Textron Lycoming O-235 Series, Lycoming O-290 Series Operator's Manual

OPERATOR'S

MANUAL

Lycoming

0-235

AIRCRAFT ENGINES

4th Edition

Part No. 60297-9

and 0-290

Approved by F.A.A.

SERIES

January 1988

LYCOMING OPERATOR'S MANUAL

ATTENTION

OWNERS, OPERATORS

MAINTENANCE PERSONNEL

This operator's manual contains a description of the engine, its

specifications, and detailed information on how to operate and maintain

Such maintenance procedures

it. with periodic inspections are also included. This manual is intended for use by owners, pilots and maintenance Avco Lycoming powered aircraft. are contained nel should refer to these for such procedures.

Neglecting to follow

periodic

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.

ty.

SERVICE BULLETINS,

Although the information contained in this manual is up-to-date at time of publication, users are through Avco ters which factory by subscription. L114 for subscription information.

in Avco Lycoming overhaul

SAFETY WARNING

the operating instructions

maintenance procedures

Consult your local FAA approved

Lycoming Service Bulletins,

are available from all Avco Lycoming

Consult the latest edition

that may be required in conjunction

Modifications and repair

can result in poor engine performance

INSTRUCTIONS

urged to keep abreast of later

AND

personnel responsible

manuals; maintenance person-

and to carry out

maintenance facili-

AND LETTERS

Instructions and Service Let-

distributors or from the

of Service Letter No.

for care of

procedures

information

SPECIAL NOTE

illustrations, pictures and drawings

The

typical of the subject matter they portray; in no instance are they to be

interpreted as examples of any specific engine, equipment or part

thereof.

shown in this publication

are

TEXTRON LYCOMING OPERATOR'S MANUAL

IMPORTANT

Proper service operation by operations. Some of specially and as recommended.

It is important tain various Warnings order to minimize the risk of vice methods that may damage the engine or render it unsafe.

It is also important to are evaluate or advise

vice might be done be involved. satisfy themselves ty will be

of all aircraft engines. The service

Textron Lycoming

designed for the task. These

not all inclusive. Textron

and repair is essential

are effective

these service operations require

to note that most Textron Lycoming

and Cautions which

understand that these Warnings

the service trade of all conceivable

or of the possible hazardous

Acordingly,

jeopardized

anyone who

thoroughly

by the service

SAFETY

personal injury or the use of

Lycoming could not possibly

that neither

NOTICE

to increase the safe, reliable

procedures recommended

methods

special tools must be used

uses a service

procedure

for performing

the use of tools

publications con-

must be carefully read in

improper ser-

and Cautions

ways in which ser-

consequences that may

procedure must

their safety

nor aircraft safe-

they select.

service

when

know,

first

NEWAND REMANUFACTURED

(LIMITED)

RECIPROCATING AIRCRAFT ENGINE

WHAT TEXTRON

Textron Lycoming warrants each new and remanufactued reciprocating engine sold by it to be free from defects in material and acceptance testing The date of first operationmust not exceed two (2) years from the date ofshipment from Textron Lycoming.

change basis, of the engine or any in material or workmanship. Lycomig will also bear the cost for labor in connection with the repair or replacement as provided in Textron Lycoming's

the period from the date of first operation, whichever occurs first, Textron Lycoming will reimburse you for a pro rata portion of the charge for the repair or replacement (at its choice) with Textron Lycoming parts,ofparts required tobe repairedorre- placed, or a replacement during the proration period extends to major parts of the engine, which are limited to crankcase, crankshaft, camshaft, cylinders, connecting rods, pistons, sump, accessory housing and gears. The proration policy does not extend to labor or to accessories, including but not limited to magnetos, caburetors or fuel injectors, fuel pumps, sarers, alternators and turbochargers and their controllers.

Lycoming distributor within 30 days of the appearance of the defect in material or workmanship.

the part of Textron Lycoming set forth above are your exclusive remedy and the exclusive liability of Textron Lycoming. This warranty allocates the risk of product failure between you and Textron Lycoming, as permitted by applicable law.

been subject to accident or used, adjusted, altered, manual, or if non-genuine Textron Lycoming parts are installed in or on the engine and are determined tobeapossible cause of the incident for which the warranty application is filed.

such alterations in engines or parts previously sold.

workmanship appearing within one (1) year from

Textron Lycoming's

In addition, if Textron Lycoming determines

until the expiration of Textron Lycoming's recommended

Any engine or

The

engine must have

Textron Lycoming's warranty does

Textron Lycoming

Textron Lycoming may change the

obligation under this warranty shall be limited

part of the engine, when Textron Lycoming has determined

Such repair or replacement will be made

then current Removal and

part so repaired or

reserves the right

Installation Labor Allowance Guidebook.

engine, if it determines that engine replacement

replaced will be

received normal

not cover normal maintenance expenses or consumable

construction of engines at any time without incurring

LYCOMING PROMISES

the date of first operation, excluding necessary aircraft

to its choice of repair or replacement, on anex-

by Textron Lycoming at no charge to you. Textron

that the engine proves to be defective in material

entitled to warranty

OBLIGATIONS

YOUR

use and service.

to deny any warranty claim

handled, maintained or stored other than as directed

Time Between Overhaul (TBO), or

is required. Textron Lycoming's obligation

for the remainder

You must apply

for warranty

if it reasonably determines

YOU

that the engine is defective

or workmanship during

two (2) years

of the original

with an authorized

any obligation to incorporate

waranty period.

Textron

items. The obligations on

that the engine or part

in your operator's

has

THIS LIMITED TATIONS, LIMITED TO ANY WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY TRADE USAGE. THIS CLAIM, WHETHER IN CONTRACT OR IN TORT, INCLUDING ANY RIGHT IN STRICT LIABILITY IN TORT TEXTRON LYCOMING'S LIABILITY ON CABLE TO THE ENGINE

WARRANTY IS EXCLUSIVE AND IN LIEU

EXPRESS OR IMPLIED OR STATUTORY,

WARRANTY IS ALSO IN LIEU OF ANY OTHER

OR ANY RIGHT ARISING FROM NEGLIGENCE

ARISING FROM ANY COURSE OF PERFORMANCE

OR PART WHICH GIVES RISE

WHETHER WRITTEN OR ORAL, INCLUDING

SUCH CLAIM SHALL NNO CASE EXCEED

OF ALL. OTHER WARRANTIES AND REPRESEN-

OR FITNESS FOR ANY PARTICULAR

OBLIGATION, LIABILITY, RIGHT OR

ON THE PART OF TEXTRON LYCOMING,

TO THE CLAIM.

BUT NOT

PURPOSE,

OR DEALING OR

THE PRICE ALLO-

AND

LIMITATION

IN NO EVENT, WHETHER LIGENCE, SHALL TEXTRON LYCOMING DAMAGES, INCLUDING BUTNOT LIMITED TOLOSSOF PROFITSOR REVENUES, LOSS OF USE OF THE ENGINE OR COST OF A

No agreement varying

Lycoming unless in writing signed by a duly authorized representative of Textron Lycoming.

Effective October

AS A RESULT OF A BREACH OF WARRANTY,

REPLACEMENT.

this warranty or Textron Lycoming's obligations

1, 1995 Revision

"J'

OF LIABILITY

BE LIABLE FOR SPECIAL OR CONSEQUENTIAL

CONTRACT OR ALLEGED NEG-

under it will be binding upon Textron

Textron

Williamsport, Pennsylvania

OR ANY OTHER

Lycoming

WARRANTY

REPLACEMENT

Textron Lycoming

inmaterial and

must not exceed

tion.

Textron

basis, of te

change

workmanship. ment as provided

part so repaired

Any

The engine warranty workmanship.

Textron

part of Textron

the

This warranty

Textron

been subject to manual, or if non-genuine

cause of the

Textron

such alterations

THIS LIMITED TATIONS,

LIMITED AND ANY

USAGE.

TRADE CLAIM,

OR ANY

TORT TEXTRON CABLE TO THE

warrants each

workmanship appearing

two (2) years from

Lycoming's obligation

replacement part,

Lycoming will

Textron

in Textron Lycoming's

in which

with an authorized

Lycoming's

Lycoming

the risk of

allocates

Lycoming reserves

accident or used,

incident for

may change the

Lycoming

engines or

in

WARRANTY

OR IMPLIED

EXPRESS

ANY WARRANTY

TO

WARRANTY

IMPLIED

THIS WARRANTY

WHETHER

IN CONTRACT

RIGHT ARISING

LYCOMING'S

ENGINE OR PART

PART -RECIPROCATING

(LIMITED)

WHAT TEXTRON

new reciprocating aircraft

under this

when TextronLycoming

also reimburse you

will be warranted

or replaced

the replacement

Textron Lycoming

does not cover

warranty

which the warranty

above are your

set forth

product failure

the right

adjusted, altered,

Textron Lycoming parts are installed

construction of

pars previously

IS EXCLUSIVE

OR STATUTORY,

OF MERCHANTABILITY

ARISING IS ALSO IN

FROM

LIABILITY

WHICH GIVES

LYCOMING

one (I) year from

within

the date of shipment

warranty shall

then current Removal

for the remainder

OBLIGATIONS

YOUR

part is installed

distributor

normal maintenance

exclusive

between

any warranty

to deny

handled, minained

application

engines at any time

sold.

AND IN

FROM

LIEU OF ANY

OR IN TORT,

NEGLIGENCE

CLAIM

ON SUCH

AIRCRAFT

PROMISES

engine replacement pat

from Textron

be limited to its

has

for the costs

and Installation

have received

must

within 30 days

remedy and

you and Textron

claim if it reasonably

in or on the engine and are determined to be a possible

is filed.

LIEU OF

WHETHER

OR FITNESS

ANY COURSE

INCLUDING

ON SHALL

RISE TO THE

first operation. The

its date of

Lycoming.

choice of repair

determined that

for labor in connection

Labor Allowance Guidebook

original warranty

of the

normal use

of the appearance

consumable

expenses or

the exclusive

Lycoming,

or stored other

without incurring

ALL OTHER

OTHER

THE PART

OR

WRITTEN

FOR

OF PERFORMANCE

OBLIGATION,

RIGHT IN

ANY

OF TEXTRON

IN NO CASE

CLAIM.

ENGINE

YOU

sold by it to be free from

or replacement,

the pan is defective

with the repair

period.

and service.

of the defect in

items. The obligations

liability of Textron

as permitted

that

determines

than as directed

any obligation

WARRANTIES

ORAL, INCLUDING

ANY PARTICULAR

LIABILITY,

STRICT

EXCEED

date of first opera-

on an ex-

in material or

or replace-

apply for

You must

material or

Lycoming.

by applicable

or part has

the engine

in your operator's

to incorporate

REPRESEN-

AND

BUT NOT

PURPOSE,

OR DEALING

RIGHT

LIABILITY

LYCOMING,

PRICE

THE

defects

law.

OR OR

AND

ALLO-

on

IN

NO

EVENT, LIGENCE, DAMAGES, ENGINE

OR COST

No agreement

Lycoming

Effective

WHETHER

SHALL

TEXTRON

INCLUDING

OF A REPLACEMENT.

varying

unless in

writing

October

AS ARESULT

BUT

this warranty

signed

1, 1995

LIMITATION

LYCOMING

NOT LIMITED

or

Textron

by a duly

authorized

Revision

"J"

OF

OF A BREACH

BE LIABLE

TO LOSS

Lycoming's

representative

LIABILITY

OF WARRANTY,

FOR

SPECIAL

OF

PROFTS

obligations

of

Textron

CONTRACT

OR

CONSEQUENTIAL

OR

REVENUES,

under

it will

Lycoming.

Williamsport,

OR ALLEGED

OR

LOSS

OF USE

be binding

Textron

Pennsylvania

NEG-

ANY OTHER

OF THE

upon

Textron

Lycoming

I

. Lycoming

WARRANTY

(LIMITED)

RECIPROCATING

OVERHAULED

AIRCRAFT

ENGINE

WHAT TEXTRON

Textron Lycoming warrants workmanship appearing testing.

The date of first

Textron Lycoming's change basis, of the in material or Lycoming

will also bear the cost

Lycoming's

Any engine

The engine

Lycoming distributor

Textron

Lycoming's

the pan ofTextron

This

warranty allocates the

Textron Lycoming reserves

been subject to accident

manual,

or if non-genuine

cause of the

Textron Lycoming

such alterations THIS LIMITED

TATIONS, EXPRESS

LIMITED TO

AND ANY TRADE

USAGE. THIS

CLAIM, WHETHER

TORT

OR ANY RIGHT TEXTRON LYCOMING'S CABLE TO THE

within one (1) year

obligation under

engine or any part of the

workrmanship. Such repair

then current Removal and

or part so repaired

must have received

within

warranty does

Lycoming set forth

or used, adjusted,

incident for which

may change

in engines or

WARRANTY IS

OR IMPLIED

ANY WARRANTY OF

IMPLIED WARRANTY

WARRANTY

IN CONTRACT

ENGINE OR

each overhauled

operation must

or replaced will

reciprocating engine sold

from the date of first

not exceed two

thi:; warranty shall be limited

engine, when Textron Lycoming

or replacement will be made

for labor in connection

Installation Labor Allowance Guidebook.

be entitled to warranty

YOUR

normal

30 days of

risk of product failure between

Textron Lycoming

parts previously sold.

