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Operator’s Manual Lycoming O-235 and O-290 Series Approved by FAA 5th Edition Part No. 60297-9 January 2007 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
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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.
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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.
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.
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.
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LYCOMING OPERATOR’S MANUAL SECTION 1 O-235 AND O290 SERIES DESCRIPTION TABLE 1 MODEL APPLICATION Magneto Propeller Flange Specification Model Carburetor (Modified) Left Right O-235-C S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2 O-235-C1,-E1,-F1,-G1 S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2 O-235-C1B,-E1B,-F1B,-G1B S4LN-200 S4LN-204 MA-3A or –3PA...
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WILL NOT ONLY VOID YOUR WARRANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS PASSED. New engines have been carefully run-in by Lycoming and therefore no further break-in is necessary insofar as operation is concerned; however, new or newly overhauled engines should be operated using only the lubricating oils recommended in the latest revision of Service Instruction No.
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES e. Set propeller governor (if applicable) in “Full RPM” position. f. Turn fuel valve to “on” position. g. Set throttle at ¼ travel. h. Move mixture control to “Full Rich”...
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The procedures described in this manual provide proper fuel-air mixture when leaning Lycoming engines. They have proven to be both economical and practical by eliminating excessive fuel consumption and reducing damaged parts replacement.
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES LEANING PRECAUTIONS Never exceed the maximum red line cylinder head temperature limit. For continuous operation cylinder head temperatures should be maintained below 435°F (224°C). On direct drive engines with manual mixture control, maintain mixture control in “Full Rich” position for rated take-off, rated maximum continuous, climb and cruise powers above 75%.
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS OPERATING CONDITIONS Oil Pressure, psi – Model Maximum Minimum Idling Start and Warm-Up O-235 –C, -E, -F, -G, -H2C, -J, -K, -M O-235-B O-235-L*, -N O-235-P O-290-D O-290-D2 * - Front of engine Fuel Pressure, psi –...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS OPERATING CONDITIONS (CONT.) O-235-N, -P Series Fuel Max. Max. Cons. Oil Cons. Cyl. Head Operation Gal./Hr. Qts./Hr. Temp. Take-Off 2800 ---- ---- 500°F (260°C) Normal Rated 2550 0.36 500°F (260°C)
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES 9. SHUT-DOWN PROCEDURE. a. Idle engine at approximately 800 to 900 RPM until there is a decided drop in cylinder head temperature. b. Move mixture control to “Idle Cut-Off”.
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-1. Power and Fuel Consumption Curve – O-235-C 3-11...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-2. Sea Level and Altitude Performance – O-235-C1, -E1, -H2 Series 3-12...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-3. Fuel Flow vs Percent Rated Power – O-235-C1, -E1, -H2 Series 3-13...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-4. Fuel Flow vs Percent Rated Power – O-235-F, -G, -J Series 3-14...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-5. Sea Level and Altitude Performance – O-235-F, -G, -J Series 3-15...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-6. Fuel Flow vs Percent Rated Power – O-235-K, -L, -M Series 3-16...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-7. Sea Level and Altitude Performance – O-235-K, -L, -M Series 3-17...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-8. Fuel Flow vs Horsepower – O-235-N, -P Series 3-18...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-9. Sea Level and Altitude Performance – O-235-N, -P Series 3-19...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-10. Power and Fuel Consumption Curve – O-290-D 3-20...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-11. Sea Level and Altitude Performance – O-290-D 3-21...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-12. Power and Fuel Consumption Curve – O-290-D2, -D2A 3-22...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS Figure 3-13. Sea Level and Altitude Performance Curve – O-290-D2, -D2A 3-23...
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-14. Sea Level and Altitude Performance Curve - O-290-D2B, -D2C 3-24...
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LYCOMING OPERATOR’S MANUAL SECTION 3 O-235 AND O-290 SERIES OPERATING INSTRUCTIONS USING CURVE TO FIND ACTUAL HORSEPOWER The following is an example of how to use the Sea Level and Altitude Performance curves, printed on these pages, to determine actual horsepower being delivered by the engine for given altitude, RPM, manifold pressure and air inlet temperature.
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SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-235 AND O-290 SERIES Figure 3-15. Power and Fuel Consumption Curve – O-290-D2B, -D2C 3-26...
