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Lycoming YO-233-B2A Series Installation And Operation Manual

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YO-233-B2A Series Engine
Installation and Operation Manual
November 2014
© 2014
Part No. 60297-40-B

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Summary of Contents for Lycoming YO-233-B2A Series

  • Page 1 YO-233-B2A Series Engine Installation and Operation Manual November 2014 © 2014 Part No. 60297-40-B...
  • Page 2 YO-233-B2A Series Engine Installation and Operation Manual November 2014 © 2014 Part No. 60297-40-B...
  • Page 4 U.S. and Canada Toll Free +1(800) 258-3279 Direct +1(570) 323-6181 Sales Department: +1(570) 327-7278 +1(570) 327-7101 (facsimile) Lycoming’s regular business hours are Monday through Friday from 8:00 A.M. through 5:00 P.M. Eastern Time (-5 GMT) Visit us on the World Wide Web at: http://www.lycoming.com...

  • Page 6: Warranty

    Lycoming will reimburse a pro rata portion of the charge for the repair or replacement (at its choice) with Lycoming parts, or parts required to be repaired or replaced, or a replacement engine, if it determines that engine replacement is required. Lycoming’s obligation during the proration period extends to major parts of the engine, which are limited to crankcase, crankshaft, camshaft, connecting rods, pistons, sump, accessory housing and gears.
  • Page 7 Lycoming parts are 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 repair 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: Record Of Revisions

    YO-233-B2A Series Engine Installation and Operation Manual RECORD OF REVISIONS Rev. No Issue Date Revision History  Added new figures in System Description and December, 2013 Engine Reception and Lift chapters  Added timing procedure  Added EIS Installation Guidelines ...
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  • Page 10: Service Document List

    YO-233-B2A Series Engine Installation and Operation Manual SERVICE DOCUMENT LIST The “Incorporation Date” column indicates the latest revision date of this report, due to a NOTE: new Service Document or Service Document revision. The words “No Effect” indicate that the Service Document caused no changes within this report.
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  • Page 12: Table Of Contents

    YO-233-B2A Series Engine Installation and Operation Manual TABLE OF CONTENTS Section Page Frontal _______________________________________________________ Record of Revisions .......................... i Service Document List ........................iii Table of Contents ..........................v List of Figures........................... ix List of Tables ............................ xi Abbreviations and Acronyms ......................xiii Introduction .............................

  • Page 13: Table Of Contents

    YO-233-B2A Series Engine Installation and Operation Manual Section Page Engine Installation ______________________________________________ — Engine Installation Overview ....................15 — Step 1. Install the Engine on Mounts ................... 15 — Step 2. Connect the Wiring Harnesses ................16 — Step 3. Connect the Throttle Linkage .................. 16 —...
  • Page 14 YO-233-B2A Series Engine Installation and Operation Manual Section Page Date Unusual Conditions (Cont.) ______________________________________ — Low Oil Pressure During Flight ................... 38 — Apply Heat to a Cold Engine ....................39 — Cold Weather Start ......................40 — Engine Operation in Hot Weather ..................40 Engine Preservation and Storage _________________________________ —...
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  • Page 16: List Of Figures

    YO-233-B2A Series Engine Installation and Operation Manual LIST OF FIGURES Fig. No. Figure Title Page System Description Section YO-233-B2A Series Engine Cylinder Number Designation Engine Reception and Lift Section Engine Lift Engine Start and Operation Cylinder Number Designations 25º Advance Timing Mark on Starter Ring Gear...
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  • Page 18: List Of Tables

    YO-233-B2A Series Engine Installation and Operation Manual LIST OF TABLES Table Table Title Page Requirements for Engine Installation Section Prerequisites for Engine Installation Engine Installation Section Engine Installation Steps and References Engine Start and Operation Section Prerequisite Requirements for Engine Operation...
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  • Page 20: Abbreviations And Acronyms

    YO-233-B2A Series Engine Installation and Operation Manual ABBREVIATIONS AND ACRONYMS Ampere Brake Horsepower BSFC Brake Specific Fuel Consumption Before Top Center British thermal unit Celsius Cylinder Head Temperature Exhaust Gas Temperature Fahrenheit Federal Aviation Administration Federal Aviation (and Space) Regulation Foreign Object Debris Ft.-lb...
  • Page 21 YO-233-B2A Series Engine Installation and Operation Manual Pilot Operating Handbook Pounds per square inch Revolutions per Minute Society of Automotive Engineers (oil viscosity) Service Bulletin Service Instruction Service Letter Supplemental Type Certificate Volt, Voltage Abbreviations and Acronyms Effectivity: YO-233-B2A Series Engine...

