Textron Lycoming IO-540 Series, Lycoming O-540 Series Operator's Manual

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Lycoming

OPERATOR'S

REVISION

60297-10-4

The page(s) the operator's

Section Added pages Section 3-12, 3-13, 3-18A/B;

page

ed

Section 2 3-11, 3-46,3-47; Added 5-11,

NO. PUBLICATION

0,10-540 Series

Operator's

in this

manual.

3 Index,

Added page

3-17, 3-18,

3-45

3-13,

page

5-12

REVISION

January

Index,

3-41,3-42,3-42,

January 1999

Index, 2-6, 2-7;

March 1999

1997

2-2,

2-5, 2-6,

3-18,

Section

4-2A/B;

4-2

revision

2-3, 2-4,

2-7, 2-8;

3-10, 3-11,

3-12A/B;

Added page

Added

4 Index,

5-9,

Manual

replace,

Add-

3-10, pages

4-2,

5-10,

MANUAL

PUBLICATION

NO.

60297-10

add to, or

delete current

CURRENT

April 1999

3-12,3-12A/B,

REVISION

PUBLICATION

DATE

March 1991

pages

3-13

in

OPERATOR'S

MANAUAL

TEXTRON Lycoming

O-540 & IO-540 SERIES

AIRCRAFT ENGINES

th EDITION October,

4

by F.AA.

Lycoming

U.S.A.

Printed in U.S.A.

Part No. 60297-10

Approved

TEXTRON

652 Oliver Williamsport,

570/323-6181

Street

PA 17701

1999

TEXTRON

LYCOMING

ATTENTION

OPERATOR'S

MANUAL

This

operator's

tions,

and detailed maintenance inspections pilots and ing powered

procedures

are also

maintenance

aircraft. Textron Lycoming to these

Neglecting maintenance loss. Also, ceeded,

pen. Consult

for

to follow

procedures

if power

for

any reason,

such

your local

SERVICE

Although of publication, Textron are available

subscription.

subscription

the information

users

Lycoming

from

Consult

information.

OWNERS,

OPERATORS,

MAINTENANCE

manual contains

information

included.

personnel

Modifications

overhaul

procedures.

the

and speed

damage

BULLETINS,

are urged Service all Textron

the

on how

that may

This manual

manuals;

SAFETY WARNING

operating

can

result

limitations

to the engine

FAA approved

INSTRUCTIONS,

contained

to keep

Bulletins,

Lycoming

latest

edition

PERSONNEL

a description

to operate

be required

is intended

responsible

and repair

maintenance

instructions

in poor

Instructions

engine

specified

and

maintenance

in this manual abreast

distributors

of Service

AND

of the engine,

and

in conjunction

for care

procedures

personnel

and

to carry

performance

in this

personal

facility.

AND LETTERS

is up-to-date

of later information

and

Service

or from

Letter

its specifica-

maintain it.

with periodic

for use,

by owners,

of Textron

are

contained

should refer

out periodic

and

manual

injury

Letters

the

factory

No.

Such

Lycom-

power

are ex-

can hap-

at time

through

which

by

L114

for

in

The

illustrations, of the as

examples

subject

matter

of

any

pictures

they

specific

and

drawings

portray;

engine,

NOTE

in

no instance

equipment

shown

in

this publication

are they

or

part

thereof.

to be

are typical

interpreted

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

Proper service

operation by Textron operations. specially and as recommended.

It is important

tain various order to vice methods

It is also are evaluate vice might be involved. satisfy ty will

of all aircraft

designed

minimize

not all

or

themselves

be jeopardized

and

Lycoming

Some

to note

Warnings

the

that

important

inclusive.

advise

be done

Acordingly,

IMPORTANT

repair is

engines.

are

effective

of these

for the

may damage

the service

or of the

thoroughly

service operations

task.

that most

and Cautions

risk of

personal

to understand

Textron

possible hazardous

anyone

by the

SAFETY

essential

The service

These special

Textron

which injury

the

engine

that

Lycoming

trade

of all

who uses

that

neither their

service

procedure

NOTICE

to increase

methods

Lycoming

or the

or render

these

could

conceivable

a service

procedures

for

performing

require the

tools

must

be carefully

use of improper

Warnings

not

ways

consequences

procedure

safety

they select.

the safe,

recommended

use of

be used

publications

it unsafe.

and Cautions

possibly

in which

nor aircraft

reliable

service

tools

when

con-

read

ser-

know,

ser-

that may

must first

safe-

in

WARRANTY

> Textron > material and >

Lycoming

acceptance esting.The Lycoming.

change in Lycoming will Lycoming's

the period

from the charge placed, or a during cylinders, connecting

to accessories,

turbochargers

Lycoming

the pan Tlis

been subject to accident manual, or if cause of die

such

workmanship appearing

Textron Lycoming's

basis, of the engine

material or workmanship.

then current Removal and Installation

In addition, if Texton

until the expiration of

date of first operation,

for the repair

replacement engine,

die proration

Any

engine or part

The engine

distributor within 30

Textron Lycoming's

of Textron Lycoming

warranty allocates

Textron

Lycoming reserves

incident for which

Textron

Lycoming may change

alterations

NEW AND

RECIPROCATING

WHAT

TEXTRON

warrants each new

date of first

also bear the cost for

or replacement

period extends

rods, pistons,

including but

and

their controlers.

so repaired or replaced

must have received

warranty

the risk of product

non-genuine Textron Lycoming

in engines

within one

operation must

obligation under

or any part

Such repair

Lycoming

not limited to magnetos,

or used,adjusted, altered,

or parts previously

this warranty shall be limited

of the egine, when

or replacement

labor in connection

determines tha

Textron Lycoming's recommended

whichever

occurs first, Texon

(at its

if it determines

to major parts of

sump, accessory

normal use

days of die appearance

does not cover

set forth above

failure between

the right to

die warranty

die construction of

(LIMITED)

REMANUFACTURED

AIRCRAFT

LYCOMING

and remanufactured

(1) year from

Labor Allowance Guidebook.

choice) with

that engine

will be entitled

YOUR

and service. You

normal maintenance

ae your exclusive

deny any warranty

handled, maintained

parts are installed in

applicaton

sold.

reciprocating

not exceed two

Textron Lycoming

will be made

with the repair or replacement

the engine proves

Lycomiug will

Textron Lycoming

replacement is required.

the engine, which

housing and

carburetors

to warranty

OBLIGATIONS

of the defect in

remedy and

you and Textron

claim if it reasonably

is filed.

engines at any time without

ENGINE

PROMISES

engine sold by

the date of first

gears. The proration

or fuel injectors,

must apply for

or on the engine and are

operation exchlding

(2) years from

to its choice of repair

has determined

by Textron Lycoming

tobe defective

Time Between

are limited to

for the remainder

material or workmanship

expenses

or stored other than as directed

in material or

Overhaul (TBO), or two

reimburse you

parts,

of parts

policy does

fuel pumps,

warranty with

or consumable items

the exclusive liability

Lycoming,

determines

incurring any obligation

YOU

it to be free from

the date of shipment

Textron

crankcase, crankshaft,

of the original

as permitted by

necessary aircraft

or replacement, on that the engine

at no charge

required to be

determined tobe a possible

to you. Textron

as provided in Textron

wornanship during

for a pro rata portion

Lycoming's obligation

not extend to labor

starters, alternators

warranty period.

an authorized

The obligations

of Textron

applicable law.

that the engine

in your operator's

defects in

from Textron

an ex-

is defective

(2) years

of the

repaired or

camshaft,

Textron

Lycoming.

or part has

to incorporate

and

re-

or

on

>

THIS

LIMITED

> TATIONS,

LIMITED

)

AND

ANY IMPLIED

TRADE

USAGE.

>

CLAIM, TORT

OR > TEXTRON >

CABLE

TO

WARRANTY

EXPRESS

TO

ANY

THIS

WHETHER

ANY

RIGHT

LYCOMING'S

THE

ENGINE

IS

OR

IMPLIED

WARRANTY

IN CONTRACT

ARISING

LIABILITY

OR PART

EXCLUSIVE

AND IN

OR STATUTORY.

OF MERCHANTABILITY

ARISING IS ALSO

OR

FROM

ON SUCH

WHICH

LIEU

WHETHER

FROM

ANY

IN

LIEU OF

IN TORT,

INCLUDING

NEGLIGENCE

CLAIM

GIVES

RISE

ANY

ON SHALL,

TO

OF ALL

WRITTEN

OR

FITNESS

COUBSE

OTHER THE

THE

CLAIM.

OTHER

FOR ANY

OF

PERFORMANCE

OBLIGATION,

ANY

RIGHT

PART

OF TEXTRON

IN NO

CASE

WARRANTIES

OR ORAL,

INCLUDING

PARTICULAR

LIABILITY,

IN STRICT

EXCEED

AND REPRESEN-

BUT

PURPOSE.

OR

DEALING

RIGHT

LIABILITY

LYCOMING,

THE

PRICE

ALLO-

NOT

OR OR

AND

IN

IN NO

EVENT, LIGENCE, DAMAGES, ENGINE

OR

No agreement

Lycoming

unless

Effective

WHETHER

SHALL

INCLUDINGBUTNOT COST

October

TEXTRON

OF

A REPLACEMENT.

varying

this warranty

in writing

signed

1, 1995

AS

LIMITATION

A RESULT

LYCOMING

LIMITED

or Textron

by

a duly

Revision

OF LIABILITY

OF

A BREACH

BE

authorized

"J"

OF

FOR

Lycoming's

representative

WARRANTY,

SPECIAL

obligations

of Textron

LIABLE

TOLOSSOFPROFITSORREVENUES,

CONTRACT

OR

CONSEQUENTIAL

under

it will

Lycoming.

Williamsport,

OR

ALLEGED OR ANY

LOSSOFUSE

be binding

Textron

NEG-

OTHER

OFTHE

upon

Textron

Lycoming

Pennsylvania

TEXTRON Lycoming

WARRANTY

REPLACEMENT

WHAT

Textron Lycoming in material and tion. must not

Textron change basis, workmanship. Textron ment as provided

Any

part so repaired or

The engine warranty

with anauthorized

workmanship.

Textron Lycoming's the part

of Textron Lycoming set

This warranty

Textron Lycoming been subject manual,

orif non-genuine Textron

cause of the

Textron such alterations

THIS LIMITED WARRANTY TATIONS.

LIMITED TO AND ANY TRADE

USAGE THIS WARRANTY

CLAIM.

WHETHER IN CONTRACT TORT OR ANY RIGHT TEXTRON LYCOMING'S CABLE TO THE

warrants each new

workmanship appearing

exceed two (2) years

Lycoming's

obligation under

of the replacement

Lycoming will also

in Textron Lycoming's

replaced will be wanrranted

in which the replacement

allocates the

to accident orused, adjusted,

incident for

Lycoming may change

EXPRESS OR IMPLIED

ANY WARRANTY

IMPLIED WARRANTY

Textron Lycoming distributorwithin

warranty

risk of product

reserves

which the warranty

in engines or parts previously

ARISING FROM NEGLIGENCE ON THE

ENGINE OR PART WHICH GIVES

PART

- RECIPROCATING

TEXTRON

(LIMITED)

reciprocating aircraft engine

within

from the date

part, when

one (1) year from of shipment from

this warranty shall

Textron Lycoming

reimburse you for the costs

then current Removal

YOUR OBLIGATIONS

part is installed must

does not cover forth above are your exclusive

the right to deny

Lycoming parts are installed

the construction of engines

IS EXCLUSIVE

OF MERCHANTABILITY

LIABILITY

normal maintenance

failure between

any warranty claim

altered, handled, maintained

application

sold.

AND IN LIEU OF ALL

OR STATUTORY,

ARISING FROM IS ALSO IN LIEU

OR IN TORT,

ON SUCH CLAIM SHALL

AIRCRAFT ENGINE

LYCOMING

for the remainder

you and Textron

is filed.

WHETHER

ANY COURSE OF PERFORMANCE

OF ANY OTHER OBLIGATION.

INCLUDING ANY

RISE TO THE CLAIM

PROMISES

replacement part sold

its date of

Textron Lycoming.

he limited to

has determined

and Installation

have received normal

30daysof

remedy and the exclusive

if it reasonably

in oron the engine

at any time without incurring

OR FITNESS FOR

first operation. The

its choice of repair

that the part

for labor in connection

Labor Allowance Guidebook.

of the original warranty

use and service. You must

the appearance of thedefect

expenses or

consumable items.

Lycoming, as permitted

determines that

or stored other than

and are determined tobe

OTHER WARRANTIES

WRITTEN

OR ORAL,

RIGHT IN STRICT

PART OF TEXTRON LYCOMING. AND

IN NO CASE EXCEED

ANY PARTICULAR

YOU

by it to be free from

or replacement,

is defective in with the repair or replace-

period.

liability of Textron

by applicable

the engine or

as directed in youroperator's

any obligation to

INCLUDING BUT

OR DEALING

LIABILITY,

THE PRICE ALLO-

defects

date of first opera-

on an ex-

material or

apply for

in materialor

The obligations

Lycoming.

law.

part has

a possible

incorporate

AND REPRESEN-

PURPOSE.

RIGHT OR

LIABILITY IN

on

NOT

OR

IN

NO EVENT, WHETHER LIGENCE, SHALLTEXTRON DAMAGES, ENGINE

Lycoming

No

INCLUDING

OR COST

agreement

unless

in writing

BUT

OF

A REPLACEMENT.

varying this

signed by a

AS A

RESULT OF A

LYCOMING BE

NOT LIMITED

warranty

duly authorized

Effective October 1,1995 Revision 'J"

LIMITATION

or Textron Lycoming's

OF LIABILITY

BREACH OF WARRANTY,

LIABLE FOR SPECIAL

TO LOSS

OF PROFITS

representative

OR CONSEQUENTIAL OR REVENUES,

obligations under

of Textron

Lycoming.

CONTRACT

it will

be binding

Williamsport,

OR ALLEGED

OR ANY OTHER

LOSS

OF USE

upon Textron

Textron

Pennsylvania

NEG-

OFTHE

Lycoming

<

Lycoming

WARRANTY

(LIMITED)

RECIPROCATING AIRCRAFT ENGINE

OVERHAULED

WHAT TEXTRON

Textron Lycoming warrants each workmanship appearing withinone (1) year testing. The date of first

Textron Lycoming's obligation under this warranty shall be limited to its choice of repair or replacement, on an ex- change basis, of the engine or any part of the engine, when Textron Lycoming has determined that the engine is defective in material or workmanship. Such repair or rep acement will be made by Textron Lycoming at no charge to you. Textron

will also bear the cost for labor in connection

Lycoming Lycoming's then current Removal and installation Labor Allowance Guidebook.

Any engine or part so repaired or replaced will be entitled to warranty for the remainder of the original warranty period.

overhauled reciprocating engine sold by it to be

operation must not exceed two (2) years from the

LYCOMING PROMISES

from the dale of first operation, excluding necessary

with the repair or replacement as provided

date of shipment from Textron Lycoming

YOU

free from defects in material and

aircraft acceptance

in Textron

YOUR OBLIGATIONS

The engine must have received normal Lycoming distributor within 30 days of the appearance of the defect in material or workmanship

Textron Lycoming's the part of Textron Lycoming set forth above are your exclusive remedy and die exclusive liability of Textron Lycoming. This warranty allocates the risk of product failure between you and Textron Lycoming, as permitted by applicable law.

TextronLycoming reservestherighttodenyanywarranty

subject to accident or used, adjusted, altered, handled,

been manual, or if non-genuine Texron Lycoming pas are installed in oron tlie egine and are determined to bea possible cause of the incident for which the warranty application is filed.

