Lycoming VO-540 Series, IVO-540 Series, TIVO-540 Series Operator's Manual
Operators Manual
Lycoming
VO-540, IVO-540,
TIVO-540 Series
Approved by FAA
2ndEdition Part No. 60297-17
652 Oliver Street
Williamsport, PA. 17701 U.S.A.
570/323-6181
May 2008
VO-540, IVO-540, TIVO-540 Series Operators Manual
Lycoming Part Number: 60297-17
©2008 by Lycoming. All rights reserved.
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
Lycomings regular business hours are Monday through Friday from 8:00 AM
through 5:00 PM Eastern Time (-5 GMT)
Visit us on the World Wide Web at:
http://www.lycoming.com
LYCOMING OPERATORS MANUAL
ATTENTION
OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL
This operators 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 OPERATORS 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 for 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.
iv
LYCOMING OPERATORS 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
V
LYCOMING OPERATORS MANUAL
¾ Left Side View VO-540-B1A
¾ Left Rear View VO-540-C1A
vi
LYCOMING OPERATORS MANUAL
SECTION 1
DESCRIPTION
Page
General.......................................................................................................................................................... 1-1
Cylinders....................................................................................................................................................... 1-1
Valve Operating Mechanism ...................................................................................................................... 1-1
Crankcase ..................................................................................................................................................... 1-1
Crankcase Cover.......................................................................................................................................... 1-1
Crankshaft .................................................................................................................................................... 1-1
Connecting Rods .......................................................................................................................................... 1-1
Pistons ........................................................................................................................................................... 1-1
Accessory Housing ....................................................................................................................................... 1-2
Cooling System ............................................................................................................................................. 1-2
Induction System.......................................................................................................................................... 1-2
Turbocharger System .................................................................................................................................. 1-2
Lubricating System...................................................................................................................................... 1-2
Priming System ............................................................................................................................................ 1-3
Ignition System............................................................................................................................................. 1-3
Table of Models ............................................................................................................................................ 1-3
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LYCOMING OPERATORS MANUAL SECTION 1
VO, IVO & TIVO-540 SERIES DESCRIPTION
SECTION 1
DESCRIPTION
Lycoming VO-540, IVO-540 and TIVO-540 series engines are six cylinder, horizontally opposed, dry
sump, air cooled models designed for installation in rotor driven aircraft.
In referring to the location of various engine components, the parts will be described in their relationship
to the engine as installed in the airframe. Thus the power take-off section is considered the top and the
accessory drive section the bottom. The section where the shroud tubes are located is the front and the
opposite section the rear. References to the left and right side of the engine are made with the observer
standing at the rear and facing front. The cylinders are numbered from top to bottom; odd numbered
cylinders on the left, even numbered cylinders on the right.
The direction of rotation of the crankshaft is clockwise viewed from the bottom of the engine. For all
accessory drives, the direction of rotation is determined when facing the drive pad.
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. Rocker shaft bearing supports are cast integral with the head along with
housings to form the rocker boxes for both valve rockers. The cylinder barrels, which are machined from
chrome nickel molybdenum steel forgings, have deep integral cooling fins and the inside of the barrels are
ground and honed to a specified finish.
Valve Operating Mechanism A conventional type camshaft is located in front of and parallel to the
crankshaft. The camshaft actuates hydraulic tappets which operate the valves through push rods and valve
rockers. The valve rockers are supported on full floating steel shafts. The valve springs bear against
hardened steel seats and are retained on the valve stems by means of split keys.
Crankcase The crankcase assembly consists of two reinforced aluminum alloy castings fastened together
by means of studs, bolts and nuts. The mating surfaces of the two castings are joined without the use of a
gasket and the main bearing bores are machined for use of precision type main bearing inserts.
Crankcase Cover The crankcase cover is made from a magnesium alloy casting and is fastened to the rear
of the crankcase. An integral cast chamber incorporates a mounting pad for the carburetor or fuel injector
and serves as a center distributing zone for the fuel air mixture on carbureted engines.