  • Page 22: Introduction

    For reference and future updates, the Service Document List at the front of this manual shows the editions of the service documents included in this manual. Change Update Distribution Lycoming Engines supplies changes in the form of revised pages or manuals (depending upon the extent of the changes) to customer subscribers. Instructions for Continued Airworthiness This manual, together with the Maintenance Manual, applicable service documents, and related publications make up the complete set of Instructions for Continued Airworthiness (ICAs).
  • Page 23 Be sure to read and obey the Warnings and Cautions in this manual and in service documents. Although Lycoming cannot know all possible hazards or damages, it does its best to make a reasonable effort to supply the best guidance and recommended practices for safe operation of its engines.
  • Page 24 Supplemental Service Information Refer to the latest revision of Service Letter No. L114 for a list of Lycoming publications available for purchase. Feedback To supply comments, suggestions, or corrections to this manual, either make a call to customer service or use the Lycoming website.
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  • Page 26: System Description

    YO-233-B2A Series Engine Installation and Operation Manual SYSTEM DESCRIPTION The Lycoming YO-233-B2A Series engine (Figure 1) is a direct-drive four-cylinder, carbureted, horizontally opposed, wet sump, air-cooled engine. Refer to Figure 1. Figure 1 YO-233-B2A Series Engine Cylinders Each of the four engine cylinders has a cylinder head, barrel, rings, pistons, push rods, valves, valve springs, and hydraulic tappets.

  • Page 27: Crankcase

    YO-233-B2A Series Engine Installation and Operation Manual Crankcase The crankcase is made up of two castings divided at the centerline of the engine. The castings are attached by a series of through-studs, bolts and nuts. The mating surfaces of the two castings are attached without a gasket.

  • Page 28: Lubrication System

    YO-233-B2A Series Engine Installation and Operation Manual Lubrication System The Lubrication System has the following:  Impeller type oil pump (in the accessory housing)  Full pressure wet oil sump  Oil collectors  Oil cooler (supplied by airframe manufacturer if necessary) ...

  • Page 29: Cylinder Number Designations

    YO-233-B2A Series Engine Installation and Operation Manual Cylinder Number Designations  The propeller is at the front of the engine and the accessories are at the rear of the engine.  When you look at the engine from the rear at the top, the left side cylinders are 2-4. Cylinder 2 is at the front of the engine.

  • Page 30: Engine Reception And Lift

    1. When the engine is received, make sure that the crating is not damaged. If the engine crate is damaged, speak to Lycoming’s Service Department and the freight shipper. If the crate is acceptable, remove the engine from the crate.

  • Page 31: Engine Deinhibition

    YO-233-B2A Series Engine Installation and Operation Manual Engine Deinhibition The engine is sent with preservative oil in the cylinder and preservative oil in the crankcase. Refer to the “Prepare a New or Rebuilt Engine for Installation” section in the “Requirements for Engine Installation”...
  • Page 32 YO-233-B2A Series Engine Installation and Operation Manual MAKE SURE THE AREA IS CLEAR WHEN LIFTING THE ENGINE. DO NOT LET THE FRONT, REAR, SIDES OR BOTTOM OF THE ENGINE TO BUMP OR STRIKE ANY OBJECTS TO PREVENT DAMAGE TO THE ENGINE OR ITS COMPONENTS.
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  • Page 34: Requirements For Engine Installation

    YO-233-B2A Series Engine Installation and Operation Manual REQUIREMENTS FOR ENGINE INSTALLATION Overview NOTICE: All requirements identified in this chapter must be completed before the engine can be installed. These requirements are for a new, rebuilt or stored engine to be put into service.
  • Page 35  Clean the oil strainers in gasoline or other organic solvent  Remove the fuel drain screen from the fuel inlet of the carburetor  If there is evidence of valve sticking, refer to the YO-233-B2A Series Engine Maintenance Manual for instructions.
  • Page 36 E. Connect the outlet hose to the outlet fitting on the fuel pump. F. Install the shipping cap. 7. Examine the spark plugs. Refer to the YO-233-B2A Series Engine Maintenance Manual for the spark plug inspection procedure. 8. If spark plugs are acceptable, install them. If the spark plugs are dirty, clean them in petroleum solvent.
  • Page 37  Clean the oil strainers in gasoline or other organic solvent  Remove the fuel drain screen from the fuel inlet of the carburetor  If there is evidence of valve sticking, refer to the YO-233-B2A Series Engine Maintenance Manual for instructions.