Textron Lycoming such alterations in engines or parts previously sold.

THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND REPRESEN- TATIONS, EXPRESS OR IMPLIED OR STATUTORY, WHETHER WRITTEN OR ORAL, INCLUDING BUT NOT LIMITED TO ANY WARRANTY AND ANY IMPLIED WARRANTY ARISING FROM ANY COURSE OF PERFORMANCE OR DEALING OR TRADE USAGE. THIS WARRANTY IS ALO IN LIEU OF ANY OTHER OBLIGATION, LIABILITY, RIGHT OR CLAIM, WHETHER IN CONTRACT OR IN TORT, INCLUDING ANY RIGHT IN STRICT LIABILITY IN TORT OR ANY RIGHT ARISING FROM TEXTRON LYCOMING'S LIABILITY ON SUCH CLAIM SHALL IN NO CASE EXCEED THE PRICE ALLO. CABLE TO THE ENGINE OR PART WHICH GIVES RISE TO THE CLAIM.

warranty does not cover normal maiutenance

may change the construction of engines at any

use and service. You must apply for warranty

expenses or consunmable items. The obligations

clainifit reasonably

maintained or stored other than as directed in

time without incurring any obligation to incorporate

OF MERCHANTABILITY OR FITNESS FOR

NEGLIGENCE ON THE PART OF TEXTRON

with all authorized Textron

determines thatthe engine or part has

ANY PARTICULAR PURPOSE,

your operator's

LYCOMING, AND

on

IN NO

EVENT, WHETHER

LIGENCE,

SHALLTEXTRON DAMAGES, ENGINE

Lycoming unless

Effective

No

INCLUDING

OR

COST

agreement

October

OF A

varying

in writing

1, 1995

ASA

RESULT

LYCOMING

BUTNOT

signed by

LIMITED

or

a duly authorized

REPLACEMENT.

this warranty

Revision

LIMITATION

OF A BREACH BE LIABLE

TO

Textron

"J"

OF LIABILITY

OF WARRANTY,

FOR SPECIAL

LOSS OPPROFITS

Lycoming's

obligations

representative

CONTRACT OR CONSEQUENTIALORANYOTHER OR REVENUES,

under

of Textron

Lycoming.

OR ALLEGED

LOSS OFUSE

it will

be binding

Textron

Williamsport,

Pennsylvania

NEG-

OFTHE

upon Textron

Lycoming

(

are described in their Thus the power take-off end is considered the front; the accessory drive end, the rear. The sump section is considered the bottom and the opposite side of the engine where the shroud tubes are located the top. Reference to the left and right side is made with the observer facing the rear of the engine. The cylinders are numbered from front to rear, odd numbers on the right, even numbers on the left. The direction of rotation for accessory drives is determined with the observer 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

are made from an aluminum

heads bustion chamber.

head along with

The cylinder barrels,

steel forgings, have deep integral are ground and honed to a specified finish.

relationship to the engine as installed

alloy casting with a fully machined

Rocker shaft bearing supports

housings to form the rocker boxes

which are machined from

cooling fins and the inside

are cast integral with the

chrome nickel molybdenum

for both valve rockers.

in the airframe.

com-

of the barrels

Valve Operating

and parallel to the crankshaft. operate the valves through

supported on full-floating steel

are hardened 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 and the main bearing bores are machined for use of precision type main bearing inserts.

Mechanism - A conventional

The camshaft actuates hydraulic

push rods and valve rockers.

shafts. The valve springs bear

steel seats and are retained

are joined without the use

type camshaft is located above

tappets which

The valve rockers

on the valve stems by means

of a gasket,

against

of split

1-1

TEXTRON

LYCOMING

OPERATOR'S MANUAL

SECTION

Crankshaft

steel forging. All sional counterweights.

Connecting Rods

tions

the crankshaft caps on the crankshaft ends each cap.

Pistons - The piston pin is a full floating type

Depending on

three

Consult the and ring combinations.

Accessory

casting and

the sump.

drives.

Oil Sump (0-540, IO-540-C,

oil drain

tor, the intake

1

- The crankshaft is made from bearing journal

vibration

from alloy

or four rings and may employ

Housing

plug, oil suction

is assured by

- The connecting

steel forgings. They

ends and bronze

pistons are

the cylinder assembly,

latest revision

is fastened to

It forms a

riser and intake

machined from

of Service Instruction

- The accessory

housing for the

screen, mounting

the rear of the

10-540 & 10-540 SERIES

a chrome nickel molybdenum

surfaces are

a system of

rods are made

bushings

are retained by two bolts and

with a plug located in each

either half-wedge or full-wedge

housing is

oil pump and

-D, -J, -N, -R) - The sump

pipe connections.

nitrided. Freedom

pendulum type

in the form

have replaceable

in the piston ends.

an aluminum alloy

pistons

may be machined

No. 1037

made from an

crankcase and

the various accessory

pad for carburetor

bearing

for proper piston

incorporates an

from tor-

dynamic

of "H" sec-

inserts in

The bearing

nuts through

forging. The

end of the pin.

for either

rings.

aluminum

the top rear of

injec-

or fuel

Oil Sump and Induction

-R) - This assembly consists

taining intake pipe together are provided an oil suction screen.

Cooling

actuated by up a pressure exhausted located at

they form

in the

System -

These engines

the forward speed

and force the air

to the

the rear of the

Assembly (Except 0-540, 10-540-C,

extensions for the induction

a mounting pad

cover and

atmosphere through

of the oil sump bolted to a mated

system. When bolted

for the air inlet

the sump

are designed to

of the aircraft.

through the

cowling.

incorporates

gills or

housing. Fuel

oil

be cooled by air

Baffles are

cylinder fins. The

augmentor tubes

-D, -J, -N,

cover con-

drain plugs

provided to build

and

pressure

air is then

usually

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

Induction

with

of the

induction in the oil each

dix flow ports.

and

ped

air flow and

The

trol portion to air flow.

measuring to convert ferential) makes

The that housed IO-540-K1A5D.

Operational basic

& 10-540

System

a Marvel-Schebler

fuel-air

oil, insuring

cylinder

Textron

type RS

in

brief description

A The Marvel-Schebler

is equipped

The

with

The

uses this

regulated

the

The

letter "D"

the basic

model

mixture

system,

a more

sump.

in the

by

Lycoming

or RSA

proportion

with

Marvel-Schebler

a manual

Bendix

fuel

RS

through

measurement

fuel pressure

distributor

RSA

flow

air

the air

applied

when

flow

used

model

a single

in

aspects still apply.

SERIES

- Textron

which

individual

to air

mixture

type

the

valve assembly,

type

and

force

proportional

configuration

housing.

Lycoming

MA-4-5

to each

is integral

uniform

the

From

intake

10-540 fuel

of

series

injector.

and

flow

the carburetor

of

MA-4-5

a manual

HA-6

fuel

throttle

established

fuel

using

into a

across

the 4th

as

Example

engines

control

injection

to operate

0-540

carburetor.

obtained

cylinder

body

injection

the

fuel force.

to

are

is

the

with

vaporization

the fuel-air

riser

pipes.

fuel

and

control

idle

and

system

the

of

a

by the

which

system

flow

This

metering

character

altered

been

- basic

same,

are equipped injection

servo servo

then

engines

The

fuel vaporization

carburetor

mixture

is a horizontal

air

the fuel

air flow.

NOTE

or 5th

has

the

series engines

Particularly

through

oil sump

of fuel

fuel injectors

is of the

signal

model

and

mixture

system

takes

single

and

mounted

cut-off.

operates

valve valve

servo

schedules

based

is

in a

force

fuel

section

in the

the

by

10-540-K1A5

performance

an

valve

stem

SECTION

are equipped

good distribution

the center

submerged

and is

in cooling

aiding

is distributed

a Ben-

either

with

schedules

the intake

at

place

follows:

float

barrel

cut-off.

idle

carburetor

measuring

by

regulator

within

on the

(fuel

model

use of

the

is used

flow in

fuel

principle

type

pressure

(jetting

suffix

dual

data

controls,

control.

to

regulator

system)

magnetos

becomes

1

zone

to

fuel

type

equip-

the

con-

pro-

of

dif-

means

for the

1-3

SPECIFICATIONS

Page

O(-540-A,-B, -E, -F , -G, -H, -L, -L Series .. ................. 2-

IO-540-A,-B, -E,-, G, -P ,-, -D, -N, -R, -T, -V Series .......... 2-2

IO-540-C,-J Series .................................... 2-3

IO-540-K, -L, -M, -S, -W Series ......................... 2-4

IO-540-AA,-AB Series ................................. 2-5

IO-540-AC Series ...................................... 2-6

Standard Engine Weights ......... ....................... 2-6

Accessory Drives ................. .................... 2-8

Revised January 1999

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

FAA Rated Rated Bore, Stroke,

Displacement Compression Firing Spark Valve (hydraulic Prop. Prop.

FAA Rated Rated Bore, Stroke, Displacement Compression

Firing

Spark

Valve rocker

(hydraulic Prop. Prop.

*0-540-A

&

Type

Certificate horsepower speed

inches

order occurs

rocker

tappets drive driven

Type

Certificate horsepower speed

inches

order

occurs

tappets drive driven

Series

10-540

RPM

cubic

ratio degrees

clearance

collapsed)

ratio

rotation

RPM

cubic

ratio

degrees

clearance

collapsed)

ratio

rotation

alternate

SERIES

SPECIFICATIONS

0-540

inches

BTC

0-540

inches

BTC

hp/rpm

SERIES

-A*

295 250

2575

5.125

4.375

541.5

8.5:1

1-4-5-2-3-6

250

.028-.080

1:1

Clockwise

SERIES

-J,-L

295

235

2400

5.125

4.375

541.5

8.5:1

1-4-5-2-3-6

23

.028-.080

1:1

Clockwise

rating:

1-4-5-2-3-6

.028-.080

Clockwise

1-4-5-2-3-6

.028-.080

Clockwise

235/2400

-B

295 235

2575

5.125

4.375

541.5

7.2:1 25

1:1

-F

295 235

2800

5.125

4.375

541.5

8.5:1

250

1:1

(except

SECTION

-E,-G-,H

295 260

2700

5.125

4.375

541.5

8.5:1

1-4-5-2-3-6

25

.028-.080

1:1

Clockwise

-A3D5).

2

2-1

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

FAA Type Rated Rated Bore,

inches...............

Stroke, Displacement Compression

Firing order Spark occurs, Valve rocker

Prop.

drive ratio

Prop. driven

-V SERIES

FAA Type Rated Rated speed, Bore,

inches ..............................

Stroke, Displacement Compression Firing

order...........................

Spark

occurs, Valve rocker Prop. drive Prop.

driven rotation

2

10-540

Certificate

horsepower.

speed,

RPM

inches ..........................................

cubic

ratio ........................................

...........................................

degrees

clearance

........................................

rotation

Certificate

horsepower

RPM

inches

...................

cubic

ratio

degrees

clearance

ratio ........................................

0-540

SPECIFICATIONS

-A, -B,

....................................

.......................................

inches

BTC ...........

(hydraulic

.....................................

IO-540-D, -N, -R,

.........

........................................

.........

inches

......................................

BTC

(hydraulic

.....................................

-E, -G,

...................

................................

tappets

................................

...............................

tappets

collapsed)

-T*, -V SERIES

.

..

...........

.......................

collapsed)

& 10-540

-P SERIES

..................

........

.......

................. 1-4-5-2-3-6

........

SERIES

2575

.....

5.125

4.375

541.5

8.7:1

1-4-5-2-3-6

028-.080

Clockwise

.....

1E4

....

2700

5.125

4.375

541.5

8.5:1

25

028-.080

Clockwise

1E4 290

20

1:1

260

1:1

°

* - IO-540-T4B5

er at 2575 pertinent

RPM.

to the IO-540-C

2-2

model

When

engine

has

an alternate

operated

at alternate

series is applicable.

rating

rating, all

Revised

of 250

horsepow-

performance

January

data

1997

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & 10-540 SERIES SECTION 2

SPECIFICATIONS

O-540-C*

FAA Type Certificate ..................................... 1E4

Rated horsepower ........................................ 250

Rated speed RPM ....................................... 2575

Bore, inches ............................................ 5.125

Stroke, inches .......................................... 4.375

Displacement cubic inches ................................. 541.5

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

Firing order ............................................ 1-4-5-2-3-6

Spark occures, degrees BTC ................................ 25

Valve rocker clearance (hydraulic tappets collapsed) ......... 028-.080

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

Prop. driven rotation

FAA Type Certificate ..................................... 1E4

Rated horsepower ........................................ 250

speed RPM .......................................

Rated

Bore, inches ............................................ 5.125

Stroke, inches .......................................... 4.375

Displacement cubic inches Compression

Firing order ............................................ 1-4-5-2-3-6

Spark

Valve rocker clearance (hydraulic tappets collapsed) .......... 028-.080

Prop. drive ratio

Prop. driven rotation ..................................... Clockwise

ratio .....................................

occurs, degrees BTC ................................

.....................................

10-540-J SERIES

.................................

........................................

SERIES

Clockwise

2575

541.5

.8.5:1

25

1:1

°

* - IO-540-C4D5D power at 2400 RPM. When operating at alternate rating, all performance data pertinent to the IO-540-W series is applicable.

Revised January 1997

model engine has an alternate

rating of 235 horse-

2-3

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

1. STANDARD

IO-540-RA5 IO-540-B1A5, IO-540-A1A5, IO-540-E1C5, IO-540-G1E5 IO-540-G IO-540-G1B5 IO-540-G1C5, IO-540-P1A5 IO-540-K1E5D IO-540-M1A5, IO-540-K1G5, IO-540-K1A5, IO-540-K1F5D, IO-540-K1E5, IO-540-L4C5, IO-540-K1J5 10-540-K1D5, IO-540-S1A5

IO-540-AA1A5

2

MODEL

............................................

..........................................

F5

...........................................

..........................................

.........

............................................

.........

ENGINE,

-B1C5,

-EB5

-GA5

-GD5

...................................

-M1B5D

-K1H5,

-K1B5,

-K1G5D

-KA5D

-LB5D

-K1F5

............

DRY

-E1A5

.....................

.....................................

......................

..................................

-K1J5D,

-K1C5,

....................................

.............................

-L1A5D

-K1K5

.................................

......................

WEIGHT

.....................

.......................

....

0-540

(CONT.)

.....

& 10-540

........

.........

SERIES

LBS.

437.00

442.00

443.00

447.00

448.00

449.00

453.00

454.00

455.00

466.00

467.00

468.00

469.00

470.00

471.00

472.00

473.00

475.00

479.00

2-4

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & 10-540 SERIES SECTION 2

SPECIFICATIONS

IO-540-AA SERIES

FAA Type Certificate ..................................... 1E4

Rated horsepower ........................................ 250

Rated speed RPM ....................................... 2425

Bore, inches ............................................ 5.125

Stroke, inches .......................................... 4.375

Displacement cubic inches ................................. 541.5

Compression ratio ........................................ 7.3:1

Firing order ............................................

Spark occurs, degrees BTC ........... .................... 20

Valve rocker clearance (hydraulic tappets collapsed) .......... 028-.080

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

Prop. driven rotation ..................................... Clockwise

IO-540-AB SERIES

FAA Type Certificate ..................................... 1E4

Rated horsepower ........................................ 230

Rated speed RPM .......................................