Crankshaft The crankshaft is made from a chrome nickel molybdenum steel forging. All bearing journal
surfaces are nitrided.
Connecting Rods The connecting rods are made in the form of H sections from alloy steel forgings.
They have replaceable bearing inserts in the crankshaft ends and 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 The pistons are machined from an aluminum alloy forging. The piston pin is of the full floating
type with a plug located at each end. Depending on the cylinder assembly, pistons may be machined for
either three or five rings and employ half wedge rings. Consult the latest revision of Service Instruction No.
1037 for proper piston and ring assemblies.
1-1
SECTION 1 LYCOMING OPERATORS MANUAL
DESCRIPTION VO, IVO & TIVO-540 SERIES
Accessory Housing The accessory housing and accessory housing cover are made from magnesium alloy
castings and are fastened to the bottom of the crankcase. This assembly forms a housing for the oil pump
and the various accessory drives. A scavenge oil sump is fastened to the bottom of the accessory housing.
Cooling System The engine is designed to be cooled by air pressure built up on one side of the cylinder
and discharged, with an accompanying drop in pressure, through cylinder finning. This cooling air on rotordriven aircraft is supplied by an external fan installed by the airframe manufacturer. Close fitting baffles
direct the flow of air around the cylinder fins and the discharge air is exhausted to the atmosphere.
Induction System (Carbureted Engines) These engines are equipped with either single or dual MA-6-AA
carburetors (see Table of Models for model application). This carburetor incorporates an automatic mixture
control and idle-cut-off. The fuel air mixture, after passing from the carburetor to the center distributing
zone is distributed to the cylinders through individual intake pipes.
Induction System (Fuel Injected Engines) (See Table of Models for model application.) Either a Bendix
RS system or RSA system is used on subject engines.
The RS system operates by measuring the air flow through the throttle body of the servo valve regulator
controls, and uses this measurement to operate a servo valve within the control. The regulated pressure
established by the servo valve is used to control the fuel distributor valve assembly, which then establishes
fuel flow in proportion to air flow and fuel vaporization takes place at the individual intake port.
The RSA system is based on the principle of measuring air flow and using the air flow signal in a stem
type regulator to convert the air force into a fuel force. This fuel force (fuel pressure differential) when
applied across the fuel metering section makes fuel flow proportional to air flow. Vaporization takes place
at individual intake ports.
Turbocharger System (TIVO-540) A turbocharger is supplied as an integral part of the TIVO-540 model.
The function of the turbocharger is to provide constant air density to the fuel injector inlet from sea level to
critical altitude. Regulating the amount of exhaust gas fed to the turbine wheel controls the output which
determines engine power. This factor is regulated by the control system which has two components, namely
the density controller and the exhaust bypass valve (waste gate). The position of the waste gate is
determined by oil pressure acting on a piston which is connected to the butterfly valve by linkage.
Increasing oil pressure on the piston closes the waste gate valve and increases power; decreasing oil
pressure opens the valve and decreases power. The bleed oil required to activate the piston is controlled by
the density controller. The density controller action is automatic and modulating to continue and reverse the
process as engine power, speed and altitude change.
Lubricating System The dry sump, fuel pressure lubrication system is actuated by an impeller type oil
pump enclosed within the accessory housing. This pump incorporates a pressure pump and a scavenge pump
driven by a common drive shaft. The pressure pump draws oil from the externally mounted supply tank and
forces it through drilled passages to the oil filter. From the filter the oil is directed through a check valve to
the oil pressure regulating valve. The check valve prevents gravity oil from draining into the crankcase
when the engine is shut down and the oil pressure valve maintains the oil pressure within limits and
discharges excess oil back to the inlet side of the pump. After completing its passage through the engine the
oil is conducted to the scavenge pump in the accessory housing and returned to the external tank.
1-2
LYCOMING OPERATORS MANUAL SECTION 1
VO, IVO & TIVO-540 SERIES DESCRIPTION
Priming System Provision for a priming system is provided on all carbureted engines. Fuel injected
engines do not require a priming system.
