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Textron Lycoming O-235-C Operator's Manual

Textron Lycoming O-235-C Operator's Manual

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OPERATOR'S MANUAL 
REVISION 
REVISION NO. 
PUBLICATION 
PUBLICATION NO. 
PUBLICATION DATE 
60297­9­1 
O­235, O­290 SERIES 
60297­9 
January 2007 
The page(s) in this revision replace, add to, or delete current pages in the operator's manual. 
PREVIOUS REVISION 
CURRENT REVISION 
None 
September 2008 
3­5, 3­6, Adds page 3­6A/B 
©2008 by Lycoming  "All Rights Reserved" 
Lycoming Engines, a division of AVCO Corporation, a wholly owned subsidiary of Textron Inc.

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  • Page 1 OPERATOR’S MANUAL  REVISION  REVISION NO.  PUBLICATION  PUBLICATION NO.  PUBLICATION DATE  60297­9­1  O­235, O­290 SERIES  60297­9  January 2007  The page(s) in this revision replace, add to, or delete current pages in the operator’s manual.  PREVIOUS REVISION  CURRENT REVISION  None  September 2008  3­5, 3­6, Adds page 3­6A/B  ©2008 by Lycoming  “All Rights Reserved”  Lycoming Engines, a division of AVCO Corporation, a wholly owned subsidiary of Textron Inc.
  • Page 2 NOTE In order to accommodate clearer type, larger charts and graphs, and more detailed illustrations, this edition of the O-235 and O-290 Series Operator’s Manual, Lycoming Part Number 60297-9 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 3 Operator’s Manual Lycoming O-235 and O-290 Series Approved by FAA 5th Edition Part No. 60297-9 January 2007 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
  • Page 4 652 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 at: http://www.lycoming.textron.com...
  • Page 5 LYCOMING OPERATOR’S MANUAL ATTENTION OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL This operator’s manual contains a description of the engine, its specifications, and detailed information on how to operate and maintain it. Such maintenance procedures that may be required in conjunction with periodic inspections are also included.
  • Page 6 LYCOMING OPERATOR’S MANUAL IMPORTANT SAFETY NOTICE Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The service procedures recommended by Lycoming are effective methods for performing service operations. Some of these service operations require the use of tools specially designed to the task. These special tools must be used when and as recommended.
  • Page 7 WARRANTY NEW AND REBUILT ENGINES (1) WARRANTY AND REMEDY: Lycoming Engines, a division of Avco Corporation (hereinafter “Lycoming”) warrants each new Lycoming reciprocating engine to be free from defect in material or workmanship under normal use and service. Lycoming’s sole obligation under this warranty is limited to replacement or repair of parts which are determined by Lycoming to have been defective within a period of twenty-four (24) months after new aircraft delivery to the original retail purchaser or first user, or twenty-four (24) months from the date of first operation.
  • Page 8 (7) Any invalidity of a provision of this Warranty shall not affect any other provision, and in the event of a judicial finding of such invalidity, this Agreement shall remain in force in all other respects. Effective September 2006 Revision “M” Lycoming Engines 652 Oliver Street Williamsport, Pennsylvania 17701 (570) 323-6181 www.lycoming.textron.com...

  • Page 9: Table Of Contents

    LYCOMING OPERATOR’S MANUAL TABLE OF CONTENTS Page SECTION 1 DESCRIPTION SECTION 2 SPECIFICATIONS SECTION 3 OPERATING INSTRUCTIONS SECTION 4 PERIODIC INSPECTIONS SECTION 5 MAINTENANCE PROCEDURES SECTION 6 TROUBLE-SHOOTING SECTION 7 INSTALLATION AND STORAGE SECTION 8 TABLES...
  • Page 10 LYCOMING OPERATOR’S MANUAL ¾ Right Front View – O-235-C, O-290-D Rear View – O-290-D2...

