Textron Lycoming O-235 Series Operator'S Manual Download Page 1

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Summary of Contents for Lycoming O-235 Series

Page 1: ...OPERATOR S MANUAL Lycoming 0 235 and 0 290 SERIES AIRCRAFT ENGINES 4th Edition January 1988 Approved by F A A Part No 60297 9...

Page 2: ...res can result in poor engine performance and power loss Also if power and speed limitations specified in this manual are exceeded for any reason damage to the engine and personal injury can happen Co...

Page 3: ...con tain various Warnings and Cautions which must be carefully read in order to minimize the risk of personal injury or the use of improper ser vice methods that may damage the engine or render it un...

Page 4: ...ne replacement is required Textron Lycoming s obligation during theproration period extends to major parts of the engine whichare limited to crankcase crankshaft camshaft cylinders connectingrods pist...

Page 5: ...N THE PART OF TEXTRON LYCOMING AND TEXTRON LYCOMING S LIABILITY ON SUCH CLAIMSHALL NNO CASE EXCEED THE PRICE ALLO CABLETO THE ENGINEORPARTWHICHGIVESRISETO THE CLAIM LIMITATIONOF LIABILITY IN NOEVENT W...

Page 6: ...on the part of Textron Lycoming setforth aboveare your exclusiveremedy and theexclusive liabilityof Textron Lycoming This warrantyallocates the risk of productfailure between you andTextron Lycoming a...

Page 7: ...GES INCLUDINGBUT NOT LIMITED TO LOSSOF PROFTS OR REVENUES LOSSOF USE OFTHE ENGINEORCOST OFA REPLACEMENT No agreement varying this warranty or Textron Lycoming s obligations under it will be binding up...

Page 8: ...nal maintenanceexpensesor consumableitems Theobligationson the pan ofTextron Lycomingsetforth abovt areyourexclusive remedyand theexclusive liabilityofTextron Lycoming This warrantyallocatesthe risk o...

Page 9: ...INCLUDING BUTNOT LIMITED TO LOSSOF PROFITSOR REVENUES LOSSOF USE OFTHE ENGINEORCOST OFA REPLACEMENT No agreement varying this warranty or Textron Lycoming s obligations under it will be binding upon...

Page 10: ...1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 DESCRIPTION SPECIFICATIONS OPERATING INSTRUCTIONS PERIODIC INSPECTIONS MAINTENANCE PROCEDURES TROUBLE SHOOTING INSTALLATION AND...

Page 11: ...5 314 Right Fmnt View 0 235 C 0 290 D...

Page 12: ...Rear View O 290 D2...

Page 13: ...Cylinders 1 1 Valve Operating Mechanism 1 1 Crankshaft 1 2 Crankcase 1 2 Oil Sum p 1 2 Connecting Rods 1 2 Pisto ns 1 2 Accessory Housing 1 2 Gears 1 2 Cooling System 1 3 Lubricating System 1 3 Induc...

Page 14: ...cing the drive pad The direction of rotation of the crankshaft viewed from the accessory end of the engine is clockwise Cylinders The cylinders are of conventional air cooled construction with the two...

Page 15: ...orates an oil suction screen carburetor mounting pad the intake riser and intake pipe connections The fuel air mixture as it passes through the riser is vaporized by the heated oil that surrounds the...

Page 16: ...two Marvel Schebler carburetors MA 3A or MA 3SPA See Table 1 for model application Both carburetors are of the single barrel float type and are equipped with manual mixture control and idle cut off Pa...

Page 17: ...tor Flange Specification Modified MA 3A or 3PA AS 127 2 MA 3A or 3PA AS 127 2 MA 3A or 3PA AS 127 2 MA 3A or 3PA AS 127 1 MA 3A or 3PA AS 127 1 S4LN 1227 4251 4252 4252 or 4281 S4LN 21 S4LN 21 S4LN 21...

Page 18: ...LYCOMING OPERATOR S MANUAL SPECIFICATIONS Page Specifications 0 235 2 1 Specifications 0 290 2 2 Accessory Drives 2 2 Alternate Power Ratings 2 3 Detail Weights 2 4...