Ignition System Dual ignition is furnished by magnetos assembled on each side of the accessory housing.
Consult Table of Models for model application.
TABLE OF MODELS
MODEL APPLICATION
Model* Left Right Carburetor Fuel Injector
VO-540-B1A, -B2A
VO-540-B1B, -B1F
VO-540-B1C, -B2C
VO-540-B1D, -B2D
VO-540-B1E, -B2E
VO-540-B2G
VO-540-B1B3
VO-540-B1H3
VO-540-C1A, -C2A
VO-540-C1B, -C2B
VO-540-C2C
VO-540-C1C3
IVO-540-A1A
TIVO-540-A2A
S6LN-20
S6LN-204
S6LN-204
S6LN-204
S6LN-20
S6LN-1209
S6LN-204
S6LN-1209
S6LN-204
S6LN-20
S6LN-1209
S6LN-204
S6LN-204
S6LN-204
S6RN-21
S6RN-200
S6RN-200
S6RN-200
S6RN-21
S6RN-1208
S6RN-200
S6RN-1208
S6RN-200
S6RN-21
S6RN-1208
S6RN-200
S6RN-200
S6RN-200
MA-6AA
MA-6AA
MA-6AA
MA-6AA(2)
MA-6AA(2)
MA-6AA(2)
MA-6AA
MA-6AA
MA-6AA(2)
MA-6AA(2)
MA-6AA(2)
MA-6AA(2)
RSA-10AD1
RS-5BD2
* - Models with number 2 in suffix incorporate spring coupling drives. Models with
number 3 in suffix incorporate counterweighted crankshaft.
1-3
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LYCOMING OPERATORS MANUAL
SECTION 2
SPECIFICATIONS
Page
Specifications VO-540-B Series ............................................................................................................... 2-1
Specifications VO-540-C Series ............................................................................................................... 2-1
Specifications IVO-540 Series .................................................................................................................. 2-2
Specifications TIVO-540 Series ............................................................................................................... 2-2
Accessory Drives .......................................................................................................................................... 2-3
Detail Weights .............................................................................................................................................. 2-3
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LYCOMING OPERATORS MANUAL SECTION 2
VO, IVO & TIVO-540 SERIES SPECIFICATIONS
SECTION 2
SPECIFICATIONS
VO-540-B SERIES
FAA Type Certificate ....................................................................................................................................304
Rated horsepower...........................................................................................................................................305
Rated speed, RPM........................................................................................................................................3200
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 7.3:1
Firing order ....................................................................................................................................... 1-4-5-2-3-6
Spark occurs, degrees BTC..............................................................................................................................25
Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080
Crankshaft drive ratio .................................................................................................................................... 1:1
Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise
VO-540-C SERIES
FAA Type Certificate ....................................................................................................................................304
Rated horsepower...........................................................................................................................................305
Rated speed, RPM........................................................................................................................................3200
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 8.7:1
Firing order ....................................................................................................................................... 1-4-5-2-3-6
Spark occurs, degrees BTC..............................................................................................................................25
Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080
Crankshaft drive ratio .................................................................................................................................... 1:1
Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise
2-1
SECTION 2 LYCOMING OPERATORS MANUAL
SPECIFICATIONS VO, IVO & TIVO-540 SERIES
SPECIFICATIONS
IVO-540 SERIES
FAA Type Certificate ..............................................................................................................................E11EA
Rated horsepower...........................................................................................................................................305
Rated speed, RPM........................................................................................................................................3200
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 8.7:1
Firing order ....................................................................................................................................... 1-4-5-2-3-6
Spark occurs, degrees BTC..............................................................................................................................25
Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080
Crankshaft drive ratio .................................................................................................................................... 1:1
Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise
TIVO-540 SERIES
FAA Type Certificate ................................................................................................................................. 1E14
Rated horsepower...........................................................................................................................................315
Rated speed, RPM........................................................................................................................................3200
Bore, inches.................................................................................................................................................5.125
Stroke, inches..............................................................................................................................................4.375
Displacement, cubic inches.........................................................................................................................541.5
Compression ratio ....................................................................................................................................... 7.3:1
Firing order ....................................................................................................................................... 1-4-5-3-2-6
Spark occurs, degrees BTC..............................................................................................................................25
Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080
Crankshaft drive ratio .................................................................................................................................... 1:1
Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise
2-2
LYCOMING OPERATORS MANUAL SECTION 2
VO, IVO & TIVO-540 SERIES SPECIFICATIONS
SPECIFICATIONS
Accessory Drives Drive Ratio Direction of Rotation
Starter, electric
Starter, manual
*Generator
Magnetos S6LN
Magnetos S6RN
Fuel pump
Vacuum pump
Hydraulic pump
Tachometer
1.000:1
2.600:1
2.600:1
1.500:1
1.500:1
0.803:1
1.219:1
1.083:1
0.500:1
Clockwise
Clockwise
Clockwise
Clockwise
Counterclockwise
Counterclockwise
Clockwise
Clockwise
Counterclockwise
* - Inoperative as generator drive when hand crank is installed.
