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LYCOMING OPERATOR’S MANUAL

SECTION 6

TROUBLE-SHOOTING

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.......................................................................................................................................... 6-3

High Oil Temperature ................................................................................................................................. 6-3

Excessive Oil Consumption......................................................................................................................... 6-4

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Summary of Contents for AIO-320

Page 1: ...complete manual current as of the date of issue The manual incorporates all previously issued revisions This manual will be kept current by revisions available from Lycoming distributors or from the factory All revisions will be accompanied by an Operator s Manual Revision page which will identify the revision level the date of the revision and the pages revised added or deleted All revisions will...

Page 2: ...Operator s Manual Lycoming IO 320 Series Approved by FAA 3rd Edition Part No 60297 31 652 Oliver Street January 2007 Williamsport PA 17701 U S A 570 323 6181 ...

Page 3: ...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 Factory 570 323 6181 Sales Department 570 327 7268 Fax 570 327 7101 Lycoming s regular business hours are Monday through Friday from 8 00 AM through 5 00 PM Eastern Time 5 GMT Visit us on the World Wide Web...

Page 4: ...ngine 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 Consult your local FAA approved maintenance facility SERVICE BULLETINS INSTRUCTIONS AND LETTERS Although the information contained in this manual is up to date at time of publication users are urged to keep abreast of later in...

Page 5: ...rious Warnings and Cautions which must be carefully read in order to minimize the risk of personal injury or the use of improper service methods that may damage the engine or render it unsafe It is also important to understand that these Warnings and Cautions are not all inclusive Lycoming could not possibly know evaluate or advise the service trade of all conceivable ways in which service might b...

Page 6: ...to Lycoming s Warranty Administration within 60 days of being found to require repair or replacement by the purchaser or service facility Warranty adjustment is contingent upon the Purchaser complying with the Lycoming s Warranty Administration disposition instructions for defective parts Failure to comply with all of the terms of this paragraph may at Lycoming s sole option void this warranty 3 T...

Page 7: ...S UNDER IT IS BINDING UPON LYCOMING UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED REPRESENTATIVE OF LYCOMING 6 All legal actions based upon claims or disputes pertaining to or involving this warranty including but not limited to Lycoming s denial of any claim or portion thereof under this warranty must be filed in the courts of general jurisdiction of Lycoming County Commonwealth of Pennsylvan...

Page 8: ...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 7 INSTALLATION AND STORAGE 7 1 SECTION 8 TABLES 8 1 v ...

Page 9: ...LYCOMING OPERATOR S MANUAL vi ...

Page 10: ...ylinders 1 1 Valve Operating Mechanism 1 1 Crankcase 1 1 Crankshaft 1 1 Connecting Rods 1 1 Pistons 1 2 Accessory Housing 1 2 Oil Sump 1 2 Cooling System 1 2 Induction System 1 2 Lubrication System 1 2 Priming System 1 3 Ignition System 1 3 Model Application Table 1 3 ...

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Page 12: ...h reverse rotation Cylinders The cylinders are of the conventional air cooled construction with the two major parts head and barrel screwed and shrunk together The heads are made from an aluminum alloy casting with a fully machined combustion chamber Rocker shaft bearing supports are cast integral with the head along with housings to form the rocker boxes for both valve rockers The cylinder barrel...

Page 13: ... takes place at the intake ports A brief description of the fuel injector follows The Bendix RSA type fuel injection system is based on the principle of measuring airflow and using the airflow signal in a stem type regulator to convert the air force into a fuel force This fuel force fuel pressure differential when applied across the fuel metering section jetting system makes fuel flow proportional...

Page 14: ...y housing In addition model IO 320 C1A incorporates oil jets in the crankcase The oil jets furnish an oil spray to provide internal cooling for the pistons Priming System Provision for a primer system is provided on all engines employing a carburetor Fuel injected engines do not require a priming system Ignition System Two magnetos furnish dual ignition Consult Table 1 for model application Bendix...

