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LYCOMING OPERATOR’S MANUAL

SECTION 5

MAINTENANCE PROCEDURES

Page

General.......................................................................................................................................................... 5-1

Ignition and Electrical System

Ignition Harness and Wire Replacement................................................................................................ 5-1

Timing Magneto to Engine

Single Magneto ....................................................................................................................................... 5-1

Dual Magnetos........................................................................................................................................ 5-1

Generator or Alternator Output ............................................................................................................. 5-6

Fuel System

Repair of Fuel Leaks................................................................................................................................. 5-6

Fuel Injector Inlet Screen Assembly ....................................................................................................... 5-6

Fuel Grades and Limitations ................................................................................................................... 5-6

Air Intake Ducts and Filter...................................................................................................................... 5-6

Idle Speed and Mixture Adjustment ....................................................................................................... 5-6

Lubrication System

Oil Grades and Limitations...................................................................................................................... 5-7

Oil Suction and Pressure Screens............................................................................................................ 5-7

Oil Relief Valve ......................................................................................................................................... 5-7

Cylinders....................................................................................................................................................... 5-7

Turbocharger

Density Controller................................................................................................................................... 5-11

Generator or Alternator Drive Belt Tension........................................................................................... 5-11

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Summary of Contents for TIO-540-A1A

Page 1: ...ming engines are TIO 540 A1A A1B A2A A2B A2C F2BD J2B J2BD N2BD R2AD S1AD U2A V2AD W2A AH1A and AJ1A This manual is current as of the date of issue All previously issued revisions are included This manual will be kept current by revisions available from Lycoming distributors or from the factory All revisions will be accompanied by an Operator s Manual Revision page which will identify the revision...

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Page 3: ...Operator s Manual Lycoming TIO 540 Series Angle Valve Cylinder Heads Approved by FAA 4th Edition Part No 60297 23A 652 Oliver Street November 2005 Williamsport PA 17701 U S A 570 323 6181 ...

Page 4: ...enced in this publication are trademarks or registered trademarks of their respective companies For additional information Mailing address Lycoming Engines 652 Oliver Street Williamsport PA 17701 U S A Phone Factory 570 323 6181 Sales Department 570 327 7268 Fax 570 327 7101 Lycoming s regular business hours are Monday through Friday from 8 00 AM through 5 00 PM Eastern Time 5 GMT Visit us on the ...

Page 5: ...CYLINDER HEADS 60297 23A November 2005 The page s in this revision replace add to or delete current pages in the operator s manual PREVIOUS REVISION CURRENT REVISION August 2006 3 3 3 4 May 2008 2 3 3 55 3 56 3 57 January 2013 3 4 2013 Avco Corporation All Rights Reserved Lycoming Engines is a division of Avco Corporation ...

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Page 7: ...EDURES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER LOSS ALSO IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED FOR ANY REASON DAMAGE TO THE ENGINE AND PERSONAL INJURY CAN HAPPEN CONSULT YOUR LOCAL FAA APPROVED MAINTENANCE FACILITY SERVICE BULLETINS INSTRUCTIONS AND LETTERS Although the information contained in this manual is up to date at time of publication users are urged ...

Page 8: ...n various Warnings and Cautions which must be carefully read in order to minimize the risk of personal injury or the use of improper service methods that may damage the engine or render it unsafe It is also important to understand that these Warnings and Cautions are not all inclusive Lycoming could not possibly know evaluate or advise the service trade of all conceivable ways in which service mig...

Page 9: ...ECTION 1 DESCRIPTION 1 1 SECTION 2 SPECIFICATIONS 2 1 SECTION 3 OPERATING INSTRUCTIONS 3 1 SECTION 4 PERIODIC INSPECTIONS 4 1 SECTION 5 MAINTENANCE PROCEDURES 5 1 SECTION 6 TROUBLE SHOOTING 6 1 SECTION 7 INSTALLATION AND STORAGE 7 1 SECTION 8 TABLES 8 1 ...

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Page 11: ...ION Page General 1 1 Cylinders 1 1 Valve Operating Mechanism 1 1 Crankcase 1 1 Crankshaft 1 1 Connecting Rods 1 1 Pistons 1 1 Accessory Housing 1 1 Oil Sump and Induction Assembly 1 2 Cooling System 1 2 Induction System 1 2 Turbocharger System 1 2 ...