ARISING

LIABILITY

use and service.

the appearance

not cover nominal

abovt are your exclusive

the right to deny any

altered, handled, maintained

the warranty

PART WHICH GIVES

parts are installed

rpplication

the construction

EXCLUSIVE AND IN

OR STATUTORY,

MERCHANTABILITY ARISING FROM IS ALSO IN

O IN TORT, INCLUDING

FROM NEGLIGENCE

ON SUCH CLAIM SHALL

of engines at any

LYCOMING PROMISES

by it to be free from defects

operation, excluding necessary

(2) years from the

date of shipment

to its choice of repair

has determined

by Textron Lycoming

with the repair or

for the remainder

replacement as provided

OBLIGATIONS

You must apply

of the defect

maintenance

you and Textron Lycoming,

warranty claim if it reasonably

is filed.

LIEU OF ALL OTHER

WHETHER

ANY COURSE OF PERFORMANCE

LIEU OF ANY

ON THE

RISE TO

for warranty with

in material

or workmanship.

expenses or consumable

remedy and the exclusive

determines that

or stored other than as

in or on the

engine and are

time without incurring

WRITTEN

OR FITNESS FOR ANY

OTHER OBLIGATION,

THE CLAIM.

WARRANTIES AND REPRESEN-

OR ORAL, INCLUDING

ANY RIGHT

PART OF TEXTRON

IN NO CASE EXCEED

YOU

in material and

aircraft acceptance

from Textron

at no charge to you. Textron

of the original

liability of Textron Lycoming.

as permitted by

determined to be

any obligation

PARTICULAR PURPOSE,

IN STRICT LIABILITY

Lycoming.

or replacement, on

that the engine is defective

in Textron

warranty

an authorized

items. The

obligations on

applicable law.

the engine or part has

directed in your operator's

to incorporate

OR DEALING

LIABILITY,

RIGHT OR

LYCOMING,

THE PRICE ALLO-

an ex-

period.

Textron

a possible

BUT

NOT <

OR

AND

<

IN

I

IN

NO EVENT,

LIGENCE, DAMAGES, ENGINE

OR

No

agreement

Lycoming

Effective

WHETHER

SHALL

INCLUDING

COST

unless

in

October

TEXTRON

OF

A

varying

writing

1, 1995

AS

A RESULT

LYCOMING

BUT

NOT

signed

warranty

by a

LIMITED

or

duly

REPLACEMENT. this

Revision

LIMITATION

OF

A BREACH

BE LIABLE

TO

LOSS

Textron

Lycoming's

authorized

representative

J"

OF

LIABILITY

OF

WARRANTY,

FOR

SPECIAL

OF PROFITS

obligations

OR OR

of Textron

CONTRACT

CONSEQUENTIAL

REVENUES,

under

Lycoming.

it will

LOSS

be

Williamsport,

OR

ALLEGED

OR

OF

binding

Textron Lycoming

NEG-

ANY

OTHER

USE OF

THE

upon

Textron

Pennsylvania

i

LYCOMING

Induction System - These engines are equipped with either of two Marvel-Schebler carburetors, MA-3A or MA-3SPA. See Table 1 for model and are equipped with ticularly tained from sump and is submerged in oil, insuring a more uniform vaporization of fuel and aiding in cooling the mixture is distributed to

Ignition

Table tion

System -These engines are

speed of the aircraft. Close

a pressure and force the air through

application. Both carburetors

manual mixture control and

good distribution of the fuel-air

the center zone induction system,

each cylinder by individual

System - Dual ignition is

1 for proper model application.

wiring is so arranged as shown

designed to be cooled by air

pressure wet sump lubrication

oil in the sump. From the riser

furnished by two magnetos.

Depending on installation

in either figure 5-1, 5-2

pressure

fitting baffles build

the cylinder fins. The air

system is

are of the single barrel float

"idle cut-off". Par-

mixture to each cylinder is

which is integral with the

the fuel-air

intake pipes.

Consult

the igni-

or 5-3.

is then

type

ob-

LYCOMING

OPERATOR'S

TABLE 1

MODEL APPLICATION

MANUAL

Model

0-235-C 0-235-C,-E1,

-F1,-G1

0-235-C1B,-E1B,

-F1B,-G1B

0-235-C2A,-E2A,-F2A,

-G2A,-K2A,-J2A

0-235-L2A*,-N2A*,-P2A*

0-235-M1*

0-235-C2B,-E2B,-F2B,

-G2B,-K2B,-J2B 0-235-C2C,-H2C 0-235-K2C

0-235-L2C, -N2C**

0-290-D 0-290-D2 0-290-D2A

0-290-D2B

0-290-D2C * 0-235-L2A,

optional

-M1, -N2A, -P2A

equipment.

Magneto

Left S4LN-21 S4LN-20 S4LN-21

S4LN-200 S4LN-204 S4LN-21 S4LN-20

S4LN-21 S4LN-20

S4LN-21

S4LN-1227 4251 4252

4252

or

4281 S4LN-21

S4LN-21 S4LN-21 S4LN-21 S4LN-200

Right

S4LN-20

or

S4LN-204 S4LN-20

or

S4LN-204

S4LN-1209 4250 4250

or

4252 4250

or

4281 S4LN-20

S4LN-20 S4LN-20 S4LN-20 S4LN-204

may have two

Carburetor Flange

MA-3A MA-3A

MA-3A or -3PA AS-127-1

MA3A-3PA

MA-3A or -3PA MA-3A or -3PA MA-3A or -3PA

MA3A or -3PA

MA-3SPA MA-3SPA MA-3SPA MA-3SPA MA-3SPA

(2) S4LN-21

or -3PA AS-127-2

or -3PA

Propeller

Specification

(Modified)

AS-127-2

AS-127-2 AS-127-1

AS-127-2

AS-127-1 AS-127-1 AS-127-1

AS-127-1

AS-127-2 AS-127-2 AS-127-2 AS-127-2 AS-127-2

magnetos as

** 0-235-L2C,

1-4

-N2C may have

two (2) 4252

magnetos as optional

equipment.

LYCOMING

SPECIFICATIONS

Specifications -0-235 ................................... 2-1

Specifications - 0-290 ................................... 2-2

Accessory Drives ...................................... 2-2

Alternate Power Ratings ..... .......................... 2-3

Detail Weights ........................................ 2-4

OPERATOR'S

MANUAL

Page

LYCOMING

OPERATOR'S

MANUAL

SECTION 2 0-235 AND 0-290 SERIES

SPECIFICATIONS

0-235 SERIES

*-C-E -C1C -F-G-J -N-P

FAA Type Certificate Take-off horsepower

Take-off

RPM Rated horsepower Rated RPM Bore, inches Stroke, inches Displacement,

cu. in.

223 115

2800 2800

115

2800

4.375 4.375

3.875

233.3 233.3

223 115

108

2600

3.875

Compression ratio 6.50:1 6.75:1

Prop. drive

ratio

1:1 1:1

223

125

2800

125

2800

4.375

3.875

233.3

9.7:1

1:1

223 116

2800

116

2550

4.375

3.875

233.3

8.1:1

Prop. driven rotation

(viewed Firing Spark

Rocker clearance, * - 0-235-C1

from rear)

orders

occurs, BTC

cold .007/.009

has provision

FAA Type Certificate Take-off

horsepower

Take-off RPM

horsepower

Rated

Rated RPM Bore, inches Stroke, inches

Displacement, cu. in.

Compression ratio

Prop. drive ratio

Clockwise Clockwise

1-3-2-4

25

1-3-2-4

25

.007/.009

for two position prop.

-K-L-M 223

118

2800

118

2800

4.375

3.875

233.3

8.5:1

1:1

-H -K2C 223

115

2800

108

2600

4.375

3.875

233.3

6.75:1

1:1

Clockwise

1-3-2-4 1-3-2-4

.007/.009 .007/.009

control valve.

Clockwise

25 20

223

118

2800

115

2700

4.375

3.875

233.3

8.5:1

1:1

Prop. drive rotation

20

Clockwise

1-3-2-4

25

Clockwise

1-3-2-4

20

.007/.009

(viewed from rear)

orders

Firing Spark occurs, BTC Rocker

clearance.

cold

Clockwise

1-3-2-4

.007/.009 .007/.009

NOTE

Engine

models

model that varies Spark

advance

is also

are categorized

according to

in specification within a

found on

name plate.

their basic series.

series is listed separately.

Any

1:1

2-1

0-235

AND 0-290

LYCOMING

SERIES

OPERATOR'S

SPECIFICATIONS

0-290

SERIES

MANUAL

SECTION

2

FAA

Type Take-off Take-off Rated Rated RPM Bore, Stroke, Displacement, Compression Propeller Propeller

(viewed Firing Spark

Valve

(hyd.

Valve

(cold)

Accessory Starter

Generator Generator Alternator Vacuum Hydraulic Tachometer Magneto Fuel Pump Prop. AN

Drive

* -

Facing

Certificate horsepower RPM

horsepower

inches

drive ratio driven

from

order

occurs,

rocker

tappets

rocker

Drive

(Optional)

Pump

Governor

Drive

cubic

ratio

rotation

rear)

BTC

clearance

collapsed)

clearance

Pad.

in.

Drive

13.556:1

229 130

2800

125

2600

4.875

3.875

289.0

6.50:1 1:1

Clockwise

1-3-2-4

25

.007/.009

Ratio

1.910:1

2.500:1

3.250:1

1.300:1

0.500:1

1.000:1

0.500:1

0.866:1

1.000:1

-D2,

-D2A 229

140

2800

135

2600

4.875

3.875

289.0

7.50:1 1:1

Clockwise

1-3-2-4

18

.028-.080

*Direction

Counter-Clockwise

Counter-Clockwise Counter-Clockwise

Plunger

Counter-Clockwise

-D2B,

-D2C 229

140

2800

135

2600

4.875

3.875

289.0

7.00:1 1:1

Clockwise

1-3-2-4

25

.028-.080

of Rotation

Clockwise Clockwise Clockwise

Clockwise

Operated

Clockwise

2-2

LYCOMING

OPERATOR'S

MANUAL

SECTION

0-235-C2C 0-235-H2C 0-235-L

0-235-M

0-235-N

0-235-P

Series

2

ALTERNATE

0-235

.....................................

.........................

................................

...........................

.................................

0-235

POWER RATINGS

SERIES

.........

AND 0-290

100

SERIES

hp/2400

105 hp/2400

110 hp/2550 112 hp/2600

hp/2700

115

hp/2400

105 110 hp/2550 112 hp/2600 115 hp/2700 rpm

103 hp/2400

hp/2550

108

hp/2600

110

hp/2700

113

hp/2400

103

110 hp/2600

hp/2700

113

rpm rpm

rpm

rpm rpm rpm

rpm

rpm rpm

rpm rpm rpm rpm

rpm rpm rpm

2-3

LYCOMING

OPERATOR'S

MANUAL

SECTION 2

DETAIL

1. STANDARD ENGINE (Average)

MODEL

0-235-C. ......... ... .. ... .... ... 240.00 lbs.

0-235-C1B... .... ....................... ... 241.00 lbs.

0-235-C1, -C2A ...

0-235-C1C, -C2B, -H2C ... .......... ... 243.00 lbs.

O-235-C2C .. ................. ......... ..... 244.00 lbs.

O-235-K2C, -L2C .... ............................ 248.00 Lbs.

O-235-E B, -F1B, -N2C ..... .................. .. 249.00 lbs.

O-235-E2A, -F2A ....... ...... ......... ...... 250.00 lbs.

O-235-F2B . . ..... ..... ...... ........... 251.00 lbs.

O-235-K2A, -L2A .. ..................... .... 252.00 lbs.

O-235-N2A. ..................... 252.00 lbs.

0-235-G1, -G2A, -J2A, -K2B. ........................ 253.00 lbs.

0-235-M1, -P2A .................. ..... 255.00 lbs.

0-290-D ........................... ...... ...... 260.00 lbs.

O-290-D2A, -D2C .............................. .. 264.00 lbs.

0-290-D2B ............. ......... ..... 265.00 lbs.

............... ......

WEIGHTS

0-235 AND 0-290 SERIES

. 242.00 lbs.

2-4

LYCOMING

OPERATOR'S

MANUAL

OPERATING

General ...................... ......................... 3-1

Prestarting Items of Maintenance ........................ 3-2

Starting Procedure .................... .................. 3-2

Cold W eather Ground Running and Checks Before Take-Off Operation in Flight

Use of Carburetor Heat Control .......................... 3-6

Engine Operating Shut-Down Procedure

Performance Curves ............................

Flight Chart ....................

Starting ..................................

Warm-Up ...........................

.....................................

Conditions ..................................

................................

INSTRUCTIONS

.................................

.................