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Page 16: ...ge Explanatory Note 2 1 Specifications IO 320 A1A A2A E1A E1B E2A E2B 2 2 Specifications IO 320 B1A B1B B1C B1D B2A E1A D1B AIO 320 LIO 320 2 2 Specifications IO 320 C1A C1B 2 2 Specifications IO 320 B1E D1C 2 3 Accessory Drive Ratio 2 3 Detail Weights 2 3 ...

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Page 18: ...e divided according to model designation When differences among models can be clearly stated the specifications of more than one model are combined in a single group otherwise each model has its specifications listed separately Also as additional models are added to this series new specification pages containing data pertinent to the new models will be added 2 1 ...

Page 19: ...ted speed RPM 2700 Bore inches 5 125 Stroke inches 3 875 Displacement cubic inches 319 8 Compression ratio 8 5 1 Firing order 1 3 2 4 Spark occurs degrees BTC 25 Valve rocker clearance hydraulic tappets collapsed 028 080 Propeller drive ratio 1 1 Propeller drive rotation All but LIO 320 Series Clockwise LIO 320 Series Counterclockwise IO 320 C1A C1B FAA Type Certificate 1E12 Rated horsepower 160 R...

Page 20: ...clockwise Starter 16 556 1 Counterclockwise Generator 1 910 1 Clockwise Generator 2 500 1 Clockwise Alternator 3 250 1 Clockwise Tachometer 0 500 1 Clockwise Magneto 1 000 1 Clockwise Vacuum Pump 1 300 1 Counterclockwise Prop Gov AN20010 Mounted on Accy Hsg 0 866 1 Clockwise Mounted on Crankcase 0 895 1 Clockwise Fuel Pump AN20003 1 000 1 Counterclockwise Dual Drives When applicable Viewed facing ...

Page 21: ...AL SPECIFICATIONS IO 320 SERIES DETAIL WEIGHTS CONT IO 320 SERIES LBS A1A A2A 280 E1B 283 B1B E1A E2A E2B 285 B1A B2A B1C 287 B1D 288 D1A 291 D1B 293 C1A 301 D1C 306 B1E 307 C1B 313 AIO 320 SERIES LBS A1A A2A 306 A1B A2B B1B C1B 307 2 4 ...

Page 22: ... 1 Cold Weather Starting 3 2 Ground Running and Warm Up 3 2 Ground Check 3 3 Operation in Flight 3 4 Fuel Mixture Leaning Procedure 3 4 Leaning to Exhaust Gas Temperature Gage 3 4 Leaning to Flowmeter 3 5 Leaning with Manual Mixture Control 3 5 Engine Flight Chart 3 5 Operating Conditions 3 6 Engine Shut Down 3 7 Performance Curves 3 9 ...

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Page 24: ...ould 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 Cruising should be done at 65 to 75 power until a total of 50 hours has accumulated or oil consumption has stabilized This is to ensure proper seating of the rings and is applicable to new engines and engine...

Page 25: ...system must be cleared of vapor it is recommended that the same procedure be used as outlined for cold engine start 4 COLD WEATHER STARTING During extreme cold weather it may be necessary to preheat the engine and oil before starting 5 GROUND RUNNING AND WARM UP The engines covered in this manual are air pressure cooled and depend on the forward speed of the aircraft to maintain proper cooling Par...

Page 26: ...e runs smoothly because magneto drop off is affected by the variables listed above Make the magneto check in accordance with the following procedures 1 Controllable Pitch Propeller With propeller in minimum pitch angle set the engine to produce 50 65 power as indicated by the manifold pressure gage Mixture control should be in the full rich position At these settings the ignition system and spark ...

Page 27: ...es 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 Maintain mixture control in Full Rich position for rated ...