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Page 13: ...ocated above and parallel to the crankshaft The camshaft actuates hydraulic tappets which operate the valves through push rods and valve rockers The valve rockers are supported on full floating steel shafts The valve springs bear against hardened steel seats and are retained on the valve stems by means of split keys Crankcase The crankcase assembly consists of two reinforced aluminum alloy casting...

Page 14: ...rporates a Slope controller The position of the waste gate is determined by oil pressure acting on a piston which is connected to the butterfly valve by linkage Increasing oil pressure on the piston closes the waste gate valve and increases power decreasing oil pressure opens the valve and decreases power The bleed oil required to activate the piston is controlled by either the density controller ...

Page 15: ...ON 2 SPECIFICATIONS Page TIO 540 A1A A1B A2A A2B A2C F2BD J2B J2BD N2BD 2 1 TIO 540 R2AD S1AD U2A 2 2 TIO 540 V2AD W2A AH1A 2 3 TIO 540 AJ1A 2 4 Accessory Drives Drive Ratio 2 4 Direction of Rotation 2 4 Standard Engine Dry Weight 2 4 ...

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Page 17: ...F2BD FAA Type Certificate E14EA Rated horsepower 325 Rated speed RPM 2575 Bore inches 5 125 Stroke inches 4 375 Displacement cubic inches 541 5 Compression ratio 7 3 1 Firing order 1 4 5 2 3 6 Spark occurs degrees BTC 20 Valve rocker clearance hydraulic tappets collapsed 028 080 Prop drive ratio 1 1 Prop driven rotation Clockwise TIO 540 J2B J2BD N2BD FAA Type Certificate E14EA Rated horsepower 35...

Page 18: ...ted speed RPM 2700 Bore inches 5 125 Stroke inches 4 375 Displacement cubic inches 541 5 Compression ratio 7 3 1 Firing order 1 4 5 2 3 6 Spark occurs degrees BTC 20 Valve rocker clearance hydraulic tappets collapsed 028 080 Prop drive ratio 1 1 Prop driven rotation Clockwise TIO 540 U2A FAA Type Certificate E14EA Rated horsepower 350 15 000 ft Rated speed RPM 2500 Bore inches 5 125 Stroke inches ...

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Page 20: ...ockwise Alternator 3 200 1 Clockwise Alternator Optional 3 630 1 Clockwise Vacuum Pump 1 300 1 Counterclockwise Hydraulic Pump 1 385 1 Clockwise Hydraulic Pump 1 300 1 Clockwise Tachometer 500 1 Clockwise Propeller Governor 895 1 Clockwise Propeller Governor 947 1 Clockwise Magneto Drive Single 1 500 1 Clockwise Magneto Drive Dual 750 1 Clockwise Fuel Pump AN 1 000 1 Counterclockwise Fuel Pump Plu...

Page 21: ...OMING OPERATOR S MANUAL SECTION 2 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS SPECIFICATIONS 1 STANDARD ENGINE DRY WEIGHT CONT MODEL LBS TIO 540 N2BD 549 TIO 540 J2B 565 TIO 540 V2AD 565 TIO 540 U2A 578 2 5 ...

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Page 23: ...restarting Items of Maintenance 3 1 Starting Procedures 3 1 Cold Weather Starting 3 2 Ground Running and Warm Up 3 2 Ground Check 3 3 Operating in Flight Leaning Procedure 3 4 Engine Flight Chart 3 5 Operating Conditions 3 7 Engine Shut Down Procedure 3 10 Performance Curves 3 11 ...

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Page 25: ...tion is concerned New or newly overhauled engines should be operated using only the lubricating oil recommended in the latest revision of Service Instruction No 1014 NOTE Cruising should be done at 65 to 75 power until a total of 50 hours has accumulated or oil consumption has stabilized This is to insure proper seating of the rings and is applicable to new engines and engines in service following...

Page 26: ... and determine trouble NOTE If engine fails to achieve a normal start assume it to be flooded and use standard clearing procedure Then repeat above procedure b TIO 540 Series Hot Engine Because of the fact that the fuel percolates and the system must be cleared of vapor it is recommended that the same procedure as outlined above be used for starting a hot engine 4 COLD WEATHER STARTING During extr...