  • Page 11: Description

    LYCOMING OPERATOR’S MANUAL SECTION 1 DESCRIPTION Page General................................1-1 Cylinders............................... 1-1 Valve Operating Mechanism ........................1-1 Crankshaft ..............................1-1 Crankcase ..............................1-1 Oil Sump ............................... 1-1 Connecting Rods ............................1-2 Pistons ................................1-2 Accessory Housing ............................1-2 Gears ................................1-2 Cooling System .............................
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  • Page 13 LYCOMING OPERATOR’S MANUAL SECTION 1 O-235 AND O-290 SERIES DESCRIPTION SECTION 1 DESCRIPTION The Lycoming O-235 series, O-290-D series and O-290-D2 series engines are four cylinder, direct drive, horizontally opposed, wet sump, air-cooled models. In referring to the location of the various engine components, the parts are described in their relationship to the engine as installed in conventional airframes.
  • Page 14 SECTION 1 LYCOMING OPERATOR’S MANUAL DESCRIPTION O-235 AND O-290 SERIES Connecting Rods – Made in the form of “H” sections from alloy steel forgings. They have replaceable bearing inserts in the crankshaft ends and split type bronze bushings in the piston ends. The bearing caps on the crankshaft ends are retained by means of two bolts and nuts through each cap.
  • Page 15 LYCOMING OPERATOR’S MANUAL SECTION 1 O-235 AND O290 SERIES DESCRIPTION TABLE 1 MODEL APPLICATION Magneto Propeller Flange Specification Model Carburetor (Modified) Left Right O-235-C S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2 O-235-C1,-E1,-F1,-G1 S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2 O-235-C1B,-E1B,-F1B,-G1B S4LN-200 S4LN-204 MA-3A or –3PA AS-127-2 O-235-C2A,-E2A,-F2A,-G2A,...
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  • Page 17: Specifications

    LYCOMING OPERATOR’S MANUAL SECTION 2 SPECIFICATIONS Page Specifications – O-235-C, -E Series; O-235-C1C ..................2-1 Specifications – O-235-F, -G, -J, -N, -P, -K, -L, -M Series ............... 2-2 Specifications – O-235-H Series; O-235-K2C.................... 2-3 Specifications – O-290-D; O-290-D2, -D2A, -D2B, -D2C ................. 2-4 Accessory Drives ............................
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  • Page 19 LYCOMING OPERATOR’S MANUAL SECTION 2 O-235 AND O-290 SERIES SPECIFICATIONS SECTION 2 SPECIFICATIONS O-235-C*, -E SERIES FAA Type Certificate ............................223 Take-off horsepower............................115 Take-off RPM ..............................2800 Rated horsepower............................115 Rated RPM..............................2800 Bore, inches..............................4.375 Stroke, inches..............................3.875 Displacement, cubic inches.........................233.3 Compression ratio ............................. 6.50:1 Prop.
  • Page 20 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-235 AND O-290 SERIES SPECIFICATIONS (CONT.) O-235-F, -G, -J FAA Type Certificate ............................223 Take-off horsepower............................125 Take-off RPM ..............................2800 Rated horsepower............................125 Rated RPM..............................2800 Bore, inches..............................4.375 Stroke, inches..............................3.875 Displacement, cubic inches.........................233.3 Compression ratio ............................9.7:1 Prop. drive ratio ............................. 1:1 Prop.
  • Page 21 LYCOMING OPERATOR’S MANUAL SECTION 2 O-235 AND O-290 SERIES SPECIFICATIONS SPECIFICATIONS (CONT.) O-235-H FAA Type Certificate ............................223 Take-off horsepower............................115 Take-off RPM ..............................2800 Rated horsepower............................108 Rated RPM..............................2600 Bore, inches..............................4.375 Stroke, inches..............................3.875 Displacement, cubic inches.........................233.3 Compression ratio ............................. 6.75:1 Prop. drive ratio ............................. 1:1 Prop.
  • Page 22 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-235 AND O-290 SERIES SPECIFICATIONS (CONT.) O-290-D FAA Type Certificate ............................229 Take-off horsepower............................130 Take-off RPM ..............................2800 Rated horsepower............................125 Rated RPM..............................2600 Bore, inches..............................4.875 Stroke, inches..............................3.875 Displacement, cubic inches.........................289.0 Compression ratio ............................. 6.50:1 Prop. drive ratio ............................. 1:1 Prop.
  • Page 23 LYCOMING OPERATOR’S MANUAL SECTION 2 O-235 AND O290 SERIES SPECIFICATIONS SPECIFICATIONS (CONT.) Accessory Drive Drive Ratio *Direction of Rotation Starter 13.556:1 Counterclockwise Generator 1.910:1 Clockwise Generator (Optional) 2.500:1 Clockwise Alternator 3.250:1 Clockwise Vacuum Pump 1.300:1 Counterclockwise Hydraulic Pump 1.300:1 Counterclockwise Tachometer 0.500:1 Clockwise...
  • Page 24 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-235 AND O-290 SERIES DETAIL WEIGHTS 1. STANDARD ENGINE (Average). MODEL LBS. O-235-C .................................240 O-235-C1B..............................241 O-235-C1, -C2A ............................242 O-235-C1C, -C2B, -H2C ..........................243 O-235-C2C..............................244 O-235-K2C, -L2C ............................248 O-235-E1B, -F1B, -N2C..........................249 O-235-E2A, -F2A ............................250 O-235-F2B ..............................251 O-235-K2A, -L2A, -N2A ..........................252 O-235-G1, -G2A, -J2A, -K2B ........................253 O-235-M1, -P2A ............................255...
  • Page 25 LYCOMING OPERATOR’S MANUAL SECTION 3 OPERATING INSTRUCTIONS Page General................................3-1 Prestarting Items of Maintenance ......................3-1 Starting Procedure............................3-1 Cold Weather Starting ..........................3-2 Ground Running and Warm-Up ........................ 3-2 Checks Before Take-Off ..........................3-3 Operation in Flight ............................3-3 Use of Carburetor Heat Control.........................
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  • Page 27: Prestarting Items Of Maintenance