Page 28: ... or may not be accomplished by roughness 3 Enrich until engine runs smoothly and power is regained As shown in Figure 3 1 if engine speed and throttle setting are kept constant at normal cruise conditions the affect of leaning on engine power and engine temperatures will be as shown Power drops rapidly when the engine is leaned beyond peak exhaust gas temperature also best power is attained on the...

Page 29: ...OPERATING CONDITIONS Average Oil Inlet Temperature Ambient Air Desired Maximum Above 80 F 26 66 C 180 F 82 C 245 F 118 C Above 60 F 15 55 C 180 F 82 C 245 F 118 C 30 F to 90 F 1 11 C to 32 22 C 180 F 82 C 245 F 118 C 0 F to 70 F 17 77 C to 21 11 C 170 F 77 C 225 F 107 C Below 10 F 12 22 C 160 F 71 C 210 F 99 C Oil Pressure psi Maximum Minimum Idling Normal Operating 90 60 25 Start and Warm Up 100 ...

Page 30: ...ed 2350 97 8 8 33 500 F 260 C IO 320 B C D AIO 320 LIO 320 Series Normal Rated 2700 160 72 500 F 260 C Performance Cruise 75 Rated 2450 120 10 0 40 500 F 260 C Economy Cruise 65 Rated 2350 104 8 8 35 500 F 260 C the engine maintain cylinder head temperatures between 150 F and 435 F during continuous operation 9 ENGINE SHUT DOWN a Set propeller at minimum blade angle where applicable b Idle until t...

Page 31: ...NUAL OPERATING INSTRUCTIONS IO 320 SERIES Figure 3 1 Representative Effect of Leaning on Cylinder Head Temperature EGT Exhaust Gas Temperature Engine Power and Specific Fuel Consumption at Constant Engine RPM and Manifold Pressure 3 8 ...

Page 32: ...LYCOMING OPERATOR S MANUAL SECTION 3 IO 320 SERIES OPERATING INSTRUCTIONS IO 320 A E Series 3 9 ...

Page 33: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS IO 320 SERIES IO 320 A Series 3 10 ...

Page 34: ...LYCOMING OPERATOR S MANUAL SECTION 3 IO 320 SERIES OPERATING INSTRUCTIONS IO 320 E Series 3 11 ...

Page 35: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS IO 320 SERIES IO 320 B D Series AIO 320 LIO 320 B 3 12 ...

Page 36: ...LYCOMING OPERATOR S MANUAL SECTION 3 IO 320 SERIES OPERATING INSTRUCTIONS IO 320 B D AIO 320 LIO 320 3 13 ...

Page 37: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS IO 320 SERIES IO 320 C Series LIO 320 C 3 14 ...

Page 38: ...LYCOMING OPERATOR S MANUAL SECTION 3 IO 320 SERIES OPERATING INSTRUCTIONS IO 320 C Series LIO 320 C 3 15 ...

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Page 40: ...NUAL SECTION 4 PERIODIC INSPECTIONS Page General 4 1 Pre Starting Inspection 4 1 Daily Pre Flight 4 2 25 Hour Inspection 4 2 50 Hour Inspection 4 2 100 Hour Inspection 4 3 400 Hour Inspection 4 4 Non Scheduled Inspection 4 4 ...

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Page 42: ...e meant for the engine only Consult the airframe manufacturer s handbook for additional instructions Pre Starting Inspection The daily pre flight inspection is a check of the aircraft prior to the first flight of the day This inspection is to determine the general condition of the aircraft and engine The importance of proper pre flight inspection cannot be over emphasized Statistics prove several ...

Page 43: ...ly with the following inspection after every 25 hours of operating time a Lubrication System Engines Equipped with Oil Pressure Screen 1 Remove oil suction and oil pressure screens and check carefully for presence of metal particles that are indicative of internal engine damage Clean and reinstall the oil suction and oil pressure screens Drain and renew the lubricating oil NOTE Change the oil at l...