Bore, inches ............................................ 5.125

Stroke, inches ........................................ 4.375

Displacement cubic inches ................................. 541.5

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

Firing order ............................................ 1-4-5-2-3-6

Spark occurs, degrees BTC ................................ 23

Valve rocker clearance (hydraulic tappets collapsed) .......... 028-.080

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

Prop. driven rotation ..................................... Clockwise

1-4-5-2-3-6

2400

°

Added January 1997 2-5

TEXTRON LYCOMING

SECTION 2

SPECIFICATIONS

10-540-AC

FAA Type Certificate .................................... 1E4

Rated horsepower ........................................ 300

speed RPM ........................................

Rated

Bore, inches ............................................ 5.125

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

Displacement cubic inches Compression

Firing order ................................... 1-4-5-2-3-6

Spark occurs, degrees BTC ................................. 20

Valve rocker clearance (hydraulic tappets collapsed) .......... 028-.080

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

Prop. driven rotation ..................................... Clockwise

STANDARD ENGINE,

1.

0-540-L3C5D..........................................

O-540-J1A5D,-J2A5D, -J1B5D, -J2B5D ..................... 387.00

O-540-J3A5D,-J3C5D 0-540-B1A5,-B2A5,-B4A5 0-540-B1B5,-B2B5,-B4B5,-J3A5 O-540-A2B,-B1D5

0-540-FB5 ............................................

0-540-B2C5,-E4A5

0-540-E4B5 .............................................

0-540-E4C5 0-540-A1A,-A1A5, 0-540-A1B5,-A1C5,-A4B5 0-540-A1D,-A4C5, 0-540-A3D5,-H1B5D, 0-540-G1A5,-G2A5 0-540-H1A5,-H2A5

ratio ......................................

MODEL LBS.

............................................

.................................

DRY WEIGHT

...................................

....................................

-A4A5 ..............................

-A1D5,

-H2B5D

.....................................

............

OPERATOR'S

0-540

SERIES

..............................

.........

.............................

-A4D5 .........

...........................

.......................

MANUAL

& 10-540 SERIES

2700

4.375

541.5

8.7:1

387.00

388.00

395.00

................ 395.00

.396.00

400.00

402.00

403.00

404.00

405.00

406.00

............

406.00

412.00

415.00

416.00

2-6

Revised

January

1999

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & IO-540 SERIES SECTION 2

1. STANDARD ENGINE, DRY WEIGHT (CONT)

IO-540-AB1A5 ......... . .. .............. .......... 382.00

IO-540-W1A5,-W1A5D ................................. 400.00

IO-540-W3A5D ........................................ 401.00

IO-540-C1C5,-C2C, -C4C5, -C4D5 ........................ 402.00

IO-540-C1B5,-C4B5 ................................... 404.00

IO-540-J4A5 ...........................................

IO-540-C4B5D,-C4D5D ................................. 410.00

IO-540-D4A5,-D4B5, -T4A5D, -T4B5D ..................... 412.00

IO-540-V4A5D ........................................ 414.00

IO-540-T4B5 .......................................... 418.00

IO-540-T4C5D .......................................... 424.00

10-540-N1A5 .......................................... 428.00

IO-540-R1A5 ............... ................ 437.00

IO-540-B1A5,-B1C5, -EA5 .............................. 442.00

IO-540-A1A5,-E1B5 .................................... 443.00

IO-540-E1C5,-G1A5 ................................... 447.00

IO-540-G1E5 ......................................... 448.00

IO-540-G1F5 ......................................... 449.00

10-540-G1B5 ......................................... 453.00

IO-540-G1C5,-G1D5, -AC1A5 ........................... 454.00

10-540-P1A5 ......................................... 455.00

IO-540-K1E5D ........................................ 466.00

IO-540-M1A5,-M1B5D .................................

IO-540-K1G5,-K1H5, -K1J5D,-L1A5D, -M C5 ............. 468.00

IO-540-K1A5,-K2A5,-K

IO-540-K1F5D,-K1G5D ................................. 469.00

IO-540-K1E5,-K1A5D .................................. 470.00

IO-540-L1C5,-L1B5D

IO-540-K J5 ........................................... 472.00

IO-540-K1D5,-K1F5 .................................... 473.00

10-540-S1A5 ......................................... 475.00

IO-540-AA1A5,-AA1B5 ................................. 479.00

B5, -K1C5, -K1K5 ................

...................................

409.00

467.00

469.00

471.00

Revised January 1999 2-7

TEXTRON LYCOMING OPERATOR'S MANUAL

SECTION 2

2. ACCESSORY DRIVES

*Accessory Drive

Starter Generator Generator (Optional) Alternator

Alternator (Optional) Vacuum Pump Hydraulic Pump Hydraulic Pumpt Tachometer

Propeller Governor Propeller Governor Magneto Drive: Single Magneto Drive: Dual Fuel

Pump -

Mag)

Fuel Pump - AN (Dual

Mag)

Fuel Pump - Plunger

Operated

AN (Single

Drive Ratio

16.556:1

1.910:1

2.500:1

3.200:1

3.630:1

1.300:1

1.385:1

1.300:1 .500:1 .895:1 .947:1

1.500:1 .750:1

1.000:1

.500:1

0-540

& 10-540

*

* Direction

Counter-Clockwise

SERIES

of Rotation

Clockwise Clockwise Clockwise Clockwise

Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise

Clockwise

* - When applicable.

* * - Viewed

t - Dual magneto drive.

- Wide

facing drive

have opposite rotation to the above.

cylinder flange

pad - NOTE

series.

2-8

that engines

Added

with "L" in prefix

January

1997

will

OPERATING INSTRUCTIONS

Page

General .............................................. 3-1

Prestarting Items of Maintenance Starting Procedures Ground

Ground Check ......................................... 3-4

Operating in Flight

Engine

Performance Curves .....................................

Running and Warm-Up

Leaning Procedure ....................................

Use of Carburetor Heat ................................ 3-7

Engine Operating Conditions

Flight Chart ...................................

Shut-Down

......................................

..................................

Procedure

..........................

.............................

3-2 3-2 3-4

3-7

3-10 3-12 3-18

- 18

3

AB

Revised

January

1997

TEXTRON

LYCOMING OPERATOR'S

MANUAL

0-540 & 10-540 SERIES

SECTION 3

OPERATING INSTRUCTIONS

1. GENERAL.

to long life, economy

YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN ENGINE SPEED, THE USE OF SPECIFIED FUELS AND LUBRICANTS,

OTHER ITEM

CONTRIBUTES MANCE 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

POWER RANGE SPECIFIED

AND

FORGET THAT

MAINTENANCE SPECIFICATIONS FOR YOUR ENGINE WILL

NOT ONLY VOID YOUR LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS

PASSED.

New therefore, no further break-in is necessary insofar as operation is concerned; however, the lubricating oils recommended in the latest edition of Service Instruc- tion No. 1014.

Close adherence to these

and satisfactory operation

NOTE

THE FRONT OF THIS

REPAIRS AND

OF ENGINE OPERATION

QUITE SO MUCH

VIOLATION OF THE

WARRANTY BUT WILL

engines have been carefully

new or newly overhauled engines

instructions will greatly contribute

of the engine.

MANUAL REGARDING

ALTERATIONS. PERHAPS

AND MAINTENANCE

TO SATISFACTORY PERFOR-

FOR THE ENGINE. DO

OPERATION AND

SHORTEN THE

run-in by Textron Lycoming

should be operated using only

NO

NOT

and

Cruising been the proper in service cylinders.

this section. or

should be done at 65% to 75%

accumulated or the oil consumption

seating of the following

The minimum

Under no circumstances

automotive

fuel (regardless

rings and is applicable

cylinder replacement

fuel octane rating

NOTE

is listed in

should

of octane

power until a total of 50 hours has

has stabilized. This is

or top overhaul

fuel of a lower

rating) be

engines and engines

to new

the flight chart,

used.

to insure

of one or

Part 9 of

octane rating

more

3-1

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

2. PRESTARTING

aircraft maintenance in

Section

before

3. STARTING

3

engines

4

under

the

engine

inspection

PROCEDURES

The following

ting

characteristics

from

these

procedures.

Cranking

5

minutes

a. 0-540

periods

rest

between

Series

(1) Perform (2) Set (3) Set (4) Turn

carburetor

propeller

fuel valve

ITEMS

for the

Daily

is

started.

starting

of various

should

pre-flight

OF

first

flight

that

should

Pre-Flight

procedures

installations

be limited

cranking

inspection.

heat control

governor

to "on"

0-540

MAINTENANCE.

of

the

day,

be

performed.

Inspection.

are

recommended:

will

necessitate

NOTE

from

ten (10)

periods.

in

"cold"

(if applicable)

position.

there

They

to

twelve

position.

in

"Full

&

10-540

Before

are

several

These

must

However,

(12)

RPM"

SERIES

starting

items

are described

be

observed

the

some

seconds

star-

variation

with

position.

the

of

3-2

(5) Move (6) Turn on

(7) Pump strokes cold

for

engines (8) Open (9)

Set

magneto

handbook

mixture

boost pump.

throttle

a

cold

engine.

may

be

throttle

selector

for

correct

control

to

full

to

open

"Full

and

If engine

primed

with

approximately

switch.

position.

Rich".

back

is

equipped

1 to

3

1/4

travel.

Consult

to

idle

strokes

airframe

position

with

priming

of

the

priming

manufacturer's

for

system,

2 to pump.

3

TEXTRON LYCOMING

OPERATOR'S

MANUAL

0-540 & 10-540

(10) Engage starter.

When engine starts, place

(11) position.

(12) Check oil is not indicated within thirty trouble.

b. IO-540 Series (Cold Engine)

(1) Perform pre-flight inspection. (2) Set propeller governor in "Full RPM". (3) Turn fuel

Open

(4) (5) Turn boost

position (6) Return (7) Set magneto,

handbook (8) Engage starter.

SERIES

pressure gage for indicated

valve to "on"

throttle approximately

pump on

until a slight but

mixture

selector

correct position.

for

and move mixture

steady flow is indicated.

control to

switch. Consult

magneto selector switch in

seconds, stop engine and

position.

1/4

"Idle Cut-off"

pressure. If oil pressure

travel.

control

position.

airframe

SECTION 3

"Both"

determine

to "Full Rich"

manufacturer's

(9) When engine position.

Move mixture

(10)

Check oil pressure

(11) is not indicated trouble.

engine fails to

If engine over

procedure.

with throttle

starts, place

control slowly

gage for

within thirty

achieve a normal

seconds, stop

wide open and

magneto

indicated pressure.

NOTE

start, assume

selector switch

and smoothly

the engine

ignition off.

in "Both"

to "Full

If oil pressure and determine

it to beflooded.

Then repeat above

Rich".

Crank

3-3

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

-Because

starting

for

WEATHER

cooled proper

these

that

less

or

stated

Operate

angle

not

do

3

check

the aircraft

mixture

up

SECTION

Engine

Hot

is recommended

it used

COLD

4.

be necessary

GROUND

5.

pressure maintain operating mended

ground

Any minutes, imum

a. Head b. Leave c.

blade d. Warm

and

percolates,

fuel

the

that

engine.

a hot

STARTING.

preheat

to

RUNNING

and

cooling.

engines

the following

that

if indicated

in this

engine

the

setting.

at approximately

exceed

the

depend

Particular

on

requires

manual.

into "Full

in

on

2200

procedure,

same

engine

WARM-UP.

AND

the

on

ground.

the

precautions

NOTE

throttle

full

the

Rich".

the

RPM

head

wind.

ground

1000-1200

on

cylinder

system

the

During

oil before

and

forward

is necessary,

care

To prevent

observed.

be

operation

temperature

only

ground.

the

0-540

must

outlined

as

extreme

Subject

movement

overheating,

the

with

RPM.

& 10-540

cleared

be

on page

weather,

cold

starting.

engines

the

of

therefore,

limited

be

must

Avoid

should

propeller

prolonged

exceed

SERIES

of vapor;

3-3,

it may

are

aircraft

is recom-

it

to three

the

minimum

in

be

air

to

when

max-

idling

Engine

e. without

GROUND

6.

Warm

a. b. Check

Leave

c.

is warm

engine

the

CHECK.

up as

both

mixture

enough

faltering.

in

above.

"Full

directed

oil pressure

for

and

Rich".

take-off

oil

the

when

temperature.

throttle

can

be

opened

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

Aircraft manifold at

&

(Where

d.

to

range

check

ing feathering

1000-1500

feathering

proper

e. A

ignition

the

propeller

put,

engine

the variables following

(Controllable

(1) angle, manifold tion. harder these power

that

pressure

approximately

Switch

(2) both note

RPM drop-off

not

Do

f.

usually

is

10-540

applicable)

operation

check

(twin

action RPM; position.

magneto

system,

pitch

runs

above.

listed

procedures.

the

set

pressure

these

At

because

conditions,

settings

equipped

are

gage,

2100-2200

from

engine

until drop-off,

should

and

normal

past

operate

sufficient

SERIES

Move

and

engine)

be

can

momentarily

then

not

Do

check

affect

and

smoothly

Make

Pitch

engine

gage.

settings,

the

of

ignition

only

will

with

may

both

regains

return

then

exceed

not

is usually

a single

on

to check

propeller

the

return

the

on

checked

allow

important.

is

magneto

mixture

because

the

Propeller)

produce

to

Mixture

ignition

the

greater

problems

indicate

NOTE

fixed

magneto

check

RPM.

magnetos

speed

to both.

50

magneto

drop-off

full

to

ground

by

pulling

the RPM

drop-off.

strength.

magneto

With

-65%

50

control

system

pressure

can

fuel

propellers,

pitch

one

to

switch

and

Drop-off

RPM

of a

a sign

too

for

and

control

pitch

low

recommended

not

is

running

propeller

the

to drop

Additional

They

important

The

drop-off

in

check

propeller

power

should

spark

and

within

occur.

distribution

- air

drop-off

note

and

the

to

should

between

lean

too

a

long

minimize

will

SECTION

through position.

engine

the

control

than

more

factors,

load-power

are

is affected

accordance

minimum

in

indicated

as in the

be

plugs

cylinders.

the

checks

Mag

equipped

or not

engine

with

drop-off;

other

not

magnetos.

or too

period;

a few

complete

its

feather-

Full

but

between

into

500

other

is

thing

by

with

rich

full

must

Under

quality.

operating

return

magneto

exceed

smooth

A

mixture.

rich

seconds fouling.

plug

the the

RPM.

than

out-

that

the the

pitch

the

by

posi-

work

low

at

with

and

175

3

to

OPERATING

must

rapid

engines

be

Subject

a. and (avoid

FLIGHT.

IN

are

operated

opening

equipped

accordingly.

closing)

and

with

of

dynamic

a

Use

the

smooth,

a

throttle.

counterweight

steady

movement

system

3-5

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

airframe

See

b.

settings.

Mixture

Fuel

c.

Improper problems, cedures ing practical parts tron tion

Manual tion, airspeed. the Lycoming

Never

For tained below

On

"Full

(above port In such tion tion altitudes

Always Operate

powers

wise

particularly

described

Textron

following

or during

Lycoming

eliminating

by

replacement.

Lycoming

time

any

leaning

flow

fuel

However,

aircraft

exceed

maximum below

400°F. engines

Rich" approximately

a case

for

-not to over-rich

due

above

return

the

at

and

specified

3

manufacturer's

Leaning

fuel/air

in

It is

aircraft

fuel/air

the

may

indication,

whatever

general

engines.

maximum

the

service

435°F.

(205°C.)

manual

with

position

climb,

adjust

economy.