Page 27: ...t Additional factors other than the ignition system affect magneto drop off They are load power output propeller pitch and mixture strength The important thing is that the engine runs smoothly because magneto drop off is affected by the variables listed above Make the magneto check in accordance with the following procedures 1 Controllable Pitch Propeller With propeller in minimum pitch angle set ...

Page 28: ...coming engines they have proven to be both economical and practical by eliminating excessive fuel consumption and reducing damaged parts replacement It is therefore recommended that operators of all Lycoming aircraft power plants utilize the instructions in this publication any time the fuel air mixture is adjusted during flight Manual leaning may be monitored by exhaust gas temperature indication...

Page 29: ...l TIT is the value established in Step b This sets the mixture at best power 2 LEANING TO FLOWMETER Lean to applicable fuel flow tables or lean to indicator marked for correct fuel flow for each power setting 3 LEANING WITH MANUAL MIXTURE CONTROL Without flowmeter or TIT gage a Slowly move mixture control from Full Rich position toward lean position b Continue leaning until slight loss of power is...

Page 30: ... 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 1 Representative Effect of Leaning on Cylinder Head Temperature EGT Exhaust Gas Temperature or TIT Turbine Inlet Temperature Engine Power and Specific Fuel Consumption at Constant Engine RPM and Manifold Pressure 3 6 ...

Page 31: ...160 F 71 C 245 F 118 C Engine oil temperature should not be below 140 F 60 C during continuous operation OIL PRESSURE PSI Normal Operation Maximum Minimum Idling Start and Warm Up All Models 95 55 25 115 FUEL PRESSURE PSI MIN MAX IDLE MIN TIO 540 A1A A1B A2A A2B A2C Inlet to fuel pump 2 65 Inlet to fuel injector 25 65 12 TIO 540 F2BD U2A Inlet to fuel pump 2 65 Inlet to fuel injector 30 65 12 TIO ...

Page 32: ...Normal Rated 2575 325 1 45 475 F 246 C Performance Cruise 75 Rated 2575 245 21 0 0 82 475 F 246 C Economy Cruise 60 Rated 2200 195 14 0 0 65 475 F 246 C TIO 540 J2B J2BD N2BD Normal Rated 2575 350 1 56 475 F 246 C Performance Cruise 75 Rated 2575 260 22 0 0 87 475 F 246 C Economy Cruise 60 Rated 2200 210 15 0 0 70 475 F 246 C TIO 540 R2AD Normal Rated 2500 340 2 07 475 F 246 C Performance Cruise 7...

Page 33: ...260 C TIO 540 V2AD Normal Rated 2600 350 38 3 1 16 480 F 249 C Performance Cruise 75 Rated 2400 260 23 0 0 86 480 F 249 C Economy Cruise 60 Rated 2200 210 15 9 0 70 480 F 249 C Horsepower at propeller shaft after 10 horsepower extracted at the accessory drives TIO 540 W2A Normal Rated 2600 350 43 0 1 16 480 F 249 C Performance Cruise 75 Rated 2400 260 23 0 0 86 480 F 249 C Economy Cruise 60 Rated ...

Page 34: ...ted 2500 310 34 3 1 00 480 F 249 C Performance Cruise 75 Rated 2400 233 19 8 0 76 480 F 249 C Economy Cruise 60 Rated 2200 201 14 7 0 65 480 F 249 C MAXIMUM TURBINE INLET TEMPERATURE 1650 F 898 8 C At Bayonet Location For maximum service life of the engine maintain cylinder head temperature between 150 F 65 6 C and 435 F 223 86 C during continuous operation e Engine Shut Down Procedure 1 Set prope...

Page 35: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 2 Sea Level Altitude Performance Curve TIO 540 A1A A2A A1B A2B Sheet 1 of 3 3 11 ...

Page 36: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 3 Sea Level Altitude Performance Curve TIO 540 A1A A2A A1B A2B Sheet 2 of 3 3 12 ...

Page 37: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 4 Sea Level Altitude Performance Curve TIO 540 A1A A2A A1B A2B Sheet 3 of 3 3 13 ...

Page 38: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 5 Fuel Flow vs Percent Rated Power Curve TIO 540 A1A A2A A1B A2B 3 14 ...