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS SECTION 3 OPERATING INSTRUCTIONS 1. GENERAL. Close adherence to these instructions will greatly contribute to long life, economy and satisfactory operation of the engine. NOTE YOUR ATTENTION IS DIRECTED IN PARTICULAR TO THE WARRANTIES THAT APPEAR IN THE FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED FUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS.

  • Page 28: Cold Weather Starting

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES e. Set propeller governor (if applicable) in “Full RPM” position. f. Turn fuel valve to “on” position. g. Set throttle at ¼ travel. h. Move mixture control to “Full Rich” i.

  • Page 29: Checks Before Take-Off

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS 6. CHECKS BEFORE TAKE-OFF. a. Warm up as directed above. b. Check both oil temperature and oil pressure. c. Set carburetor air heat control for “full heat” to check operation. Loss of manifold pressure or RPM (or both), depending on whether a fixed pitch or controllable pith propeller is installed on the aircraft, will result if the control is working properly.
  • Page 30 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES LEANING PRECAUTIONS Never exceed the maximum red line cylinder head temperature limit. For continuous operation cylinder head temperatures should be maintained below 435°F (224°C). On direct drive engines with manual mixture control, maintain mixture control in “Full Rich” position for rated take-off, rated maximum continuous, climb and cruise powers above 75%.

  • Page 31: Operating Instructions

    LYCOMING OPERATOR’S MANUAL  SECTION 3  O­235 AND O­290 SERIES  OPERATING INSTRUCTIONS  WARNING  REFER  TO  THE  PILOT’S  OPERATING  HANDBOOK  OR  AIRFRAME  MANUFACTURER’S  MANUAL  FOR  ADDITIONAL  INSTRUCTIONS  ON  THE  USE  OF  CARBURETOR  HEAT  CONTROL.  INSTRUCTIONS  FOUND  IN  EITHER  PUBLICATION  SUPERSEDE THE FOLLOWING INFORMATION.  F.  Use of Carburetor Heat Control – Under certain moist atmospheric conditions (generally at a relative  humidity  of  50%  or  greater)  and  at temperatures  of  20°  to  90°F  it  is  possible  for  ice  to  form  in  the  induction system. Even in summer weather ice may form. This is due to the high air velocity through ...

  • Page 32: Engine Flight Chart

    SECTION 3  LYCOMING OPERATOR’S MANUAL  OPERATING INSTRUCTIONS  O­235 AND O­290 SERIES  If this  happens, apply  full carburetor air heat and open the throttle to limiting  manifold pressure  and RPM. This will result  in a  slight additional drop in  manifold pressure, which  is  normal, and  this  drop  will  be  regained  as  the  ice  is  melted  out  of  the  induction  system.  When  ice  has  been  melted  from  the  induction  system,  return the  carburetor  heat  control  to the  full  cold  position.  In  those aircraft equipped with a carburetor air temperature gauge, partial heat may be used to keep ...
  • Page 33 LYCOMING OPERATOR’S MANUAL  SECTION 3  O­235 AND O­290 SERIES  OPERATING INSTRUCTIONS  O­235 Series  O­290­D, ­D2 Series  Oil Sump Capacity  6 Qts.  8 Qts.  Minimum Safe Quantity of Oil in Sump  2 Qts.  2 Qts.  Refer  to  the  latest  revision  of  Service  Bulletin  No.  480  for  oil  and  filter  change  and  screen  cleaning  requirements.  Added September 2008  3­6A/B...