DETAIL WEIGHTS
1. STANDARD ENGINE, DRY WEIGHT
MODEL LBS.
VO-540-B1B.............................................................................................................................................429.00
VO-540-B1A, -B1C, -B1F........................................................................................................................430.00
VO-540-B2A, -B2C..................................................................................................................................433.00
IVO-540-A1A ...........................................................................................................................................435.00
VO-540-B1D, -B1E ..................................................................................................................................439.00
VO-540-C1A, -C2A..................................................................................................................................441.00
VO-540-B2D, -B2E ..................................................................................................................................442.00
VO-540-B2G.............................................................................................................................................443.00
VO-540-C2A, -C2B, -B1B3 .....................................................................................................................444.00
VO-540-C2C, -B1H3................................................................................................................................445.00
VO-540-C1C3...........................................................................................................................................453.00
Above weight includes carburetor or fuel injector, magnetos, spark plugs, ignition harness, priming system
(where applicable), and inter-cylinder baffles.
TIVO-540-A2A.........................................................................................................................................507.00
Above weight includes fuel injector, magnetos, spark plugs, ignition harness, turbocharger controls, oil
lines and baffles.
2-3
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LYCOMING OPERATORS MANUAL
SECTION 3
OPERATING INSTRUCTIONS
Page
General.......................................................................................................................................................... 3-1
Prestarting Items of Maintenance .............................................................................................................. 3-1
Starting Procedures
Carbureted Engines .................................................................................................................................. 3-1
Fuel Injected Engines ............................................................................................................................... 3-2
Cold Weather Starting ................................................................................................................................ 3-2
Ground Running and Warm-Up ................................................................................................................ 3-3
Checks Before Take-Off .............................................................................................................................. 3-3
Operation in Flight
Use of Carburetor Heat Control.............................................................................................................. 3-4
Fuel Mixture Leaning Procedure ............................................................................................................ 3-5
Engine Shut-Down ....................................................................................................................................... 3-5
Engine Flight Chart ..................................................................................................................................... 3-5
Operating Conditions .................................................................................................................................. 3-6
Performance Curves .................................................................................................................................... 3-8
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LYCOMING OPERATORS MANUAL SECTION 3
VO, IVO & TIVO-540 SERIES OPERATING INSTRUCTIONS
SECTION 3
OPERATING INSTRUCTIONS
1. GENERAL. Close adherence to these instructions will greatly contribute to long life, economy and
satisfactory operation of the engine.
NOTE
YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THE
FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED
FUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS. PERHAPS NO OTHER ITEM
OF ENGINE OPERATION AND MAINTENANCE CONTRIBUTES QUITE SO MUCH TO
SATISFACTORY PERFORMANCE AND LONG LIFE AS THE CONSTANT USE OF
CORRECT GRADES OF FUEL AND OIL, CORRECT ENGINE TIMING, AND FLYING
THE AIRCRAFT AT ALL TIMES WITHIN THE SPEED AND POWER RANGE SPECIFIED
FOR THE ENGINE. DO NOT FORGET THAT VIOLATION OF THE OPERATION AND
MAINTENANCE SPECIFICATIONS FOR YOUR ENGINE 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. 1014.