Page 19: ...3 116 2800 116 2550 4 375 3 875 233 3 8 1 1 1 1 Clockwise Clockwise 1 3 2 4 1 3 2 4 25 20 007 009 007 009 control valve FAA Type Certificate Take off horsepower Take off RPM Rated horsepower Rated RPM...

Page 20: ...or Generator Optional Alternator Vacuum Pump Hydraulic Pump Tachometer Magneto Fuel Pump Prop Governor AN Drive Facing Drive Pad 229 130 2800 125 2600 4 875 3 875 289 0 6 50 1 1 1 Clockwise 1 3 2 4 25...

Page 21: ...H2C 100 hp 2400 rpm 0 235 L Series 105 hp 2400 rpm 110 hp 2550 rpm 112 hp 2600 rpm 115 hp 2700 rpm 0 235 M Series 105hp 2400 rpm 110 hp 2550 rpm 112 hp 2600 rpm 115 hp 2700 rpm 0 235 N Series 103 hp...

Page 22: ...0 235 C1 C2A 242 00 lbs 0 235 C1C C2B H2C 243 00lbs O 235 C2C 244 00 lbs O 235 K2C L2C 248 00Lbs O 235 EB F1B N2C 249 00 lbs O 235 E2A F2A 250 00 lbs O 235 F2B 251 00lbs O 235 K2A L2A 252 00 lbs O 23...

Page 23: ...of Maintenance 3 2 Starting Procedure 3 2 Cold Weather Starting 3 3 Ground Running and Warm Up 3 3 Checks Before Take Off 3 3 Operation in Flight 3 4 Use of Carburetor Heat Control 3 6 Engine Flight C...

Page 24: ...ERATION AND MAINTENANCE SPECIFICA TIONS FOR YOUR ENGINE WILL NOT ONLY VOID YOUR WAR RANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS PASSED New engines have been carefully...

Page 25: ...heat control in cold position e Set propeller governor if applicable in Full RPM position f Turn fuel valve to on position g Set throttle at 1 4 travel h Move mixture control to Full Rich i Turn boos...

Page 26: ...th the propeller in minimum blade angle setting c Leave the mixture control in Full Rich d Avoid prolonged idling at low RPM as this practice may result in fouled plugs Limit ground running to minimum...

Page 27: ...h manifold pressure gage may check magneto drop off with engine operating at approximately 1800RPM 2000RPM maximum 2 Switch from both magnetos to one and note drop off return to both until engine rega...

Page 28: ...ents for temperature rise Rough operation due toover rich fuel air mixture is most likely to be encountered at altitude above 5 000feet Always enrich mixture before increasing power C LEANING TO EXHAU...

Page 29: ...ormations generally begin in the vicinity of the butterfly and will often build up to such an extent that a drop in manifold power output results This loss of power is reflected by a drop in manifold...

Page 30: ...to the cold position In those aircraft equipped with a carburetor air temperature gage partial heat may be used to keep the mixture temperature above the freezing point 32 F WARNING Caution must be e...

Page 31: ...t Air Grades Grades All Temperatures SAE 15W50 or 20W50 Above 80 F 26 6 C SAE 60 SAE 60 Above 60 F 15 5 C SAE 50 SAE 40 or SAE 50 30 1 11 C to 90 F 32 2 C SAE 40 SAE 40 0 17 8 C to 70 F 21 1 C SAE 30...

Page 32: ...temperatu operation LYCOMING OPERATOR S MANUAL 0 235 AND 0 290 SERIES OPERATING CONDITIONS Cont START WARM UP 100 115 Maximum Minimum Idling 85 60 25 90 60 25 START WARM UP 100 Maximum Desired Minimum...

Page 33: ...5 Rated 2350 94 7 5 Economy Cruise 65 Rated 2250 81 6 5 0 290 D2 Series Take Off 2800 140 Normal Rated 2600 135 12 6 Performance Cruise 75 Rated 2350 101 7 2 Economy Cruise 65 Rated 2200 87 6 3 Max Ma...