Page

3-3 3-3 3-3 3-4

3-8

3-10A

.. 3-11

LYCOMING

0-235 AND 0-290 SERIES SECTION 3

OPERATOR'S

SECTION 3

MANUAL

OPERATING

1. GENERAL. tribute to long life, economy and satisfactory operation of the engine.

YOUR ATTENTION IS DIRECTED IN PARTICULAR TO THE

WARRANTIES THAT APPEAR IN THE FRONT OF THIS MANUAL REGARDING SPECIFIED ALTERATIONS. PERHAPS NO OTHER ITEM OF ENGINE OPERATION AND MAINTENANCE CONTRIBUTES QUITE SO MUCH TO SATISFACTORY THE CONSTANT USE CORRECT ENGINE TIMING,

ALL TIMES WITHIN THE SPEED AND POWER RANGE

SPECIFIED FOR THE ENGINE. DO NOT FORGET THAT VIOLA- TION OF TIONS FOR YOUR

RANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS PASSED.

New engines therefore no further break-in is necessary insofar as operation is concern- ed; however, new or newly overhauled engines should be operated using only the lubricating oils recommended in the latest edition of Service In- struction

Close adherence to these

FUELS AND

OF CORRECT GRADES OF

THE OPERATION AND MAINTENANCE

ENGINE WILL NOT ONLY

have been carefully run-in

No. 1014.

INSTRUCTIONS

instructions will greatly con-

NOTE

ENGINE SPEED, THE

LUBRICANTS, REPAIRS

PERFORMANCE

AND FLYING THE AIRPLANE

NOTE

AND LONGLIFE AS

FUEL AND OIL

SPECIFICA-

VOID YOUR WAR-

by Lycoming and

USE OF

AND

AT

Cruising should be done at 65% to 75% power until a total of 50 hours has

accumulated or oil consumption seating of the rings and is applicable to new engines, and engines in ser-

vice following cylinder replacement or top overhaul at one of more

cylinders.

The minimum fuel octane rating is listed in the Flight Chart, Part 8 of this section. Under no circumstances should fuel of a lower octane rating or automotive (regardless of octane rating) be used.

has stabilized. This is to

insure proper

3-1

LYCOMING OPERATOR'S

SECTION 3 0-235 AND 0-290 SERIES

2. PRESTARTING ITEMS OF MAINTENANCE. Before starting the aircraft engine for the first maintenance inspection Section 4 under Daily before the

3. STARTING PROCEDURE.

a. Perform pre-flight inspection. b. Head airplane into wind. c. Lock wheels by either wheel brakes or chocks. d. Set carburetor heat control in "cold" position.

engine is started.

flight of the day, there are several that should be performed. Pre-Flight Inspection. They

MANUAL

items of

These are described in

must be observed

e. Set propeller governor f. Turn fuel valve to "on" position. g. Set throttle at 1/4 travel. h. Move mixture control to "Full Rich". i. Turn boost pump on.

j. Pump throttle to full open

for a cold engine. If engine is equipped with a priming system, cold

engine may k. Set magneto selector switch. Consult airframe manufacturer's

handbook for correct position.

1. Engage starter. m. When engine fires, place magneto switch in "Both" position. n. Check oil pressure gage. If oil pressure is not indicated within thirty

seconds, stop engine and determine trouble.

3-2

be primed with 1 to 3

(if applicable) in "Full RPM"

and back to idle position for

strokes of the priming pump.

position.

2 to 3 strokes

LYCOMING

OPERATOR'S

MANUAL

0-235 AND

4. COLD

0-290

SERIES

WEATHER STARTING.

be necessary to preheat

5. GROUND

pressure maintain operating recommended

Any ground check

three minutes, the maximum

RUNNING AND

cooled and depend

proper

cooling.

these engines

that the

that requires

or less if

as stated in this

a. Head the aircraft b. If

a controllable

the ground only

c.

Leave the mixture

pitch propeller

with the propeller in minimum

d. Avoid prolonged fouled plugs. warm engine

e. Use of the solute minimum.

Limit ground

for take-off.

carburetor air

On some the air filter and dirt engine

with the resultant heat should be ing

properly.

used on the ground

During

the engine and oil

extreme cold

before starting.

WARM-UP.

on the forward

Particular

on the ground.

following procedures

care

is necessary,

To prevent

movement

be

NOTE

the indicated cylinder

into the

full throttle manual

wind.

operation must

head temperature

is installed, operated

control in "Full Rich".

idling at

low RPM as

running

to minimum

this practice may

heat on the ground

installations

the air does

and foreign substances can

cylinder

and piston ring

only to

make certain it

SECTION

weather, it

Subject engines

of the aircraft

therefore,

overheating,

observed.

be limited to

the engine

blade angle setting.

time necessary

must be held

not pass through

be taken into the

wear. Carburetor

is function-

3

may

are air

to

when

it is

exceeds

on

result in

to

to an ab-

air

6. CHECKS BEFORE

a. Warm

b. Check both

c. Set carburetor

Loss fixed pitch

will

up as directed

oil temperature

air heat

of manifold pressure

or controllable

result if the

control is working

position after check.

TAKE-OFF.

above.

and oil pressure.

control for "full

or RPM pitch propeller

(or both), depending

heat" to check

is installed

properly.

Return control

operation.

on whether

on the aircraft,

to "cold"

3-3

a

LYCOMING

OPERATOR'S

MANUAL

SECTION 3

d. A proper magneto check the ignition system, output, propeller pitch and that the engine runs variables listed above. Make following

(1) Controllable Pitch

angle, set the engine to produce manifold position. At these settings work harder Under these conditions, ignition Magneto checks distribution quality.

Aircraft

with manifold

operating

(2) Switch from both both until engine note drop-off, then and should not exceed 50 smooth drop-off past mixture.

(3) Do not

seconds

fouling.

procedures:

pressure gage. Mixture

that are equipped with fixd pitch

pressure

at approximately 1800 RPM

operate on a single magneto

is usually sufficient to check

affect magneto drop-off. They

smoothly because drop-off

because

of the greater

at low power settings will

gage, may check

magnetos to one and note

regains speed and switch

return to both. Drop-off should

normal is usually a sign of a

0-235 AND 0-290

is important. Additional factors,

mixture strength. The important

the magneto check in accordance

Propeller - With propeller

50 to 65% power as indicated

control should be in the

the ignition system and spark

pressure within

problems, if they exist,

NOTE

propellers, or not equipped

magneto drop-off

(2000 RPM maximum).

RPM difference between

for too long a period, 2 to

drop-off and will minimize

is affected by the

in minimum pitch

only indicate fuel-air

drop-off, return to

to the other magneto and

too lean or too rich

SERIES

other then

are, load-power

thing is

with the

by the

full rich

plugs must

the cylinders.

will occur.

with engine

not exceed 175

magnetos. A

3

plug

7. OPERATION IN FLIGHT. A. See airframe manufacturer's instructions for correct manifold

pressure for power settings.

B.

Fuel Mixture Leaning Procedure

flight is

take-off and climb manual provide proper engines, they eliminating excessive replacement. It is therefore

responsible for many engine

power settings. The procedures

fuel-air mixture when leaning

have proven to be both economical

fuel consumption and reducing

recommended that operators

-Improper fuel-air mixture problems, particularly during

described in this

Avco Lycoming

and practical by

damaged parts

of all Avco

during

LYCOMING OPERATOR'S MANUAL

AND 0-290 SERIES

0-235

Lycoming tion any time

Never exceed

continuous operation

For tained

On direct drive control in "Full Rich" tinuous, from high elevation airport

result from over-richness.

may enough to obtain struments for temperature rise. mixture is most likely

Always enrich

C. LEANING TO

(1) Above 75% power -Never lean beyond 150°F. on rich side of peak

EGT unless aircraft operator's manual shows otherwise. Monitor cylinder head temperature.

(2)

D. LEANING WITH MANUAL MIXTURE CONTROL. (At 75%

power or

(1) Slowly move mixture control from "Full Rich" position toward lean position.

aircraft powerplants

the fuel-air

LEANING

the maximum red line cylinder

below 435°F.

climb and cruise

75% power and below

less without

(224°C.).

engines with manual mixture

position for rated take-off rated

smooth operation - not

to be encountered at altitude

mixture before increasing

EXHAUST GAS TEMPERATURE

flowmeter

utilize the

mixture is

PRECAUTIONS

cylinder

powers above

or during climb, roughness or

head temperatures

such a case adjust

In

Rough operation due to over-rich

-Operate at peak

or EGT

instructions

adjusted during

head temperature limit.

control maintain mixture

75%. However,

mixture control

for economy. Observe in-

power.

EGT.

gage.)

SECTION

in this publica-

flight.

should be

maxmimum con-

during take-off

loss of power

fuel-air

above 5,000 feet.

GAGE.

3

main-

only

(2) Continue leaning until engine roughness is noted. (3) Enrich until

E. ALTERNATE

propellers.)

(1) Slowly move watching tachometer.

(2) At this point enrich until is obtained at this point.

engine runs smoothly

METHOD. (In calm

mixture control toward lean

Continue leaning until

RPM just peaks. Correct

and power is regained.

air and engines with fixed pitch

position while closely

RPM decreases.

fuel-air ratio

3-5

LYCOMING OPERATOR'S MANUAL

SECTION 3 0-235 AND 0-290 SERIES

NOTE

Leaning may be done at any altitude that the engine will accept leaning: The greater the altitude the more important leaning becomes. Proper leaning is important because more engine power and increased air speed are obtained along with decreased fuel consumption, longer spark plug life, less lead fouling, temperatures. Engine damage from leaning the mixture does not occur at the specified cruise power power plant, but is the result of improper leaning atpower settings above recommended

Use of Carburetor Heat Control

F.

conditions, it is possible for ice to form in the induction system even in summer weather. This is due to the high air velocity through the car- buretor venturi and the absorption of heat from this air by evaporization of the fuel. The temperature in the mixture chamber may drop 20°F. to 70°F. below

this air contains a large cause begin in the vicinity of the extent that a drop in manifold power output results. This loss of power is reflected by a drop in manifold with constant

RPM in detected, this condition will continue to such an extent that the reduced power will cause complete engine stoppage.

To avoid this condition, all installations are equipped with a system for preheating the incoming air supply to the carburetor. In this way, sufficient heat is added to replace the heat loss to vaporization of fuel, and the mixing point of water. This air preheater is essentially a tube or jacket through which the exhaust pipe from one or more cylinders is passed, and the air flowing over these surfaces is raised to the required temperature before entering the carburetor. Consistently high temperatures are to decided variation of the mixture. High charge temperatures also favor detonation and preignition, both of which are to be avoided if normal service life the proper method

cruise.

precipitation in the form

speed propellers and a drop

installations equipped with

chamber's temperature cannot

is to be expected from the

and more normal oil

for the model engine in a basically

-Under certain moist atmospheric

the temperature of the incoming

amount of moisture, the

of ice. These ice formations generally

butterfly and will often build

pressure in installations

fixed pitch propellers. If not

be avoided because of a loss

engine. The following outline

of utilizing the carburetor

and cylinder head

healthy

air. If

cooling process will

up to such an

equipped

in manifold pressure and

drop to the freezing

of power and a

is

heat control.

0-235

AND 0-290 SERIES

LYCOMING

OPERATOR'S

MANUAL

SECTION

3

(1) Take-Off- Take-off cold position. The possibility remote.

(2) Flight

the cold foggy or hazy lookout

Operation -The carburetor

position during normal flight

days, regardless of outside temperature,

for loss of power. This countable loss in manifold whether aircraft. When and

a constant speed or fixed pitch

this situation arises, apply

open the throttle to limiting in a slight additional this drop will system.

be regained

When the ice has been the carburetor heat In those aircraft partial

heat may be used

freezing

Caution must

that do not have form that raised crystals ice due carburetor. aircraft that

point (32°F.).

would ordinarily

in temperature

are melted

to the temperature

It is advisable,

are not equipped with a carburetor

be exercised when operating

equipped

a carburetor

into liquid form.

should be made with

carburetor heat in full

of icing at wide throttle

air heat control should

operations. On damp, cloudy,

loss of power will be shown

pressure or RPM or

both, depending on

propeller is installed on the

full carburetor air heat

manifold pressure. This will

drop in manifold pressure which

as the ice is melted

out of the

melted from the induction

control should be returned to

to keep the

WARNING

air temperature

pass through

by use

drop as it

therefore,

with a carburetor

mixture temperature

the induction

of partial heat

This moisture

passes through

to use

air temperature

with partial heat on aircraft

gage. Moisture

to the point

can form carburetor

either full

air temperature gage.

opening is very

be left in

keep a sharp

by unac-

result

is normal and

induction

system,

the cold position.

gage,

above

the

in crystal

system, can

where the

the venturi of heat or

no heat in

be

the

(3)

Landing Approach

- In making

buretor air heat should However,

Heat" should under heat should See aircraft

if icing

conditions are

be applied.

these conditions,

be returned to "Full Cold"

flight manual for specific

usually be in the "Full

an approach

known or suspected,

In the case

as for

that full power

an aborted

landing, the carburetor

prior to power application.

instructions.

for a landing,

Cold" position.

then

need be applied

car-

"Full

3-7

LYCOMING

OPERATOR'S

MANUAL

SECTION 3 0-235 AND 0-290 SERIES

8. ENGINE FLIGHT CHART.

Fuel and Oil Model

O-235-C, -E, -H2C

O-235-F, -G, -J, -K, -L, -M,

O-290-D, -D2 ....