Page 44: ...y at connections for security of anchorage and for wear due to rubbing or vibration for dents and cracks d Exhaust System Check attaching flanges at exhaust ports on cylinder for evidence of leakage If they are loose they must be removed and machined flat before they are reassembled and tightened Examine exhaust manifolds for general condition e Cooling System Check cowling and baffles for damage ...

Page 45: ...to the items listed for daily pre flight 50 hour and 100 hour inspections the following maintenance check should be made after every 400 hours of operation Valve Inspection Remove rocker box covers and check for freedom of valve rockers when valves are closed Look for evidence of abnormal wear or broken parts in the area of the valve tips valve keeper springs and spring seats If any indications ar...

Page 46: ...neto 5 1 Slick Magneto 5 1 Fuel System Repair of Fuel Leaks 5 4 Fuel Injector Fuel Inlet Screen Assembly 5 4 Fuel Grade and Limitations 5 5 Air Intake Ducts and Filter 5 5 Idle Speed and Mixture Adjustment 5 5 Lubrication System Oil Grades and Limitations 5 5 Oil Suction and Oil Pressure Screens 5 6 Oil Pressure Relief Valve 5 6 Cylinders 5 6 Generator or Alternator Belt Tension 5 10 ...

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Page 48: ...the impulse coupling or retard breaker magneto whichever is applicable is installed on the left side of the engine 1 Remove a spark plug from No 1 cylinder and place a thumb over the spark plug hole Rotate the crankshaft in direction of normal rotation until the compression stroke is reached this is indicated by a positive pressure inside the cylinder tending to push the thumb off the spark plug h...

Page 49: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES IO 320 SERIES FIRING ORDER Figure 5 1 Ignition Wiring Diagram 5 2 ...

Page 50: ...LYCOMING OPERATOR S MANUAL SECTION 5 IO 320 SERIES MAINTENANCE PROCEDURES FIRING ORDER Figure 5 2 Ignition Wiring Diagram Optional 5 3 ...

Page 51: ...ine Rotate the magneto in its mounting flange to a point where the light comes on then slowly turn it in the opposite direction until the light goes out Bring the magneto back slowly until the light just comes on Repeat this with the second magneto NOTE Some timing lights operate in the reverse manner as described above the light comes on when the breaker points open Check your timing light instru...

Page 52: ...ove the cockpit mixture control lever with a smooth achometer for any change during the leaning process Caution must position before the RPM can drop to a point where the engine cuts out An increase of more than rich idle mixture An immediate decrease in RPM if not preceded by a momentary increase indicates the idle mixture is too lean If step 4 indicates that the idle adjustment is too rich or to...

Page 53: ...within the specified limits If the pressure under normal operating conditions should consistently exceed the maximum or minimum specified limits adjust the valve as follows With the engine warmed up and running approximately 2000 RPM observe the reading on the oil pressure gage If the pressure is above maximum or below minimum specified limits stop engine and screw the adjusting screw outward to d...

Page 54: ...ton pin plugs Insert piston pin puller through piston pin assemble puller nut then proceed to remove piston pin Do not allow connecting rod to rest on the cylinder bore of the crankcase Support the connecting rod with heavy rubber band discarded cylinder base oil ring seal or any other non marring method d Removal of Hydraulic Tappet Sockets and Plunger Assemblies It will be necessary to remove an...

Page 55: ...ting rod of the cylinder being assembled is at the top center position that corresponds with both valves closed 1 Place each plunger assembly in its respective tappet body and assemble the socket on top of plunger assembly 2 Assemble piston with rings so that the cylinder number stamped on the piston pin boss is toward the front of the engine The piston pin should be a hand push fit If difficulty ...

Page 56: ... barrel as directed in Figure 5 3 and tighten inch hold down nuts to 300 in lbs 25 ft lbs torque using the sequence shown in Figure 5 3 b Remove shims and using the same sequence tighten the inch cylinder base nuts to 600 in lbs 50 ft lbs torque NOTE Cylinder assemblies not using hold down plate are tightened in the same manner as above omitting the shims Figure 5 3 Location of Shims Between Cylin...