Page 34: ...e off 2800 Normal Rated 2600 Performance Cruise 75 Rated 2350 Economy Cruise 65 Rated 2250 Take off 2800 Normal Rated 2550 Performance Cruise 75 Rated 2300 Economy Cruise 65 Rated 2200 118 9 5 89 6 7...

Page 35: ...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 th...

Page 36: ...LYCOMING OPERATOR S MANUAL 0 235 AND 0 290 SERIES SECTION 3 CURVE NO 8210 hRxNRE SETTING Figure 3 l Power and Fuel Consumption Curve o 235 c 3 11...

Page 37: ...Figure 3 2 Sea Level and Altitude Performanc e 0 235 C1 El H2 Series...

Page 38: ...LYCOMING OPERATOR S MANUAL 0 235AND 0 290SERIES SECTION 3 Figure 3 3 Fuel Flow vs Percent Rated Power 0 235 C1 El H2 Series 3 13...

Page 39: ...Figure 3 4 Sea Level and Altitude Performance 0 290 D...

Page 40: ...LYCOMING OPERATOR S MANUAL 0 235 AND 0 290 SERIES SECTION 3 CURVE NO 8583 A 2 J Figure 3 5 Power and Fuel Consumption Curve 0 290 D 3 15...

Page 41: ......

Page 42: ...LYCOMING OPERATOR S MANUAL 0 235AND 0 290SERIES SECTION 3 Figure 3 7 Power and Fuel Consumption Curve 0 290 D2 D2A 3 17...

Page 43: ......

Page 44: ...e altitude performance curve Example Point C 4 Connect point A and point C with a straight line 5 Read horsepower on line CA for given altitude Example At 1800 feet with a power setting of 2400 RPM an...

Page 45: ...LYCOMING OPERATOR S MANUAL SECTION 3 o 235 AND 0 290 SERIES Figure 3 9 Power and Fuel Consumption Curve 0 290 D2B D2C 3 20...

Page 46: ...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...

Page 47: ......

Page 48: ...FLOW VS PERCENT RATED POWER AVCOLYCOMING0 235 K L M SERIES COMPRESSION RATIO 8 50 1 SPARK ADVANCE 20 BTC CARBURETOR MARVEL SCHEBLER MA 3Aor MA 3PA FUEL GRADE MINIMUM 100 1OOLL PERCENT RATED POWER Fig...

Page 49: ...LYCOMING OPERATOR S MANUAL SECTION 3 0 235 AND 0 290 SERIES Figure 3 13 Sea Level and Altitude Performance 0 235 K L M Series 3 24...

Page 50: ...ND 0 290 SERIES SECTION 3 FUELFLOWvs HORSEPOWER LYCOMING0 235 N P SERIES CURVE NO 13401 10 MINIMUM ALLOWABLE FUEL FLOW 0 I 9 8 7 5 0 60 70 80 90 100 110 BRAKE HORSEPOWER Figure 3 14 Fuel Flow vs Horse...

Page 51: ...z LYCOMING OPERATOR S MANUAL 0 235 AND 0 290 SERIES SECTION 3 z Figure 3 15 Sea Level and Altitude Performance 0 235 N P Series 3 26...

Page 52: ...ATOR S MANUAL PERIODIC INSPECTIONS Page Pre Starting Inspection 4 1 Daily Pre Flight 4 2 25 Hour Inspection 4 2 50 Hour Inspection 4 2 100 Hour Inspection 4 4 400 Hour Inspection 4 5 Non Scheduled Ins...

Page 53: ...eant for the engine only Consult the airframe manufacturer s handbook for addi tion instructions Pre Starting Inspection The daily pre flight inspection is a check of the aircraft prior to the first f...

Page 54: ...ons 2 25 HOUR INSPECTION After the first twenty five hours operating time new remanufactured or newly overhauled engines should undergo a 50 hour inspection including draining and renewing lubricating...

Page 55: ...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 wit...

Page 56: ...heck terminals for security and cleanliness b Magnetos Check condition of breakers points Check for excessive oil in the breaker compartment if found wipe dry with a clean lintless cloth The felt loca...