5,000

the

engine

economy

best

in the

Procedure.

mixture

this

rules

(224°C.)

for

75%).

roughness

mixture

airplane

during

take-off

during

manual

engines;

excessive

therefore

power-plants,

mixture monitored

be

and

instruments

should

GENERAL

cylinder

life,

during

economy

for

mixture

rated

However,

mixture Observe fuel/air feet.

at

instruments

to full

maximum

mixture

instructions

flight

and

provide

have

they

consumption

fuel

recommended

utilize

is adjusted

by exhaust

observation

by

observed

be

RULES cylinder

line

red

head

high

cruise

control,

take-off,

or loss

control

mixture

owners

climb

during

power

of

only

is

rich

power

economy

for

manual.

0-540

for

is responsible

power

climb

fuel/air

proper

to be

proven

that

instructions

the

during

gas

of engine

used

are

performance

for

most

before

mixture

the

by

head

temperatures

powers.

maintain

maximum

and

take-offfrom

result

may

enough

to

temperature

likely

increasing

for

cruise

10-540

&

recommended

many

for

settings.

economical

reducing

this

in

speed

the

should

operation

mixture

cruise

elevation

high

over-richness.

from

smooth

Rough

rise.

encountered

power

unless

when

mixture

both

and

operators,

flight.

temperature

in leaning

operator

temperature

cruise

obtain

to be

performance

power;

SERIES

power

engine

pro-

The

lean-

and

damaged

Tex-

all

of

publica-

indica- and/or

mixture,

of Textron

limit.

main-

be

and

control

in

powers

air-

opera-

settings.

cruise

other-

at

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

During

& 10-540

let-down

0-540

carbureted

A. LEANING

a. Normally

Maximum

(1) beyond manual

(2) Best

Operate

B. LEANING

to applicable

Lean

fuel-flow

rect

C. LEANING

flowmeter

Carbureted

a.

Slowly

(1)

lean position.

(2) Continue

(3)

OF

USE

8.

atmospheric to the heat ture incoming process begins that a drop propellers ped complete

form

high

from this chamber

in the

a drop

in

with

in the

air velocity

air. If

can

manifold

fixed

engine

SERIES

flight

injected

or fuel

TO EXHAUST

aspirated

Power

150°F. shows

Economy

peak

at

FLOWMETER.

TO

for each

WITH

or EGT

Enrich

CARBURETOR

conditions

cause

in power

and

gage).

Engines.

move

leaning

until

induction

through

by vaporization

air

drop

may

this air

precipitation

vicinity

pressure

drop

a

propellers.

pitch

stoppage.

operations

engines

Cruise

side

rich

on

otherwise.

Cruise

EGT.

fuel-flow

power

MANUAL

mixture

until

engine

HEAT

at temperature

system,

the carburetor

much

as

contains

the butterfly

of

output

in manifold

could

in

may be

it

to obtain

TEMPERATURE

GAS

fuel

with

(approximately

of peak

Monitor

(approximately

or lean

tables

setting.

MIXTURE

control

runs

in

installations

If

from

engine

smoothly

CONTROL

of 200

in summer

even

the fuel.

of

as 70°F.

amount

large

a

form

the

and

result.

pressure

not corrected,

necessary

smooth

injectors

unless

EGT

cylinder

75%

to indicator

"Full

roughness

and

900,

to

venturi

The

below

of moisture,

of ice.

build up

may A loss

equipped

RPM

and

this condition

to manually

operation.

carburetors.

or

power)

75%

aircraft

temperatures.

head

power

marked

CONTROL

position

Rich"

is noted.

is regained.

power

Under

-

it is possible

weather.

the

and

temperature

the

formation

Ice

to such

power

of

with

in installations

SECTION

lean

GAGE.

lean

Never

-

operator's

and below)

for cor-

(Without

toward

for

is due

in the

of

cooling

the

generally

extent

an

reflected

speed equip-

cause

may

moist

mix-

certain

This

absorption

is

constant

3

-

ice

to of

the

by

3-7

TEXTRON LYCOMING OPERATOR’S MANUAL

SECTION 3

O-540 & IO-540 SERIES

Figure 3-l. Representative Effect of Leaning on Cylinder

Head Temperature. EGT (Exhaust Gas Temperature), Engine

Power and Specific Fuel Consumption at Constant Engine

RPM and Manifold Pressure

3-a

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

preheating heat is added mixing This air preheater haust these surfaces carburetor. a loss in temperatures be avoided following

& 10-540

To

avoid this condition,

the incoming air

to replace the heat

chamber's

pipe from one

power and a

outline

(1)

Take-off - Take-offs cold position. remote.

(2) Flight in the cold position foggy lookout whether aircraft. When open the throttle to limiting additional drop will be regained the

ice has been

heat

control should equipped with be

used to keep the mixture temperature

(320F.).

temperature

is essentially

is raised to

Consistently

also

favor detonation

if normal service

is the proper

The possibility

Operation

or hazy days, regardless of

for loss

a constant

SERIES

all installations

supply to the carburetor.

loss due to

cannot drop

a tube or jacket

or more cylinders

the required temperature

high temperatures

decided variation

- The carburetor

during normal

in manifold pressure

speed or fixed

this situation

in manifold

as the

ice is melted out

melted from

be returned to

a carburetor

and preignition,

life is to be

method

of utilizing

should

be made with

of icing at

arises, apply manifold pressure. This will

pressure which

air temperature

are equipped

vaporization of

to the freezing

is passed,

are to

of the mixture.

expected from

the carburetor

wide throttle

air heat

flight operations.

outside temperature, keep

or RPM

pitch propeller

full carburetor

of the induction

the induction

the cold position.

with a system

In this

point

through

and the air flowing

be avoided because

carburetor heat

or both, depending

is normal and

system the carburetor

gage may

above the freezing

which the ex-

before

both of which

the engine. The

opening is very

control should

On damp,

is installed

system. When

Only in

SECTION

way, sufficient

fuel; and the

entering the

High charge

heat

air heat and

result in an

partial heat

for

of water.

over-

are to

control.

in full

be left

cloudy,

a sharp

on the

this drop

aircraft

point

3

of

on

Exercise carburetor

the induction system can melt then drop sharply in temperature, refreeze to use air-temperature

caution

and accumulate to form carburetor

either full heat or no heat in

when operating

air-temperature gage. Ice

from the partial heat. If this moisture

gage.

WARNING

with partial carburetor

crystals that would normally pass

when passing through the

icing. It is advisable,

aircraft not equipped with a carburetor

heat, if

venturi it could

there is no

through

should

therefore,

3-9

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

9.

ENGINE

0-540

-B

Series

-A3D5,

-A,

-F,

-J,

10-540

-C*,-D,-N,-VSeries

-A,

-M,

I -AB,-ACSeries

3

(3)

Landing

buretor

However, be applied. conditions,

returned craft

flight

FLIGHT

MODELS

-E Series

-G,

-H

Series

-LSeries

MODELS

-B,

-E,

-G,

-P,

-R,

-S,

Approach

air

heat

if icing

In the as for

to

"Full manual

-J,

-T,

should

conditions

event

an

Cold"

for

CHART

-

-K,

-L,

-W,

-AA,

- In

making

generally

are

that

full

aborted

Fuel

landing,

prior

to

specific

Requirements

91/96

0-540

an approach

be

in

the

suspected,

power

need

the

carburetor

full

power

instructions.

-

80/87 91/96

or 100/1OOLL

100/1OOLL

or 100/100LL

100/1OOLL

&

10-540

for a

"Full

Cold"

the

"Full

be

applied

heat

application.

*Aviation

Octane,

Octane

SERIES

landing,

position.

Heat"

should

under

should

See

the

Grade

Minimum Minimum Minimum Minimum

Minimum

car-

these

be

air-

Fuel

* -

3-10

Refer

to

Aviation

ed to above

the

grade

2

c.c. per

listed

latest

1OOLL

engines.

edition

gal.

are

of

Service

fuels

approved

NOTE

in

which

Instruction

the

lead

for

continuous

Revised

No.

1070.

content

use

is

limit-

in the

January

1999

TEXTRON

0-540

&

10-540

9.

ENGINE

Average

Ambient

All Above

Above

30

°

0

Below

*

- Refer

0-540 All

(Minimum

0-540-L3C5D,-J3C5D

(Minimum

10-540 All

(Minimum

IO-540-AB1A5,

-W1A5, IO-540-T4C5D 10-540-ACA5.

(Minimum

Revised

Air

Temperature

80°F. 60°F.

°

(-1.11°C.

(-17.77°C.)

10°F.

to the

MODELS

Series

Except

MODELS

Series

Except

-W1A5D,

January

LYCOMING

SERIES

FLIGHT

(26.67°C.) (15.55°C.)

to 90°F.

to

70F.(21.11°C.)

(-12.22°C.)

latest

Below

safe

quantity

safe

quantity

Below

safe

quantity

-T4A5D,

-W3A5D

......................

................................

safe

quantity

safe quantity

1999

CHART

edition

(CONT.).

-

Oil

Requirements

ALL

(32.22°C.)

of

Service

Oil

Sump

...........................

in

sump)

..........

in sump)

............................

in sump)

-T4B5,

........................

in

sump)

in

sump --

OPERATOR'S

-

MODELS

*Recommended

MIL-6082B

Grades

----- SAE

SAE SAE SAE SAE

Capacity

.................

.....................

.................

-T4B5D,

.....................

AB1A5,

SAE15W-50or20W50 60 50 40 30 20

Instruction

..............

-V4A5D,

8

U.S.

Qts.

-AC1AS).....

MANUAL

SECTION

MIL-L-22851

Ashless

SAE

No.

(10

Dispersant

Grades

SAE

40 or

SAE

40,30,20W40

SAE

30,

1014.

12

2-3/4

12

2-3/4

8 U.S.

U.S.

11 U.S.

2

8

2

Qts.

4 U.S.

Grade

60

SAE

40

20W30

U.S. U.S. U.S. U.S.

U.S. U.S.

Max.)

U.S.

3-11

3

Oil

50

Qts. Qts. Qts. Qts.

Qts. Qts.

Qts.

Qts. Qts. Qts.

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

9.

ENGINE FLIGHT

Oil Pressure, psi Normal

All

Oil Temperature: (118°C.). For maintained flight cruise

FUEL

0-540 Series

-L3C5D*

IO-540-AB1A5, -C1B5, -C1C5,

-C4B5,

-D4A5,

-T4B5, T4B5D, -T4C5D, -V4A5D,

-W1A5, Inlet to fuel Inlet

3

CHART (CONT.).

Max. Min. Idling

Operation

Models 95

The maximum

maximum

between 165°F.

conditions.

PRESSURE

(Except -L3C5D)

-C4B5D, -C4D5,

-D4B5,

-W1A5D, -W3A5D

to fuel

-N1A5, -T4A5D,

pump injector

engine life, desired

OPERATING CONDITIONS

(PSI)

-C4D5D,

(73.8°C.)

0-540

55 25

permissible

MIN. MAX.

0.5 8.0 3 30

-2 35 14

oil temperature

and 200°F. (93.3°C.)

45

& 10-540 SERIES

Start & Warm-Up

115

is 245°F.

should be

in level-

IDLE

MIN.

12

IO-540-L1C5

Inlet to Inlet to

IO-540-L1B5D

Inlet to Inlet to fuel

* 3-12

fuel pump fuel injector

fuel pump

injector

- Above compressor

outlet pressure

-2 18

35 55

40 40

Revised

12

April

1999

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & 10-540 SERIES

OPERATING

FUEL PRESSURE (PSI)

IO-540-K1F5, -K1G5, -K1G5D,

-K1H5, -K1J5, -K1J5D Inlet to fuel pump Inlet to fuel injector

IO-540-M1B5D

Inlet to fuel pump Inlet

to fuel

injector

IO-540-K1A5,1A 1A5D, -K1B5,

-K1B5D,

-K2A5, -M1A5, -M1C5 Inlet to fuel pump Inlet to fuel injector

IO-540-AC1A5

Inlet to fuel pump Inlet to fuel injector

-K1F5D,

-K1K5,

CONDITIONS (CONT.)

SECTION 3

MIN. MAX. IDLE MIN.

-2 40 18 55

-2 18

-2 55 18 55

-2

29 65

45

65

12

10-540-G1B5, -G1C5, -G1D5,

-K1D5, -P1A5, -S1A5 Inlet to fuel pump

Inlet

to fuel injector

IO-540-J4A5,

Inlet to fuel pump Inlet to fuel injector

Revised April 1999 3-12A/B

-R1A5

-4 18

-4 45 14 45

40 40

12

TEXTRON

0-540

FUEL

&

10-540

PRESSURE

LYCOMING

SERIES

OPERATING

(PSI)

OPERATOR'S

CONDITIONS

MIN.

(CONT.)

MAX.

MANUAL

SECTION

IDLE

MIN.

3

IO-540-AA1A5,

Inlet

to

fuel

pump

Inlet

to

fuel

injector

10-540-A1A5,

-E1A5,

-G1F5,

Inlet

to

All inlet

-E1B5,

-K1C5, fuel

injector

IO-540Models

with

the

-AA1B5

-B1A5,

-G1A5,

-K1E5,

fuel

-B1C5,

--G1E5,

--K1E5D

listed

injector

NOTE

have

in

idle

-4 18

20

55 psi

cut-off.

55 55

26

maximum

to fiel

12

pump

Revised

April

1999

3-13

TEXTRON

LYCOMING OPERATOR'S

MANUAL

SECTION 3

OPERATING CONDITIONS (Cont.)

Fuel Max. *Max

Operation RPM HP Gal./Hr. Qts./Hr.

0-540-A

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

Normal Rated Performance Cruise

(75%

Economy Cruise

Normal Rated Performance Cruise

Economy Cruise

Rated)

(60%

Rated)

(75% Rated) (60%

Rated)

2575 2350 2200

2700 2450 2350

250 -----

0-540-B Series

235 -----

0-540-E,

260 -----

Cons. Oil Cons. Cvl. Head

190 16.3 150 12.5

175 15.5 140 12.2

195 19.0 155 14.0

0-540 & 10-540

Series

0.83

0.63

0.50

0.78

0.58

0.47

-G,

-H

0.87

0.65

0.52

500 F.

500 F. 500 F.

500°F. 500 F. 500 F.

500 F. 500 F. 500 F.

SERIES

Temp

(260 C.) (260°C.) (260°C.)

(260°C.) (260°C.) (260 C.)

(260°C.) (260°C.) (260°C.)

Normal Rated Performance

(75% Rated)

Economy Cruise

(65%

* - At Bayonet cylinder head operation.

3-14

Cruise

Rated)

temperature

2800 2800 2800

Location

0-540-F 235

175 15.0 155 13.5

-For

maximum

between

Series

-----

service

150°F.

0.78

0.58

0.51

life of the engine

and 435

0

F. during

500 F. 500 F. 500 F.

(260°C.) (260°C,) (260°C.)

maintain

continuous

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540 & 10-540 SERIES

OPERATING

Operation

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

* -At Bayonet Location - For cylinder head temperature between 150°F. and 435°F. during continuous operation.

** - Model ted at cruise conditions up to 75% power resulting in a BSFC of .430 Ibs./BHP./hr. is .500 Ibs./BHP./hr.

0-540-J

RPM

2400 235 2200 175 2000 140

2400 235 2200 175 2000

Engines - manual

Minimum allowable

CONDITIONS

Fuel Max.

Cons. Oil Cons.

HP Gal./Hr.

0-540-J Series **

14.0 0.58 500°F. (260°C.)