Page 57: ...r in its respective position by placing rocker between bosses and sliding valve rocker shaft in place to retain rocker Before installing exhaust valve rocker place rotator cap over end of exhaust valve stem 8 Be sure that the piston is at top center of compression stroke and that both valves are closed Check clearance between the valve stem tip and the valve rocker In order to check this clearance...

Page 58: ...OTING 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 6 3 High Oil Temperature 6 3 Excessive Oil Consumption 6 4 ...

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Page 60: ... Lack of fuel Check fuel system for leaks Fill fuel tank Clean dirty lines strainers or fuel valves cranking for a few seconds Turn ignition switch on and proceed to start in a normal manner Defective spark plugs Clean and adjust or replace spark plugs Defective ignition wire Check with electric tester and replace any defective wires Defective battery Replace with charged battery Improper operatio...

Page 61: ...ed by sluggish operation red exhaust flame at night Extreme cases indicated by black smoke from exhaust Readjustment of fuel injector by authorized personnel is indicated Mixture too lean indicated by overheating or backfiring Check fuel lines for dirt or other restrictions Readjustment of fuel injector by authorized personnel is indicated Leaks in induction system Tighten all connections Replace ...

Page 62: ...th tester Check ignition timing Rough Engine Cracked engine mount Replace or repair mount Defective mounting bushings Install new mounting bushings Uneven compression Check compression Low Oil Pressure Insufficient oil Fill to proper level with recommended oil Air lock or dirt in relief valve Remove and clean oil pressure relief valve Leak in suction line or pressure line Check gasket between acce...

Page 63: ...mine sump for metal particles If found overhaul of engine is indicated Defective temperature gage Replace gage Excessive Oil Consumption Low grade of oil Fill tank with oil conforming to specifications Failing or failed bearings Check sump for metal particles Worn piston rings Install new rings Incorrect installation of piston rings Install new rings Failure of rings to seat new nitrided cylinders...

Page 64: ...N AND STORAGE Page Preparation of Engine for Installation 7 1 General 7 1 Inspection of Engine Mounting 7 1 Attaching Engine to Mounts 7 1 Oil and Fuel Line Connections 7 1 Propeller Installation 7 1 Preparation of Fuel Injectors for Installation 7 2 ...

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Page 66: ...cating oil should be drained while the engine is hot This will remove any residual preservative oil that may have been present CAUTION DO NOT ROTATE THE CRANKSHAFT OF AN ENGINE CONTAINING PRESERVATIVE OIL BEFORE REMOVING THE SPARK PLGUS BECAUSE IF THE CYLINDERS CONTAIN ANY APPRECIABLE AMOUNT OF THE MIXTURE THE RESULTING ACTION KNOWN AS HYDRAULICING WILL CAUSE DAMAGE TO THE ENGINE ALSO ANY CONTACT ...

Page 67: ...ft until piston is at top center Oil will spill out of spark plug hole In order to preserve the top wall of the cylinder it will be necessary to either rock the engine or blow compressed air with very light pressure into the spark plug hole Following the engine firing order preserve the remainder of the cylinders in the same manner When all cylinders have been treated then spray the exhaust port a...

Page 68: ...ing to Specification MIL O 6081 Grade 1010 Before using de preserve in accordance with instructions Shipping Case ngine should be secured in a suitable engine shipping container The date of preservation and the following legend should be legibly marked on the side of the container On Date the engine was preserved for 60 days short term storage with preservative oil and cylinder and crankcase dehyd...

Page 69: ...SECTION 7 LYCOMING OPERATOR S MANUAL INSTALLATION AND STORAGE IO 320 SERIES Figure 7 1 Fuel Metering System 7 4 ...

Page 70: ...LYCOMING OPERATOR S MANUAL SECTION 7 IO 320 SERIES INSTALLATION AND STORAGE Figure 7 2 Fuel Injector 7 5 ...