  • Page 34: Operating Conditions

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS OPERATING CONDITIONS Oil Pressure, psi – Model Maximum Minimum Idling Start and Warm-Up O-235 –C, -E, -F, -G, -H2C, -J, -K, -M O-235-B O-235-L*, -N O-235-P O-290-D O-290-D2 * - Front of engine Fuel Pressure, psi –...
  • Page 35 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES OPERATING CONDITIONS (CONT.) O-235-F, -G, -J Fuel Max. *Max. Cons. Oil Cons. Cyl. Head Operation Gal./Hr. Qts./Hr. Temp. Normal Rated 2800 10.7 0.56 500°F (260°C) Performance Cruise (75% Rated) 2500 0.31 500°F (260°C)
  • Page 36 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS OPERATING CONDITIONS (CONT.) O-235-N, -P Series Fuel Max. Max. Cons. Oil Cons. Cyl. Head Operation Gal./Hr. Qts./Hr. Temp. Take-Off 2800 ---- ---- 500°F (260°C) Normal Rated 2550 0.36 500°F (260°C) Performance Cruise (75% Rated) 2300...
  • Page 37 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES 9. SHUT-DOWN PROCEDURE. a. Idle engine at approximately 800 to 900 RPM until there is a decided drop in cylinder head temperature. b. Move mixture control to “Idle Cut-Off”. c.
  • Page 38 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-1. Power and Fuel Consumption Curve – O-235-C 3-11...
  • Page 39 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-2. Sea Level and Altitude Performance – O-235-C1, -E1, -H2 Series 3-12...
  • Page 40 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-3. Fuel Flow vs Percent Rated Power – O-235-C1, -E1, -H2 Series 3-13...
  • Page 41 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-4. Fuel Flow vs Percent Rated Power – O-235-F, -G, -J Series 3-14...
  • Page 42 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-5. Sea Level and Altitude Performance – O-235-F, -G, -J Series 3-15...
  • Page 43 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-6. Fuel Flow vs Percent Rated Power – O-235-K, -L, -M Series 3-16...
  • Page 44 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-7. Sea Level and Altitude Performance – O-235-K, -L, -M Series 3-17...
  • Page 45 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-8. Fuel Flow vs Horsepower – O-235-N, -P Series 3-18...
  • Page 46 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-9. Sea Level and Altitude Performance – O-235-N, -P Series 3-19...
  • Page 47 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-10. Power and Fuel Consumption Curve – O-290-D 3-20...
  • Page 48 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-11. Sea Level and Altitude Performance – O-290-D 3-21...
  • Page 49 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-12. Power and Fuel Consumption Curve – O-290-D2, -D2A 3-22...
  • Page 50 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-13. Sea Level and Altitude Performance Curve – O-290-D2, -D2A 3-23...
  • Page 51 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-14. Sea Level and Altitude Performance Curve - O-290-D2B, -D2C 3-24...
  • Page 52 LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS USING CURVE TO FIND ACTUAL HORSEPOWER The following is an example of how to use the Sea Level and Altitude Performance curves, printed on these pages, to determine actual horsepower being delivered by the engine for given altitude, RPM, manifold pressure and air inlet temperature.
  • Page 53 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-15. Power and Fuel Consumption Curve – O-290-D2B, -D2C 3-26...

  • Page 54: Periodic Inspections

    LYCOMING OPERATOR’S MANUAL SECTION 4 PERIODIC INSPECTIONS Page Prestarting 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 Inspections ......................... 4-4...
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  • Page 56 LYCOMING OPERATOR’S MANUAL SECTION 4 O-235 AND O-290 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 57 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS O-235 AND O-290 SERIES 1. DAILY PRE-FLIGHT. a. Be sure all switches are in the “Off” position. b. Be sure magneto ground wires are connected. c. Check oil level. d. See that fuel tanks are full. e.
  • Page 58 LYCOMING OPERATOR’S MANUAL SECTION 4 O-235 AND O-290 SERIES PERIODIC INSPECTIONS Drain and refill sump with new oil on installation not employing replaceable external oil filter. See latest revision of Service Instruction No. 1014 for recommended lubricating oils. Seasonal grades are listed in Section 3, Paragraph 8 of this manual.
  • Page 59 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS O-235 AND O-290 SERIES f. Priming Nozzles – Disconnect primer nozzles from engine and check for equal flow. g. Valve Rockers (O-235 and O-290-D) – Check clearance. See Page 5-9, Paragraph (11) for valve rocker clearance.