  • Page 38: Step 2. Supply Interface Items

    YO-233-B2A Series Engine Installation and Operation Manual 11. Remove the oil filter and install a new oil filter. Refer to the YO-233-B2A Series Engine Maintenance Manual. 12. If the carburetor was prepared for storage: A. Put a container under the carburetor.

  • Page 39: Step 3. Measure Engine Dimensions

    YO-233-B2A Series Engine Installation and Operation Manual  Indicator light in cockpit for ignition source  Ignition switch. As both channels retard for starting the ignition switch should not ground either channel during starting  For the power control body, a standard mechanical push-pull or power lever control in the cockpit and appropriate cable linkage and bracket ...

  • Page 40: Engine Installation

    YO-233-B2A Series Engine Installation and Operation Manual ENGINE INSTALLATION Engine Installation Overview All requirements identified in the chapter “Requirements for Engine Installation” NOTICE: must be completed before engine installation. Refer to the engine installation drawing in Appendix B. Complete the following steps in Table 3 to install the engine.

  • Page 41: Step 2. Connect The Wiring Harnesses

    YO-233-B2A Series Engine Installation and Operation Manual 3. Torque the mounting hardware to the torque as per airframe manufacturer’s maintenance manual. 4. Disconnect the hoist from the lifting eyes. Step 2. Connect the Wiring Harnesses 1. Examine the airframe receptacles for the airframe interface, and airframer power. Look closely at the pins and sockets.

  • Page 42: Step 10. Make Remaining Engine Connections

    Champion’s L-1499A Ignition Lead Assembly and Maintenance Manual (available via subscription at www.championaerospacepubs.com. Step 13. Add Oil 1. Add oil to the engine. Refer to the YO-233-B2A Series Engine Maintenance Manual. Step 14. Engine Pre-Oil Procedure IF THE PRE-OIL PROCEDURE IS NOT DONE, HIGH-SPEED BEARING FAILURE CAN OCCUR.

  • Page 43: Step 15. Add Fuel

    YO-233-B2A Series Engine Installation and Operation Manual 3. Put the mixture control in idle cut-off and the fuel selector or shut off in the OFF position. If the engine does not have an idle cut-off, open the throttle to the FULL OPEN position and put fuel and ignition switches in the OFF position.

  • Page 44: Engine Installation Checklist

    YO-233-B2A Series Engine Installation and Operation Manual Engine Installation Checklist ENGINE INSTALLATION CEHCKLIST Requirement Done Comment Make sure the engine is securely installed on the engine mounts. Make sure that the hardware that attaches the engine to the engine mounts is torqued as per the airframe manufacturers specified torque values.
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  • Page 46: Engine Start And Operation

    OPERATE THIS ENGINE IN ACCORDANCE WITH SPECIFICATIONS IN THIS MANUAL. YOU ALSO MUST COMPLETE THE RECOMMENDED MAINTENANCE IN ACCORDANCE WITH THE YO-233-B2A SERIES ENGINE MAINTENANCE MANUAL. DO NOT OVERHAUL THIS ENGINE IN THE FIELD. IF AN ENGINE MUST BE DISASSEMBLED OR OVERHAULED, SEND THE ENGINE TO EITHER LYCOMING ENGINES OR AN AUTHORIZED OVERHAUL FACILITY.
  • Page 47 Refer to the section “Measure the Oil Level and Add Oil” in the YO-233-B2A Series Engine Maintenance Manual. 8. Make sure that the engine crankcase breather is attached tightly and that there are no blockages to the breather air flow.
  • Page 48 YO-233-B2A Series Engine Installation and Operation Manual BEFORE EACH FLIGHT, ALWAYS EXAMINE THE FUEL HOSES AND FITTINGS FOR LEAKAGE. IF YOU NEED TO REPLACE A HOSE OR FITTING, REFER TO THE ILLUSTRATED PARTS CATALOG TO ORDER THE CORRECT PART. 16. Correct all problems before engine start.
  • Page 49 YO-233-B2A Series Engine Installation and Operation Manual D. Attach the 10-pin connector on the Timing Tester (Figure 3) to the 10-pin port on the side of the Ignition Module. Alternately attach the Ignition Module to the aircraft 10-pin connector (Aircraft Connector must be supplying power to the connector).
  • Page 50 YO-233-B2A Series Engine Installation and Operation Manual G. Look at the light (on the Timing Tester or the Ignition Module) (which is not illuminated at this point) and turn the drive gear on the Ignition Module counterclockwise (CCW) until the light (on the Timing Tester or the Ignition Module) illuminates.