Page 57: ...d be removed including the piston and connecting rod assembly and inspected for further damage Replace any parts that do not conform with limits shown in the latest publication of Special Ser vice Pub...

Page 58: ...uel Leaks 5 7 Carburetor Inlet Screen Assembly 5 7 Fuel Grades and Limitations 5 7 Air Intake Ducts and Filters 5 7 Idle Speed and Mixture Adjustment 5 7 Lubrication System Oil Grades and Limitations...

Page 59: ...ough several combinations of magnetos are used on this series engines see Table of Models for model application the timing procedures in the followingparagraphs are the same for all magnetos NOTE Eith...

Page 60: ...LYCOMING OPERATOR S MANUAL 0 235AND 0 290SERIES SECTION 5 FIRINGORDER 1 3 2 4 Figure 5 1 Ignition Wiring Diagram 5 2...

Page 61: ...LYCOMING OPERATOR S MANUAL 0 235AND 0 290SERIES SECTION 5 FIRING ORDER 1 3 2 4 Figure 5 2 Ignition Wiring Diagram Optional 5 3...

Page 62: ...LYCOMING OPERATOR SMANUAL 0 235 AND 0 290SERIES SECTION 5 FIRINGORDER 1 3 2 4 Figure 5 3 Ignition Wiring Diagram Optional 5 4...

Page 63: ...click at a time until a strong spark jumps between the spring and the frame Hold the magneto firmly so the coupling will not move beyond the point where it trips and the spark occurs Reverse the rota...

Page 64: ...negative lead to any unpainted portion of the engine Rotate the magneto in its mounting flange to a point where the light comes on then slowly turn it in the opposite direction until the light goes o...

Page 65: ...lable at some locations it is permissible to use higher octane fuel Fuel of a lower octane then specified is not to be used Under no circumstances should automotive fuel be used regardless of octane r...

Page 66: ...ately 50 RPM Each time the adjustment is changed the engine should be run up to 2000 RPM to clear the engine before proceeding with the RPM check Make the final adjustment of the idle speed adjustment...

Page 67: ...aximum or minimum specified limits adjust the valve as follows With the engine warmed up and running at approximately 2000 RPM observe the reading on the oil pressure gage If the pressure is above max...

Page 68: ...s and valves must be identified so that they can be assembled in the same location from which they were removed b Removal of Valves and Valve Springs from Cylinder Place the cylinder over a block of w...

Page 69: ...plunger assembly use special Avco Lycoming service tool In the event that the tool is not available the hydraulic tappet plunger assembly may be removed by bending a hook in the end of a short piece...

Page 70: ...body and assembly socket on top of plunger assembly 2 Assemble piston so that the cylinder number stamped on the piston pin boss is toward the front end of the engine The piston pin should be a push...

Page 71: ...nch pounds 25 foot pounds torque in the following sequence Begin with the upper right hand nut and proceed in a clockwise direction b Repeat the above steps and tighten the 1 2inch hold down nuts to 6...

Page 72: ...and 080 inch If the clearance does not come within these limits remove the push rod and insert a longer or shorter push rod as required to correct clearance NOTE Inserting a long rod will cause a decr...

Page 73: ...Start 6 1 Failure of Engine to Idle Properly 6 2 Low Power and Uneven Running 6 2 Failure of Engine to Develop Full Power 6 3 Rough Engine 6 3 Low Oil Pressure 6 4 High Oil Temperature 4 Excessive Oi...

Page 74: ...ing aircraft engines TROUBLE PROBABLE CAUSE REMEDY Failure of Engine to Start Lack of fuel Check fuel system for leaks Fill fuel tank Clean dirty lines strainers or fuel cocks Underpriming Overpriming...

Page 75: ...y 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 indic...

Page 76: ...ing and synchronization Replace connectors on spark plug wire Adjust valve clearance Failure of Engine to Develop Full Power Throttle lever out of adjustment Adjust throttle lever Leak in the induc ti...

Page 77: ...on line Check gasket between or pressure line accessory housing and crankcase Dirty oil strainers Remove and clean oil strainers High oil See High Oil Temp temperature erature in Trouble column Defect...