  • Page 60: Maintenance Procedures

    LYCOMING OPERATOR’S MANUAL SECTION 5 MAINTENANCE PROCEDURES Page Ignition and Electrical System Ignition Harness and Wire Replacement....................5-1 Timing Magnetos to Engine ........................5-1 Generator and Alternator Output......................5-4 Fuel System Repair of Fuel Leaks..........................5-4 Carburetor Inlet Screen Assembly......................5-4 Fuel Grades and Limitations ........................
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  • Page 62 LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES SECTION 5 MAINTENANCE PROCEDURES The procedures described in this section are provided to guide and instruct personnel in performing such maintenance operations that may be required in conjunction with the periodic inspections listed in the preceding section.
  • Page 63 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES FIRING ORDER 1-3-2-4 Figure 5-1. Ignition Wiring Diagram FIRING ORDER 1-3-2-4 Figure 5-2. Ignition Wiring Diagram (Optional)
  • Page 64 LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES FIRING ORDER 1-3-2-4 Figure 5-3. Ignition Wiring Diagram (Optional) Conventional Magneto – Hold the No. 1 lead wire spring 1/8 in. away from the frame. Turn the gear counterclockwise vigorously through the flux lines until a strong spark occurs at the lead. Reverse the rotation into the flux until the timing pin hole appears in the center of the vent plug hole and insert the timing pin into the hole.
  • Page 65 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES 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 instructions. (4) After both magnetos have been timed, check, as described below, to ascertain that both magnetos are set to fire simultaneously.
  • Page 66 LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES (3) Set throttle stop screw so that the engine idles at the airframe manufacturer’s recommended idling RPM. If the RPM changes appreciably after making idle mixture adjustment during the succeeding steps, readjust the idle speed.
  • Page 67 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES e. Oil Relief Valve (Adjustable) – The adjustable oil relief valve enables the operator to maintain engine oil pressure 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 at approximately 2000 RPM, observe the reading on the oil pressure gage.
  • Page 68 LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES d. Removal of Hydraulic Tappet Sockets and Plunger Assemblies (O-290-D2 Series) – It will be necessary to remove and bleed the hydraulic tappet plunger assembly so that dry tappet clearance can be checked when the cylinder assembly is reinstalled.
  • Page 69 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES (2) Assemble piston so that the cylinder number stamped on the piston pin boss is toward the front end of the engine. The piston pin should be a push fit. If difficulty is experienced in inserting the piston pin, it is probably caused by carbon or burrs in the piston pin hole.
  • Page 70 LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES CAUTION AFTER ALL CYLINDER BASE NUTS HAVE BEEN TIGHTENED, REMOVE ANY NICKS IN THE CYLINDER FINS BY FILING OR BURRING. (9) Assemble each push rod in its respective shroud tube, and assemble each rocker in its respective position by placing rocker between bosses and sliding valve rocker shaft in place to retain rocker.
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  • Page 72: Trouble-Shooting

    LYCOMING OPERATOR’S MANUAL SECTION 6 TROUBLE-SHOOTING Page Failure of Engine to Start..........................6-1 Failure of Engine to Idle Properly......................6-1 Low Power and Uneven Running....................... 6-2 Failure of Engine to Develop Full Power....................6-2 Rough Engine ............................... 6-3 Low Oil Pressure............................6-3 High Oil Temperature ..........................
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  • Page 74: Failure Of Engine To Start

    LYCOMING OPERATOR’S MANUAL SECTION 6 O-235 AND O-290 SERIES TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING General – Experience has proven the best method of “trouble-shooting” is to decide on the various possible causes of a given trouble and then to eliminate these causes one by one, beginning with the most probable. The following chart lists some of the more common engine troubles usually found in maintaining aircraft engines.
  • Page 75 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-235 AND O-290 SERIES TROUBLE PROBABLE CAUSE REMEDY Low Power and Uneven Running Mixture too rich; indicated by Check primer shut-off valve for sluggish engine operation, red leakage. Readjustment of exhaust flange at night. Extreme carburetor by authorized cases indicated by black smoke personnel is indicated.