  • Page 51: Step 2. Daily Pre-Flight Inspection

    YO-233-B2A Series Engine Installation and Operation Manual GREEN LIGHT ROTATE CLOCKWISE UNTIL GREEN LIGHT COMES ON Figure 6 Green Light on Timing Tester N. Install flat washers, new lock washers, and nuts to attach the Ignition Module to the engine.

  • Page 52: Step 3. Start The Engine

    YO-233-B2A Series Engine Installation and Operation Manual BEFORE EACH FLIGHT, ALWAYS EXAMINE THE FUEL HOSES AND FITTINGS FOR LEAKAGE. IF YOU NEED TO REPLACE A HOSE OR FITTING, REFER TO THE ILLUSTRATED PARTS CATALOG TO ORDER THE CORRECT PART. 4. Correct all problems before engine start.

  • Page 53: Step 4. Do The Operational Test

    If the smoke continues, stop the engine. Drain the preservative oil and add new oil. Refer to the YO-233-B2A Series Engine Maintenance Manual NOTICE: Full power is available within 4 seconds for a cold engine and 6 seconds for a hot engine after an in-flight engine restart as long as no other faults are present.

  • Page 54: Step 5. Do The Engine Run-Up

    6. Stop the engine and allow it to cool. 7. Examine the engine. If the engine does not operate correctly, refer to the “Fault Isolation” chapter in the YO-233-B2A Series Engine Maintenance Manual to identify and correct the cause. Correct all problems.
  • Page 55 11. The engine is ready for take-off when the throttle can be opened without faltering and there are no faults and no corrective action is necessary. 12. After 10 hours of engine operation for new, rebuilt or overhauled engines, do the 10-hour inspection. Refer to the YO-233-B2A Series Engine Maintenance Manual. Fuel Mixture Leaning Procedure NOTICE: Incorrect fuel-air mixture during flight can cause engine problems, particularly during take-off and climb power settings.
  • Page 56 YO-233-B2A Series Engine Installation and Operation Manual Table 2 Lean Mixture Settings at Various Engine Powers if Using Aviation Fuels Condition Power Lean Mixture Settings Leaning to Exhaust Gas Above 75% power Never lean beyond 150°F (66°C) on the Temperature (EGT) Gage rich side of peak EGT unless aircraft operator’s manual shows otherwise.
  • Page 57 YO-233-B2A Series Engine Installation and Operation Manual The temperature in the venturi can decrease as much as 70°F (21°C) below the temperature of the incoming air. If this air contains a large amount of moisture, the cooling process can cause precipitation in the form of ice.

  • Page 58: Step 6. Stop The Engine

    YO-233-B2A Series Engine Installation and Operation Manual Step 6. Stop the Engine Before engine shutdown, keep the engine speed between 1000 and 1200 RPM until the operating temperatures have stabilized. At this time the engine speed should be increased to approximately 1800 RPM for 15 to 20 seconds, then decreased to 1000 to 1200 RPM and shut-down immediately using the mixture control.
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  • Page 60: Flight Test

    Although new and rebuilt engines sent by Lycoming Engines receive a test cell run-in before shipment, this flight test is done to make sure that the engine is in compliance with all operational parameters before release for service.
  • Page 61 YO-233-B2A Series Engine Installation and Operation Manual 9. After landing and shutdown, look for leaks at fuel and oil fittings. Identify and correct the cause of any leaks. 10. Calculate fuel and oil consumption and compare the limits given in Appendix A. If the oil consumption value is above the limits in Appendix A.

  • Page 62: Unusual Conditions

    Refer to the section “Volcanic Ash” section in this Volcanic ash chapter. Engine soaked in water Examine the engine. Refer to the YO-233-B2A Series Engine Maintenance Manual. Moisture and unwanted materials can cause damage to all systems on the engine.

  • Page 63: Volcanic Ash

    YO-233-B2A Series Engine Installation and Operation Manual Volcanic Ash 1. Given the dynamic conditions of volcanic ash, Lycoming recommends not to operate the engine in areas where volcanic ash is present - in the air or on the ground. 2. Ash on the ground and runways can cause contamination of the engine compartment and subsequent engine damage during aircraft landing or take-off.

  • Page 64: Apply Heat To A Cold Engine

    11. If the oil pressure indication system is operating correctly and oil pressure loss/oil starvation has occurred, remove the engine as per instructions in Chapter 72-10 in the YO-233-B2A Series Maintenance Manual. Send the engine to either Lycoming Engines or an authorized overhaul facility for evaluation.