Page 39: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 6 Sea Level Altitude Performance Curve TIO 540 A2C Sheet 1 of 3 3 15 ...

Page 40: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 7 Sea Level Altitude Performance Curve TIO 540 A2C Sheet 2 of 3 3 16 ...

Page 41: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 8 Sea Level Altitude Performance Curve TIO 540 A2C Sheet 3 of 3 3 17 ...

Page 42: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 9 Fuel Flow vs Percent Rated Power TIO 540 A2C 3 18 ...

Page 43: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 10 Limiting Manifold Pressure vs Altitude TIO 540 A2C 3 19 ...

Page 44: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 11 Sea Level Altitude Performance Curve TIO 540 F2BD Sheet 1 of 3 3 20 ...

Page 45: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 12 Sea Level Altitude Performance Curve TIO 540 F2BD Sheet 2 of 3 3 21 ...

Page 46: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 13 Sea Level Altitude Performance Curve TIO 540 F2BD Sheet 3 of 3 3 22 ...

Page 47: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 14 Fuel Flow vs Percent Rated Power TIO 540 F2BD 3 23 ...

Page 48: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 15 Maximum Manifold Pressure vs Altitude TIO 540 F2BD 3 24 ...

Page 49: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 16 Sea Level Altitude Performance Curve TIO 540 J2B J2BD N2BD Sheet 1 of 3 3 25 ...

Page 50: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 17 Sea Level Altitude Performance Curve TIO 540 J2B J2BD N2BD Sheet 2 of 3 3 26 ...

Page 51: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 18 Sea Level Altitude Performance Curve TIO 540 J2B J2BD N2BD Sheet 3 of 3 3 27 ...

Page 52: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 19 Fuel Flow vs Percent Rated Power TIO 540 J2B J2BD N2BD 3 28 ...

Page 53: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 20 Maximum Manifold Pressure vs Altitude TIO 540 J2B J2BD N2BD 3 29 ...

Page 54: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 21 Sea Level Altitude Performance Curve TIO 540 R2AD Sheet 1 of 3 3 30 ...

Page 55: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 22 Sea Level Altitude Performance Curve TIO 540 R2AD Sheet 2 of 3 3 31 ...

Page 56: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 23 Sea Level Altitude Performance Curve TIO 540 R2AD Sheet 3 of 3 3 32 ...

Page 57: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 24 Maximum Manifold Pressure vs Altitude TIO 540 R2AD 3 33 ...

Page 58: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 25 Sea Level Altitude Performance Curve TIO 540 S1AD Sheet 1 of 4 3 34 ...

Page 59: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 26 Sea Level Altitude Performance Curve TIO 540 S1AD Sheet 2 of 4 3 35 ...

Page 60: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 27 Sea Level Altitude Performance Curve TIO 540 S1AD Sheet 3 of 4 3 36 ...

Page 61: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 28 Sea Level Altitude Performance Curve TIO 540 S1AD Sheet 4 of 4 3 37 ...

Page 62: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 29 Fuel Flow vs Percent Rated Power TIO 540 S1AD 3 38 ...

Page 63: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 30 Maximum Manifold Pressure vs Altitude TIO 540 S1AD 3 39 ...

Page 64: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 31 Sea Level Altitude Performance Curve TIO 540 V2AD Sheet 1 of 3 3 40 ...

Page 65: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 32 Sea Level Altitude Performance Curve TIO 540 V2AD Sheet 2 of 3 3 41 ...

Page 66: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 33 Sea Level Altitude Performance Curve TIO 540 V2AD Sheet 3 of 3 3 42 ...

Page 67: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 34 Fuel Flow vs Percent Rated Power TIO 540 V2AD 3 43 ...

Page 68: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 35 Maximum Manifold Pressure vs Altitude TIO 540 V2AD 3 44 ...

Page 69: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 36 Sea Level Altitude Performance Curve TIO 540 U2A Sheet 1 of 3 3 45 ...

Page 70: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 37 Sea Level Altitude Performance Curve TIO 540 U2A Sheet 2 of 3 3 46 ...

Page 71: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 38 Sea Level Altitude Performance Curve TIO 540 U2A Sheet 3 of 3 3 47 ...