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LYCOMING OPERATOR’S MANUAL SECTION 4 O-235 AND O-290 SERIES PERIODIC INSPECTIONS SECTION 4 PERIODIC INSPECTIONS NOTE Perhaps no other factor is quite so important to safety and durability of the aircraft and its components as faithful and diligent attention to regular checks for minor troubles and prompt repair when they are found.
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SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS O-235 AND O-290 SERIES 1. DAILY PRE-FLIGHT. a. Be sure all switches are in the “Off” position. b. Be sure magneto ground wires are connected. c. Check oil level. d. See that fuel tanks are full.
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LYCOMING OPERATOR’S MANUAL SECTION 4 O-235 AND O-290 SERIES PERIODIC INSPECTIONS Drain and refill sump with new oil on installation not employing replaceable external oil filter. See latest revision of Service Instruction No. 1014 for recommended lubricating oils. Seasonal grades are listed in Section 3, Paragraph 8 of this manual.
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O-235 AND O-290 SERIES f. Priming Nozzles – Disconnect primer nozzles from engine and check for equal flow. g. Valve Rockers (O-235 and O-290-D) – Check clearance. See Page 5-9, Paragraph (11) for valve rocker clearance. h. Carburetor – Check throttle body attaching screws for tightness. The correct torque for these screws is 40 to 50 in.-lbs.
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LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES SECTION 5 MAINTENANCE PROCEDURES The procedures described in this section are provided to guide and instruct personnel in performing such maintenance operations that may be required in conjunction with the periodic inspections listed in the preceding section.
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SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES FIRING ORDER 1-3-2-4 Figure 5-1. Ignition Wiring Diagram FIRING ORDER 1-3-2-4 Figure 5-2. Ignition Wiring Diagram (Optional)
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LYCOMING OPERATOR’S MANUAL SECTION 5 O-235 AND O-290 SERIES MAINTENANCE PROCEDURES FIRING ORDER 1-3-2-4 Figure 5-3. Ignition Wiring Diagram (Optional) Conventional Magneto – Hold the No. 1 lead wire spring 1/8 in. away from the frame. Turn the gear counterclockwise vigorously through the flux lines until a strong spark occurs at the lead.
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It is recommended that personnel be familiar with the latest revision of Service Instruction No. 1070 regarding specified fuel for 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 airframe manufacturer’s handbook.
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Oil Sump Capacity – O-235 Series........................6 U. S. Quarts O-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.
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LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES e. Oil Relief Valve (Adjustable) – The adjustable oil relief valve enables the operator to maintain engine oil pressure within the specified limits. If the pressure under normal operating conditions should...
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This is accomplished in the following manner: A special Lycoming tool is available for removal of the sockets and plunger assemblies. In the event the tool is not available, proceed as described below.
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LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-235 AND O-290 SERIES (2) Assemble piston so that the cylinder number stamped on the piston pin boss is toward the front end of the engine. The piston pin should be a push fit. If difficulty is experienced in inserting the piston pin, it is probably caused by carbon or burrs in the piston pin hole.
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(10) O-290-D2 Series – Be sure that the piston is at top center compression stroke and that both valves are closed. Check clearance between the valve stem tip and the valve rocker. In order to check this clearance, place the thumb of one hand on the valve rocker directly over the end of the push rod and push down so as to compress the hydraulic tappet spring.
LYCOMING OPERATOR’S MANUAL SECTION 6 TROUBLE-SHOOTING Page Failure of Engine to Start..........................6-1 Failure of Engine to Idle Properly......................6-1 Low Power and Uneven Running....................... 6-2 Failure of Engine to Develop Full Power....................6-2 Rough Engine ............................... 6-3 Low Oil Pressure............................6-3 High Oil Temperature ..........................
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LYCOMING OPERATOR’S MANUAL SECTION 6 O-235 AND O-290 SERIES TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING General – Experience has proven the best method of “trouble-shooting” is to decide on the various possible causes of a given trouble and then to eliminate these causes one by one, beginning with the most probable.
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SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-235 AND O-290 SERIES TROUBLE PROBABLE CAUSE REMEDY Low Power and Uneven Running Mixture too rich; indicated by Check primer shut-off valve for sluggish engine operation, red leakage. Readjustment of exhaust flange at night. Extreme...