10.2 0.47 500

0-540-L3C5D ***

15.0 0.58 500°F. (260°C.)

140 10.3 0.47

maximum service life of the engine

leaning to best

BSFC at take-off and climb conditions

(Cont.)

Qts./Hr.

-- 0.78 500°F. (260 C.)

-- 0.78 500 F. (260 C.)

SECTION 3

*Max

Cyl. Head

Temp

F. (260°C.)

500 F. (260°C.)

economy is

maintain

permit-

Model 0-540-J3A5D Engines - Manual leaning is permitted at cruise con- ditions up to 85% power resulting in a BSFC .420 Ibs./BHP./hr. at best economy and .460 at take-off and climb conditions is .500 Ibs./BHP./hr.

*** -Model 0-540-L Engines ted at cruise Ibs./BHP./hr. Minimum allowable BSFC at take-off and climb is .550 Ibs./BHP./hr.

Ibs./BHP./hr. at best power.

-Manual leaning at best economy

conditions up to 75% power

Minimum allowable BSFC

is permit-

resulting in a BSFC of .430

3-15

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION 3

0-540 & 10-540 SERIES

OPERATING CONDITIONS (Cont.)

Fuel

Operation

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

RPM HP Gal./Hr.

IO-540-A, -B, -E, -G, -P Series

2575 290 ----- 0.97 500°F. (260°C.) 2350 220 16.5

2200 175 12.0 0.5 500°F. (260°C.)

IO-540-C,

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

Normal Rated Performance Cruise

(75% Rated)

Economy Cruise

(60% Rated)

* - At Bayonet cylinder head temperatures between 150°F. and 435°F. during continuous operation.

** - Limiting manifold pressure for continuous operation of IO-540-C4B5,

-C4C5, -J4A5 with Hartzell propeller HCE2Y type hub and 8465-7R blades.

Do not exceed 27 inches manifold pressure below 2300 RPM.

2575 250 ----- 0.83 500°F. (260°C.)

2350 190 16.5 0.63 500°F. (260°C.) 2200 150 12.5 0.50 500°F. (260°C.)

IO-540-D,

2700 260 2450 195 2350 155 12.0 0.52 500°F. (260°C.)

IO-540-K, -L, -M, -S Series

2700 300 --

2450 225 18.0 2350 180 12.8 0.60 500°F. (260°C.)

Location - For maximum

Cons.

-J Series

-N,

-R, -T, -V Series

15.0

service life of the engine maintain

Max.

Oil Cons.

Qts./Hr.

0.73 500°F. (260°C.)

*Max

Cyl. Head

Temp

**

-- 0.87 500°F. (260°C.)

0.65 500°F.

1.0 500°F. (260°C.)

0.75 500°F. (260°C.)

(260°C.)

3-16

TEXTRON

LYCOMING OPERATOR'S

MANUAL

0-540 & 10-540 SERIES SECTION 3

OPERATING

Cruise

head

RPM

2000

2425

2200

1900

2200

2000

Location

temperatures

Operation

Normal Rated 2400

Performance

(75% Rated) 2200

Economy

(60%

Normal Rated Performance Cruise

(75% Rated)

Economy

(60% Rated)

Normal Rated 2400 Performance Cruise

(75%

Economy

(60%

* - At Bayonet tain tinuous

Rated

Rated)

Cruise

Rated)

cylinder

operation.

CONDITIONS

Fuel Max. *Max. Cons.

HP

235 ---- 0.78

175 12.5 0.58

140 10.1 0.47

IO-540-AA

250 --- 0.83

190 14.5 0.63

150

230 ---- 0.78

175

140

- For maximum

Gal./Hr.

[O-540-W

IO-540-AB Series

between

Series

11.5

12.5

10.1 service life

150°F.

(CONT.)

Oil Cons.

Qts./Hr.

0.50

0.58

0.47 of the engine main-

and 435°F.

Cyl.Head

Temp..

500°F. (260°C.)

500°F.(260°C.)

F.(260°C.)

500

500°F.(260°C.)

con-

during

Revised

January

1997

3-17

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

Operation

Normal Performance

Economy

(75%

(60%

e.

Engine

(1) (2) Idle

ture. (3) (4)

Rated

Rated)

Cruise

Rated)

Set

Move mixture When

3

OPERATING

RPM

2700

Cruise

2400

2200

Shut

Down

propeller

until

there

engine

HP

10-540-AC

300

225

180

-

at

minimum

is a

decided

control

stops,

CONDITIONS

Fuel Cons.

Gal./Hr.

Series

23.7

19.0

12.6

blade

angle

decrease

to "Idle

turn

Cut-off".

ignition

0-540

(CONT.)

Max.

Oil Cons.

Qts./Hr.

0.98

0.73

0.58

(high

in

switch

& 10-540

480°F.(249°C.)

RPM).

cylinder

off.

SERIES

*Max.

Cyl. Head

Temp.

head

tempera-

3-18

Revised

January

1999

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

& 10-540

PART

COMPRESSION

SPARK

CARBURETR, MIXTURE OPERATNG

GRADE,

FUEL

- 21

20

- 17

PERCENT 7

15

POWER

SERIES

THROTTLE

LYCOMING

RATIO

TIMING

MARVEL-SCHEBLER

SETTING

CONDITIONS

MININUM

RPM

70

CURVE

FUEL CONSUMPTION

0-540-A SERIES

8.50:1

BTC

25

MA-4-5

RICH

FULL

SEA LEVEL

STD

91/96

S

SECTION 3

E NO. 11800

Added

3-2.

Figure

January

20

ABSOLUTE

Part

1997

22

MANIFOLD

Throttle

0-540-A

NOTE

ENTER THIS

ALTITUDE,

EXAMPLE

G OF

POINT

PERFORMANCE

24

PRESSURE-IN

26

CURVE HG

Fuel Consumption

TO OBTAIN

CUPE WITH

ALTITUDE

ON

28

-

Curve

3-18A/B

FUEL CONSUPTION Al

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

z

o

10-540

&

250

200

SERIES

SEA

LYCOMING

COMPRESSION

ADVANCE

SPARK

CARBURETOR, FUEL MIXTURE

OPERATING

GRADE,

SETTING

CONDITIONS

MINIMUM

CURVE

POWER

LEVEL

0-540-A

RATIO

MARVEL-SCHEBLER

STD

FULL

SEA

25

CURVE

SERIES

8.50:1 BTC

MA-4-5

91/96

RICH

LEVEL

RATED

POWER

SECTION

11799

NO.

3

Figure

3-3.

Sea

Level

Power

Curve

2400

0-540-A

-

2600

3-19

HP T

APPROIMATELR

EAC°AL'VRIATIA

H5L«PS>L « T TTE•

60 ACTU //

1 CORRECTION FR

\ R'M"

Figure

-

3-4.

/ /

Sea

___

/<

IT

Level

and

Altitude

Performance

Curve

HEATER USED

TE__ _ MP. ANOW % ACTUAL INLET A-

-

0-540-A

TEMP

1

z

p _

0

TEXTRON

0-540

& 10-540

LYCOMING

OPERATOR'S

SERIES

THROTTLE

PART

LYCOMING

COMPRESSION

TIMING

SPARK CARBURETOR,

MIXTURE SETTING OPERATING CONDITIONS STD SEA LEVEL FUEL GRADE,MINIMUM

23

21

20

19

FUEL CONSUMPTION

0-540-B

RAT O MARVEL-SCHEBLER

MANUAL

CURVE

SERIES

7.20:1

°

BTC

25

MA-4-5

FULL RICH

80/87

SECTI

NQ, 10822-B

ON 3

18

16

15

I

14

18

Figure

ENGINE

RFM

FOR ACTUAL ALTITUDE POWER SEE

20

ABSOLUTE MANIFOLD

3-5. Part

22

Throttle

24

PRESSURE-IN.

Fuel

NOTE

ALTITUDE, ENTER THIS CURVE WITH

POINT "0" OF EXAMPLE ON

ALTITUDE PERFORMANCE CURVE.

Consumption

TO OBTAIN FUEL CONSUMPTION

EQUIVALENT SEA LEVEL MAN. PRESS

26

28

HG.

Curve

AT

-

0-540-B

3-21

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

3

POWER

0-540

&

10-540

CURVE NO. 10821-B

SERIES

POWER

3-22

Figure 3-6.

Sea Level Power

Curve - 0-540-B

ACTUAL

TO FIND ALTITUDE,R AND AIR INLET

AN FULL THROTTLE

L LOCATE

FOR

CURVE

S ON SEA LEVEL

2 LOCATE

HORSEPOWER

PM, MANIFOLD

TEMPERATURE

MANIFOLD

RPM

GIVEN

PRESSURE

ALTITUDE

CURVE

FROM

PRESS

m

0

m

0

r

m

n

Figure

3-7. Sea

Level

and

Altitude

Performance

- 0-540-J,-L

w

TEXTRON LYCOMING OPERATOR'S MANUAL

SECTION 3

USING

following is an example of how

The

Performance curves for normally aspirated engines, printed on these pages,

to determine actual horsepower

altitude,

(figure 3-8) is for illustration purposes only.

RPM, manifold pressure and oil

1. Determine

performance curve for observed manifold pressure and RPM. Example:

At 2100

Repeat above procedure on sea

2. Point "B".

Transfer value

3. Example:

Connect point "A" and

4.

5. Read horsepower on with a power setting of 2100

feet

157. Point "D".)

6. Correct temperatures from Add correction for temperatures above temperature of variation, 1% for each 10 approximately correction:

CURVE TO FIND ACTUAL

being delivered by the engine

equivalent

RPM and 23.2 inches manifold

obtained in

Point "C".

power approximately

157 + 6 = 163 horsepower

the standard altitude temperature

for temperatures below

14°F. at an altitude of 1500

horsepower. Since

6

full throttle

step 2 to altitude

point "C" with a straight

line "CA" for given altitude

1% for each 10°variation in intake

standard. (Example:

°

variation is 4%. 4% of 157

0-540 & 10-540

HORSEPOWER

to use the Sea Level and

inlet temperature. This example

horsepower

pressure, locate Point "A".

level performance curve. Example:

performance

line.

RPM and 23.2 in. Hg., horsepower

standard, subtract correction

temperature

- Point "E".)

(Example: At 1500

With an air inlet

feet, 54°F. - 14°F. = 40

is below standard,

SERIES

Altitude

for given

on altitude

curve.

shown below.

horsepower is

add

is

air

°

STANDARD ALTITUDE

Pressure Altitude

(Thousands) SL

Standard Altitude

Temperature

3-24

(°F.) 59 52 45

TEMPERATURES

2 3 6 8 1012 14 16

38 31 23 16 9 + 2 -5 -12

IN DEGREES F.

18 20 22 24

-19 -27

ALTUTUDE PERFORMANCE

-

CURVE

RATIO

MIXTURE

239

NOTE

SE ES

AIRCRAFT ENGINE

PERFORMANCE DATA

MAXIMUM POWER MIXTURE UNLESS OTHERWISE

ENGINE

MODEL O-540-B

COMPRESSON

CARBURETOR

MARVEL-SCHEBLER

FUEL

GRADE. MINIMUM 80/87

NO EXTERNAL

USED

HEATER

7 2

MA 4 5

, I

29

4

Figure 3-8.

Sea Level and

Altitude

TEXTRON

SECTI

SECTION

ON 3

24

23

z

LYCOMING

THROTTLE

PART

LYCOMING

COMPRESSION RATIO

TIMING

SPARK

CARBURETOR MARVEL SCHEBLER MA-4-5 MIXTURE OPERATING

FUEL GRADE,

SETTING

OPERATOR'S

FUEL

0-540-E,-G-H

CONDITIONS

MINIMUM

25

FULL SEA

&

8.50:1

LEVEL

0-540

CONSUMPTION

STD

MANUAL 10-540

CURVE NO 12954

BTC RICH 91/96

SERIES

3-26

12

45

Figure

ABSOLUTE

3-9. Part

22

MANIFOLD

Throttle

Fuel Consumption

O-540-E, -G, -H

PERFORMANCE

24

PRESSURE

26

CURVE.

IN.HG.

Curve

28

-

ESS RORANCE

ADEM

AT GIVEN

RE TERTUe

ALTITUE

AHRR~ %'O

RWIARTO V

T T

S TAI.

O

TITUE

P

POWER j-

RATED

.

O PBRM

- 0

—

/

ALTITUDE

AN

I LAATE AO

3

TEMPERATURE.

;LET

AIR

IULTTTL

SuRvW E

R

"6, HW

mDIM°

C

TO

TRAMPRU

COWCT aC vr RfEA

oruY

APIEMIX E. ACI0 F

SuMRT uNE AWI

HO

O.WER

RMACKiT r D

T LITU

IIATIT I% C—RT/RC / FMR

ATIOR

ErHalUI// / 220

MUANIFOLDPRE

RPM,

/

—

—T j 260

cURVE NO 12ss

ALTITUDE PERFORMANCE

1:;

8

o

240

—

*

LYCOMING

AIRCRAFT

PERFORMANCE

POWER

MAXIMUM

MARVEL SCHEBLER

ENGINE

DATA

MIXTURE

MA-45 -

O

>

Level and

200

3-10.

Frr

Sea

e - vrl^Ters

e-'z

xs

< A t /' ¢ t X

Figure

Altitude

Performance

Curve

- O-540-E,

-G,

-II

Z

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

- 20

-10

3

18

6

PART

ENGINE

HELICOPTER

CARBURETOR. FUEL COMPRESSION SPARK FUEL CONSUMPTION

GRADE,

TIMING

20

MARVEL-SCHEBLER

MINIMUM

RATIO

FUEL

ABSOLUTE

SPECIFIC

THROTTLE

MODEL

TOLERANCE

CONSUMPTION U.S. G.PH.

22

MANIFOLD

FUEL

CONSUMPTION

FUEL

24

PRESSURE

CONSUMPTION

0-540

0-540F

26

- IN HG

&

SERIES MA-4-5

100/100LL

8501

25°BTC

± 4%

10-540

CURVE NO 12613A

28

SERIES

3-28

125

Figure

150

3-11.

175

ACTUAL

Part

0-540-F

HORSEPOWER

Throttle

Series

OBTAIN

TO

THIS CURVE

ENTER POWER OBTAINED AS POINT FORMANCE

200

Consumption

Fuel

NOTE

FUEL CONSUMPTION

"F" OF

CURVE. 225 250

ACTUAL

WITH

FROM FLIGHT

EXAMPLE

ON ALTITUDE

AT ALTITUDE,

ALTITUDE

CONDITION

PER-

m

z

19 20 21 22

ABSOLUTE MANIFOLD

Figure

23 24 25 26 27

IN HG

PRESSURE

Sea

3-12.

28 29

Level

and

Altitude

Performance

Curve

- 0-540-F

Series

z

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION 3 0-540 & 10-540 SERIES

CURVE 12742-A

PART

THROTTLE

LYCOMING 10-540-A-B-E-G-P SERIES

COMPRESSION

SPARK TIMING 20 BTC

FUEL INJECTOR BENDIX RS-IO

MIXTURE

CONTROL - MANUAL

FUEL

GRADE,MINIMUM

22

FUEL CONSUMPTION

RATIO

TO BEST ECONOMY OR

POWER AS INDICATED

8.70:1

BEST

100/100LL

21

20

19

18

17

16

15

14

13

12

11

10

45

100 120 140 160 200 220 240 260 280 300

ACTUAL

Figure 3-13. Part

PERCENT

RATED

POWER 85

NOTE

FUEL CONSUMPTION

FOR RATED

IS 24.6 U.S GAL/HR

BRAKE

HORSEPOWER

Throttle Fuel Consumption

IO-540-A, -B, -E, -G, -P

POWER

-

3-30

Figure

3-14.