* Refer to the latest edition of Service Instruction No. 1070.

Aviation grade are

approved for continuous

. . . . . .....

100LL fuels in which the lead

.. . . . ................

-N, -P .... . 100/100LL

NOTE

content is limited to 2 c.c. per gallon

use in the above listed engines.

*Aviation Grade

. 80/87 octane minimum

octane minimum

. ..80/87 octane minimum

Fuel

**Recommended Grade Oil

Average

Ambient Air

All Temperatures Above 80°F. Above 60°F. (15.5°C.) 30 (-1.11°C.) to 90°F. (32.2°C.) SAE 40 SAE 40

0°(-17.8°C.) to 70°F.

Below 10°F. (-12.2 C.) ** Refer to the latest edition of Service Instruction No. 1014.

Oil Sump Capacity 6 Qts. 8 Qts. Minimum Safe Quantity

of Oil in Sump

It is recommended that the lubricating oil be changed every 50 flying hours (or every 25 hours,

Oil Pressure, psi

0-235 Series

-C, -E, -F, -G, -H2C, -J, -K, -M

-B,

-L*, -N

-P 90 55 15

* Front of engine

(26.6°C.)

(21.1°C.) SAE 30

if engine does not have

OPERATING CONDITIONS

MIL-L-6082

Grades

....--

SAE 60 SAE SAE 50

SAE 20

0-235 Series -D2 Series

2 Qts.

a full-flow oil filter).

Maximum Minimum

90 60 90 60

90

MIL-L-22851

Ashless Dispersant

Grades

SAE 15W50 or 20W50

60

SAE 40 or SAE 50 SAE 40, 30 or 20W40

SAE 30 or 20W30

0-290-D,

2 Qts.

Idling

25 15

50 15

LYCOMING

OPERATOR'S

MANUAL

SECTION 3

All 0-235

-L, -N, -P 0-290 Series

-D

-D2

-D2 Fuel All

0-290-D

Above 30 (-1.11°C.)

0° (-17.8°C.) to 70°F.

Below

series,

pressure

0-235 models,

Average Ambien

(psi)

Temperature

60°F. (15.5°C.)

to 90°F.

10°F.

(-12.2°C.)

OPERATING

except

O-290-D2

290-D2

t Air

(32.2°C.) (21.1°C.)

0-235 AND 0-290 SERIES

CONDITIONS

START/WARM-UP

100 115

Maximum

85 90 60 25

START/WARM-UP

100

Maximum

5

Desired

180°F.

180°F. (82°C.)

170°F.

160°F. (71°C.)

(Cont.)

Minimum

60

Desired Minimum

3

Oil Inlet Temperature

(82°C.) (77°C.)

Idling

25

0.5

Maximum

245°F. (118°C.) 245"F.

(118°C.) 245 F. (118"C.) 245°F.

(118 C.)

Engine operation.

oil temperatu

not be below 140"F.

(60"C.) during continuous

3-8A

0-235

AND 0-290

LYCOMING

SERIES

OPERATOR'S

MANUAL

SECTION

3

OPERATING

Operation

Normal Performance Cruise

Economy

Normal Rated

Performance Cruise

Economy

Take-Off Normal Performance Cruise

Economy Cruise

Rated (75% Rated) 2350 86 7.3 (65%

(75% Rated) (65% Rated)

(75% (65%

Cruise

Rated)

Cruise

Rated

Rated) 2350 Rated)

RPM

2800 115

2250 75

2800 2500 2400

2800 2600

2250

CONDITIONS

HP

0-235-C,

0-235-F, -G, -J

125 10.7

94 7.3 81 5.8

0-290-D

130 125

94 7.5 81

0-290-D2

Fuel Cons.

Gal./Hr.

-E

10.7

5.8

Series

11.9

6.5 Series

(CONT.)

Max. *Max.

Oil Cons. Qts./Hr.

0.52

0.29

0.25

0.56

0.31

0.27

0.56

0.31

0.27

Cyl. Head

Temp.

500°F. (2600C.) 500°F. (260°C.) 500°F. (260°C.)

500°F. (260°C.) 500°F. (260°C.) 500°F. (260°C.)

500°F. (260°C.) 500°F.

(260°C.)

500°F.

(260°C.)

500°F.

(260°C.)

Take-Off Normal Performance Cruise

Economy Cruise

* - At

cylinder head

ing continuous

Rated (75% Rated) (65%

Rated) 2200

Bayonet Location

temperatures

operation.

2800 2600

2350 101

140 135

87 6.3

- For maximum between 150°F.

12.6

7.2

service life

(65°C.) and 400°F.

0.60

0.34

0.29

500°F. (260°C.) 500°F.

(260°C.)

500°F.

(260°C.)

500°F.

(260°C.)

of the engine, maintain

(204°C.) dur-

3-9

LYCOMING OPERATOR'S

MANUAL

SECTION 3

OPERATING

Operation

Normal Performance Cruise

Economy Cruise

Take-off 2800 Normal Rated 2700 Performance Cruise

Economy Cruise

Take-off 2800 Normal Rated 2600 Performance Cruise

Economy Cruise

Rated (75% Rated) 2500 (65% Rated) 2400

(75% Rated) 2425 (65% Rated) 2300

('75% Rated) 2350 (65% Rated) 2250

RPM HP Gal./Hr.

2800

CONDITIONS

Fuel Cons.

0-235-K, -L, -M

118 9.5

89 6.7 77 5.8

0-235-K2C

118 115 9.2

86 6.4

75 5.6

0-235-H Series

115 -- 108 10.7

81 7.3

70 5.8

0-235 AND 0-290 SERIES

(CONT.)

Max. Max. Oil Cons. Cyl. Head Qts./Hr.

.39 500°F. (260°C.) .30 .27

.38

.29 .25

.36 .27 .23

Temp.

500°F. (260°C.) 500°F.

(260°C.)

500°F. (260°C.) 500°F. (260°C.)

Take-off 2800 Normal Rated 2550 Performance Cruise

(75% Rated) 2300

Economy Cruise

65% Rated) 2200

3-10

0-235-N, -P

116 108 9.2

81 70 5.3

6.2

.36 .27 .23

500°F. (260°C.) 500°F.

(260°C) 500°F. (260°C.) 500°F. (260°C.)

LYCOMING

SECTION 3 0-235 AND 0-290 SERIES .9 SHUT-DOWN PRO('EDURE.

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. After engine stops, set magneto switch at the "off" position; this will prevent after-firing.

OPERATOR'S

MANUAL

Revised

March.

1982

3-10A

LYCOMING OPERATOR’S MANUAL

0-235 AND 0-290 SERIES

hRxNRE SETTING

SECTION 3

CURVE NO. 8210

Figure 3-l. Power and Fuel Consumption Curve

o-235-c

3-11

Figure 3-2. Sea Level and Altitude

Performanc

e - 0-235-C1, -El, -H2 Series

LYCOMING OPERATOR’S MANUAL

0-235 AND 0-290 SERIES SECTION 3

Figure 3-3. Fuel Flow vs Percent Rated Power.

0-235-C1, -El, -H2 Series

3-13

Figure 3-4. Sea Level and Altitude Performance. 0-290-D

LYCOMING OPERATOR’S MANUAL

0-235 AND 0-290 SERIES

.2-=---J-

SECTION 3

CURVE NO. 8583-A

--

Figure 3-5. Power and Fuel Consumption Curve-

0-290-D

3-15

LYCOMING OPERATOR’S MANUAL

0-235 AND 0-290 SERIES

SECTION 3

Figure 3.7. Power and Fuel Consumption Curve-

0-290-D2, -D2A

3-17

LYCOMING OPERATOR'S MANUAL

0-235 AND

The following is

Performance horsepower manifold pressure from

1. Determine equivalent mance curve 2400 RPM and

2. Repeat above

-Point "B").

3. Transfer (Example - Point "C").

4. Connect point

5. Read feet with a power setting of

99.5, Point "D").

6. Correct power approximately air temperature Add corrections for temperatures temperature of variation. approximately add correction:

0-290 SERIES

USING

curve on opposite page)

CURVE TO FIND

an example of how to use the

curves,

being delivered

and air inlet

for observed

23.8 in. Hg., locate procedure on sea level performance

value obtained

"A" and point "C"

horsepower

from the standard altitude

above

22°F. at an altitude

1% for

each 10°variation

3 horsepower.

99.5 + 3 = 102.5 horsepower,

printed

on line "CA" for

temperatures below standard,

standard.

ACTUAL HORSEPOWER

on these pages,

by the engine

temperature.

is for illustration purposes

full throttle horsepower

manifold pressure

Point "A").

in Step 2

2400 RPM and 23.8 in. Hg.,

to the altitude

with a straight line.

given altitude

1% for each 10°F. variation

(Example -

of 1800

is 3%. 3%

Since

temperature

Sea Level and Altitude

to determine

for given

This example

and RPM

temperature shown below.

With an air

feet, 52°F. - 22"F.

of 99.5 horsepower

Point "E").

SECTION

-

altitude, RPM,

(using figures

only.

on altitude perfor-

(Example

curve (Example

performance curve

(Example -At

horsepower is

is below standard,

actual

- At

1800

in intake

subtract for

inlet

= 30°F.

3

is

STANDARD

Pressure Altitude

(Thousands)

Standard Altitude

(Temperature

°F.)

ALTITUDE TEMPERATURES

SL

2 4 6 8 10

59 52 45

38 31 23 16 9

12 14 16 18

IN DEGREES

20 22 24

+ 2 -5 -12

F.

-19 -27

3-19

LYCOMING OPERATOR’S MANUAL

SECTION 3 o-235 AND 0.290 SERIES

3-20

Figure 3-9. Power and Fuel Consumption Curve .

0-290-D2B,-D2C

LYCOMING OPERATOR’S MANUAL

o-235 AND O-290 SERIES

SECTION 3

Figure 3-10. Fuel Flow vs Percent Rated Power -

0-235-F. -G Series

3-21

LYCOMING

OPERATOR'S

MANUAL

0-235

AND 0-290

9

SERIES

FUEL FLOW VS. PERCENT RATED POWER

AVCO LYCOMING 0-235-K, -L, -M SERIES

COMPRESSION RATIO 8 50 1 SPARK ADVANCE 20°BTC CARBURETOR. MARVEL SCHEBLER MA-3A or MA-3PA FUEL GRADE. MINIMUM 100/1OOLL

I

SECTION 3

PERCENT RATED POWER

Figure 3-12. Fuel Flow vs Percent Rated Power -

0-235-K, -L, -M Series

3-23

3-24

Figure

SECTION

3-13.

Sea

Level

and Altitude

Performance

-

0-235-K,

-L,

-M Series

3

LYCOMING

OPERATOR'S

0-235 AND

MANUAL

0-290

SERIES

0-235

0

I

AND

10

9

8

7

0-290

LYCOMING

OPERATOR'S

SERIES

FUEL FLOW vs. HORSEPOWER

LYCOMING

MINIMUM-ALLOWABLE FUEL FLOW

0-235-N,

MANUAL

-P SERIES

CURVE NO. 13401

SECTION

3

5

0

60

70 80

90

BRAKE HORSEPOWER

100

110

120

Figure 3-14. Fuel Flow vs. Horsepower

0-235-N, -P Series

3-25

3-26

Figure

3-15. Sea Level

0-235-N,

and Altitude

-P

Series

Performance

SECTION 3

z

LYCOMING

OPERATOR'S

0-235 AND 0-290 SERIES

MANUAL

--

LYCOMING

PERIODIC INSPECTIONS

Pre-Starting Inspection ................................. 4-1

Daily Pre-Flight ................................ ..... 4-2

25-Hour Inspection

50-Hour Inspection

100-Hour Inspection

400-Hour Inspection ..... ............................... 4-5

Non-Scheduled Inspection ............................... 4-5

.....................................

....................................

OPERATOR'S

MANUAL

Page

4-2 4-2 4-4

0-235

AND

0-290

LYCOMING

SERIES

OPERATOR'S

MANUAL

SECTION

4

Perhaps the aircraft regular found.

The

pages

the tion instructions.

Pre-Starting

aircraft the

phasize. responsible

centration, carelessness

operator

do

engine

general

The

importance

Among

no other

and

checks

not constitute

only.

Inspection

prior to

condition

Statistics

to

the major

reluctance

bred

PERIODIC

factor its components

for

minor

should

Consult

the

first flight

bear

of

of proper

prove

poor

pre-flight.

causes

by familiarity

SECTION

INSPECTION

NOTE

is quite

a

the

-The

the aircraft

troubles

in mind

complete

airframe

daily

of

so important

as

faithful

and

that

aircraft

manufacturer's

pre-flight

the day.

and engine.

pre-flight

several

hundred

of poor

pre-flight

to acknowledge

and

haste.