  • Page 65: Cold Weather Start

    YO-233-B2A Series Engine Installation and Operation Manual APPLY THE HOT AIR UNIFORMLY AND NOT CONCENTRATED IN ONE SPOT TO PREVENT HEAT DAMAGE TO NON-METAL PARTS. HEAT BUILD- UP CAN DAMAGE WIRING, HOSES, ETC. 5. If cowl flaps are installed, open the flow flaps to prevent heat build-up.
  • Page 66 YO-233-B2A Series Engine Installation and Operation Manual 2. Monitor temperatures closely. A. Maintain sufficient airspeed to provide cooling of the engine. B. Keep cowl flaps (if equipped) fully open during the climb. Effectivity: YO-233-B2A Series Engine Unusual Conditions Copyright, Lycoming Engines...
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  • Page 68: Engine Preservation And Storage

    The Lycoming warranty does not include corrosion unless otherwise identified on the notice tag for new, rebuilt, or overhauled engines sent from Lycoming Engines. Because climate conditions are different in various geographic areas, Lycoming can only give general recommendations for corrosion prevention. The owner and operator must take into account...

  • Page 69: Engine Preservation

    NOTICE: Lycoming recommends frequent inspection of engines that are stored in humid conditions and/or in flight less than once a week. The Lycoming warranty does not include corrosion. The main emphasis in engine preservation is to decrease the risk of corrosion of engine parts which can decrease engine service life.
  • Page 70 YO-233-B2A Series Engine Installation and Operation Manual 6. Install and torque the oil drain plug in accordance with the latest revision of the Table of Limits SSP-1776. 7. Fill the spray gun with the preservative oil mixture. 8. Fill the oil sump with the specified preservative oil mixture.

  • Page 71: 60 To 180-Day Engine Preservation

    G. Remove the accessories. Examine the drives and shafts for moisture or corrosion. 2. When the inspection is complete, install the accessories. 3. At the first sign of corrosion speak to a Lycoming authorized distributor or a Lycoming Technical Service at 877-839-7878 (877-TEX-SUPT).

  • Page 72: Cold Weather Storage

    Cold Weather Storage In cold weather, if possible, store the aircraft in a heated hangar between flights. Add oil to the engine as required with the specified oil grade. Refer to YO-233-B2A Series Engine Maintenance Manual. Effectivity: YO-233-B2A Series Engine...
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  • Page 74: Appendix A - Engine Specifications And Operating Limits

    YO-233-B2A Series Engine Installation and Operation Manual APPENDIX A Table A-1 YO-233-B2A Series Engine Specifications Number of Cylinders Cylinder Arrangement - Firing Order 1-3-2-4 ○ Spark Plugs 8 (Spark advance 25 BTC) Cooling Method Maximum Continuous Horsepower* @ RPM & BSFC 115 HP @ 2800 PRM @ 0.50...
  • Page 75 All locations and rotations are as viewed from the anti-propeller end of the engine unless specified differently. NOTE: For optional starters and alternators, refer to the latest revision of Lycoming Service Instruction No. 1154. Appendix A Effectivity: YO-233-B2A Series Engine...
  • Page 76 YO-233-B2A Series Engine Installation and Operation Manual Table A-2 Table of Operating Limits for Engine Minimum Oil Pressure - Idling 15 psi* 103 kPa** Oil Pressure Range - Continuous Operation 55* to 90 psi 379** to 621 kPa Maximum Oil Pressure - Starting, Warm-up, Taxi, and Take-...
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  • Page 78: Installation And Wiring Diagrams

    YO-233-B2A Series Engine Installation and Operation Manual APPENDIX B INSTALLATION AND WIRING DIAGRAMS The Champion Dual CDI Ignition System interfaces to the airframe through the 10-Pin connector on the Control Module. Figure 1 shows the Pin Out of the 10-Pin Connector as viewed from the pin side as well as a description of each of the pins.
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  • Page 80: Appendix C - Substantiated And Faa Approved Data

    YO-233-B2A Series Engine Installation and Operation Manual APPENDIX C SUSBSTANTIATED AND FAA APPOVED DATA Performance Charts Figure 1 Fuel Flow vs Horsepower Effectivity: YO-233-B2A Series Engine Appendix C Copyright, Lycoming Engines Page 55 Lycoming Engines is a division of Avco Corporation...
  • Page 81 YO-233-B2A Series Engine Installation and Operation Manual Figure 2 Sea Level and Altitude Performance Appendix C Effectivity: YO-233-B2A Series Engine Page 56 Copyright, Lycoming Engines November 2014 Lycoming Engines is a division of Avco Corporation...

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