Page 71: ...SECTION 7 LYCOMING OPERATOR S MANUAL INSTALLATION AND STORAGE IO 320 SERIES Figure 7 3 Magneto Connections 7 6 ...

Page 72: ...LYCOMING OPERATOR S MANUAL SECTION 7 IO 320 SERIES INSTALLATION AND STORAGE Figure 7 4 Optional Oil Cooler Connections 7 7 ...

Page 73: ...SECTION 7 LYCOMING OPERATOR S MANUAL INSTALLATION AND STORAGE IO 320 SERIES Figure 7 5 Installation Draw Typical IO 320 B Series 7 8 ...

Page 74: ...LYCOMING OPERATOR S MANUAL SECTION 7 IO 320 SERIES INSTALLATION AND STORAGE 7 9 ...

Page 75: ...SECTION 7 LYCOMING OPERATOR S MANUAL INSTALLATION AND STORAGE IO 320 SERIES 7 10 ...

Page 76: ... TABLES Page Table of Limits 8 1 Ground Run After Top Overhaul 8 2 Flight Test After Top Overhaul 8 3 Full Throttle HP at Altitude 8 4 Table of Speed Equivalents 8 4 Centigrade Fahrenheit Conversion Table 8 5 Inch Fraction Conversions 8 6 ...

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Page 78: ... AND INFORMATION CONCERNING TOLERLANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN LYCOMING AIRCRAFT ENGINES CONSULT LATEST REVISION OF SPECIAL SERVICE PUBLICATION NO SSP 1776 CONSULT LATEST REVISION OF SERVICE INSTRUCTION NO 1029 AND NO 1150 FOR INFORMATION PRETINENT TO CORRECTLY INSTALLING CYLINDER ASSEMBLY 8 1 ...

Page 79: ...SECTION 8 LYCOMING OPERATOR S MANUAL TABLES IO 320 SERIES 8 2 ...

Page 80: ...LYCOMING OPERATOR S MANUAL SECTION 8 IO 320 SERIES TABLES 8 3 ...

Page 81: ...58 7 22 000 44 0 4 000 87 5 16 000 56 5 22 500 43 3 5 000 84 6 17 000 54 3 23 000 42 2 6 000 81 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 9 000 73 5 19 000 50 0 25 000 38 5 TABLE OF SPEED EQUIVALENTS Sec Mi M P H Sec Mi M P H Sec Mi M P H 72 0 50 24 0 150 14 4 250 60 0 60 22 5 160 13 8 260 51 4 70 21 2 170 13 3 270 45 0 80 20 0 180 12 8 280 40 ...

Page 82: ... 0 137 78 280 536 0 17 8 0 32 0 143 33 290 554 0 12 22 10 50 0 148 89 300 572 0 6 67 20 68 0 154 44 310 590 0 1 11 30 86 0 160 00 320 608 0 4 44 40 104 0 165 56 330 626 0 10 00 50 122 0 171 11 340 644 0 15 56 60 140 0 176 67 350 662 0 21 11 70 158 0 182 22 360 680 0 26 67 80 176 0 187 78 370 698 0 32 22 90 194 0 193 33 380 716 0 37 78 100 212 0 198 89 390 734 0 43 33 110 230 0 204 44 400 752 0 48 ...

Page 83: ...69 21 32 6562 3382 16 669 11 64 1719 0232 4 366 43 64 6719 3545 17 065 3 16 1875 0276 4 762 11 16 6875 3712 17 462 7 32 2187 0376 5 556 23 32 7187 4057 18 256 15 64 2344 0431 5 593 47 64 7344 4235 18 653 1 4 25 0491 6 350 3 4 75 4418 19 050 9 32 2812 0621 7 144 25 32 7812 4794 19 844 19 64 2969 0692 7 540 51 64 7969 4987 20 241 5 16 3125 0767 7 937 13 16 8125 5185 20 637 11 32 3437 0928 8 731 27 3...

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