NOTE
Cruising should be done at 65% to 75% power until a total of 50 hours has accumulated or
oil consumption has stabilized. This is to insure proper seating of the piston rings and is
applicable to new engines, and engines in service following cylinder replacement or top
overhaul of one or more cylinders.
The minimum fuel octane rating is listed in the flight chart, Part 9 of this section. Under no circumstances
should fuel of a lower octane rating or automotive fuel (regardless of octane rating) be used. Personnel
should be familiar with the latest revision of Service Instruction No. 1070.
2. PRESTARTING ITEMS OF MAINTENANCE. Before starting the aircraft engine for the first flight of the
day, there are several items of maintenance inspection that should be performed. These are described in
Section 4 under Daily Pre-Flight Inspection. They must be observed before the engine is started.
3. STARTING PROCEDURES (NORMAL).
a. Carbureted Engines.
(1) Perform pre-flight inspection.
(2) Carburetor heat cold.
(3) Turn fuel valve on.
3-1
SECTION 3 LYCOMING OPERATORS MANUAL
OPERATING INSTRUCTIONS VO, IVO & TIVO-540 SERIES
(4) Place mixture control in Full Rich.
(5) Crack throttle to detent.
(6) Set magneto selector switch. Consult airframe manufacturers handbook for correct position.
(7) While cranking engine, prime just long enough to build fuel pressure to normal range.
(8) When engine starts, move magneto selector switch to Both.
(9) Set engine at fast idle, if oil pressure is not indicated within 30 seconds stop the engine and
determine reason.
b. Fuel Injected Engines.
(1) Perform pre-flight inspection.
(2) Inlet heat cold.
(3) Turn fuel valve on.
(4) Turn on boost pump until a slight but steady flow is indicated.
(5) Move mixture control to idle cut-off.
(6) Crack throttle approximately 1/8 open.
(7) Set magneto selector switch. Consult airframe manufacturers handbook for correct position.
(8) Engage the starter switch.
(9) When engine starts, move the magneto selector switch to Both.
(10) Move mixture control slowly and steadily to Full Rich.
(11) Set engine at fast idle, if oil pressure is not indicated within 30 seconds, stop the engine and
determine trouble.
WARNING
NEVER ATTEMPT TO HAND CRANK A HOT ENGINE. ALLOW THE ENGINE TO COOL
FOR AT LEAST FIVE MINUTES BEFORE CRANKING.
4. COLD WEATHER STARTING. During cold weather it may be necessary to preheat the engine and oil
before starting.
3-2
LYCOMING OPERATORS MANUAL SECTION 3
VO, IVO & TIVO-540 SERIES OPERATING INSTRUCTIONS
CAUTION
ENGINES EQUIPPED WITH PISTON OIL JETS DURING EXTREME COLD WEATHER
(-20°F AND BELOW) IT WILL BE NECESSARY TO PRE-HEAT THE ENGINE FOR A
SUFFICIENT LENGTH OF TIME TO ALLOW THE HEAT TO PENETRATE
CRANKSHAFT AND LOOSEN CONGEALED OIL IN PASSAGES BETWEEN THE MAIN
BEARINGS AND CONNECTING ROD BEARINGS.
BECAUSE THE HEAT PENETRATES THE ALUMINUM CRANKCASE MORE RAPIDLY
THAN THE STEEL CRANKSHAFT, IT IS POSSIBLE FOR THE OIL TO CIRCULATE
AROUND THE ANNULUS OF THE MAIN BEARING AND THROUGH THE PISTON OIL
JETS. THIS CIRCULATION, WHILE GIVING A SAFE READING ON THE OIL
TEMPERATURE AND OIL PRESSURE GAUGES, COULD OCCUR WITHOUT
DISLODGING THE CONGEALED OIL IN THE CRANKSHAFT OIL PASSAGES,
CAUSING OIL STARVATION TO THE CONNECTING ROD BEARINGS.
