Lycoming O-290 User manual

Operator’s Manual

Lycoming

O-235 and O-290 Series

Approved by FAA

5th Edition Part No. 60297-9

652 Oliver Street January 2007

Williamsport, PA. 17701 U.S.A.

570/323-6181

O-235 and O-290 Series Operator’s Manual

Lycoming Part Number: 60297-9

Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of

Lycoming.

All brand and product names referenced in this publication are trademarks or registered

trademarks of their respective companies.

For additional information:

Mailing address:

Lycoming Engines

652 Oliver Street

Williamsport, PA 17701 U.S.A.

Phone:

Factory: 570-323-6181

Sales Department: 570-327-7268

Fax: 570-327-7101

Lycoming’s regular business hours are Monday through Friday from 8:00 AM

through 5:00 PM Eastern Time (-5 GMT)

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http://www.lycoming.textron.com

LYCOMING OPERATOR’S MANUAL

ATTENTION

OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL

This operator’s manual contains a description of the engine, its specifications, and detailed information on

how to operate and maintain it. Such maintenance procedures that may be required in conjunction with

periodic inspections are also included. This manual is intended for use by owners, pilots and maintenance

personnel responsible for care of Lycoming powered aircraft. Modifications and repair procedures are

contained in Lycoming overhaul manuals; maintenance personnel should refer to these for such procedures.

SAFETY WARNING

NEGLECTING TO FOLLOW THE OPERATING INSTRUCTIONS AND TO CARRY OUT PERIODIC

MAINTENANCE PROCEDURES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER

LOSS. ALSO, IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED,

FOR ANY REASON; DAMAGE TO THE ENGINE AND PERSONAL INJURY CAN HAPPEN. CONSULT

YOUR LOCAL FAA APPROVED MAINTENANCE FACILITY.

SERVICE BULLETINS, INSTRUCTIONS AND LETTERS

Although the information contained in this manual is up-to-date at time of publication, users are urged to

keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters

which are available from all Lycoming distributors or from the factory by subscription. Consult the latest

revision of Service Letter No. L114 for subscription information.

SPECIAL NOTE

The illustrations, pictures and drawings shown in this publication are 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.

iii

LYCOMING OPERATOR’S MANUAL

IMPORTANT SAFETY NOTICE

Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The

service procedures recommended by Lycoming are effective methods for performing service operations.

Some of these service operations require the use of tools specially designed to the task. These special tools

must be used when and as recommended.

It is important to note that most Lycoming publications contain various Warnings and Cautions which

must be carefully read in order to minimize the risk of personal injury or the use of improper service

methods that may damage the engine or render it unsafe.

It is also important to understand that these Warnings and Cautions are not all inclusive. Lycoming could

not possibly know, evaluate or advise the service trade of all conceivable ways in which service might be

done or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses a

service procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will be

jeopardized by the service procedure they select.

LYCOMING OPERATOR’S MANUAL

TABLE OF CONTENTS

Page

SECTION 1 DESCRIPTION 1-1

SECTION 2 SPECIFICATIONS 2-1

SECTION 3 OPERATING INSTRUCTIONS 3-1

SECTION 4 PERIODIC INSPECTIONS 4-1

SECTION 5 MAINTENANCE PROCEDURES 5-1

SECTION 6 TROUBLE-SHOOTING 6-1

SECTION 7 INSTALLATION AND STORAGE 7-1

SECTION 8 TABLES 8-1

LYCOMING OPERATOR’S MANUAL

¾ Right Front View – O-235-C, O-290-D

Rear View – O-290-D2

LYCOMING OPERATOR’S MANUAL

SECTION 1

DESCRIPTION

Page

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

Cylinders.......................................................................................................................................................1-1

Valve Operating Mechanism ......................................................................................................................1-1

Crankshaft....................................................................................................................................................1-1

Crankcase .....................................................................................................................................................1-1

Oil Sump.......................................................................................................................................................1-1

Connecting Rods .......................................................................................................................................... 1-2

Pistons ...........................................................................................................................................................1-2

Accessory Housing.......................................................................................................................................1-2

Gears .............................................................................................................................................................1-2

Cooling System.............................................................................................................................................1-2

Lubrication System......................................................................................................................................1-2

Induction System..........................................................................................................................................1-2

Ignition System.............................................................................................................................................1-2

Table of Models............................................................................................................................................1-3

This Page Intentionally Left Blank.