4

to safety

and diligent

prompt

the items

inspection,

inspection

This

inspection

accidents

inspection

the need

repair

listed

handbook

cannot

occur

for

and

durability

attention

when

in the

but

are

is a check

is to

be over

yearly

are lack

a

check

they are

following

meant

for

for addi-

of

the

determine

em-

directly

of

con-

list,

of to

4-1

LYCOMING OPERATOR'S MANUAL

SECTION

1. DAILY PRE-FLIGHT.

a. Be sure

b. Be sure magneto ground wires are connected. c. Check oil level. d. See that e. Check

at 50 hour inspection. Repair any major leaks before aircraft is flown. f. Open the fuel drain to remove

ment. g. Make sure all shields and

missing or aircraft is flown.

h. Check controls for general condition, travel and freedom of opera- tion.

i. Induction system air filter should be inspected and serviced in ac- cordance with the airframe manufacturer's recommendations.

2. 25-HOUR

time, a 50 hour inspection including draining and renewing lubricating oil.

3. 50-HOUR

flight inspection, every 50 hours of operation.

4

the "Off"

all switches

fuel tanks are

fuel and oil line connections,

damaged, repair or replacement

INSPECTION. After the

new, remanufactured or newly

INSPECTION. In addition

the following maintenance checks

are in

full.

cowling are in place and secure.

any accumulation of water

overhauled engines should

0-236 AND 0-290

position.

note minor indications for

should be made before the

first twenty-five hours operating

to the items listed for daily

should be made after

SERIES

repair

and sedi-

If any are

undergo

pre-

Ignition System - Remove

a.

Replace if necessary.

Examine spark plug leads of cable and ceramics for corrosion and

deposits. This condition

cleaning of the spark plug

proper condition is found, clean the cable ends, spark plug walls and ceramics with a dry, clean ketone. All parts should be clean and dry before reassembly.

Check ignition harness for security of mounting clamps and be sure

connections are tight at spark plug and magneto terminals.

4-2

cloth or a clean cloth moistened

spark plugs; test, clean and

is evidence of either leaking

walls or connector ends. Where

spark plugs, im-

with methyl-ethyl

regap.

this

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES SECTION 4

b. Fuel and Induction System - Check primer lines for leaks and security of clamps. Drain carburetor and clean carburetor fuel strainer. Check mixture freedom of movement, security of clamps and lubricate if necessary Check carburetor air intake ducts for leaks, security, filter damage;

evidence of dust or other solid material in the ducts is indicative of

inadequate filter care or damaged filter. Check vent lines for evidence of filter or oil seepage; if present, fuel pump may require replacement.

c. Lubrication System - Check oil lines for leaks, particularly at con- nections; for security of anchorage and for wear due to rubbing or vibration, for dents and cracks.

Drain and refill sump with new oil on installation not employing replaceable external oil filter. See the latest revision to Service In- struction are listed in Section 3, Paragraph 8 of this manual.

Remove oil suction and oil pressure screens and clean thoroughly.

Note carefully for presence of metal particles that are indicative of

internal engine damage.

If engine is equipped with external oil filters, replace at this time. Before disposing of filter, check interior for traces of metal particles that might be evidence of internal engine damage.

No. 1014 for recommended

control and throttle

lubricating oils. Seasonal

linkage for travel,

grades

d. Exhaust

cylinders removed and machined flat before they are reassembled and tightened.

Examine exhaust manifolds for general condition.

e. Cooling System - Check cowling for damage and secure anchorage. Any damaged or missing part of the cooling system must be repaired or replaced before the aircraft resumes operation.

f. Cylinders - Check rocker box covers for evidence of oil leaks. If found, replace gasket and tighten screws to specified torque (50 inch pounds).

Check cylinders for evidence of excessive heat which is indicated by burned paint on the cylinder. This condition is indicative of internal damage to the cylinder and, if found, its cause must be determined and corrected before the aircraft resumes operation.

System - Check attaching

for evidence of leakage. If

flanges at exhaust ports

they are loose, they must

on be

4-3

SECTION

Heavy

and

barrel cant used leakage condition and

operation.

ditions,

4.

100-HOUR

pre-flight shouldbe

a.

Electrical

cessories. Replace and

cleanliness.

b.

Magnetos

oil

in the breaker

cloth.

The accordance magneto Paragraph

c.

Engine

temperature mounting,

d

Cylinders

LYCOMING

4

discoloration

attachment

during

which

is

the

and made

faulty clamps

to

assembly

stops

neither cylinder

Any

felt

engine

lb of

Accessories

tight

harmful

If

it can

INSPECTION.

50

hour

after

every

System

shielded

-Check compartment,

located

with

the magneto

timing.

this manual.

and

pressure

connections

-Check

and appearance

area is

usually

of the barrel

after

cylinder

nor detrimental

be proven

should

be replaced.

In

inspection

-Check cables

or loose

condition

at

- Engine

visually

addition

one

hundred

all

wiring that wires

of breakers

if found,

the breaker

Timing

mounted

sensing

and

for

OPERATOR'S

0-235 AND

of seepage

due to

emission

at

has

that

the following

manufacturer's

procedure

units

terminals.

cracked

the factory,

been

in service

to the

the leakage

to

the

hours

of

connected

are damaged

and check

points.

wipe

points

is

accessories

should

or broken

MANUAL

at

the cylinder

engine

exceeds

items

maintenance

operation.

to

the engine

should

terminals

Check

dry with should

be

instructions.

described

be checked

fins.

0-290

SERIES

of thread

or

by slight

for awhile.

performance

these

listed

for daily

be

replaced.

for

security

for

excessive

a clean

lintless

lubricated

in Section

such

as pumps,

for

head

lubri-

gas

This

con-

checks

or

ac-

Check

secure

in

5,

e. Engine

security ly worn.

f Primer

for

equal

g.

Valve

Paragraph

h.

Carburetor

The

correct

4-4

Mounts

and

excessive

Nozzles

flow.

Rockers

11 for valve

-

Check

torque

- Check wear.

-

Disconnect

(0-235

and

rocker

throttle

for these

engine

0-290-D)

mounting

Replace

primer

clearance.

body

screws

any

bushings

nozzles

-

Check

attaching

is 40 to

bolts

and

that

from

engine

clearance.

screws

50 inch

pounds.

bushings

are excessive-

and

check

See Page

for

5-15,

tightness.

for

LYCOMING

0-235 AND 0-290 SERIES SECTION 4

OPERATOR'S

MANUAL

i. Lubrication

filter.

5. 400-HOUR INSPECTION.

pre-flight, 50 hour check should be made after every 400 hours of operation.

Valve

Inspection - Remove rocker

valve rockers when valves are closed. Look for evidence of abnormal

wear or broken parts and spring seat. If any indications are found, the cylinder and all of its components assembly) and inspected for further damage. Replace any parts that do not conform with limits shown

System - Drain and renew

In addition to

and 100 hour inspections,

box covers and check for freedom

in the area of the valve tips, valve

should be removed (including

in the latest publication

lubrication oil. Replace

the items listed for daily

the following maintenance

keeper, springs

the piston and connecting rod

of Special Ser-

oil

vice Publication No. SSP1776.

6. NON-SCHEDULED INSPECTIONS. Occasionally, service bulletins or service instructions are issued by Avco Lycoming Division that re- quire inspection procedures publications, usually obsolete after corrective modification has been accomplished. All such publications are available from Avco ,ycoming distributors, or from the factory by tion information. Maintenance facilities should have an up-to-date file of these publications available at all times.

subscription. Consult Service

are limited to specified engine

that are not listed in

Letter No. L114 for subscrip-

this manual. Such

models and become

of

4-5

LYCOMING OPERATOR'S

MAINTENANCE PROCEDURES

Ignition and Electrical System

Harness and Wire Replacement ......................... 5-1

Timing Magnetos to Engine ............................ 5-1

Generator or Alternator

Fuel System

Repair of Fuel Leaks .................................. 5-7

Carburetor

Fuel

Grades and Limitations Air Intake Ducts Idle Speed and Mixture

Lubrication System

Inlet Screen Assembly

and Filters .........

Output .........................

...................... 5-7

...........................

Adjustment .....................

MANUAL

.................. 5-7

Page

5-6

5-7

Oil Grades and Limitations ........................... 5-8

Oil Sump Oil Suction and Oil

Oil Relief Valve .................... .................. 5-9

Cylinder Assembly

Removal of Cylinder Assembly ......................... 5-9

Assembly of Cylinder Assembly ....................... 5-12

Generator Drive Belt Tension ........................... 5-14

Capacity ....................................

Pressure Screens .....................

5-8 5-8

LYCOMING

OPERATOR'S

MANUAL

0-235 AND 0-290 SERIES

SECTION 5

MAINTENANCE PROCEDURES

The procedures described in this section are provided to guide and in- struct personnel in performing required in conjunction with the periodic inspections listed in the preceding section. No operations that will be found in the applicable Avco Lycoming Overhaul Manual.

1. IGNITION AND ELECTRICAL SYSTEM. a. Ignition Harness and Wire Replacement - In the event that an ig-

nition harness ing diagram to be sure harness is correctly installed. Mark location of clamps and locations.

b.

Timing Magnetos to Engine

magnetos model application) are

the same

Either the impulse coupling

plicable) is installed on the left side of the engine.

clips to be certain the replacement

are used on this series

attempt is made to include repair

or an individual lead is to be

the timing

for

all magnetos.

such maintenance operations

replaced, consult the wir-

is clamped at correct

- Although several combinations engines, (see Table of Models

procedures,

NOTE

or retard breaker magneto (whichever

in the following

SECTION 5

that may be

and replacement

for

paragraphs,

is ap-

of

(1) Remove 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 spark normal rotation until the the starter ring at

the two o'clock position on the Consult specification At this point, the engine

a spark plug from No. 1 cylinder

plug hole. Continue rotating

gear is in exact alignment with

the cylinder tending to

the crankshaft in direction

advance timing mark on the

front face of the starter

for correct timing mark for

is ready for assembly of the

and place a thumb over

push the thumb off

front face of

the small hole located

housing.

your installation.

magnetos.

5-1

of

LYCOMING

OPERATOR'S

MANUAL

SECTION 5

0-235

AND 0-290

SERIES

5-2

FIRING

Figure 5-1. Ignition Wiring Diagram

ORDER

1-3-2-4

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES SECTION 5

Figure 5-2.

FIRING ORDER 1-3-2-4

Ignition Wiring Diagram

(Optional)

5-3

LYCOMING

OPERATOR'S

MANUAL

SECTION 5

0-235 AND

0-290 SERIES

5-4

Figure

FIRING ORDER 1-3-2-4

5-3. Ignition

Wiring

Diagram

(Optional)

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES SECTION 5

All timing one cylinder advance engine magnetos.

The

method of positioning the cylinder advance engine firing position is contained in the following paragraphs. The method for Bendix magnetos may be found on page 5-6.

(Impulse Coupling Magneto) Hold the No. 1 lead wire spring 1/16 in. to

1/8 in. away from the magneto

click at a time until a strong spark jumps between the spring and the frame. Hold the the

point where it trips and the proximately 25 until vent plug hole. Hold the rotor by inserting the timing pin, and line the timing pin with the center of the vent plug hole.

(Conventional Magneto) Hold the No. 1 lead wire spring 1/8 in. away from the frame. flux

lines until a strong spark occurs

to the

flux until the timing pin hole

hole and insert

procedures, except positioning

firing position, are the

Slick magnetos in the number

frame and turn the impulse

magneto firmly so the coupling

spark occurs. Reverse the rotation

the timing pin hole appears

Turn the gear counter-clockwise

at the lead. Reverse the rotation

appears in the center of the vent

the timing pin into

the hole.

the magneto in the number

same for all

one

coupling one

will not move beyond

ap-

in the center of the

vigorously through the

in-

plug

5-5

LYCOMING OPERATOR'S MANUAL

SECTION 5 0-235 AND 0-290 SERIES

NOTE

If the crankshaft is accidently turned in the direction opposite normal rotation, repeat the above procedure as accumulated backlash will make the final timing incorrect.

(2) Remove the inspection plugs from both magnetos and turn the drive

shafts in direction of normal

chamfered tooth on the distributor gear is aligned in the center of

the inspection window. Being sure that the gear does not move from this position, install gaskets and magnetos on the engine. Secure with washers

and nuts; tighten

NOTE

rotation until the first

only finger tight.

painted

In order to turn

pawl

on the

(3) Using a battery powered timing light, attach the positive lead to a suitable terminal connected to the ground terminal of the magneto and

the negative lead to any unpainted the magneto in its mounting on,

then slowly turn it in the opposite out. Bring the magneto back slowly until the light just comes on. Repeat this with the second magneto.

Some

timing lights operate in the light comes on when the breaker points open. Check your timing light in- structions.

(4) After both magnetos have to

ascertain that both magnetos

(5)

Back off the crankshaft a few out. Bring until

the timing mark and the alignment. Tighten nuts

c. Generator or Alternator Output - The generator or alternator (whichever is applicable) should be checked to determine that the specified voltage and current are being obtained.

the shaft on an impulse coupling

impulse coupling

the crankshaft slowly back

At this point, both lights

to specified torque

with

the finger.

flange to a point where the

NOTE

reverse manner as described above,

been timed, check, as described

are set to fire simutaneously.

degrees, the timing lights should

hole in the starter housing

(150 inch pounds).

magneto, depress the

portion of the engine.

direction until the light

in direction of normal rotation

should go on simultaneously.