5. GROUND RUNNING AND WARM-UP.
a. Leave aircraft control in Full Rich.
b. Idle engine until oil pressure reaches 50 psi minimum. Consult airframe manufacturers handbook for
rotor and engine speed.
c. Limit ground running to minimum time necessary to warm engine for take-off.
6. CHECKS BEFORE TAKE-OFF.
a. Check both oil temperature and oil pressure.
b. Set carburetor air heat control for Full Heat to check proper operation. Loss of RPM and manifold
pressure will result if heat control is working properly. Return heat control to cold position after
check.
c. With rotor angle at minimum pitch, increase RPM to 3200 and check magneto drop-off. Switch from
both magnetos to one and note drop-off, return to both magnetos until engine regains speed and switch
to the other magneto and note drop-off, then return to both. Drop-off should not exceed 200 RPM
on either magneto and should be within 50 RPM of each other.
NOTE
Do not operate too long on one magneto, 2 to 3 seconds is sufficient and will minimize plug
fouling.
3-3
SECTION 3 LYCOMING OPERATORS MANUAL
OPERATING INSTRUCTIONS VO, IVO & TIVO-540 SERIES
a. Use of Carburetor Heat Control Under certain moist atmospheric 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
carburetor venturi and the absorption of heat from this air by evaporation of the fuel. The temperature
in the mixture chamber may drop 20°F to 70°F below the temperature of the incoming air. If this air
contains a large amount of moisture, the cooling process will cause precipitation in the form of ice.
These ice formations generally begin in the vicinity of the butterfly throttle and will often build up to
such an extent that engine operation is noticeably affected. This ice will obstruct the carburetor
passage resulting in a decreased flow of mixture and consequently a drop in manifold pressure and
RPM. If not 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 mixture chamber temperatures cannot drop to the freezing point of water. This pre-heater
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 be avoided because of the danger of detonation,
especially when operating at high power output. The application of excessive heat will produce
expansion of the charge with a resultant loss of density. Since power output depends upon the mass of
charge induced into the cylinders, heating the mixture will involve a loss of power and a decided
variation of the mixture. High charge temperatures favor both detonation and pre-ignition, both of
which are to be avoided if normal service life is to be expected from the engine. The following outline
is the proper method of utilizing the carburetor heat control:
The carburetor air heat control should be left in the cold position during normal flight operations.
On damp, cloudy, foggy or hazy days, regardless of the outside air temperatures, keep a sharp lookout
for loss of power. This loss of power will be shown by an unaccountable loss of manifold pressure and
RPM. When this situation arises, apply full carburetor air heat. This will result in a slight additional
drop in manifold pressure which is normal, and this drop will be regained as the ice is melted out of
the induction system. When the ice has been melted from the induction system, the carburetor heat
control should be returned to the cold position. In those aircraft equipped with a carburetor air
temperature gauge, partial heat may be used to keep the mixture temperature above the freezing point
(32°F).
WARNING
CAUTION MUST BE EXERCISED WHEN OPERATING WITH PARTIAL HEAT ON
AIRCRAFT THAT DO NOT HAVE A CARBURETOR AIR TEMPERATURE GAUGE.
MOISTURE IN CRYSTAL FORM THAT WOULD ORDINARILY PASS THROUGH THE
INDUCTION SYSTEM, CAN BE RAISED IN TEMPERATURE BY USE OF PARTIAL HEAT
TO THE POINT WHERE THE CRYSTALS ARE MELTED INTO LIQUID FORM. THIS
MOISTURE IN TURN CAN FORM CARBURETOR ICE DUE TO THE TEMPERATURE
DROP AS IT PASSES THROUGH THE VENTURI OF THE CARBURETOR. IT IS
ADVISABLE, THEREFORE, TO USE EITHER FULL HEAT OR NO HEAT IN AIRCRAFT
THAT ARE NOT EQUIPPED WITH A CARBURETOR AIR TEMPERATURE GAUGE.
b. See airframe manufacturers instructions for correct manifold pressure for various power settings.