LYCOMING OPERATOR’S MANUAL SECTION 1

O-235 AND O-290 SERIES DESCRIPTION

SECTION 1

DESCRIPTION

The Lycoming O-235 series, O-290-D series and O-290-D2 series engines are four cylinder, direct drive,

horizontally opposed, wet sump, air-cooled models.

In referring to the location of the various engine components, the parts are described in their relationship

to the engine as installed in conventional airframes. Thus the power take-off end is considered the front and

the accessory drive section the rear. The sump section is considered the bottom and the opposite side of the

engine where the shroud tubes are located is the top. References to the left and right side of the engine are

made with the observer facing the rear of the engine. Thus the front cylinder on the left bank is number 2

and the rear cylinder is number 4. The front cylinder on the right bank is number 1 and the rear cylinder is

number 3. The direction of rotation for accessory drives is determined by the observer facing 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 major parts, head and

barrel, screwed and shrunk together. The heads are made from an aluminum alloy casting with a fully

machined combustion chamber. The barrels, which are machined from chrome nickel molybdenum steel

forgings with deep integral cooling fins, are ground and honed to a specified finish.

The valve rocker shaft bearing supports and the rocker box housing are cast integrally with the head. The

valves are cooled by means of fins which completely surround the area of the exhaust valve and portions of

the intake valves. Valve guides and valve seats are shrunk into machined recesses in the head.

Valve Operating Mechanism – The valve operating mechanism is located on the topside. The camshaft is

located parallel to and above the crankshaft and operates in aluminum bearings. The camshaft in turn

actuates the valves by means of tappets. The valve rockers are supported on full floating steel shafts. The

valve springs bear against hardened steel seats.

NOTE

Hydraulic tappets which automatically keep the valve clearance at zero are employed on the

O-290-D2 series engines while solid tappets are employed on the O-235 and O-290-D series.

Proper valve clearance on the latter models is maintained by means of an adjusting screw

located in the valve rocker.

Crankshaft – Made from a chrome nickel molybdenum steel forging. All bearing surfaces are nitride

hardened. The expansion plug in the crankshaft must be removed on those models employing a two position

hydro control or variable pitch propeller.

Crankcase – Crankcase assembly consists of two reinforced aluminum alloy castings divided at the center

line of the engine and fastened together by bolts and nuts. The mating surfaces of the crankcase are joined

without the use of a gasket, and main bearing bores are machined for use of precision type main bearing

inserts.

Oil Sump – Incorporates 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 riser.

1-1

SECTION 1 LYCOMING OPERATOR’S MANUAL

DESCRIPTION O-235 AND O-290 SERIES

Connecting Rods – Made in the form of “H” sections from alloy steel forgings. They have replaceable

bearing inserts in the crankshaft ends and split type bronze bushings in the piston ends. The bearing caps on

the crankshaft ends are retained by means of two bolts and nuts through each cap.

Pistons – Machined from an aluminum alloy. Two compression rings and an oil regulating ring are

employed on all pistons. In addition, the O-235 series employs an oil scraper ring below the piston pin. The

piston pin is of the full floating type with a plug located at each end to prevent the pin from touching the

cylinder wall.

Accessory Housing – Made from an aluminum casting and is fastened to the rear of the crankcase and the

top rear of the oil sump. It forms a housing for the oil pump and the various accessory drives.

Gears – Are of the conventional type and precision machined, hardened to insure long life and satisfactory

operating qualities.

Cooling System – These engines are designed to be cooled by air pressure actuated by the forward speed of

the aircraft. Close fitting baffles build up a pressure and force the air through the cylinder fins. The air is

then exhausted through gills or augmentor tubes usually located at the rear of the cowling.