Page 72: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 39 Fuel Flow vs Brake Horsepower TIO 540 U2A 3 48 ...

Page 73: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 40 Maximum Manifold Pressure vs Altitude TIO 540 U2A 3 49 ...

Page 74: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 41 Sea Level Altitude Performance Curve TIO 540 W2A Sheet 1 of 3 3 50 ...

Page 75: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 42 Sea Level Altitude Performance Curve TIO 540 W2A Sheet 2 of 3 3 51 ...

Page 76: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 43 Sea Level Altitude Performance Curve TIO 540 W2A Sheet 3 of 3 3 52 ...

Page 77: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 44 Fuel Flow vs Brake Horsepower TIO 540 W2A 3 53 ...

Page 78: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 45 Maximum Manifold Pressure vs Altitude TIO 540 W2A 3 54 ...

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Page 82: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 49 Fuel Flow vs Brake Horsepower TIO 540 AH1A 3 58 ...

Page 83: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 50 Maximum Manifold Pressure vs Altitude TIO 540 AH1A 3 59 ...

Page 84: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 51 Sea Level Altitude Performance Curve TIO 540 AJ1A Sheet 1 of 4 3 60 ...

Page 85: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 52 Sea Level Altitude Performance Curve TIO 540 AJ1A Sheet 2 of 4 3 61 ...

Page 86: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 53 Sea Level Altitude Performance Curve TIO 540 AJ1A Sheet 3 of 4 3 62 ...

Page 87: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 54 Sea Level Altitude Performance Curve TIO 540 AJ1A Sheet 4 of 4 3 63 ...

Page 88: ...SECTION 3 LYCOMING OPERATOR S MANUAL OPERATING INSTRUCTIONS TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 3 55 Fuel Flow vs Percent Rated Power TIO 540 AJ1A 3 64 ...

Page 89: ...LYCOMING OPERATOR S MANUAL SECTION 3 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS Figure 3 56 Maximum Manifold Pressure vs Altitude TIO 540 AJ1A 3 65 ...

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Page 91: ...neral 4 1 Pre Starting Inspection 4 1 Daily Pre Flight Engine 4 2 Daily Pre Flight Turbocharger 4 2 10 Hour Inspection Engine 4 2 25 Hour Inspection Engine 4 2 50 Hour Inspection Engine 4 2 100 Hour Inspection 4 4 400 Hour Inspection 4 5 Non Scheduled Inspections 4 5 ...

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Page 93: ...ection but are meant for the engine only Consult the airframe manufacturer s handbook for additional instructions Pre Starting Inspection The daily pre flight inspection is a check of the aircraft prior to the first flight of the day This inspection is to determine the general condition of the aircraft and engine The importance of proper pre flight inspection cannot be over emphasized Statistics p...

Page 94: ...ct mounting and connections of turbocharger for security oil leakage and air or exhaust gas leakage b Check engine crankcase breather for restrictions to breather 3 10 HOUR INSPECTION ENGINE Within ten 10 hours of operating time for new rebuilt or newly overhauled engines replace the oil filter and conduct an inspection of the contents of the used oil filter for traces of metal particles 4 25 HOUR...

Page 95: ...efore disposing of used element check interior folds for traces of metal particles that might be evidence of internal engine damage Drain and renew lubricating oil on installations not employing replaceable full flow filters d Exhaust System Check attaching flanges at exhaust ports on cylinders for evidence of leakage If they are loose they must be removed and machined flat before they are reassem...

Page 96: ... wipe dry with a clean lintless cloth The felt located at the breaker points should be lubricated in accordance with the magneto manufacturer s instructions Check magneto to engine timing Timing procedure is described in Section 5 1 b of this manual NOTE Engines equipped with pressurized ignition system should be checked using the Bendix Model 11 10090 airflow tester as described in latest revisio...

Page 97: ...ve rocker box covers and check for freedom of valve rockers when valves are closed Look for evidence of abnormal wear or broken parts in the area of the valve tips valve keeper springs and spring seats If any indications are found the cylinder and all of its components should be removed including the piston and connecting rod assembly and inspected for further damage Replace any parts that do not ...

