 BSFC Lb Hp hr Fuel Flow Lb Hr ...

Page 111: ...March 2004 Superior Air Parts Inc Specification Data Figure 14 Minimum Oil Quantity Minimum Oil Quantity Superior Vantage O IO 360 Series 0 0 5 1 1 5 2 2 5 3 3 5 30 20 10 0 10 20 30 Roll Angle Deg Oil Quantity U S Quarts Pitch Angles 30 30 20 0 10 10 Engine Left Engine Right ...

Page 112: ...unds Per Hour IO 360 108 Table 2 Fuel Filter Requirements 100 Mesh Screen 0 005 Max Particle Size Table 3 Fuel Pump Inlet Pressure Limits Minimum PSIG Maximum PSIG IO 360 2 0 35 0 Table 4 Oil Heat Rejection Airside Heat Rejection Crankcase Pressure Typical 1 450 BTU Minute Oil Heat Rejection Maximum 2 1000 BTU Minute Minimum 1800 Ft3 Min Sea Level 6 3 In H2O Baffle Press Drop Cylinder Cooling Airf...

Page 113: ...ight Magneto Carburetor Fuel Pump Starter Spark Plug Harness IO 360 Unison 4371 Unison 4371 Precision RSA 5 Aero Acc AF15473 SkyTec 149 12LS Unison M4001 Table 7 Engine Weight Location of Center of Gravity Center of Gravity Engine Weight Lb X In Y In Z In IO 360 Axxx 290 lbs 39 2 69 7 10 IO 360 Bxxx 293lbs 44 2 75 7 05 Table 8 Engine Moment of Inertia Moment of Inertia About the Center of Gravity ...

Page 114: ...Take off 75 F Maximum Allowable 240 F Recommended Cruising 130 F 200 F Table 11 Operating Conditions Operation RPM MAP HP Fuel Cons Lbs Hr Max Oil Cons Qts Hr Max Cyl Head Temp Maximum Rated 2700 WOT 180 108 Best Pwr 75 500 F Performance Cruise 80 Rated 2500 26 144 72 Best Pwr 50 500 F Economy Cruise 60 Rated 2400 24 108 52 Peak EGT 40 500 F Table 12 Accessory Temperature Limits Magnetos 185 F Amb...

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