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NOTE
In order to accommodate clearer type, larger charts and graphs, and more
detailed illustrations, this edition of the IO-320 Series Operator's Manual,
Lycoming Part Number 60297-31 is presented in an 8-1/2 x 11 inch
format. This edition is a 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 be supplied in the 8-1/2 x 11 inch format.
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Summary of Contents for Lycoming IO-320-A1A
- Page 1 In order to accommodate clearer type, larger charts and graphs, and more detailed illustrations, this edition of the IO-320 Series Operator’s Manual, Lycoming Part Number 60297-31 is presented in an 8-1/2 x 11 inch format. This edition is a complete manual, current as of the date of issue.
- Page 2 Operator’s Manual Lycoming Approved by FAA 3rd Edition Part No. 60297-31 January 2007 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
- Page 3 IO-320 Series Operator’s Manual Lycoming Part Number: 60297-31 ©2006 by Lycoming. All rights reserved. Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of Lycoming. All brand and product names referenced in this publication are trademarks or registered trademarks of their respective companies.
- Page 4 LYCOMING OPERATOR’S MANUAL ATTENTION OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL SAFETY WARNING Neglecting to follow the operating instructions and to carry out periodic maintenance procedures can result in poor engine performance and power loss. Also, if power and speed limitations specified in this manual are exceeded, for any reason, damage to the engine and personal injury can happen.
- Page 5 LYCOMING OPERATOR’S MANUAL IMPORTANT SAFETY NOTICE...
- Page 6 Warranty will be warranted for the balance of the original warranty period or for the spare part warranty, whichever is the greater. Replacement of parts may be with either new or reconditioned parts, at Lycoming’s election. A claim for warranty on any part claimed to be defective must be reported in writing to Lycoming’s Warranty Administration within 60 days of being found to require repair or replacement by the purchaser or service facility.
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Page 7: General
Lycoming parts or parts approved by Lycoming for direct acquisition from sources other than Lycoming itself are not warranted by Lycoming, and this warranty shall be void to the extent that such repairs and alterations, in Lycoming’s sole judgment, affect the durability, safety or reliability of the engine or any part thereof, or damage genuine Lycoming or Lycoming-approved parts. - Page 8 LYCOMING OPERATOR’S MANUAL TABLE OF CONTENTS...
- Page 9 LYCOMING OPERATOR’S MANUAL...
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Page 10: Table Of Contents
LYCOMING OPERATOR’S MANUAL SECTION 1 DESCRIPTION Page General................................1-1 Cylinders............................... 1-1 Valve Operating Mechanism ........................1-1 Crankcase ..............................1-1 Crankshaft ..............................1-1 Connecting Rods ............................1-1 Pistons ................................1-2 Accessory Housing ............................1-2 Oil Sump ............................... 1-2 Cooling System ............................. 1-2 Induction System............................ - Page 11 This Page Intentionally Left Blank.
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Page 12: Cylinders
LYCOMING OPERATOR’S MANUAL SECTION 1 IO-320 SERIES DESCRIPTION SECTION 1 DESCRIPTION NOTE The letter “L” in the model prefix denotes the reverse rotation of the basic model. Example: model IO-320-C has clockwise rotation of the crankshaft. Therefore, LIO-320-C has counterclockwise rotation of the crankshaft. Likewise, the rotation of the accessory drives of... -
Page 13: Pistons
SECTION 1 LYCOMING OPERATOR’S MANUAL DESCRIPTION IO-320 SERIES Pistons – Accessory Housing – Oil Sump (Except AIO Series) – Crankcase Covers (AIO Series) – Cooling System – Induction System – Lubrication System –... -
Page 14: Priming System
LYCOMING OPERATOR’S MANUAL SECTION 1 IO-320 SERIES DESCRIPTION Priming System – Ignition System – TABLE 1 MODEL APPLICATION... - Page 15 This Page Intentionally Left Blank.
- Page 16 SECTION 2 SPECIFICATIONS Page 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..........................
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- Page 18 LYCOMING OPERATOR’S MANUAL SECTION 2 IO-320 SERIES SPECIFICATIONS SECTION 2 SPECIFICATIONS...
- Page 19 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS IO-320 SERIES SPECIFICATIONS...
- Page 20 LYCOMING OPERATOR’S MANUAL SECTION 2 IO-320 SERIES SPECIFICATIONS SPECIFICATIONS (CONT.) DETAIL WEIGHTS 1. Engine, Standard, Dry Weight.
- Page 21 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS IO-320 SERIES DETAIL WEIGHTS (CONT.)
- Page 22 LYCOMING OPERATOR’S MANUAL SECTION 3 OPERATING INSTRUCTIONS Page General................................3-1 Prestarting Items of Maintenance ......................3-1 Starting Procedures ............................. 3-1 Cold Weather Starting ..........................3-2 Ground Running and Warm-Up ........................ 3-2 Ground Check .............................. 3-3 Operation in Flight ............................3-4 Fuel Mixture Leaning Procedure ......................