Rotate

light comes

goes

the

below,

go

are in

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES SECTION 5

2. FUEL SYSTEM. a. Repair

is replaced, only a fuel soluable lubricant, such as clean engine oil or Loctite Hydraulic Sealant, may be used on the threads. Any other thread lubricant

b. Carburetor Inlet

distortion or openings

ditions. Clean assembly in

stall

in the throttle

c. Fuel Grades

subject engines is listed in the Engine Flight Chart on page 3-8 of this manual. In the event locations, it is octane then specified is not to be used. Under no circumstances should automotive

These engines are equipped with solid stem valves and should use higher

octane fuel only for limited

be familiar with Service Instruction No. 1070 regarding specified fuel for

Avco Lycoming engines.

d Air Intake Ducts and Filter - Check all air intake ducts for dirt or

restrictions. Inspect and service air filters as instructed in the air- frame manufacturer's handbook.

e. Idle Speed and Mixture Adjustment -

(1) Start the engine and warm up in the usual manner until oil and cylinder head temperatures are normal.

of Fuel Leaks -In the event a

or compound

Screen Assembly -Remove

in the strainer. Replace for

the screen asembly, place the

body, then tighten to

and Limitations -The recommended

that the specified fuel is not

permissible to use higher octane

fuel be used (regardless

must not be used.

solvent and dry with compressed

NOTE

operation. It is recommended

line or fitting in the fuel system

and check the screen for

either of these con-

air. To in-

gasket on the assembly and

35 - 40 inch pounds torque.

aviation grade

available at some

fuel. Fuel of a lower

of octane rating).

that personnel

install

for

(2) Check magnetos. If the "mag-drop" is normal, proceed with idle adjustment.

(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 suc- ceeding steps, readjust the idle speed.

LYCOMING

OPERATOR'S

MANUAL

SECTION

5

(4) When the idling speed mixture control lever

0-235 AND 0-290

has been stabilized, move

with smooth, steady pull toward

SERIES

the cockpit

the "Idle Cut- Off" position and observe the tachometer for any change during the leaning process. Caution

must be exercised to

return the mixture control to the "Full Rich" position before the RPM can drop to a point where the engine cuts out. An increase of more than 50 RPM while "leaning"

out indicates an excessively

rich idle mixture. An immediate decrease in RPM (if not preceded by a momentary in- crease) indicates

the idle mixture

is too lean.

If the above indicates that the idle adjustment is too rich or too lean, turn the idle mixture correction,

and check this new

procedure. Make additional

adjustment in the direction

position by repeating the

adjustments as necessary

required for

above

until a check results in a momentary pick-up of approximately 50 RPM. Each time the adjustment is changed, RPM to clear the engine Make the final

adjustment of the idle speed

the desired idling RPM

before proceeding with

with closed throttle. The

the engine should be run

adjustment to obtain

above method aims

up to 2000

the RPM check.

at a setting that will obtain maximum RPM with minimum manifold pressure. In case the setting does not remain stable, check the idle linkage; any looseness in this linkage would cause erratic idling. In all cases,

allowance should be made for

the effect of weather condi-

tions and field altitude upon idling adjustment.

3. LUBRICATION SYSTEM. a. Oil Grades and Limitations -Service the engine with grade recom-

mended in Flight Chart, Section 3-8.

b. Oil Sump Capacity -

0-235 Series .................................. 6 U.S. Quarts

0-290-D and -D2 Series .......................... 8 U.S. Quarts

Minimum Safe Quantity in Sump ................. 2 U.S. Quarts

c. Oil Suction and Oil Pressure Screens. For engines without a full-flow

oil filter, change oil and inspect and clean screens every 25 hours.

NOTE

On installations employing full-flow oil filters, step c. is not practical at this time, but should be observed at the 100 hour inspection.

5-8

LYCOMING OPERATOR'S MANUAL

AND 0-290 SERIES

0-235

c. Oil Relief Valve - Subject engines are equipped with either an ad-

justable

crankcase half to the rear will maintain the oil pressure adjusting pressure. The non-adjustable valve can control pressure by the addi- tion of a maximum of nine pressure

pressure.

d Oil Relief

the operator to maintain

If the pressure exceed the follows:

With the engine warmed RPM, observe the reading above screw the adjusting screw pressure. Depending on installation, ly a screw driver slot the turned with either a screw driver or a box wrench.

4. CYLINDER

disassembly field operation, cylinder entire assembly. Valve replacement should be undertaken only as an emergency measure.

or a non-adjustable oil

of no. 3 cylinder pad. The adjustable

screw inward to increase

STD-425 washers under the cap

or a spacer (P/N 73629 or 73630)

Valve (Adjustable) -The adjustable

engine oil pressure within

under normal operating conditions

maximum or minimum specified

on the oil pressure gage.

maximum or below minimum

out to decrease pressure and

and is turned with a screw

screw driver slot plus a pinned

ASSEMBLY. Although the

and reassembly is given here,

maintenance be confined to

relief valve located in the

within specified limits by

pressure and outward to

under the cap to decrease

oil relief valve enables

the specified limits. should consistently

limits, adjust the valve

up and running at approximately

specified limits, stop engine

the adjusting screw

driver; or may have

.375-24 castellated nut and

complete procedure for

it is recommended that, as

SECTION

right

valve

screwing the

decrease

to increase

as

2000

If the pressure is

and

in to increase

may have on-

may be

replacement of the

5

a

a. Removal of

Remove exhaust

(1) (2) Remove rocker box drain

clips that interfere

Cylinder Assembly

manifold.

with the removal

-

tube, intake pipe, priming

of cylinder.

lines and any

LYCOMING

SECTION 5 0-235 AND 0-290 SERIES

OPERATOR'S

MANUAL

(3) Disconnect ignition cable Remove

approximately (4) Remove

enabling removed when the

(5) Remove shroud tube.

(6) Remove the crankcase. as the piston falling.

The tappets, push rods, rocker that they can be assembled

removed.

Removal of Valves

b.

cylinder tion. Remove the split ings and valve head. Hold the valve stems so that the valve will not fall out and remove the cylinder from the holding block. The valves may now be removed from the inside of the cylinder.

rocker box

at top

valve rockers

the valve rockers to be removed.

cylinder is taken from

push rods

cylinder

leaves the cylinder.

over a block

Compress the valve springs

base nuts and

Do not

and Valve

of wood so

keys from the end of the valve

spring seats may now be removed

at spark plugs and remove

cover and rotate

center of the

by sliding

by grasping the

allow the piston

Hold

NOTE

arms and valves must be

in the same location from which

Springs from

as to hold the

using the valve spring compressor.

crankshaft

compression

the valve rocker

Valve rocker shaft can the engine.

ball end and

pull cylinder

to drop against shroud tubes

Cylinder -

valves in a closed

stem. The valve spr-

spark plugs.

until piston

stroke.

shaft aside

pulling rod out

directly away

the crankcase

to prevent their

identified so

they were

Place the

from the cylinder

is

be

of

from

posi-

c. Removal

plugs. then proceed on cylinder pad discarded cylinder base

5-10

of Piston from Connecting

Insert piston pin puller through

to remove

of the crankcase. Support

Rod - Remove the piston

piston pin, assemble puller

piston pin. Do

oil ring seals or any other

not allow connecting

with heavy rubber bands,

method.

rod to

nut;

rest

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES SECTION 5

d Removal of Hydraulic Tappet Sockets and Plunger Assemblies -

(0-290-D2 Series) It will be necessary to remove and bleed the

hydraulic checked when ed in the following manner: A special Avco Lycoming tool is available

for removal of the sockets and plunger assemblies. In the event the tool is not available,

The hydraulic tappet socket may usually be removed by inserting

the forefinger ly stick to the finger

If the grasping However, care must be exercised remove Lycoming service tool. In the event that the tool is not available, the hydraulic tappet plunger assembly in the end of a short piece of lockwire, inserting the lockwire around the edge of the plunger hook engages assembly out of the tappet body by gently pulling the wire.

Never use a magnet to remove hydraulic plunger assemlies from the crankcase. This can cause the check ball to remain off its seat rendering

the unit inoperative.

tappet plunger assembly so

the cylinder assembly is reinstalled.

proceed as described

into the concave end of the

firmly enough to be pulled

socket cannot be removed

the edge of the socket with

the hydraulic tappet plunger

assembly, and turning the

the spring of the plunger

CA UTION

that dry tappet clearance can

This is accomplish-

below.

socket. The socket will usual-

in this manner, it may be removed

to avoid scratching

may be removed by bending

out of the tappet body.

a pair of needle nose pliers.

assembly, use special

assembly. Draw the plunger

the socket. To

Avco

a hook

wire so that the

be

by

e. Assembly of Valves in Cylinder - Prelubricate valve stems with

Molytex Grease 0 or equivalent and insert each valve stem in its

respective

valves are held against the seats and assemble the lower valve spring seat, auxiliary valve seat and outer valve spring over the valve stem

and guide. Place the upper valve spring seat on top of the springs.

When wound coils marked with dye or lacquer) toward the cylinder.

valve guide. Place cylinder

NOTE

installing valve springs, place

over a block of wood so

the dampener end of spring

that the

(close

LYCOMING OPERATOR'S MANUAL

SECTION 5 0-235 AND 0-290 SERIES

Using a valve spring compressor, compress the valve springs and place the split keys in the groove around the upper end of the valve stem. Slowly release the pressure allow the upper spring seat to lock itself in place around the valve keys.

f Assembly of Hydraulic Tappet Plunger Assemblies - (0-290-D2 Series) To assemble the unit, unseat the ball by inserting a thin clean bronze wire through the oil inlet hole. With the ball off its seat, insert the plunger and twist clockwise so that the spring catches.

g. Assembly of Cylinder and

that the connecting rod of the cylinder being assembled is at the top

center position with both tappets on the low side of the cam in a posi-

tion that corresponds with both valve closed.

(1) 0-290-D2 Series - Place each hydraulic tappet plunger assembly in its respective body and assembly socket on top of plunger assembly.

Assemble piston so that the

(2) 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. During assembly, always use a generous amount of oil, both in the piston pin hole and on the piston pin.

(3) Assemble one piston pin plug at each end of the piston pin and place a new cylinder base oil seal ring around the cylinder skirt. Coat piston, rings and the inside of the cylinder generously with oil.

(4) Using piston so that the intake and exhaust ports are toward the bottom of the engine.

a piston ring compressor,

on the valve spring compressor

Related Parts - Rotate the

cylinder number stamped

assemble the cylinder over the

crankshaft so

and

on the

(5) Push the cylinder down onto the cylinder mounting studs. (6) Insert a new shroud tube (7) Pull the cylinder back far enough to insert one end of each shroud

tube into position in the cylinder head, and hold shroud tube so that rubber seals will enter the seal seats in the crankcase. Push the cylinder all the way down.

oil seal over each end of

shroud tube.

LYCOMING

OPERATOR'S

MANUAL

0-235 AND 0-290 SERIES

NOTE

Before installing

thru-stud

1. 90% SAE 50W engine oil and 10% STP.

2. Parker Thread Lube.

3. 60% SAE

(8) Assemble directed in the

At anytime studs on the cylinder

(a) Tighten the pounds with the

(b) Repeat the above to 600 inch

420 inch pounds

cylinder base hold down nuts,

threads with any

30W engine oil and 40%

one of the following lubricants.

the cylinder base hold

following

a cylinder

on the opposite side

steps.

NOTE

is replaced, it

1/2 inch or 7/16 inch hold

(25 foot

pounds) torque

upper right hand nut and proceed

steps and tighten the 1/2 inch

pounds (50 foot pounds)

(35 foot pounds)

Parker Thread Lube.

is necessary to

in the following

torque

stated.

SECTION 5

lubricate the crankcase

down nuts and tighten

of the engine.

retorque the thru-

down nuts to 300 inch

sequence:

Begin

in a clockwise direction.

hold down nuts

or 7/16 inch hold down nuts

using the exact

sequence

as

to

(c) Tighten the 3/8 inch hold pounds) torque;

Some 0-235 Series engines

these nuts ing sequence

to 300 inch pounds (25 foot pounds)

stated in step

sequence of tightening

(d) As a final check five seconds.

If the nut does not turn,

tightened to the correct torque.

down nuts to 300 inch pounds

is optional.

NOTE

employ only 3/8 inch hold

torque using the tighten-

(a).

hold the torque wrench on

it may be presumed to

(25 foot

down nuts. Tighten

each nut for about

be

5-13

LYCOMING OPERATOR'S MANUAL

SECTION 5

all cylinder

After

cylinder

fins by filing

Assemble

(9) assemble between rocker.

(10) 0-290-D2

pression

the valve

ween

clearance,

the end of

over hydraulic

check valve

the clearance

If rod and clearance.