Lubrication System – The full pressure wet sump lubrication system is actuated by an impeller type oil

pump contained within the accessory housing.

Induction System – These engines are equipped with either of 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”. Particularly good distribution of the fuel-air

mixture to each cylinder is obtained from the center zone induction system, which is integral with the sump

and is submerged in oil, insuring a more uniform vaporization of fuel and aiding in cooling the oil in the

sump. From the riser the fuel-air mixture is distributed to each cylinder by individual intake pipes.

Ignition System – Dual ignition is furnished by two magnetos. Consult Table 1 for proper model application.

Depending on installation, the ignition wiring is so arranged as shown in either Figure 5-1, 5-2 or 5-3.

1-2

LYCOMING OPERATOR’S MANUAL SECTION 1

O-235 AND O290 SERIES DESCRIPTION

TABLE 1

MODEL APPLICATION

Magneto

Model Left Right Carburetor

Propeller Flange

Specification

(Modified)

O-235-C S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2

O-235-C1,-E1,-F1,-G1 S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2

O-235-C1B,-E1B,-F1B,-G1B S4LN-200 S4LN-204 MA-3A or –3PA AS-127-2

O-235-C2A,-E2A,-F2A,-G2A,

-K2A,-J2A S4LN-21 S4LN-20 MA-3A or –3PA AS-127-1

O-235-L2A*,-N2A*,-P2A* S4LN-21 S4LN-20 or

S4LN-204 MA-3A or –3PA AS-127-1

O-235-M1* S4LN-21 S4LN-20 or

S4LN-204 MA-3A or –3PA AS-127-2

O-235-C2B,-E2B,-F2B,-G2B,

-K2B,-J2B S4LN-1227 S4LN-1209 MA-3A or –3PA AS-127-1

O-235-C2C,-H2C 4251 4250 MA-3A or –3PA AS-127-1

O-235-K2C 4252 4250 or

4252 MA-3A or –3PA AS-127-1

O-235-L2C,-N2C** 4252 or

4281 4250 or

4281 MA-3A or –3PA AS-127-1

O-290-D S4LN-21 S4LN-20 MA-3SPA AS-127-2

O-290-D2 S4LN-21 S4LN-20 MA-3SPA AS-127-2

O-290-D2A S4LN-21 S4LN-20 MA-3SPA AS-127-2

O-290-D2B S4LN-21 S4LN-20 MA-3SPA AS-127-2

O-290-D2C S4LN-200 S4LN-204 MA-3SPA AS-127-2

* - O-235-L2A, -M1, -N2A, -P2A may have two (2) S4LN-21 magnetos as optional equipment.

** - O-235-L2C, -N2C may have two (2) 4252 magnetos as optional equipment.

1-3

This Page Intentionally Left Blank.

LYCOMING OPERATOR’S MANUAL

SECTION 2

SPECIFICATIONS

Page

Specifications – O-235-C, -E Series; O-235-C1C......................................................................................2-1

Specifications – O-235-F, -G, -J, -N, -P, -K, -L, -M Series.......................................................................2-2

Specifications – O-235-H Series; O-235-K2C............................................................................................2-3

Specifications – O-290-D; O-290-D2, -D2A, -D2B, -D2C.........................................................................2-4

Accessory Drives ..........................................................................................................................................2-5

Alternate Power Settings.............................................................................................................................2-5

Detail Weights .............................................................................................................................................. 2-6

This Page Intentionally Left Blank.

LYCOMING OPERATOR’S MANUAL SECTION 2

O-235 AND O-290 SERIES SPECIFICATIONS

SECTION 2

SPECIFICATIONS

O-235-C*, -E SERIES

FAA Type Certificate ....................................................................................................................................223

Take-off horsepower......................................................................................................................................115

Take-off RPM..............................................................................................................................................2800

Rated horsepower...........................................................................................................................................115

Rated RPM...................................................................................................................................................2800

Bore, inches.................................................................................................................................................4.375

Stroke, inches..............................................................................................................................................3.875

Displacement, cubic inches.........................................................................................................................233.3

Compression ratio..................................................................................................................................... 6.50:1

Prop. drive ratio ............................................................................................................................................. 1:1

Prop. driven rotation (viewed from rear)............................................................................................Clockwise

Firing orders............................................................................................................................................ 1-3-2-4

Spark occurs, BTC.........................................................................................................................................25°

Rocker clearance, cold......................................................................................................................... .007/.009

* - O-235-C1 has provision for two position prop. control valve.