  • Page 76: High Oil Temperature

    LYCOMING OPERATOR’S MANUAL SECTION 6 O-235 AND O-290 SERIES TROUBLE-SHOOTING TROUBLE PROBABLE CAUSE REMEDY Rough Engine Cracked engine mount. Replace mount. Unbalanced propeller. Remove propeller and have it checked for balance. Defective mounting bushings. Install new mounting bushings. Malfunctioning engine. Check entire engine.

  • Page 77: Excessive Oil Consumption

    SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-235 AND O-290 SERIES TROUBLE PROBABLE CAUSE REMEDY Excessive Oil Consumption Low grade of oil. Fill tank with oil conforming to specification. Failing or failed bearing. Check sump for metal particles. Worn piston rings. Install new rings.

  • Page 78: Installation And Storage

    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 Preparation of Carburetor for Installation ....................
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  • Page 80 LYCOMING OPERATOR’S MANUAL SECTION 7 O-235 AND O-290 SERIES INSTALLATION AND STORAGE SECTION 7 INSTALLATION AND STORAGE 1. PREPARATION OF ENGINE FOR INSTALLATION. Before installing an engine that has been prepared for storage, remove all dehydrator plugs, bags of desiccant and preservative oil from the engine. Preservation oil can be removed by removing the bottom spark plugs and turning the crankshaft three or four revolutions by hand.
  • Page 81 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-235 AND O-290 SERIES 2. PREPARATION OF CARBURETOR FOR INSTALLATION. Carburetors that have been prepared for storage should undergo the following procedures before being placed in service. Carburetor – Remove the fuel drain plug and drain preservative oil. Remove the fuel inlet strainer assembly and clean in a hydrocarbon solvent.
  • Page 82 LYCOMING OPERATOR’S MANUAL SECTION 7 O-235 AND O-290 SERIES INSTALLATION AND STORAGE NOTE Oils of the type mentioned are to be use in Lycoming aircraft for corrosion prevention only, and not for lubrication. See the latest revision of Lycoming Service Instruction No. 1014 and Service Bulletin No.
  • Page 83 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-235 AND O-290 SERIES Figure 7-3. Installation Drawings...
  • Page 84 LYCOMING OPERATOR’S MANUAL SECTION 8 TABLES Page Table of Limits ............................. 8-1 Inspection Forms After Top Overhaul or Cylinder Change with New Rings Ground Run............................8-2 Flight Test ............................... 8-3 Full Throttle HP at Altitude........................8-4 Table of Speed Equivalents ......................... 8-4 Centigrade-Fahrenheit Conversion Table....................
  • Page 85 This Page Intentionally Left Blank.
  • Page 86 LYCOMING OPERATOR’S MANUAL SECTION 8 O-235 AND O-290 SERIES TABLES SECTION 8 TABLES TIGHTENING TORQUE RECOMMENDATIONS INFORMATION CONCERNING TOLERANCES 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 PERTINENT TO CORRECTLY INSTALLING CYLINDER ASSEMBLY.
  • Page 89 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-235 AND O-290 SERIES FULL THROTTLE HP AT ALTITUDE (Normally Aspirated Engines) Altitude % S.L. Altitude % S.L. Altitude % S.L. H.P. H.P. H.P. 10,000 70.8 19,500 49.1 98.5 11,000 68.3 20,000 48.0 1,000 96.8 12,000 65.8...
  • Page 90 LYCOMING OPERATOR’S MANUAL SECTION 8 O-235 AND O-290 SERIES TABLES CENTIGRADE-FAHRENHEIT CONVERSION TABLE Example: To convert 20°C to Fahrenheit, find 20 in the center column headed (F-C); then read 68.0°F in the column (F) to the right. To convert 20°F to Centigrade; find 20 in the center column and read –6.67°C in the (C) column to the left.
  • Page 91 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-235 AND O-290 SERIES INCH FRACTIONS CONVERSIONS Decimals, Area of Circles and Millimeters Inch Decimal Area Inch Decimal Area Fraction Equiv. Sq. In. Equiv. Fraction Equiv. Sq. In. Equiv. 1/64 .0156 .0002 .397 .1964 12.700 1/32 .0312...

This manual is also suitable for:

Lycoming o 290 seriesLycoming o 235 seriesLycoming o-290-dLycoming o-290-d2

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