Inserting

(11) 0-235,

compression adjusting clearance following

nuts have

base

or burring.

each push

rocker

each

bosses

Series -

stroke

place the

tappet

clearance,

insert a longer

long rod

a

0-290D

stroke

screw

between

manner:

sliding

and

Be sure that and that stem tip

thumb of

the push

spring. While

not come

does

will cause

Series

and

in valve rockers

the valve

CAUTION

tightened

been

rod in

in its

both valves and the

rod and

which

or shorter push

- Be sure that

its respective respective valve rocker

valve rocker.

one hand

push down

holding should

within these

NOTE

a decrease

both

and

tip

0-235 AND 0-290

remove

position

shaft

the piston is at

are closed.

on the valve

be between

that the

valves

using clearance

valve rocker.

Check

In order

so as to

spring

the

.028

limits,

rod, as required

valve clearance.

in

piston

are closed.

SERIES

nicks

any

shroud

by placing

in place

tube,

to retain

top center com-

clearance

to check

directly

rocker

compress

compressed,

and .080

remove

the push

to correct

is at top

Assemble

adjust

gage

Adjust

in the

and

rocker

bet- this

the

inch.

center

the

in the

Set tappets clearance After

(12) All Engines

drain harness.

5. GENERATOR

belt 25 methods

after run-in,

adjusting,

tubes and

hours after installation.

checking generator

of

.007 in.

with

DRIVE BELT

clearance

the adjusting

lock

-Install gaskets exhaust

manifold.

-.009 in.

TENSION.

Refer

drive

clearance

should

and rocker

to Service Instruction

be from

screw

Install

Check the tension

belt tension.

cold. Recheck

.006 in.

in place

box covers,

spark plugs

with the

tappet

to .012

intake pipes,

and

No. 1129

in.

locknut.

ignition

of a new

for

LYCOMING OPERATOR'S MANUAL

TROUBLE-SHOOTING

Page

Failure Failure of Engine Low Power and Uneven Running Failure of

Rough Engine Low High Oil Temperature Excessive Oil Consumption

Cold Weather Difficulties ................................ 6-

Engine

of Engine to Start ................................

to Idle Properly .........................

..........................

Engine to Develop Full Power

..........................................

Oil Pressure .......................................

..................................

.............................

Does Not Stop ................................

...................

6-1 6-2 6-2 6-3 6-3 6-4

6-5

.6

4

LYCOMING OPERATOR'S

MANUAL

0-235 AND 0-290 SERIES

General

is to decide on eliminate The following usually found

TROUBLE

Failure of Engine to

-Experience these causes

Start

has

the various possible

chart lists

in maintaining

PROBABLE CAUSE Lack of fuel Check fuel system for

Underpriming

Overpriming

Incorrect setting

Defective

plugs

SECTION 6

TROUBLE-SHOOTING

proven the

one by one,

some of the

best method

causes of

beginning with

aircraft

throttle

spark

a given trouble

more common

engines.

leaks. Fill dirty lines, strainers or fuel cocks.

Prime with engine priming system.

Open engine.

Set

Clean spark

SECTION 6

of "trouble-shooting"

the most probable.

REMEDY

throttle

at 1/4 open

and adjust plug or

and then to

engine troubles

fuel tank. Clean

and "unload"

position.

or replace

plugs.

Defective

Improper of magneto

points Water in carburetor

battery

operation

breaker

points.

timing

with charged

Check

of magnetos.

inter-

Replaced battery.

Clean nal

Drain carburetor and fuel

lines.

6-1

LYCOMING OPERATOR'S MANUAL

SECTION 6 0-235 AND 0-290 SERIES TROUBLE Failure of Engine

to

Start

(Cont.)

Failure of Engine Incorrect carburetor Adjust throttle stop to to Idle Properly idle adjustment obtain correct idle.

Low Power and Uneven Running

PROBABLE CAUSE REMEDY

Internal failure

Idle mixture Leak in the induc-

tion system

Low cylinder

compression

Insufficient spark

Mixture too rich; indicated by sluggish engine operation, red exhaust flame at night. Extreme cases indicated by black smoke from exhaust.

Mixture too lean; indicated by over- heating or back- firing.

oil sump

Check for metal particles. If found, complete overhaul of engine is indicated.

Adjust mixture. Tighten all connections in

inauction system. Replace any parts that are defec- tive.

Check condition of piston rings, and valves.

Check entire ignition system.

Check primer shut-off valve for leakage. Read- justment of carburetor by authorized personnel is indicated.

Check fuel lines and filters for dirt or other restric-

tions. Readjustment of

carburetor is indicated.

strainer

Leaks in induction system

Defective spark plugs

Poor fuel

Tighten all connections. Replace defective parts.

Clean or replace spark plugs.

Fill tank with fuel of recommended grade.

LYCOMING

OPERATOR'S

MANUAL

0-235 AND TROUBLE PROBABLE Low Power and

Uneven (Cont.)

Failure of Engine to Develop Full Power

0-290 SERIES

Running

Magneto breaker

not working

points properly

Defective wire

Improper ignition timing

Defective plug connectors

Incorrect valve clearance

Throttle lever out of adjustment

Leak in tion system

Restriction in carburetor air scoop

ignition

spark

terminal

the induc-

CAUSE

SECTION 6

REMEDY

points. Check

Clean nal timing

Check wire

tester. Replace tive wire.

Check

and Replace

spark plug wire.

Adjust

Tighten all and replace defective parts.

Examine remove restrictions. Clean air filter.

of magnetos.

with electric

any defec-

magnetos

synchronization.

connectors

valve

throttle

air

for timing

clearance.

lever.

connections,

scoop and

inter-

on

Rough Engine

Improper

ignition

Faulty

Cracked

mount.

Unbalanced

propeller

engine

fuel

tank with

Fill mended fuel.

Tighten Check system with tester. Check ignition timing.

Replace

Remove propeller and have

it checked

recom-

connections.

all

mount.

balance.

for

6-3

LYCOMING OPERATOR'S MANUAL

SECTION 6 TROUBLE Rough Engine

(Cont.)

Low Oil Pressure

0-235 AND 0-290 SERIES

PROBABLE CAUSE REMEDY

Defective bushings bushings.

Malfunctioning Check entire engine. engine

Insufficient oil

Air lock or dirt in Remove and clean oil relief valve pressure relief valve.

Leak in suction line Check gasket between or pressure line. accessory housing and

Dirty oil strainers Remove and clean oil

High oil See "High Oil Temp- temperature erature" in "Trouble"

Defective pressure Replace gage.

gage. Stoppage -

intake passage Clean suction strainer.

mounting Install

with oil of recommended grade.

crankcase.

strainers.

column.

oil pump Check line

new mounting

Fill sump to proper

for obstruction

level

High Oil

Temperature

Insufficient

cooling for deformation or

Insufficient oil Fill oil sump to proper

supply

Low grade of oil Replace with oil conform-

Clogged strainers

air Check

oil lines

or

air inlet and outlet

obstruction.

level with mended grade.

ing to specification. Remove

strainers.

oil of recom-

and clean

oil

LYCOMING OPERATOR'S MANUAL

0-235 AND 0-290 SERIES

TROUBLE PROBABLE CAUSE

High Oil

Temperature

(Cont.)

Excessive Oil Consumption

Cold Weather Difficulties

Excessive blow-by

Failing or failed

bearing

Defective tempera- ture gage

Low grade of oil

Failing or failed bearing

Worn piston rings. Incorrect instal-

lation of piston rings

Cold oil

Inaccurate pres- sure readings

SECTION 6

REMEDY

Usually caused by worn or stuck rings. Complete

overhaul required.

Examine sump for metal particles. If found, com- plete overhaul of engine

s indicated.

Replace gage.

Fill tank with oil conform- ing to specification.

Check sump to metal particles.

Install new rings. Install new rings.

Move aircraft into a heated hangar. Heat oil.

In extreme cold weather, oil pressure readings up to approximately do not necessarily indicate malfunctioning.

100 lbs.

Weak battery

Overpriming

Install fully charged battery.

Leave throttle open and ignition "off". Put mixture

control in "Idle Cut-Off" and crank until engine

starts. Immediately return to "full rich" mixture.

LYCOMING OPERATOR'S MANUAL

SECTION 6

TROUBLE

Engine Does Not Stop

PROBABLE CAUSE

Linkage does not permit full travel of "Idle Cut-Off"

Leaking "Idle Cut-Off"

Faulty ignition

switch

0-235 AND 0-290 SERIES

REMEDY

Readjust linkage for full travel.

Overhaul carburetor.

Check ground wires, overhaul switch.

LYCOMING

INSTALLATION AND STORAGE

OPERATOR'S

MANUAL

Page

Preparation

General ..................

Inspection Attaching Oil and Fuel Propeller

Preparation

Corrosion Prevention in Engine Installed

in Inactive Aircraft ................................

Installation Drawing .................................

of Engine for Installation

...........................

of Engine

Engine

Line Connection ...........................

Installation

of Carburetor

Mounting .........................

to Mounts

..................................

...........................

for Installation

.....................

.................

7-1

7-2 7-2 7-2 7-2 7-2

7-2

7-3 7-5

LYCOMING

OPERATOR'S

MANUAL

0-235 AND 0-290 SERIES

SECTION 7

INSTALLATION

ENGINE FOR

1. PREPARATION

stalling an engine

OF

that has

been prepared

dehydrator plugs, bags of dessicant

Preservation and turning preservative

be facilitated

will operation. drained a cold place should for a period of cylinders. before

After the safety-wired, should again

engine with

they are clean,

will be a small

there but this tion, the lubricating

will remove

oil can be removed by removing the crankshaft

oil will then

three or four

drain through

if the engine is

Preservative oil which

by removing the

oil sump plug.

be removed

to an environment

24 hours before

If this is

attempting

oil sump has

and

be turned

the clean

not possible,

to drain the engine.

been drained,

the sump refilled

several revolutions

oil. When installing

if not, wash them

amount of preservative

can cause

no harm.

However,

oil should

any residual

preservative oil

tilted from side

be drained

SECTION 7

AND STORAGE

INSTALLATION.

for storage,

and preservative oil from

remove all

the engine.

the bottom spark plugs

revolutions

the spark plug

by hand. The

holes. Draining

to side during

has accumulated in the sump

Engines that

preservative

heat the cylinders

the plug should

with lubricating

to saturate

spark plugs,

in clean petroleum

oil remaining

after twenty-five

while the engine

that may have

have been stored

of at least

70°F. (21°C.)

oil is drained

with heat

be replaced,

oil. The crankshaft

the interior of

make sure

solvent.

in the

hours been present.

Of course,

is hot. This

Before

the above

can be

from the

lamps

the

that

engine,

of opera-

in-

in

Do not rotate

removing

before

preciable amount

will cause damage

ing,

oil with painted surfaces

vative

the crankshaft

the spark

of mixture,

to the engine.

CAUTION

of an engine

because

plugs,

the resulting

should be avoided

containing preservative

if the cylinders

action, known

Also, any

contact of the

contain

as hydraulic-

ap-

preser-

oil

7-1

LYCOMING OPERATOR'S

MANUAL

SECTION

General

silica-gel upon into the thoroughly removed and cleaned fuel be removed also note if eliminated gasoline

Inspection

engine has been damaged

7

- Should

any of the dehydrator

or similar

their removal

engine, that portion

cleaned

drain screen

located and cleaned any valves are

by coating

and lubrication

of Engine

removed, make

by distortion

material, be

from the

before using

in gasoline

the valve

Mounting

or misalignment

stresses within the engine.

Attaching

dations

Oil and Fuel

ed out on

Propeller

tion relative

Engine to Mounts

for method of

Line Connections

the accompanying

Installation

- Consult the

to propeller

mounting the engine.

broken during

engine,

of the engine

the engine.

or some other

in the fuel

a hydrocarbon

in

sticking. If

stem generously

oil.

- If the

sure that the

- See airframe

-The oil

installation

installation.

0-235 AND

containing crystals

plugs,

their term of

and if any

of the contents must be The

disassembled

oil strainers

hydrocarbon

inlet of

the carburetor

solvent.

The operator

they are, this condition

with a mixture

aircraft

is one from

engine mount

as this can

produce abnormal

manufacturer's

and fuel line

connections

drawings.

airframe manufacturer

0-290 SERIES

of

storage or

should

fall

and

should

be

solvent. The

also

should

should can be

of

an

which

is not bent or

recommen-

are call-

for informa-

PREPARATION

2.

Carburetors

following

Carburetor

Remove

procedures before

- Remove the

the fuel inlet

vent. Reinstall

OF CARBURETORS

that have

been prepared

strainer assembly

the fuel drain

FOR

for storage should

being placed in service.

fuel drain plug

and drain preservative

and clean

plug and

fuel inlet strainer

INSTALLATION.

undergo

in a hydrocarbon

assembly.

the

oil.

sol-

0-235

AND

0-290

LYCOMING

SERIES

OPERATOR'S

MANUAL

SECTION

7

CORROSION

Corrosion cylinder two days. mended

can occur,

walls

Therefore,

for inactive

sion condition

Ground running

the following to aggravate

a. As

soon as possible

into

the hangar,

be

performed.

b. Remove

remove c.

corrosion

both

Spray the

preventive revolutions either

of the

Spraying Systems

airless

trap in the

spray the air line

nozzle

should

Co.,

before

PREVENTION

IN

of

engines

the following

engines

for

a period

the

engine for

procedure;

rather

than

or

other

sufficient

spark

plugs

interior

with

spark

"Gunjet"

gun

of each

the

plug

be accomplished

is not

of a

conventional

spraying

INACTIVE

especially

that will

and will be

up to thirty

briefperiods

in fact,

minimize

after

the engine

shelter

cowling

from

cylinder

oil while

starter.

holes.