O-235-C1C

FAA Type Certificate ....................................................................................................................................223

Take-off horsepower......................................................................................................................................115

Take-off RPM..............................................................................................................................................2800

Rated horsepower...........................................................................................................................................108

Rated RPM...................................................................................................................................................2600

Bore, inches.................................................................................................................................................4.375

Stroke, inches..............................................................................................................................................3.875

Displacement, cubic inches.........................................................................................................................233.3

Compression ratio..................................................................................................................................... 6.75:1

Prop. drive ratio ............................................................................................................................................. 1:1

Prop. driven rotation (viewed from rear)............................................................................................Clockwise

Firing orders............................................................................................................................................ 1-3-2-4

Spark occurs, BTC.........................................................................................................................................25°

Rocker clearance, cold......................................................................................................................... .007/.009

2-1

SECTION 2 LYCOMING OPERATOR’S MANUAL

SPECIFICATIONS O-235 AND O-290 SERIES

SPECIFICATIONS (CONT.)

O-235-F, -G, -J

FAA Type Certificate ....................................................................................................................................223

Take-off horsepower......................................................................................................................................125

Take-off RPM..............................................................................................................................................2800

Rated horsepower...........................................................................................................................................125

Rated RPM...................................................................................................................................................2800

Bore, inches.................................................................................................................................................4.375

Stroke, inches..............................................................................................................................................3.875

Displacement, cubic inches.........................................................................................................................233.3

Compression ratio....................................................................................................................................... 9.7:1

Prop. drive ratio ............................................................................................................................................. 1:1

Prop. driven rotation (viewed from rear)............................................................................................Clockwise

Firing orders............................................................................................................................................ 1-3-2-4

Spark occurs, BTC.........................................................................................................................................25°

Rocker clearance, cold......................................................................................................................... .007/.009

O-235-N, -P

FAA Type Certificate ....................................................................................................................................223

Take-off horsepower......................................................................................................................................116

Take-off RPM..............................................................................................................................................2800

Rated horsepower...........................................................................................................................................116

Rated RPM...................................................................................................................................................2550

Bore, inches.................................................................................................................................................4.375

Stroke, inches..............................................................................................................................................3.875

Displacement cubic inches..........................................................................................................................233.3

Compression ratio....................................................................................................................................... 8.1:1

Prop. drive ratio ............................................................................................................................................. 1:1

Prop. driven rotation (viewed from rear)............................................................................................Clockwise

Firing orders............................................................................................................................................ 1-3-2-4

Spark occurs, BTC.........................................................................................................................................20°

Rocker clearance, cold......................................................................................................................... .007/.009

O-235-K, -L, -M

FAA Type Certificate ....................................................................................................................................223

Take-off horsepower......................................................................................................................................118

Take-off RPM..............................................................................................................................................2800

Rated horsepower...........................................................................................................................................118

Rated RPM...................................................................................................................................................2800

Bore, inches.................................................................................................................................................4.375

Stroke, inches..............................................................................................................................................3.875

Displacement, cubic inches.........................................................................................................................233.3

Compression ratio....................................................................................................................................... 8.5:1

Prop. drive ratio ............................................................................................................................................. 1:1

Prop. driven rotation (viewed from rear)............................................................................................Clockwise

Firing orders............................................................................................................................................ 1-3-2-4

Spark occurs, BTC.........................................................................................................................................20°

Rocker clearance, cold......................................................................................................................... .007/.009

2-2

LYCOMING OPERATOR’S MANUAL SECTION 2

O-235 AND O-290 SERIES SPECIFICATIONS

SPECIFICATIONS (CONT.)

O-235-H