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LYCOMING OPERATORS MANUAL SECTION 3
VO, IVO & TIVO-540 SERIES OPERATING INSTRUCTIONS
c. Fuel Mixture Leaning Procedures
(1) Carbureted Engines.
All engines are equipped with automatic altitude compensated carburetors and should never be
manually leaned.
(2) Fuel Injected Engines.
Lean mixture as directed in airframe manufacturers handbook. When operating with manually
leaned mixture, monitor cylinder head temperatures carefully.
8. ENGINE SHUT-DOWN.
a. Valve sticking problems can be greatly reduced by proper shutdown procedures. Engine shutdown at
high ambient air and cylinder head temperatures can result in carbon formation in the exhaust valve
guides. Therefore, after landing, if cylinder head temperature is 400°F or above and ambient air
temperature is 70°F or above, idle the engine at 2200 RPM until a significant drop in head
temperature is noted before shutdown, at least 40°F. As ambient temperatures increase, it may be
necessary to increase idle time before shutdown.
b. Move mixture control to idle cut-off.
c. When engine stops, turn switches off.
9. ENGINE FLIGHT CHART.
FUEL AND OIL
Model *Aviation Grade Fuel
VO-540-B Series........................................................................................................... 80/87 octane, minimum
VO-540-C Series....................................................................................................... 100/130 octane, minimum
IVO-540 Series ......................................................................................................... 100/130 octane, minimum
TIVO-540 Series....................................................................................................... 100/130 octane, minimum
* - Refer to the latest revision of Service Instruction No. 1070.
NOTE
Aviation grade 100LL fuels in which the lead content is limited to 2 c.c. per gallon are
approved for continuous use in the above listed engines.
FUEL PRESSURE
Model Max. Min.
VO-540 Series (inlet to carburetor) 8.0 0.5
IVO-540 Series (inlet to fuel injector) 45 20
TIVO-540 Series (inlet to fuel injector) 45 29
3-5
SECTION 3 LYCOMING OPERATORS MANUAL
OPERATING INSTRUCTIONS VO, IVO & TIVO-540 SERIES
ALL MODELS
*Recommended Grade Oil
Average
Ambient Air
MIL-L-6082
Grades
MIL-L-2285
Ashless Dispersant
Grades
Above 60°F
30° to 90°F
0° to 70°F
Below 10°F
SAE 50
SAE 50
SAE 30
SAE 20
SAE 40 or SAE 50
SAE 40
SAE 40 or SAE 30
SAE 30
* - Refer to latest revision of Service Instruction No. 1014.
OPERATING CONDITIONS
Average *Oil Inlet Temperature
Ambient Air Desired Maximum
Above 60°F
30° to 90°F
0° to 70°F
Below 10°F
180°F (82°C)
180°F (82°C)
180°F (82°C)
170°F (71°C)
235°F (113°C)
235°F (113°C)
235°F (113°C)
210°F ( 99°C)
* - Engine oil temperature should not be below 140°F (60°C) during continuous operation.
OIL PRESSURE
Oil Pressure, psi Max. Min. Idling
VO-540 and IVO-540 Series 85 55 25
TIVO-540 Series 70 50 25
LIMITING MANIFOLD PRESSURE
Model Sea Level 1000 feet
VO-540-B1D, -B2D, -B1E, -B2E, -B2G 27.5 in. hg. 27.3 in. hg.
Model Sea Level 3000 feet
VO-540-C1A, -C2A, -C1B, -C2B, -C2C 26.0 in. hg. 25.2 in. hg.
Model Sea Level 2500 feet
VO-540-C1C3 26.5 in. hg. 25.8 in. hg.
Model Sea Level 3000 feet
IVO-540-A1A 27.0 in. hg. 26.0 in. hg.
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