- Page 23 This Page Intentionally Left Blank.
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Page 24: General
LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS SECTION 3 OPERATING INSTRUCTIONS 1. GENERAL. NOTE YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THE FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED FUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS. PERHAPS NO OTHER ITEM... -
Page 25: Cold Weather Starting
SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES a. Fuel Injected Engines (Cold). b. Fuel Injected Engines (Hot). 4. COLD WEATHER STARTING. 5. GROUND RUNNING AND WARM-UP. NOTE Any ground check that requires full throttle operation must be limited to three minutes, or less if the indicated cylinder head temperature should exceed the maximum stated in this manual. -
Page 26: Ground Check
LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS 6. GROUND CHECK. Controllable Pitch Propeller – NOTE Aircraft that are equipped with fixed pitch propeller, or not equipped with manifold pressure gage, may check magneto drop-off with engine operating at a maximum of 2000-2100 RPM. -
Page 27: Operation In Flight
SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES 7. OPERATION IN FLIGHT. Fuel Mixture Leaning Procedure. 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... -
Page 28: Leaning To Flowmeter
LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS (1) Maximum Power Cruise (approximately 75% power) – Never lean beyond 150°F on rich side of peak EGT unless aircraft operator’s manual shows otherwise. Monitor cylinder head temperatures. (2) Best Economy Cruise (approximately 75% power and below) – Operate at peak EGT, or if desired, drop 50°F on rich side of peak EGT. -
Page 29: Operating Conditions
SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES OPERATING CONDITIONS... -
Page 30: Engine Shut Down
LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING CONDITIONS OPERATING CONDITIONS (CONT.) IO-320-A, -E Series IO-320-B, -C, -D; AIO-320; LIO-320 Series 9. ENGINE SHUT-DOWN. - Page 31 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES...
- Page 32 LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS...
- Page 33 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES...
- Page 34 LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS...
- Page 35 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES...
- Page 36 LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS...
- Page 37 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS IO-320 SERIES...
- Page 38 LYCOMING OPERATOR’S MANUAL SECTION 3 IO-320 SERIES OPERATING INSTRUCTIONS...
- Page 39 This Page Intentionally Left Blank.
- Page 40 LYCOMING OPERATOR’S MANUAL 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...
- Page 41 This Page Intentionally Left Blank.
- Page 42 LYCOMING OPERATOR’S MANUAL SECTION 4 IO-320 SERIES PERIODIC INSPECTIONS SECTION 4 PERIODIC INSPECTIONS NOTE Perhaps no other factor is quite so important to safety and durability of the aircraft and its components as faithful and diligent attention to regular checks for minor troubles and prompt repair when they are found.
- Page 43 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS IO-320 SERIES 1. DAILY PRE-FLIGHT. 2. 25-HOUR INSPECTION. a. Lubrication System (Engines Equipped with Oil Pressure Screen)- NOTE Change the oil at least every four (4) months even if the engine has not accumulated 25 hours since the last oil change.
- Page 44 LYCOMING OPERATOR’S MANUAL SECTION 4 IO-320 SERIES PERIODIC INSPECTIONS b. Fuel and Induction System – c. Lubrication System (Engines Equipped with an External Full Flow Oil Filter) – NOTE Change the oil at least every four (4) months event if the engine has not accumulated 50 hours since the last oil change.
- Page 45 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS IO-320 SERIES b. Magnetos – c. Engine Accessories – d. Cylinders – e. Engine Mounts – f. Fuel Injector Nozzles and Fuel Lines – 5. 400-HOUR INSPECTION – Valve Inspection – 6 NON-SCHEDULED INSPECTIONS.
- Page 46 LYCOMING OPERATOR’S MANUAL SECTION 5 MAINTENANCE PROCEDURES Page General................................5-1 Ignition and Electrical System Ignition Harness and Wire Replacement....................5-1 Timing Magneto to Engine Bendix Magneto ............................. 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........................
- Page 47 This Page Intentionally Left Blank.
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Page 48: Ignition And Electrical System
LYCOMING OPERATOR’S MANUAL SECTION 5 IO-320 SERIES MAINTENANCE PROCEDURES SECTION 5 MAINTENANCE PROCEDURES 1. IGNITION AND ELECTRICAL SYSTEM. a. Ignition Harness and Wire Replacement – b. Timing Magnetos to Engine – NOTE Either the impulse coupling or retard breaker magneto (whichever is applicable) is installed on the left side of the engine. - Page 49 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES IO-320 SERIES...
- Page 50 LYCOMING OPERATOR’S MANUAL SECTION 5 IO-320 SERIES MAINTENANCE PROCEDURES...