Model

24A-8395

available,

cylinders.

IN ENGINES

AIRCRAFT

in new

be inoperative

preservation

effective

days.

NOTE

the practice

this

corrosion

where

to

gain access

each

cylinder.

with

cranking

The spray

NOTE

using

an airless

or equivalent).

personnel

spray

INSTALLED

or overhauled

for periods

procedure

in minimizing

of time

is stopped,

is not a substitute

of ground

condition.

running

move

the preservation

to

the spark

approximately

the engine

gun

nozzle

may

spray

In the

install

certain

gun

should and be

engines,

as

is recom-

the corro-

the aircraft

process

plugs

(2)

ounces

about

be placed

gun

(Spraying

event an

a

moisture

oil is hot

brief

for

will tend

is to

and

five

on

as

of

(5)

in

at

d.

With the the spark preventive cylinders

crankshaft plug oil.

Assemble

have

been

holes

stationary,

with

spark

sprayed.

again

spray

approximately

plugs

and do

each cylinder

two ounces

not turn

crankshaft

through

of corrosion

after

7-3

LYCOMING OPERATOR'S MANUAL

SECTION 7 0-235 AND 0-290 SERIES

The

corrosion preventive oil to should conform to specification MIL-L-6529, Type 1 heated to 200°F./220°F. (93°C./104C.)

necessary to flush preservative aircraft. The small quantity of oil coating the cylinders will be expelled

from the engine during the first few minutes of operation.

be used in the foregoing procedure

spray nozzle temperature.

oil from the cylinder

prior to flying the

NOTE

It is not

Oils of the type corrosion of A

vco Lycoming Service Instruction

318 for recommended lubricating oil.

mentioned are to be used in Avco

prevention only, and not

Lycoming aircraft for

for lubrication. See the latest

No. 1014 and Service Bulletin

edition

No.

7-4

MANIFOLD

PRIMER

PRESSURE

OR

CONNECTION

Figure

OIL

Installation

7-1.

SUCTION

OIL

SCREEN

DRAIN

-MANIFOLD

PRIMER

PLUG

Drawing

CONN.

-Left

PRESSURE

Side

CONN

CARB.

View

MOUNTING

PAD

z

0 0

GROUND TERMINAL

OIL SUCTION

SCREEN

Figure 7-2. Installation

Drawing - Rear

View

MAGNETO S4LN-21

MAGNETO S4LN-20

THROTTLE CLOSED

ANGULAR MAY BE CHANGED TO SUIT INSTALLATION

GROUND TERMINALS

VIEW SHOWING S4LN-20 8 S4LN-21 (IMPULSE) MAGNETOS

.85°

POSITION OF THROTTLE

Figure 7-3.

VIEWS OF CARBURETOR

Figure 7-3. Installation Drawings

Installation

Drawings

IDLE

CUT OFF

-

FUEL INLET

64°

RICH

Z

C

LYCOMING OPERATOR'S MANUAL

TABLES

Page

Table of Limits .........................................

Inspection

After Top Overhaul or Cylinder Change with New Rings

Ground Run ........................................ 8-2

Flight Test ......................................... 8-3

Throttle HP at

Full Table of Speed Equivalents Centigrade Fahrenheit

Inch Fraction Conversions ............................... 8-6

Forms

Altitude .............................

..............................

Conversion Table

................... 8-5

8-1

8-4 8-4

LYCOMING

OPERATOR'S

MANUAL

AND 0-290

0-235

TIGHTENING

FOR

FORMATION

MUST

THAT ENGINES,

PUBLICATION

CONSULT 1029 AND RECTLY

CONSULT

NO. 1150

INSTALLING

SERIES

SECTION 8

TABLES

TORQUE

CONCERNING

BE MAINTAINED

LATEST

SSP1776.

NO.

LATEST

EDITION

INFORMATION

FOR

CYLINDER

RECOMMENDATIONS

TOLERANCES

AVCO

IN

EDITION

SERVICE

OF

ASSEMBLY.

AND

LYCOMING

SPECIAL

OF

INSTRUCTION

PERTINENT

SECTION 8

IN-

AND

DIMENSIONS

AIRCRAFT

SERVICE

NO.

TO COR-

8-1

GROUND OR

CYLINDER

(DO

NOT

1.

Avoid Head

All

dusty

aircraft

cowling

2.

3.

4. Accomplish

5. Never

6.

exceed If cylinder shut

down

continuing.

GROUND

Time

5 min

10

min

10

min 5 min 5 min 5 min

5 min

Mag.

Check

Power

Check

Idle

Check

RUN

USE

head and

RUN

RPM

MAP

1000 1200 1300

1500

1600

1700

1800

CHANGE

AFTER

location

into

should

ground

200°F.

temperatures

allow

AFTER

and

wind.

be

in

run

oil

engine

Temperature

oil

FIXED

TOP

WITH

MAJOR

loose

stones.

place,

cowl

in full

flat

temperature.

reach

to

cool

I cyl

R

Adjustment

WING

OVERHAUL

NEW

RINGS

OVERHAUL)

flaps

open.

pitch.

400°F.,

before

oil

L

Required

ONLY

Type

Registration Aircraft

Owner Engine S/N Run-Up

Pressure

R L

fuel

Aircraft

ft No.

No.

Model

p By

After

No.

Temperature carb

R

Completion

1.

Visually

2. Check

Date

Amb.

Air

inspi

oil

of

lev

Fuel

Flow

GroundRun

ect engine(s)

el(s)

z

FLIGHT TEST AFTER TOP OVERHAUL

OR CYLINDER CHANGE

WITH NEW

RINGS

1. Test

2. Use standard power for climb, and at least 75% power for cruise.

3.

4. Record

(Climb)

Cruise

Adjustments Required After Flight

fly aircraft

Make climb shallow and

engine instrument readings

RPM

Time MAP

one hour.

Temperature

oil

L

at good airspeed for cooling.

during climb and cruise.

FLIGHT TEST RECORD

Pressure

R

cy

L R

oil fuel carb Amb.

R L R L

L

1. Make careful

2. Check If oil consumption is excessive,

3.

manual for cylinder for scoring.

Tested by

After

Test

visual inspection

oil level(s).

limits), remove spark

Temperature

R Air L

Flight

Fuel

Flow

R

of engine(s).

(see operator's

plugs and check

m

0

LYCOMING

OPERATOR'S

MANUAL

SECTION

Altitude

Ft. H.

0

500 1,000 2,000

2.500

3,000 4,000 5,000 6,000 7,000 8,000 9,000

Sec./Mi.

72.0

60.0

51.4

45.0

40.0

36.0

32.7

30.0

27.7

25.7

8

THROTTLE HP

FULL

(Normally Aspirated Engines)

% S. L. Altitude

P. Ft. H. P.

100

98.5

96.8

93.6

92.0

90.5

87.5

84.6

81.7

78.9

76.2

73.5 TABLE

10,000

11,000 12,000 13,000 14,000 15,000 16,000 17,000 17,500 18,000 18,500 19,000

OF SPEED

M. P. H. Sec./Mi.

50 60 70 80

90 100 110 120 130 140

24.0

22.5

21.2

20.0

18.9

18.0

17.1

16.4

15.6

15.0

0-235 AND 0-290 SERIES

AT ALTITUDE

% S. L. Altitude

70.8

68.3

65.8

63.4

61.0

58.7

56.5

54.3

53.1

52.1

51.4

50.0

19,500

20,000

20,500 21,000 21,500

22,000 22,500 23,000 23,500 24,000 24,500 25,000

EQUIVALENTS

M. P. H. Sec./Mi.

150 160 170 180 190

200 210 220

230

240

14.4

13.8

13.3

12.8

12.4

12.0

11.6

11.2

10.9

10.6

% S. L.

Ft. H. P.

49.1

48.0

47.6

46.0

45.2

44.0

43.3

42.2

41.4

40.3

39.5

38.5

M. P. H.

250 260 270

280 290 300 310 320 330 340

8-4

LYCOMING

OPERATOR'S

MANUAL

SERIES

0-290

AND

0-235

CENTIGRADE-FAHRENHEIT

Example: headed 20°F. (C)

-12.22

(F-C);

to Centigrade;

column

C

56.7

-51.1

-45.6

-40.0

-34.0

-28.9

-23.3

-17.8

-6.67

1.11

4.44

10.00

15.56

21.11

26.67

32.22

37.78

43.33

48.89

54.44

60.00

65.56

71.00

76.67

82.22

87.78

93.33

98.89

To convert

then read

to the left.

F-C

-70

-60

-50

-40

-30

-20

-10

100 110 120 130 140 150 160 170 180

190 200 210

20°C.

find

0 10 20 30 40 50

60

70

80 176.0 90

to

68.0°F. 20 in the

F

-94.0

-76.0

-58.0

-40.0

-22.0

-4.0

14.0

32.0

50.0

68.0

86.0

104.0

122.0

140.0

158.0

194.0

212.0

230.0

248.0

266.0

284.0

302.0

320.0

338.0

356.0

374.0

392.0

410.0

Fahrenheit,

column

in the

center

204.44

210.00

215.56

221.11

226.67

232.22

237.78

243.33

248.89

254.44

260.00

CONVERSION

the center

20 in

find

column

C

104.44

110.00

115.56

121.11

126.67

132.22

137.78

143.33

148.89

154.44

160.00

165.56

171.11

176.67

182.22

187.78

193.33

198.89

(F) to

and read

the right.

SECTION

TABLE

column

convert

To

-6.67°C.

F-C 220

230 240 250 260 500.0 270 280 290 300 310 320 330 626.0 340 350 360 370 380 390 400 410 420

430

440 450 460 470 480 490 500 932.0

in the

F

428.0

446.0

464.0

482.0

518.0

536.0

554.0

572.0

590.0

608.0

644.0

662.0

680.0

698.0

716.0

734.0

752.0

770.0

788.0

806.0

824.0

842.0

860.0

878.0

896.0

914.0

8

8-5

LYCOMING OPERATOR'S

MANUAL

SECTION 8

FRACTIONS

INCH

of Circles

Decimals,

Inch

Fraction

Decimal

Equiv.

1/64 .0156

1/32 .0312

3/64

1/16 .0625

3/32

7/64

1/8

5/32

11/64 .1719

3/16 .1875

7/32

15/64

1/4 .25 .0491 6.350 3/4

.0469 .0017

.0937

.1094 .125

.1562 .0192

.2187 .0376 .2344 .0431

9/32 .2812

19/64

5/16

11/32

23/64 .3594

3/8 .375

13/32 .4062

27/64

7/16 .4375

15/32

31/64

.2969 .0692 .3125 .3437 .0928

.4219 .1398

.4687 .1725 .4844 .1842

Area

Area MM

In. Equiv.

Sq. .0002 .397

.0008 .794

1.191 35/64

.0031 1.587

.0069

.0094 2.778 .0123 3.175

2.381

3.969 21/32

.0232 4.366 .0276 4.762

5.556 23/32

5.593 47/64

.0621 7.144

7.540

.0767 7.937

8.731 27/32 .1014 9.128 .1105 9.525 .1296 10.319

10.716 59/64 .1503 11.112

11.906

12.303 63/64

0-235

CONVERSIONS

and Millimeters

Inch

Fraction

1/2

17/32

9/16

19/32

39/64

5/8

43/64

11/16

25/32

51/64

13/16

55/64

7/8

29/32

Decimal Area MM

Equiv.

.5 .5312 .2217 13.494 .5469 .2349 13.891 .5625 .2485 .5937 .2769 15.081 .6094 .2916 15.478

.625 .3068 15.875 .6562 .3382 16.669 .6719 .6875 .3712 17.462 .7187 .4057 18.256 .7344 .4235 18.653 .75 .4418 19.050 .7812 .4794 19.844 .7969 .8125 .8437 .5591 21.431 .8594 .5800 21.828 .875 .6013 22.225

.9062 .6450 23.019 .9219 .6675

15/16

31/32

.9375 .6903 23.812 .9687 .7371 24.606 .9844 .7610 25.003

AND 0-290

Sq. In.

.1964

.3545

.4987 .5185

SERIES

Equiv.

12.700

14.288

17.065

20.241

20.637

23.416

Textron Lycoming O-235 Series, Lycoming O-290 Series Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

ATTENTION

SAFETY WARNING

entitled to warranty

TABLE OF CONTENTS

Cylinders

Crankcase

crankshaft ends

Piston

Gears - Are of to insure

0-235 SERIES

SERIES

1. GENERAL. tribute to long life, economy and satisfactory operation of the engine.

Use of Carburetor Heat Control

OPERATING CONDITIONS

INSPECTION. After the

INSPECTION. In addition

INSPECTION.

5. 400-HOUR INSPECTION.

Timing Magnetos to Engine

Low Power and Uneven Running

Failure of Engine to Develop Full Power

Rough Engine

Low Oil Pressure

Excessive Oil Consumption

Cold Weather Difficulties

Engine Does Not Stop

General