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LYCOMING OPERATOR’S MANUAL SECTION 6 O-235 AND O-290 SERIES TROUBLE-SHOOTING TROUBLE PROBABLE CAUSE REMEDY Rough Engine Cracked engine mount. Replace mount. Unbalanced propeller. Remove propeller and have it checked for balance. Defective mounting bushings. Install new mounting bushings. Malfunctioning engine.
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SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-235 AND O-290 SERIES TROUBLE PROBABLE CAUSE REMEDY Excessive Oil Consumption Low grade of oil. Fill tank with oil conforming to specification. Failing or failed bearing. Check sump for metal particles. Worn piston rings.
LYCOMING OPERATOR’S MANUAL SECTION 7 INSTALLATION AND STORAGE Page Preparation of Engine for Installation....................... 7-1 General............................... 7-1 Inspection of Engine Mounting ....................... 7-1 Attaching Engine to Mounts ........................7-1 Oil and Fuel Line Connections ........................ 7-1 Propeller Installation ..........................7-1 Preparation of Carburetor for Installation ....................
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LYCOMING OPERATOR’S MANUAL SECTION 7 O-235 AND O-290 SERIES INSTALLATION AND STORAGE SECTION 7 INSTALLATION AND STORAGE 1. PREPARATION OF ENGINE FOR INSTALLATION. Before installing an engine that has been prepared for storage, remove all dehydrator plugs, bags of desiccant and preservative oil from the engine.
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SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-235 AND O-290 SERIES 2. PREPARATION OF CARBURETOR FOR INSTALLATION. Carburetors that have been prepared for storage should undergo the following procedures before being placed in service. Carburetor – Remove the fuel drain plug and drain preservative oil. Remove the fuel inlet strainer assembly and clean in a hydrocarbon solvent.
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INSTALLATION AND STORAGE NOTE Oils of the type mentioned are to be use in Lycoming aircraft for corrosion prevention only, and not for lubrication. See the latest revision of Lycoming Service Instruction No. 1014 and Service Bulletin No. 318 for recommended lubricating oil.
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SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-235 AND O-290 SERIES Figure 7-3. Installation Drawings...
LYCOMING OPERATOR’S MANUAL SECTION 8 TABLES Page Table of Limits ............................. 8-1 Inspection Forms After Top Overhaul or Cylinder Change with New Rings Ground Run............................8-2 Flight Test ............................... 8-3 Full Throttle HP at Altitude........................8-4 Table of Speed Equivalents ......................... 8-4 Centigrade-Fahrenheit Conversion Table....................
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RECOMMENDATIONS INFORMATION CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN LYCOMING AIRCRAFT ENGINES, CONSULT LATEST REVISION OF SPECIAL SERVICE PUBLICATION NO. SSP-1776. CONSULT LATEST REVISION OF SERVICE INSTRUCTION NO. 1029 AND NO. 1150 FOR INFORMATION PERTINENT TO CORRECTLY INSTALLING CYLINDER...
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LYCOMING OPERATOR’S MANUAL SECTION 8 O-235 AND O-290 SERIES TABLES...
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SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-235 AND O-290 SERIES FULL THROTTLE HP AT ALTITUDE (Normally Aspirated Engines) Altitude % S.L. Altitude % S.L. Altitude % S.L. H.P. H.P. H.P. 10,000 70.8 19,500 49.1 98.5 11,000 68.3 20,000 48.0 1,000 96.8...
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LYCOMING OPERATOR’S MANUAL SECTION 8 O-235 AND O-290 SERIES TABLES CENTIGRADE-FAHRENHEIT CONVERSION TABLE Example: To convert 20°C to Fahrenheit, find 20 in the center column headed (F-C); then read 68.0°F in the column (F) to the right. To convert 20°F to Centigrade; find 20 in the center column and read –6.67°C in the (C) column to the left.
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SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-235 AND O-290 SERIES INCH FRACTIONS CONVERSIONS Decimals, Area of Circles and Millimeters Inch Decimal Area Inch Decimal Area Fraction Equiv. Sq. In. Equiv. Fraction Equiv. Sq. In. Equiv. 1/64 .0156 .0002 .397 .1964 12.700...
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