Sea

Level

and

Altitude

Performance

Curve

- 10-540-A,

-G,

-P

fr//i

Figure 3-15. Sea Level and Altitude Performance Curve - IO-540-B, -E

·Lra

gIX4D

,.

ALI Tnl

_2LI*FI2o

\

1.

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

aX I

i

<n

z

IL

&

- IC

.-

0

--

10-540

LYCOMING

COMPRESSION

SPARK

FUEL INJECTOR

GRADE,MINIMUM

FUEL MIXTURE

POWER

o2

19

I8

15

14

13

12

II

SERIES

PART THROTTLE

MODEL

RATIO

TIMING

CONTROL-

AS

MANUAL

INDICATED

FUEL CONSUMPTION

BENDIX

TO BEST ECONOMY

-

PERCENT

-RATED / V

POWER

85 /

540-C

10-

MODEL

25°BTC

RSA-5ADI BEST

OR

CURVE

SERIES

8 50

91/96

SECTION

12638

NO

I

3

10

Figure

100 120 140

ACTUAL BRAKE

3-16. Part

160 180 200 220

HORSEPOWER

Throttle Fuel

10-540-C

240 260

Consumption

Curve

-

3-33

z

w

-I

Figure

3-17. Sea Level and Altitude

CORRECT FOR DIFFERENCE BETWEEN STD.

Performance Curve - IO-540-C

z

m

TEXTRON LYCOMING

OPERATOR'S

MANUAL

0-540

10-540 SERIES

&

COMPRESSION

TIMING

SPARK FUEL INJECTOR - BENDIX MIXTURE

INDICATED

FUEL GRADE.

-71

—•,D'_§~~~~~~5

_I,

-3-

PART THROTTLE

LYCOMING MOOEL I0-O54 . -N. -R. -T. -V

RATIO

CONTROL - MANUAL TO BEST

MINIMUM

FUEL CONSUMPTION

MODEL RSASAD1

ECONOMY OR BEST POWER

PERCENT

RATED

POITER

-P

-0. -N.V

-T.

SECTION

CURVE NO 1257

8 50 1

25S BTC

91/95

WIuLL

3

Figure

3-18.

t20 14

00

Throttle

Part

IO-540-D,

Consumption

Fuel

-R, -T, -V

20i 220

160 10

ACTUAL SAAKE MaISEFWIP

-N,

240

260 260

Curve

-

3-35

z

0

Figure 3-19.

Sea Level and Altitude Performance

Curve - IO-540-D, -N, -R, T,

-

m

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540 &

10-540 SERIES

ASPIRATED

MODEL

RATIO

MINIMUM

CONTROL-

COMPRESSION SPARK TIMING

FUEL FUEL GRADE,

MIXTURE POWER

20

19

18

17

16

15

12

NORMALLY LYCOMING

INJECTOR

AS INDICATED

FUEL CONSUMPTION

BEST ECONOMY

TO

MANUAL

PERCENT

RATED /

POWER

10-540-J

BENDIX

85

MODEL

OR BEST

CURVE

SERIES

8.50:1

25° BTC

RSA-5ADI

100/100LL

SECTION

13002

NO

_

3

Figure

10

9

120

100

ACTUAL

3-20. Normally

160 180

140

BRAKE

Aspirated

IO-540-J

240

220

200

HORSEPOWER

Fuel Consumption

260

Curve

-

3-37

18

19 20

ABSOLUTE

Figure

21 22

23

24 25

MANIFOLD

3-21.

26

PRESSURE

Sea

27 28 IN

HG

Level

29

and

Altitude

PRESSURE

ALTITUDE

Performance

IN

THOUSANDS

Curve

OF

FEET

- IO-540-J

-

z

Z

TEXTRON

LYCOMING OPERATOR'S

MANUAL

0-540 &

MI

-

cf)

z

0

I-

LL

wD

Ijn

10-540 SERIES

PART THROTTLE

LYCOMING

COMPRESSION

SPARK TIMING FUEL MIXTURE

FUEL GRADE,

_z

za

22

21

20

19

17

IE

12

RATIO

NJECTOR BEIOIX MODEL

CONTROL- MAMIAL TO

MINMUM

I

FUEL CONSUMPTION

10-540- K;L,-M SERIES

MODEL-

20" BTC

RSA-

10010LL

POWER

BEST ECONOMY OR BEST

AS INICATED

iI

PERCTNT

RAT -D POWER

\

75

SECTION

CURVE NO. ro012

8.704 IOADI

3

II

Figure

100 140 160 180 200

ACTUAL BRAKE HORSEPOWER

3-22. Part

Throttle

IO-540-K,

220 240 260

Fuel Consumption

-M, -S

-L,

280 300

Curve

-

3-39

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & 10-540

FUEL FLOW vs PERCENT RATED POWER

22

20

18

16

14

12

SERIES

LYCOMING 10-540 AAIA5

NORMALLY ASPIRATED

SECTION 3

CURVE

No 13386

10

50 60 70 80 90 100

3-24. Fuel Flow vs

Figure

Revised January 1997

PERCENT

IO-540-AA Series

RATED

Percent Rated Power Curve

POWER

-

3-41

Figure

3-25. Sea Level/Altitude

IO-540-AA Series

Performanc Curve

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

& 10-540

FUEL FLOW

SERIES

vs PERCENT RATED

LYCOMING

IO-540-W

CURVE No 13383

POWER

SERIES

SECTION

3

50 60 70 80 90, 100

I I I I I

Figure 3-26. Fuel

IO-540-W,

Revised January 1997

PERCENT

RATED

Flow vs Percent Rated

-AB Series

POWER

Power

3-

-43

Added

January

0-540 & 10-540

TEXTRON

1997

3-45

It\

:1

—I

_____

a X

iI

r o

O w

111

°2

ii ' ' e

i- -s^

i" V

^in

rl

K a

11

/.

W E

/ ~-^

it

-e

LYCOMING

SERIES

OPERATOR'S

. ° '4d

* I.,

I;

N

MANUAL

SECTION

3

TEXTRON

LYCOMING

OPERATOR'S MANUAL

0-540 &

MINIMUM

160

150

10-540 SERIES

FUEL FLOW

TEXTRON

90

80

VERSUS

LYCOMING

PERCENT RATED

10-540-AC1A

Curve

SECTION

POWER

No, 13544

3

3-46

70

60

50 60

Figure

3-29.

70 80

PERCENT

Fuel

Flow

IO-540-AC

RATED POWER

vs Percent

Series

Rated

90

Power

Added

100

January

1999

SEA LEVEL

TO FIND ACTUAL HORSE POWER FROM ENGINE

ALTITUDE,

R.PM., MANIFOLD PRESSURE

ANDAIR INLET

1. LOCATEA CURVE FOR GIVEN RPM.

PRESS.

B ON SEA

LOCATE

2.

FOR R.P.M. & MANIFOLD PRESSURE ENGINE MODEL 10-540-AC

3. CONNECT A&C BY

LINE AND READ HORSEPOWER FUEL GRADE: MIN.100 LL

ATGIVENALTITUDED.

4. MODIFY HORSEPOWER AT D

VARIATION OFAR

FOR

INLET TEMPERATURE

TS

BY FORMULA:

PERFORMANCE RATED POWER 300

TEMPERATURE.

ON FULL THROTTLE

ALTITUDE

MANIFOLD

LEVEL CURVE

A STRAIGHT

280

/

HP @ 2700 RPM CURVE NO.13541

ALTITUDE PERFORMANCE

ALTITUDE

DRY MANIFOLD

ABS

PERFORMANCE

CORRECT FOR DIFFERENCE

ALTTEMP

MAXIMUM POWER MIXTURE

OTHERWISE

UNLESS

COMPRESSION RATIO: 8.7:1

FUEL INJECTOR: PAC RSA-10

T ANDACTUALINLETAIRTEMP

INACCORDANCE

PERFORMANCE

NOTED

BETWEEN STD.

WITH NOTE4

DATA

ACTUAL H.P. RECTION

EACH 10 F.

VARIATI

18 19 20

ABSOLUTE

APROX-

FOR

22 23 24 25 26 27

MANIFOLD

28 29 SEA

PRESSURE,

IN. HG

LEVEL

1 2 3 4 5

6 7 8 9 10 11

ALTITUDE

PRESSURE

Figure 3-30. Sea Level/Altitude Performance Curve

IO-540-AC Series

20

12 13 14 15 16 17 18

IN THOUSANDS

OF FEET

19 20 21 22 23 24

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

General Pre-Starting Daily 10

25

50 100 Hour

400 Hour

Non-Schedules

...............................................

Pre-Flight

Hour Inspection

Inspection.

Hour

Inspection

Hour

Inspection Inspection.

PERIODIC

Inspection

Inspections

...................................

Inspection

......................................

.....................................

................................

.....................................

....................................

................................

INSPECTION

Page

4-1 4-1 4-2 4-2 4-2

4-2A/B

4-4 4-5

4-5

Revised

January

1999

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 &

Perhaps aircraft and

for

pages the engine

no other

minor troubles

The operator

do not

10-540

its components

only. Consult

SERIES

factor is

and prompt

should

constitute

tional instructions.

Pre-Starting

aircraft prior the general

The importance

ed. Statistics

Inspection

to the first flight

condition

of proper pre-flight

prove several

sible to poor pre-flight.

Among the major centration, bred

reluctance to acknowledge

by familiarity

causes of

and haste.

PERIODIC INSPECTIONS

NOTE

safety and

quite so important

as faithful

repair when

in mind

bear

a complete

airframe

the

- The daily of the day.

aircraft

of the

hundred accidents

poor pre-flight

and

that the items

aircraft

pre-flight

and engine.

the need

to

diligent attention

they are found.

inspection,

manufacturer's

inspection

This inspection

inspection

cannot be over

occur yearly

inspection are

for a check

SECTION

durability to regular

in the following

listed

but are meant

handbook

is a check

is to determine

directly respon-

list, carelessness

of the

checks

for

addi-

for

of the

emphasiz-

lack of con-

4

4-1

TEXTRON

SECTION 4

1. DAILY

2. 10

ing time, the oil filter, ter for

2a. 25 HOUR

erating time since the overhauled draining specting

PRE-FLIGHT(ENGINE).

sure all

a. Be

sure magneto

b. Be c. Check oil level.

d. Check fuel level.

Check fuel

e.

at 50 hour

pair f. Open

ment.

g. Make

missing aircraft is flown.

Check controls

h. tion.

i. Induction

with the

dance

HOUR INSPECTION

for new,

traces of metal

and renewing

the

If the

oil every 25 hours; tion

oughly

LYCOMING

switches

and oil

inspection.

the fuel

sure all

or damaged,

drain

shields and

system

airframe manufacturer's

remanufactured,

and conduct

INSPECTION

engines

contents

engine does

screens for

before reinstallation.

OPERATOR'S

& 10-540 SERIES

0-540

position.

"Off"

in the

are

are connected.

ground

for

air filter should

particles.

should

of the

wires

line connections,

Repair

to remove

cowling

or replacement

repair

general

first inspection, new, remanufactured,

lubricating

condition,

(ENGINE).

an inspection

(ENGINE).

undergo

used oil

NOTE

not have a

also, inspect oil pressure

metal contamination,

note minor

any leaks

any accumulation

are in place

should be

travel and

inspected

be

recommendations.

Within

newly overhauled

or

of the contents

At twenty-five

a 50-hour

oil, replacing

filter.

full--flow oilfilter,

indications aircraft

before

of water and

and secure.

freedom

and serviced

ten (10)

of the

inspection

the oil

and suc-

and clean

(25) hours of

change

MANUAL

for re-

is flown.

sedi-

If any

made before

of opera-

in accor-

hours of engines,

operat- replace

used oil

or newly

including

filter, and

thor-

are the

fil-

op-

in-

4-2 Revised March 1999

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

3. 50

daily made

10-540

&

HOUR

INSPECTION

pre-flight

every 50

after

SERIES

inspection,

hours of

(ENGINE).

the following

operation.

In

addition

maintenance

to the

SECTION

items listed

checks should

4

for

be

Added

January

1999

4-2A/B

TEXTRON LYCOMING OPERATOR'S MANUAL

0-540 & 10-540 SERIES

a. Ignition System -

(1) If fouling of spark plugs

electrode gap. Rotate

(2) Examine

spark plug leads of cable and

deposits. This condition is evidence of either leaking spark plugs,

improper

cleaning

this condition

of the spark

is found, clean the cable ends, ceramics with a dry, clean methyl-ethyl

ketone.

reassembly.

(3) Check ignition harness

sure connections

b. Fuel and

security

Induction System - Check

of the clamps. Remove and

the mixture control

are

and throttle linkage for ment, security of the clamps intake ducts

material in the ducts is indicative

solid ed filter. Check

for leaks, security,

vent lines for

sent, fuel pump may require replacement.

c. Lubrication System -

has been apparent, clean them

bottom plugs to

upper position.

ceramics for corrosion and

plug walls or

connector ends.

spark plug walls and

cloth or a clean cloth moistened

All parts

should be

clean and dry

for security of mounting

tight at spark

plug and magneto

the primer lines for leaks and

clean the fuel inlet strainers.

travel, freedom of move-

and lubricate if necessary.

filter damage;

evidence

of inadequate filter care or

evidence of

fuel or oil seepage;

clamps and be

of dust or other

SECTION 4

and check

Where

with

before

terminals.

Check

Check the air

damag-

if pre-

(1) Check of anchorage

oil lines for leaks, particularly

and for wear due to

rubbing or vibration, for dents

cracks. (2) Replace elements

of used element check interior

ing that might be evidence of lubricating

d. Exhaust System

oil. (Reference Service Instruction

for evidence of leakage. If machined flat before

on external full flow oil filters.

internal engine damage. Drain

- Check attaching flanges at

they are loose, they must be

they are reassembled and tightened. haust manifolds for general condition.

at connections; for security

Before dispos-

folds for traces of metal

No. 1014 for proper oil.)

exhaust ports on cylinders

removed and

Examine ex-

and

particles

and renew

4-3

TEXTRON LYCOMING OPERATOR'S MANUAL

SECTION

e. Cooling

and secure system operation.

f. Cylinders

replace gasket

Check

paint on the cylinder.

ed the cylinder

before

Heavy discoloration attachment assembly after the cylinder harmful proven that replaced.

100 HOUR INSPECTION.

4.

flight and made after

a. Electrical System -

b. Lubrication

4

System - Check

anchorage.

must be repaired

- Check and tighten

cylinders for

and, if found,

the aircraft resumes

area is usually

of the barrel

nor detrimental

50 hour inspection,

(1) Check shielded cables or loose wires

(2) Remove if necessary.

has been in service for awhile.

leakage exceeds

every one

all wiring

spark plugs;

System

cowling, baffles

Any damaged

or replaced

rocker box covers

evidence of excessive

and appearance

at the factory,

hundred

that are damaged

and check

screws to specified

This condition

its cause must

operation.

of seepage

due to emission

to engine performance

the following

connected to

- Drain

or by slight

these conditions,

addition to the

In

hours of operation.

should be

terminals

test, clean, regap,

and renew

0-540 & 10-540

and baffle seals

or missing part

before

for evidence

heat which

is indicative

be determined

of thread lubricant

maintenance

the engine or

for security and

the aircraft resumes

of oil leaks. If

torque

is indicated by

of internal

at cylinder head

gas leakage which

This condiiton is neither

operation. If it

and

the cylinder

items listed for

replaced. Replace

and rotate

lubricating

SERIES

for damage

of the cooling

found,

(50 inch lbs.).

burn-

damage to

and corrected

and barrel

used during

stops

can be

should be

daily pre-

checks should

accessories.

clamps

cleanliness.

them. Replace

oil.

be

Any

Magnetos - Check

c.

for excessive a clean lubricated Check Slick

4-4

magneto

magnetos are

oil in the

lintless

cloth. The

in accordance

breaker points

breaker compartment,

felt located

with the magneto

to engine

timing.

covered in

for pitting

at the

manufacturer's

(Timing

the Maintenance

procedures

and minimum gap.

if found,

breaker

Procedures

wipe dry

points should

instructions.

for Bendix

Check

with

be

and

Section.)

