Lycoming O-290-g Ground Power Unit Manuals X3 On Cd on 2040-parts.com

1)       Overhaul Instructions and Parts Catalog for Lycoming Model O-290-G Series  Aircooled Engine for Ground Power Applications

2)       Lycoming O-290 GPU Conversion Information to Lycoming O-290D

 Three Manuals in 1 - Good Scanned copies. 296 Pages scanned as High resolution TIF images and then digitally cleaned page by page. Packed with invaluable data including many Photographs, diagrams and Tables (See detailed contents list below). These engines were used by the US Airforce as Ground Power Units for large aircraft and as portable generators. In the 1960’s and 1970’s many homebuilders converted these now surplus units as economical engines for homebuilt aircraft. The first manual was published under the secretary of the Airforce in September 1950 with revisions to November 1951 and reprinted in 1954. It Contains 2 manuals in one. The first being T.O. (Technical Order) 19-45-90 the Overhaul Manual and T.O. 19-45-91 being the Illustrated Parts Catalog and totals 90 pages.

The third manual is a private work compiled by Donald Pridham in 1970 and details his research into the O-290-G and its conversion to an O-290-D to enable its use in aircraft and runs to 205 pages in total.

Also included on the CD is an Adobe Acrobat version of the manuals for easy browsing (Adobe Reader 7.0 supplied on the CD). Comes in a nicely printed Jewel case. See my other auctions for more vintage aircraft and engine manuals.  

Contents

Overhaul Instructions and Parts Catalog for Lycoming Model O-290-G Series Aircooled Engine for Ground Power Applications

SECTION I - INTRODUCTION

General

Principles of Operation

Table 1 – General Specifications

Description

SECTION II – SPECIAL TOOLS LIST

General Overhaul Tools

Crankshaft Overhaul Tools

Inspection Tools

Spark Plug Bushing Tools

Valve Seat Replacement Tools

Vale Guide Replacement Tools

SECTION III – TABLE OF LIMITS

Table II – Torque Limits

SECTION IV – DISASSEMBLY, CLEANING AND INSPECTION

General

Disassembly

Disassembly of Sub-Assemblies

Cleaning Solvents and Blasting

Inspection

Table III – Data on Parts to be Magnafluxed

SECTION V – REPAIR AND REPLACEMENT

General

Table IV – Valve Seat Reconditioning Dimensions

Table V – Dimensions and Tool Listing for Valve Guide Holes in Cylinder Head

SECTION VI – REASSEMBLY

Crankshaft Assembly

Crankcase Assembly

Accessory Housing Assembly

Cylinder Assembly

Oil Sump and Accessories Assembly

Magneto Assembly and Magneto Timing

SECTION VII – ENGINE TEST, PREPARATION FOR STORAGE AND COMPLETION OF ASSEMBLY

General

Engine Test Run Schedule

Oil Consumption Test

Preparation for Storage

Completion of Engine Assembly After Test

Lycoming O-290 GPU Conversion Information to Lycoming O-290D

Chapter I - THE PROBLEM AND DEFINITIONS OF TERMS USED

Trends in lightplane development

Homebuilt aircraft

The increase in amateur aircraft construction

The diminishing supply of engines

One solution to the shortage of economical engines

Why the GPU for amateur-built aircraft?

                The Problem

Statement of the problem

Importance of the study

Limitations of the study

                Definition of Terms Used

Chapter II -  REVIEW OF THE LITERATURE

A Short History of the Lycoming Horizontally Opposed Engines

       The 0-145, patriarch of the family

       The new series

How the 0-235 grew up

The present engines

The future

Lycoming’s Ground Power Unit

Development and field use

In-service problems

The GPU returns to flight service

Variations in the 0-290-G

The FAA Position Regarding the GPU in Aircraft

Aircraft

The GPU in homebuilts

GPU parts in certificated engines

Certification of the GPU

Conversion of the Lycoming GPU to an Aircraft Power plant

Pre-purchase checking

Engine disassembly and inspection

The crankcase

The crankshaft

The camshaft

Tappets

Pistons and rings

Cylinders and valves

The sump and induction system

Lubrication

Electrical components

       Cooling and the engine baffles

Chapter III - METHOD OF PROCEDURE

       Purpose of the Study

Historical Research

Engine Conversion Project

The Goals

Chapter IV - RESULTS OF THE SURVEY ON CONVERTING THE 0-290-G

       The response

The Extent of the Conversion

Initial investment vs. reliability and performance

Conversion of the crankcase

Should the flange be removed

Flange removal methods and techniques

The installation of a breather

Drilling and tapping the breather

Countersinking the mounts

The crankshaft oil seal retaining plate

Crankcase modification for a controllable pitch propeller

The crankshaft

Crankshaft limitations

Cleaning and inspection

Grinding

Chroming of journals

Propeller bushings

Crankshaft balancing

The use of propeller extensions

Camshafts

Camshaft substitution

Tappets

Connecting Rods

Balancing

Connecting rod bolts

Shot-peening

Pistons and rings

Three-ring pistons

Four-ring pistons

Pistons and rings in general

Cylinders

Cautions

Cylinder hard-chroming

Cylinder modifications

Valves

Intake valves

Exhaust valves

The oil Sump and Induction System

The use of the GPU sump

Using an aircraft sump

The ideal induction system

The Marvel-Schebler MA4SPA carburetor

The intake pipes

Primer system

Accessory Case and Lubricator

The oil pressure by-pass spring

The oil cooling system

Oil cooler circuitry

Oil filtration methods

Filter suggestions

The oil system in general

Electrical Components

Starters

Alternators

Generators

Baffles and Cooling

The GPU baffles

Cooling in general

The Ignition

Which magneto to use?

Pro S4LN-21 on both sides

Pro S4LN-20 on the right side

Other possibilities

Timing

General Hints and Cautions

Chapter V - THE OVERHAUL AND CONVERSION

       Purchase

Disassembly and inspection

Engine stands

The Crankcase

The flange

The breather

Countersinking the engine mounts

Crankshaft oil seal retaining plate safety kit

The propeller control pad

The Crankshaft

Cleaning and inspection

The propeller bushings

Balancing the crankshaft

The Camshaft

Cleaning and inspection

The Connecting Rods

The Pistons and Rings

Cleaning and Inspection

Balance

The Tappets

The Cylinders and Valves

Cleaning and inspection

The valve guides

Grinding the valves and seats

The Sump and Induction System

Sump and carburetor

The intake pipes

Accessory Case and Lubrication

The case

The accessories

The oil cooler

Electrical

The starter

The generator

Intercylinder Cooling Baffles

Plating and Painting

Plating

Painting the cases

Painting the cylinders

Ignition

The choice of magnetos

Magneto overhaul

Timing

The Assembly

The Costs of This Conversion

Chapter VI - SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

Summary

Conclusions

Recommendations

                BIBLIOGRAPHY

APPENDIX

** Note that the sample pages are a much lower resolution than those on the CD.

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