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Page 51: Fuel System
SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES IO-320 SERIES Impulse Coupling Magneto – Conventional Magneto – NOTE In order to turn the shaft on an impulse coupling magneto, depress the pawl on the impulse coupling with the finger. NOTE Some timing lights operate in the reverse manner as described above, the light comes on when the breaker points open. -
Page 52: Fuel Grade And Limitations
Fuel Grades and Limitations – NOTE It is recommended that personnel be familiar with latest revision of Service Instruction No. 1070 regarding specified fuel for Lycoming engines. d. Air Intake Ducts and Filter – e. Idle Speed and Mixture Adjustment –... -
Page 53: Oil Suction And Oil Pressure Screens
SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES IO-320 SERIES b. Oil Suction and Oil Pressure Screens – NOTE On installations employing full flow oil filters, this step is not practical at this time, but should be observed at the 50-hour inspection, not to exceed four (4) months between oil changes. - Page 54 LYCOMING OPERATOR’S MANUAL SECTION 5 IO-320 SERIES MAINTENANCE PROCEDURES NOTE The hydraulic tappets, push rods, rocker arms and valves must be assembled in the same location from which they were removed. b. Removal of Valves and Valve Springs from Cylinder –...
- Page 55 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES IO-320 SERIES e. Assembly of Hydraulic Tappet Plunger Assemblies – f. Assembly of Valves in Cylinder – NOTE When installing valve springs, place the dampened end of spring (close wound coils marked with dye or lacquer) toward the cylinder.
- Page 56 LYCOMING OPERATOR’S MANUAL SECTION 5 IO-320 SERIES MAINTENANCE PROCEDURES NOTE At any time a cylinder is replaced, it is necessary to retorque the thru-studs on the cylinder on the opposite side of the engine. (a) Engines Using Hold-Down Plates –...
- Page 57 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDRUES IO-320 SERIES CAUTION AFTER ALL CYLINDER BASE NUTS HAVE BEEN TIGHTENED, REMOVE ANY NICKS IN THE CYLINDER FINS BY FILING OR BURRING. NOTE Inserting a longer push rod will decrease the valve clearance.
- Page 58 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 ..........................
- Page 59 This Page Intentionally Left Blank.
- Page 60 LYCOMING OPERATOR’S MANUAL SECTION 6 IO-320 SERIES TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING 1. TROUBLE-SHOOTING – ENGINE.
- Page 61 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING IO-320 SERIES...
- Page 62 LYCOMING OPERATOR’S MANUAL SECTION 6 IO-320 SERIES TROUBLE-SHOOTING...
- Page 63 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING IO-320 SERIES...
- Page 64 LYCOMING OPERATOR’S MANUAL SECTION 7 INSTALLATION 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...
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- Page 66 LYCOMING OPERATOR’S MANUAL SECTION 7 IO-320 SERIES INSTALLATION AND STORAGE SECTION 7 INSTALLATION AND STORAGE 1. PREPARATION OF ENGINE FOR INSTALLATION. 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.
- Page 67 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE IO-320 SERIES 2. PREPARATION OF FUEL INJECTORS FOR STORAGE. 3. PREPARATION OF ENGINE FOR STORAGE OR SHIPMENT. General Preservation Run Fuel Duration of Run Compound Injection Installation of Seals and Plugs...
- Page 68 LYCOMING OPERATOR’S MANUAL SECTION 7 IO-320 SERIES INSTALLATION AND STORAGE Exterior Surfaces Fuel Injector CAUTION DO NOT EXCEED THE RECOMMENDED AIR PRESSURE AS INTERNAL DAMAGE TO THE INJECTOR MAY RESULT. Shipping Case “On (Date) the engine was preserved for 60 days short term storage with preservative...
- Page 69 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE IO-320 SERIES...
- Page 70 LYCOMING OPERATOR’S MANUAL SECTION 7 IO-320 SERIES INSTALLATION AND STORAGE...
- Page 71 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE IO-320 SERIES...
- Page 72 LYCOMING OPERATOR’S MANUAL SECTION 7 IO-320 SERIES INSTALLATION AND STORAGE...
- Page 73 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE IO-320 SERIES...
- Page 74 LYCOMING OPERATOR’S MANUAL SECTION 7 IO-320 SERIES INSTALLATION AND STORAGE...
- Page 75 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE IO-320 SERIES...
- Page 76 LYCOMING OPERATOR’S MANUAL SECTION 8 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...
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- Page 78 LYCOMING OPERATOR’S MANUAL SECTION 8 IO-320 SERIES TABLES SECTION 8 TABLES...
- Page 79 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES IO-320 SERIES...
- Page 80 LYCOMING OPERATOR’S MANUAL SECTION 8 IO-320 SERIES TABLES...
- Page 81 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES IO-320 SERIES FULL THROTTLE HP AT ALTITUDE (Normally Aspirated Engines) TABLE OF SPEED EQUIVALENTS...
- Page 82 LYCOMING OPERATOR’S MANUAL SECTION 8 IO-320 SERIES TABLES CENTIGRADE-FAHRENHEIT CONVERSION TABLE...
- Page 83 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES IO-320 SERIES INCH FRACTIONS CONVERSIONS Decimals, Area of Circles and Millimeters...
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