TEXTRON

LYCOMING

OPERATOR'S MANUAL

0-540

5. 400 HOUR

flight, should

Valve

rockers broken seats.

should be inspected limits shown

SSP1776.

& 10-540

d. Engine Accessories

temperature mounting,

cylinders

e.

Engine

f.

ty and excessive

g. Primer

for equal

h. Fuel

looseness. at connections replacement

i. Carburetor

correct

50 hour

be made

Inspection

when

parts in

If any indications

and

tight connections.

- Check

Mounts

Nozzles -

flow.

Injector

Tighten to

must

- Check

torque for

INSPECTION.

and 100

after every

Remove

-

valves

the area

removed

further

for

in the

SERIES

- Engine

pressure

- Check

wear.

Nozzles

(indicating

be accomplished

are closed.

(including

damage. latest revision

sensing

cylinders

engine

Replace

Disconnect

and

60 in. lbs.

leakage)

throttle

these screws

In addition

inspections,

hour

400 hours

rocker

valve tips,

of the are found,

the piston

Replace

mounted accessories

visually

mounting

any bushings

primer

Lines

body attaching

box covers

Look

the cylinder

should

units

for

bolts

nozzles from

- Check

torque.

is 40 to

Check fuel

and security

before

50 inch pounds.

to the items

following

the

of operation.

and

evidence

for

valve

and connecting

parts that

any

Special Service

for

cracked

that

fuel

aircraft

screws

check for

keeper,

and all

SECTION

such

be checked

or broken

and bushings

are excessively

engine

injector

of lines.

resumes

maintenance

of abnormal

do not

nozzles

line for

for tightness;

for daily pre-

listed

freedom

springs

of its components

assembly)

rod

conform

Publication

as pumps,

secure

for

fins.

for securi-

worn.

and check

for

dye stains

Repair

operation.

and spring

or

the

check

of valve

wear or

and

with

No.

4

6. NON-SCHEDULED

service instructions

or

inspection

quire

usually

tions,

after corrective

available

are

subscription.

subscription

of these

file

procedures

limited to

are

modification

from Textron

Consult

information.

publications

INSPECTIONS.

are issued

Lycoming

the latest

Maintenance

available

by Textron that are specified

has been

edition

at all

Occasionally,

not listed in

models

engine

accomplished.

distributors,

of Service

facilities

times.

Lycoming

this manual.

and

All such

or from

Letter

have an up-to-date

should

service

Division

Such publica-

become

publications

the factory

No. L114

bulletins

that re-

obsolete

by

for

4-5

TEXTRON LYCOMING OPERATOR'S MANUAL

MAINTENANCE

G eneral Ignition

Fuel System

Lubrication System

Cylinders Generator

.................................................

and Electrical Ignition Harness Timing Magneto

Alternator

Generator Repair of

Carburetor Fuel Grades Air Intake Ducts

Idle Speed and

Grades and

Oil

Suction and

Oil

Relief Valve

Oil

or

Fuel Leaks ...................................

or Fuel

and Limitations

Mixture Adjustment

Limitations

...............................................

or Alternator Drive Belt

PROCEDURES

System

and Wire

to Engine

Injector Inlet

and Filter

Pressure Screens

.......................................

Replacement

.............................

Output

.........................

Screen Assembly.......5-9

............................

.....................

............................

......................

Tension ............... 5-16

................

Page

5-1

5-8

5-9

5-10 5-10 5-11 5-11

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540 & 10-540 SERIES SECTION 5

MAINTENANCE PROCEDURES

The procedures described in this section are provided to guide and in- struct personnel in performing such maintenance operations that may be required in conjunction with the periodic inspections listed in the preceding section. No attempt is made to include repair and replacement operations that

will be found in the applicable

Textron Lycoming Overhaul

Manual.

1. IGNITION AND

a. Ignition Harness

tion harness or an individual lead is to be replaced, consult the wiring diagram to be sure harness is correctly installed. Mark location of clamps and clips to be certain the replacement is clamped at correct locations.

b. Timing Magnetos to Engine (Bendix) -

(1) Remove a spark the spark plug hole. Rotate the crankshaft indirection of normal rota- tion until the compression stroke is reached, which is indicated by a positive pressure inside the cylinder tending to push the thumb off the spark plug hole. Continue rotating the crankshaft until the ad- vance timing mark on the front face of the starter ring gear is in align- ment with the small hole located at the two o'clock position on the front face of the starter housing. (Refer to Specification chapter or to engine name-plate for designated number of degrees of spark ad- vance.) At this point, the engine is ready for assembly of the magnetos.

(2) Single magneto - Remove the inspection plugs from both magnetos and turn the drive shaft in direction of normal rotation until (-20 and

-200 series) the first painted chamfered tooth on the distributor gear is aligned in the center of the inspection window (-1200 series) the applicable timing mark on the distributor gear is approximately aligned with the mark on the distributor block. See figure 5-2. Being sure the gear does not move from this position, install gaskets and magnetos on the engine. Note than an adapter is used with all magnetos. Secure with (clamps on -1200 series) washers and nuts; tighten only finger tight.

ELECTRICAL

and Wire Replacement - In the

plug from No. 1 cylinder and

SYSTEM.

event that an igni-

place a thumb over

5-1

TEXTRON LYCOMING

OPERATOR'S

MANUAL

SECTION

5

0-540

& 10-540

SERIES

5-2

Figure

5-2.

Ignition

5-1.

Timing

Marks

Wiring

cyl. 1200

- 6

Diagram

Series

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

(3) Using a suitable and the on, then out. Bring Repeat

(4) Back go out. Bring tion until alignment. Tighten

(5) Dual tion as

(6) Install

Do not

attach harness

to-engine completed.

(7) To remove

engine

mal mark

& 10-540

a battery-powered terminal

the negative magneto

slowly

the magneto

this

with the

off

the crankshaft

the timing

At this

nuts

Magnetos

directed

the magneto-to-engine

timing

procedures

magneto

rotation;

on starter

SERIES

connected

lead to

any unpainted

in its

mounting

turn

it in the

back

second

the

crankshaft

mark

point,

to

specified

- Place

in paragraph

WARNING

spark

plug ends

and

engine-to-magneto

drive as

then return

support.

far as possible in the

timing

light, attach the

to the

switch terminal

portion

flange

to

opposite

magneto.

a few

slowly back

and the

both lights

torque.

the engine

lb(1).

magneto-to-switch

a point

slowly

until the

degrees; hole in the

should

in

gasket on

to the spark

drive

direction

in direction

the No.

in

of normal

SECTION

positive lead of

engine.

the light

until the

timing

of

housing

opposite to

rotation

the magneto

lights

normal rota-

all magneto-

of the

where

light just

the

starter

go on simultaneously.

1 advance

the magneto

plugs until

connections

gear

train backlash,

direction

Rotate comes

light

goes

comes

on.

should

are in

firing

posi-

flange.

are entirely

turn nor-

to timing

5

to

(8) Remove of the magneto in

the center

(9)

Turn the magneto is centered

(10)

Observe that rotor viewing ding on specified on

the timing

rotation

in the timing

whether the

housing

of the housing.

rotating

window

the magneto

window plug

and

magnet

until the

at this time the

aligns

magneto is of

the plug

painted tooth hole.

with the R

nameplate.

from the most from the

drive shaft

built in pointer

rotor viewing

in the

of the

or L mark

right or left

normal direction

large distributor

convenient

just ahead

on the

rotor depen-

hand rotation

side

location

of

gear

of the

as

5-3

TEXTRON LYCOMING OPERATOR'S MANUAL

SECTION 5

0-540 & 10-540

SERIES

5-4

Figure 5-3. Ignition

Wiring Diagram - Dual

Magneto

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

center to the engine

green lead lead

red timing

just

tighten

the engine (16) At the

go monitored of the No.

(17) paragraph

(18) ing

& 10-540

(11)

Hold

the magneto

and

pointer over

(12) Attach

(13)

(14)

(15) Back

off indicating

to 150 inch

red

of timing

of the

light

Turn the

light comes

Rotate the magneto goes off

Repeat

Complete

indicating

the

magneto

the engine

forward No. 1

by the

1 firing position.

steps (13)

(16) is obtained.

SERIES

in its No.

R or

and

loosely clamp

lead

from the

light to

to magneto

entire magneto

on.

in the opposite

left main

mounting

up approximately

at tie

same time

firing position

left main breaker

green light,

thru

tightening

pounds.

of the

1 firing

L mark on

in

position.

timing

right switch

light

housing.

in

direction

breaker

clamps.

of the

opening.

must

open within

(15) until

magneto

10°and

position

rotor)

and install

to left

switch

adapter

direction

observing

engine,

the condition

securing

lead and

of rotor

has opened.

then carefully

the red

The right main

+ 2 engine

SECTION

(tooth

in

magneto

adapter

the black

rotation

until the red

the

clamps

until the

Then

"bump"

timing lights.

light should

breaker,

described

by torque-

5

window

lead,

light

evenly

degrees

in

(19)

Recheck timing

light.

Remove

(20) Reinstall in. lbs.

once more

adapter leads.

plugs

in timing

and if satisfactory

inspection

holes

disconnect

and torque

timing

to 12 -

15

5-5

TEXTRON LYCOMING OPERATOR'S MANUAL

SECTION 5 0-540 & 10-540 SERIES

c. Timing Magnetos to Engine (Slick) -

(1) Remove a spark plug from No. 1 cylinder and place a thumb over the spark plug hole. Rotate the crankshaft in direction of normal rota- tion until the compression stroke is reached; this is indicated by a positive pressure inside the the spark plug hole. Continue rotating the crankshaft until the ad- vance timing mark on the front face of the starter ring gear is in align- ment with the small hole located at the two o'clock position on the front face of the starter housing. (Refer to Specification chapter or to engine name-plate vance.) At this point, the engine is ready for assembly of the magnetos.

(2) Remove the ignition harness from the left (retard breaker) magneto, if installed. ed "L" on the pressure to the pin and slowly rotate the magneto drive shaft

clockwise until the shoulder of the pin seats against the distributor block. When properly engaged, the timing pin will be inserted 7/8 inch into the distributor block.

If the magneto shaft cannot be rotated and if the timing pin is not seated 7/8 inch into the distributor block, remove the pin, rotate the drive shaft 1/8 turn and repeat the insertion procedure.

Insert the Slick T-118 timing pin

face of the distributor block.

cylinder tending to push

for designated number of degrees

Apply a slight inward

NOTE

CAUTION

the thumb off

of spark ad-

in the hole mark-

Do not rotate the magneto rotor shaft with the timing pin inserted into the distributor block. This could damage the internal components of the magneto.

(3) Inspect the left magneto accessory housing mounting pad to en-

sure that magneto drive dampers, adapter, and gaskets are there and installed properly. Position the magneto on its side with the top of the magneto located outboard away from the accessory housing ver- tical centerline. Install the magneto onto the mounting pad. Be sure the drive dampers remain in place when the magneto drive is inserted into the drive gear. Secure the magneto to the accessory housing with the proper clamps, washers, and nuts. Tighten nuts only finger tight.

5-6

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

rotate

not

Do

magneto

ponents

(4)

(5)

attach

Do not to-engine completed.

(6) to

(7) Rotate until the closed.

(8) until

(9) torque. to 17

10-540

&

the

distributor

magneto.

of the

Remove Repeat

harness

timing

Attach

timing

the

timing

the

magneto

Slowly

light

the

Alternately

Continue

lbs-ft.

SERIES

magneto

block.

timing

the

2,

steps

spark

procedures

a timing

the

rotate

light

manufacturer's

light

magneto

light

required.

not

is

the

goes

tighten

to

torque.

CAUTION

with

engine

or

could

This

from

the

for

3, 4

WARNING

ends

plug

magneto-to-switch

and

the

to

assembly

on.

comes

magneto

out

tighten

or

the

This

the

magneto

both

the

damage

cause

distributor

the

(plain)

right

spark

the

to

magneto

instructions.

the

in

light

the

If

indicates

assembly breaker

mounting

alternately,

nuts

timing

magneto.

plugs

connections

condenser

direction

is on

the

in

points

nut

inserted

the

to

block.

until

of initially, breaker

opposite

open.

clamps

in

SECTION

into

internal

all magneto-

stud

rotor

several

com-

entirely

are

according

rotation

points

direction,

8 lbs-ft.

to

steps,

5

the

of

are

(10)

Rotate

(11) tional

engine

the lights ring

(12)

satisfied.

is

Repeat

direction. should

with

gear

Repeat

steps

the

in

steps

engine

The

the

out

go

the

thru

6

approximately

timing

dot

6

direction

within

on

thru

normal

9

the

10

the

for

lights

°

1

+

starter

until

second

10 should until

the

of

housing

condition

the

magneto.

°

opposite

light.

timing

the

designated

as referenced

the

to

Slowly

lights

timing

described

normal

(bump)

out.

go

mark

in

rota-

rotate

Both

step

on

1.

11

5-7

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

If magneto

(13) centerline magneto

repositioned.

ing

engine

the

Remove

(14) (15) Attach

minal 13-15

Retard

(16) retard engine pression

on,

be

engine

the dicating should

the

If Maintenance contact

Attach

(17) magneto to 13-15

5

allowed)

be

must

during

timing

the

of each

Ibs-inches.

breaker

indicating

magneto

Breaker

required

stroke

the

in

points

the

aligned

be

timing

Manual

points.

the

magneto

(left

Ibs-inches.

position

interference

removed

must

Care

repositioning

the

light

appropriate

terminal

of these

switch

- Attach

number of the

retard

the

normal

opened.

with the

for the

retard only)

using

and

number

°

(± 15

is

the

and

taken

be

from

leads

switch

a lockwasher

one

the

degrees

of

1

breaker

direction

TC

The

on the

dot

points

procedure

breaker

using

0-540

mounting

the

from

encountered,

gear

drive

or

positive

negative

cylinder.

until

is incorrect,

a lockwasher

not

the drive

of

the

P-Leads

before

points

the

timing

#1

starter

and

lead

to

magnetos.

lead

top

The

are closed.

timing

proper

to the

& 10-540

which

in the

the

drop

gear.

the

to

nut.

and

the

of

to ground.

center

timing

light

mark

housing

refer

adjustment

retard

and

SERIES

pad horizontal

is unlikely,

accessory

dampers

condenser

Torque

timing

on the

nut.

Set

on the

light

Slowly

goes

ring

within

the

to

post

Torque

nut

light

should

rotate

out

on

the

hous-

into

ter-

the

com-

in- gear ±3°.

Slick

the

of

the nut

to

(18) Install

magneto is in

timing

Some on when

Generator

d.