Page 78: ...d bearing Worn piston rings Incorrect instal lation of piston rings Cold oil Cold Weather Difficulties Fill tank with oil conform ing to specification Check sump to metal particles Install new rings I...

Page 79: ...0 290SERIES TROUBLE PROBABLE CAUSE REMEDY Engine Does Not Stop Linkage does not permit full travel of Idle Cut Off Readjust linkage for full travel Leaking Idle Cut Off Faulty ignition switch Overhaul...

Page 80: ...llation 7 1 General 7 2 Inspection of Engine Mounting 7 2 Attaching Engine to Mounts 7 2 Oil and Fuel Line Connection 7 2 Propeller Installation 7 2 Preparation of Carburetor for Installation 7 2 Corr...

Page 81: ...is not possible heat the cylinders with heat lamps before attempting to drain the engine After the oil sump has been drained the plug should be replaced safety wired and the sump refilled with lubric...

Page 82: ...line and lubrication oil Inspection of Engine Mounting If the aircraft is one from which an engine has been removed make sure that the engine mount isnot bent or damaged by distortion or misalignment...

Page 83: ...lter where the preservation process is to be performed b Remove sufficient cowling to gain access to the spark plugs and remove both spark plugs from each cylinder c Spray the interior of each cylinde...

Page 84: ...flush preservative oil from the cylinder prior to flying the aircraft The small quantity of oil coating the cylinders willbe expelled from the engine during the first few minutes of operation NOTE Oi...

Page 85: ...MANIFOLDPRESSURE CONN PRIMER CONN z 0 0 PRIMER OR MANIFOLD PRESSURE CONNECTION OILSUCTION SCREEN CARB MOUNTING PAD OILDRAIN PLUG Figure 7 1 Installation Drawing Left Side View...

Page 86: ...GROUND TERMINAL OIL SUCTIONSCREEN Figure 7 2 Installation Drawing Rear View...

Page 87: ...LS VIEWSHOWING S4LN 20 8 S4LN 21 IMPULSE MAGNETOS FUELINLET THROTTLE CLOSED 85 IDLECUTOFF ANGULAR POSITION OFTHROTTLE RICH MAYBECHANGED TOSUITINSTALLATION Z 64 C VIEWS OFCARBURETOR Figure 7 3 Installa...

Page 88: ...Limits 8 1 Inspection Forms After Top Overhaul or Cylinder Change with New Rings Ground Run 8 2 Flight Test 8 3 Full Throttle HP at Altitude 8 4 Table of Speed Equivalents 8 4 Centigrade Fahrenheit Co...

Page 89: ...ND IN FORMATION CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN AVCO LYCOMING AIRCRAFT ENGINES CONSULT LATEST EDITION OF SPECIAL SERVICE PUBLICATION NO SSP1776 CONSULT LATEST EDITION O...

Page 90: ...o 2 Head aircraft into wind 3 All cowling should be in place cowl flaps open Owner 4 Accomplish ground run in full flat pitch 5 Never exceed 200 F oil temperature Engine 6 If cylinder head temperature...

Page 91: ...trument readings during climb and cruise Tested by FLIGHT TEST RECORD RPM Temperature Time MAP oil cy L R L R Climb Cruise Adjustments Required After Flight Pressure Temperature Fuel Flow oil fuel car...

Page 92: ...18 000 18 500 19 000 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 49 1 48 0 47 6 46 0 45 2 44 0 43 3...

Page 93: ...137 78 280 536 0 17 8 0 32 0 143 33 290 554 0 12 22 10 50 0 148 89 300 572 0 6 67 20 68 0 154 44 310 590 0 1 11 30 86 0 160 00 320 608 0 4 44 40 104 0 165 56 330 626 0 10 00 50 122 0 171 11 340 644 0...

Page 94: ...12 0621 7 144 25 32 19 64 2969 0692 7 540 51 64 5 16 3125 0767 7 937 13 16 11 32 3437 0928 8 731 27 32 23 64 3594 1014 9 128 55 64 3 8 375 1105 9 525 7 8 13 32 4062 1296 10 319 29 32 27 64 4219 1398 1...

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