(whichever

specified

marked

wire

the

lights

breaker

the

voltage

ignition

harness

"right".

cap.

operate

points Alternator

or

applicable)

is

and

harness

is marked

Check

Torque

the reverse

in

open.

should

current

assemblies

for

cap-mounting

NOTE

Check

Output

are

"left"

proper

manner

be being

and the

your

- The

checked

on the

right

installation

obtained.

to

screws

as described.

timing

generator

to determine

magnetos.

magneto of "0"

Ibs-inches.

18-20

The instructions.

light

or

left

The

harness

seal

ring

comes

light

alternator

the

that

TEXTRON

LYCOMING

OPERATOR'S MANUAL

0-540 & 10-540 SERIES

a. Repair

is replaced, lic Sealant. pound. Do

b. Carburetor

assembly er. solvent place throttle body or

c. Fuel

page 3-10,

I

In

it is cified is be used

I

permissible

of FuelLeaks - In the event

use only Do not

not apply sealant to

or Fuel

and check the screen for distortion

Replace for

and dry

the gasket on

0-70 inch pounds

Grades

the event that

not to be used.

(regardless

It latest

ing specified

either

with compressed

and tighten

and Limitations

reference

or

the specified

to use higher

of octane

is recommended

edition

a line or fitting in the fuel

a fuel-soluble lubricant,

use Teflon tape

Injector Inlet

of these conditions.

the screen assembly

35-40 inch

to

torque for fuel injector.

latest

octane

Under no circumstances

rating).

that personnel

Service

of

fuel for Textron Lycoming

or any other

the first two threads.

Screen Assembly

Clean screen

air. To install

and install

pounds

See recommended

-

of Service

edition

fuel is not available

fuel. Fuel

NOTE

Instruction

of a lower

familiar

be

No.

SECTION 5

system

such as

or openings in the strain-

Loctite Hydrau-

form of thread

- Remove

the screen

the assembly

torque for

fuel grades

Instruction

at some

octane

automotive

should

with the

regard-

1070

engines.

com-

assembly

assembly,

in the

carburetor

1070.

No.

locations,

than spe-

the

on

fuel

in

d. Air Intake

restrictions. manufacturer's handbook.

Idle

e.

(1) Start

cylinder

(2) Check idle adjustment.

Revised

Ducts and

Inspect and

and

Speed

the engine

temperatures

head

magnetos.

January 1999

Mixture

Filter - Check

air filters

service

Adjustment

and warm

If the

up in

are normal.

"mag-drop"

all air intake

as instructed

-

the usual

normal,

is

ducts for dirt

in the

manner

proceed

airframe

until oil

or

and

with

5-9

TEXTRON

SECTION 5

(3)

Set throttle manufacturer's recommended preciably ing

steps, readjust the idle

LYCOMING OPERATOR'S

stop screw so

after making idle mixture adjustment

0-540 & 10-540

that the engine

idling RPM. If the RPM

speed to the desired

MANUAL

SERIES

idles at the

during the succeed- RPM.

aircraft

changes ap-

(4) When the idling speed mixture control lever Cut-Off" position ing the leaning mixture control drop to a 35 RPM while "leaning out" indicates and excessively rich idle mixture. mentary

If the above indicates turn the idle and check this additional adjustments as necessary pickup of approximately 10 to 25 RPM. Each time the adjustment is changed, before proceeding with the idle speed throttle. The RPM

with minimum manifold pressure. main stable, cause

erratic idling.

of

weather conditions and field

3. LUBRICATION SYSTEM. a. Oil Grades

the recommendations shown in Section 3.

point where the engine cuts

An immediate increase) indicates

mixture adjustment

new position by repeating the

the engine should be run

adjustment

above method aims at a setting

check the

andLimitations

and observe the tachometer

process. Caution must

to the "Full Rich" position

that the

to obtain the

idle linkage; any

In all cases, allowance

has been stabilized, move

with a very slow, steady pull

for any change dur-

be exercised to return the

before the RPM can

out. An increase of more than

decrease

RPM check. Make final adjustment

in RPM (if not

the idle mixture is too

idle adjustment

in the direction

until a check results in

up to 2000 RPM to clear the

desired idling

In case the setting does

looseness in

altitude upon idling adjustment.

-Service

is too rich

required

above procedure. Make

that will obtain maximum

should

be made for the

the engine in accordance

the cockpit

toward the "Idle

preceded by

lean.

or too lean,

for correction,

a momentary

RPM with closed

this linkage would

a mo-

engine

of the

not re-

effect

with

b. Oil

Suction and

tion remove,

5-10

Oil Pressure Screens

inspect

for metal particles,

- At each clean

and reinstall.

Revised

fifty hours

January

inspec-

1999

TEXTRON LYCOMING OPERATOR’S MANUAL

O-540 & IO-540 SERIES SECTION 5

NOTE

If

an engine does not have a fill-flowoil filteq change oil ev-

ery 25 hours; also, inspect oil pressure and suction screens

metal contamination, and clean thoroughly before reinstalla-

tion.

c. Oil Relief Valve (Non-Adjustable) -The function of the oil pressure

relief valve is not maintain engine oil pressure within specified limits. The valve, although not adjustable, may be controlled by the addition of a maximum of nine STD-425 washers under the cap to increase pressure or the use of a spacer (Textron Lycoming P/N 73629 or

73630) to decrease pressure. A modification on later models has elim-

inated the need for the spacers. Particles of metal or other foreign matter lodged between the ball and seat will result in faulty readings. It

is advisable, therefore, to disassemble, inspect and clean the valve if excessive pressure fluctuations are noted.

d. Oil Relief Valve (Adjustable) - The adjustable oil relief valve en-

ables the operator to maintain engine oil pressure within the specified

limits. If the pressure under normal operating conditions should con-

sistently exceed the maximum or minimum specified limits, adjust the

valve as follows:

With the engine warmed up and running at approximately 2000 RPM,

observe the reading on the oil pressure gage. If the pressure is above maximum or below minimum specified limits, stop engine and screw the adjusting screw out to decrease pressure and in to increase pressure. Depending on installation, the adjusting screw may have only a screw drive slot; or it may have the screw driver slot plus a pinned .37524castellated nut and may be turned with either a screw drive or a box wrench.

NOTE

Check applicable parts catalog

for

optional sizelpressure-ca-

pacity relief-valvesprings.

4. CYLINDERS. It is recommended that as a field operation, cylinder maintenance be confined to replacement of the entire assembly. For valve replacement consult the proper overhaul manual. This should be undertaken only as an emergency

measure.

Revised January 1999

for

5-11

TEXTRON LYCOMING OPERATOR'S MANUAL

& 10-540 SERIES

SECTION 5

a. Removal of CylinderAssembly -

(1) Remove exhaust manifold and cooling baffles. (2) Remove rocker box drain tube, intake pipe, baffle and any clips

that might interfere with the removal of the cylinder. (3) Disconnect ignition cables and remove the bottom spark plug. (4) Remove rocker box cover and rotate crankshaft until piston is

approximately at top center of the compression stroke. This is indi- cated by a positive thumb off of bottom

Slide valve rocker shafts from

(5) valve rockers. Valve rocker shafts can be removed at the cylinder is removed from the engine. valve stem.

(6) Remove shroud tube. shroud tubes

The hydraulic tappets, be assembled in the same moved.

(7) Remove employed), then crankcase. crankcase,

Remove of Piston

b.

Insert piston

plugs. semble connecting the connecting oil ring seal,

c. Remove

will be necessary sembly assembly is

5-12

puller nut; then

so that dry tappet

push rods by grasping ball

Detach shroud tube spring

through holes in cylinder

cylinder base nuts and

Be careful not to allow

as the piston leaves

rod to rest on the cylinder

rod

or any other non-marring

of Hydraulic

reinstalled. This

pressure inside of cylinder spark plug

Remove rotator cap

NOTE

push rods, rocker arms

location from which they

remove cylinder by pulling

the cylinder.

from Connecting

pin puller (P/N

proceed to remove

with heavy rubber

Tappet Sockets

to remove

and bleed the hydraulic

clearance can

is accomplished

0-540

tending to push

hole.

cylinder head and remove

from exhaust

end and pulling rod out

and lock plate and pull

head.

and valves must

were re-

hold down plugs (where

directly away from

the piston to drop against the

Remove the

Rod -

64843) through piston

bore of the crankcase.

band, discarded

method.

and Plunger

be checked

in the following

piston pin,

pin. Do not allow

cylinder

Assemblies -

tappet

when the cylinder

Revised

January 1999

the

of

piston pin

as-

Support

base

It

plunger as-

manner:

TEXTRON

LYCOMING OPERATOR'S

MANUAL

0-540

Never crankcase. the

& 10-540

(1) Remove inger cannot the edge care

(2) To Textron Lycoming available,

hook in

a so that the

plunger assembly

the

use

unit inoperative.

d. Assembly

unseat the

unit, hole. With

that the spring

so is inserted.

e. Assembly

the connecting

that center of

the intake and

on

over top the compression

SERIES

the hydraulic

into the

must be exercised

a magnet This can

concave end

removed

be

of the socket

remove

compression center. If

the hydraulic

the end of

hook engages

cause the

Hydraulic

of

ball by

the ball

catches. All

Cylinder

of

exhaust tappet

stroke.

in this manner,

service

out

to remove

inserting

off its seat,

rod

stroke.

the tappet

push rod

tappet

socket and

of the

with a pair

avoid scratching

to

plunger

tappet

tool. In the

plunger

tappet

a short

and Related

of the cylinder

piece of

spring

the

tappet body

of the

CAUTION

hydraulic

check ball

Tappet Plunger

a thin clean

insert

oil must be removed

This can

bodies. Rock

bodies do

by inserting

socket

withdrawing.

be removed

it may

of needle nose

the socket.

assembly,

event that the

assembly

lockwire,

of the plunger

by gently

plunger

to remain

Assemblies

the plunger

Parts -

being

be checked

not move

off its seat,

wire through

Rotate the

assembled

crankshaft back

SECTION

If the

by

pliers. However,

use the special

tool is not

may be

assemblies

and twist

by placing

the crankshaft

removed

inserting

assembly.

pulling

To assemble

-

the

before the

crankshaft

is at

two fingers

from

rendering

clockwise

the foref-

socket

grasping

by

the wire

Draw

the wire.

the

oil inlet

plunger

the top

and forth

is

5

so

on

Place each

(1) assemble

Assemble

(2)

pin boss

piston

a handpush

be of pin, it is During piston

the socket

probably

assembly,

hole and

plunger

piston with

is toward

assembly

on top

fit. If difficulty

caused by always

on the

of plunger

rings

the front

carbon

use a

piston

in its respective

assembly.

so that the

engine. The

of the

experienced

is

or burrs in

generous

quantity

pin.

number

in inserting

the piston

tappet body

stamped

pin should

piston

the

of oil, both

pin hole.

and

on the

piston

in the

5-13

TEXTRON

SECTION 5 0-540 & 10-540 SERIES

(3) Assemble one piston pin plug at each end of the piston pin and place a new rubber oil seal ring around the cylinder skirt. Coat piston

and rings and the inside of the cylinder generously with oil.

LYCOMING OPERATOR'S

MANUAL

Cylinder

hold- down plate

4

5-14

-Shim- 4 req d per cylinder (.010 IN. thick X 50/70 IN wide

During initial

tightening,use

two shims between each plate and the barrel, located as shown. Remove shims be-

fore final tightening.

5-4. Location of Shims

Figure

and Hold-Down Plates (where applicable) and

Sequence of Tightening Cylinder Base Hold-Down Nuts

Between Cylinder Barrel

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

0-540

Before threads

1.

2.

3.

At

on the

&

(4) Space assemble the

bottom

the ring

installing

with any

90%

SAE Parker Thread 60%

SAE 30

(5) Assemble hold-down

any time

cylinder

(a) (Engines cylinder in figure (25

10-540

piston

the

of

compressor

cylinder

one

50W

engine

Lube.

engine

hold-down

nuts

a

cylinder

on

the opposite

base hold-down

5-4,

foot

lbs.)

SERIES

ring

hold-down

following

oil and

oil

and

tighten

is

replaced,

using

and

tighten

torque,

gaps.

as

and

cylinder

the engine.

of the

Then,

over

the

Push

it is

pushed

NOTE

nuts,

lubricants,

10%

40% Parker

plates

as

NOTE

it is

side

of the

hold-down

plates

1/2 inch

using

piston

the cylinder

(where

directed

necessary

the sequence

a piston

so that

off.

lubricate

or combinations

STP.

Thread

applicable)

in the

engine.

plates)

and

cylinder

hold-down

ring compressor,

the intake

all the

way

crankcase

Lube.

and cylinder

following

to retorque

- Install

barrel,

nuts to

shown

SECTION

port

on,

catching

through

of

lubricants.

steps.

the thru-studs

shims

between

as

directed

300 inch

in figure

5

is at

stud

base

lbs.

5-4.

Cylinder

ner

as above

(b) Remove inch cylinder

assemblies

omitting

(c) Tighten

lbs.)

torque.

(d) After

value.

shims,

base

not

using

the shims.

the

3/8 inch

Sequence

completing

and

using

nuts,

to 600

NOTE

hold-down

of

tightening

the

same

in. lbs.

plate are

sequence,

tightened

nuts

is

(50

foot lbs.)

in the same

to 300 inch

optional.

recheck

tighten

lbs. (25

final

the 1/2

torque.

man-

foot

torque

5-15

TEXTRON

LYCOMING

OPERATOR'S

MANUAL

SECTION

After

all

cylinder

fins

(6) Install

Install

(7) Assemble rotator in

its respective

sliding (8)

and that stem the the spring. should within push

Inserting

5

by filing

shroud

cap

valve

Be

sure that

both

tip and

thumb

push

rod

While

be between

these

rod,

a longer

base

new

tube and

each

over

rocker

valves

the

of

one

and

holding

limits,

as

required

nuts

or

burring.

shroud

push

end

position

shaft

the

are

valve

hand

push

.028

remove

push

CAUTION

have

been

tube

oil seals

lock

in place

rod

in its

of exhaust

by placing

in place

piston

is

closed.

rocker.

on

the

down

the

spring

and

the

to

correct

NOTE

rod will

In

so

.080

tightened,

as

respective

valve

rocker

to retain

at top

Check

order

valve

rocker

as to

compress

compressed,

inch.

push

rod

clearance.

decrease

0-540

remove

on both

required

shroud

stem.

Assemble

between

rocker.

center

of

clearance

to check

directly

If clearance

and

insert

the

& 10-540

any

nicks

ends

of shroud

for type

tube.

each

bosses

compression

between

this

clearance,

over

the

hydraulic

the

valve

does

a. longer

valve

clearance

SERIES

in

tube.

of

cylinder.

Then

place

rocker

and

stroke

the

valve place

the

end

tappet clearance not

come

or shorter

the

by

of

(9) Install

box

5.

GENERATOR

Check

the

vice

Instruction

drive

belt

5-16

intercylinder

drain

tubes and

tension

No.

tensions.

baffles,

exhaust

OR

ALTERNATOR

of

a new

1129

for

rocker manifold.

belt

25

methods

DRIVE

hours

of

checking

box

after

covers,

intake

BELT

TENSION.

installation.

generator

pipes,

rocker

Refer

to

or alternator

Ser-

Textron Lycoming IO-540 Series, Lycoming O-540 Series Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY WARNING

WARRANTY

TABLE OF CONTENTS

Cylinders - The cylinders are of conventional air cooled construction with the two major parts, head and barrel, screwed and shrunk together. The

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 and the main bearing bores are machined for use of precision type main bearing inserts.

Crankshaft

Connecting Rods

pistons

OPERATING CONDITIONS

aircraft prior the general

HOUR INSPECTION