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Page 99: ...erator or Alternator Output 5 6 Fuel System Repair of Fuel Leaks 5 6 Fuel Injector Inlet Screen Assembly 5 6 Fuel Grades and Limitations 5 6 Air Intake Ducts and Filter 5 6 Idle Speed and Mixture Adjustment 5 6 Lubrication System Oil Grades and Limitations 5 7 Oil Suction and Pressure Screens 5 7 Oil Relief Valve 5 7 Cylinders 5 7 Turbocharger Density Controller 5 11 Generator or Alternator Drive ...

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Page 101: ...ay be marked at 20 and 25 Consult specifications for correct timing mark for your installation At this point the engine is ready for assembly of the magneto 2 Single Magneto Remove the inspection plugs from both magnetos and turn the drive shaft in direction of normal rotation until 1200 series the applicable timing mark on the distributor gear is approximately aligned with the mark on the distrib...

Page 102: ... or L mark on rotor and install magneto to the engine and loosely clamp in position 12 Attach red lead from the timing light to left switch adapter lead green lead of timing light to right switch adapter lead and the black lead of the light to magneto housing 13 Turn the entire magneto in direction of rotor rotation until the red timing light comes on 14 Rotate the magneto in the opposite directio...

Page 103: ...LYCOMING OPERATOR S MANUAL SECTION 5 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES Figure 5 1 Ignition Wiring Diagram Figure 5 2 Timing Marks 6 Cyl 1200 Series 5 3 ...

Page 104: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 5 3 Ignition Wiring Dual Magneto 5 4 ...

Page 105: ...n the timing pointer is indicating within the width of the L or R mark If breaker timing is incorrect loosen breaker screws and correct Retorque breaker screws to 2 to 25 in lbs 3 Retard Breaker Remove timing light leads from the main breaker terminals Attach one positive lead to retard breaker terminal and second positive lead to the tachometer breaker terminal if used 4 Back the engine up a few ...

Page 106: ...ons it is permissible to use higher octane fuel Fuel of a lower octane than specified is not to be used Under no circumstances should automotive fuel be used regardless of octane rating NOTE It is recommended that personnel be familiar with the latest revision of Service Instruction No 1070 regarding specified fuel for Lycoming engines d Air Intake Ducts and Filter Check all air intake ducts for d...

Page 107: ...the oil pressure relief valve is to 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 Lycoming P N 73629 or 73630 to decrease pressure A modification on later models has eliminated the need for the spacers Particles of metal or other ...

Page 108: ... from Connecting Rod Remove the piston pin plugs Insert piston pin puller through piston pin assemble propeller nut then proceed to remove piston pin Do not allow connecting rod to rest on the cylinder bore of the crankcase Support the connecting rod with heavy rubber band discarded cylinder base oil ring seal or any other non marring method c Removal of Hydraulic Tappet Sockets and Plunger Assemb...

Page 109: ...t bodies do not move the crankshaft is on the compression stroke 1 Place each plunger assembly in its respective tappet body and assemble the socket on top of plunger assembly 2 Assemble piston with rings so that the number stamped on the piston pin boss is toward the front of the engine The piston pin should be of a hand push fit If difficulty is experienced in inserting the piston it is probably...

Page 110: ...directed in Figure 5 5 and tighten inch hold down nuts to 300 in lbs 25 ft lbs torque using the sequence shown in Figure 5 5 b Remove shims and using the same sequence tighten the inch cylinder base nuts to 600 in lbs 50 ft lbs torque NOTE Cylinder assemblies not using hold down plate are tightened in the same manner as above omitting the shims c Tighten the inch hold down nuts to 300 in lbs 25 ft...

Page 111: ...factory to maintain a predetermined constant for desired horsepower The density controller is set to a curve see Figure 5 6 thru 5 10 under the following conditions Engines at operating temperatures full throttle with oil pressure at 80 psi 5 psi If it is suspected that either the manifold pressure or compressor discharge pressure is not within limits it may be checked to the curve See AiResearch ...

Page 112: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 5 6 Density Control Full Throttle Setting Limits TIO 540 A1A A2A A1B A2B 5 12 ...

Page 113: ...LYCOMING OPERATOR S MANUAL SECTION 5 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES Figure 5 7 Density Control Full Throttle Setting Limits TIO 540 A2C 5 13 ...

Page 114: ...SECTION 5 LYCOMING OPERATOR S MANUAL MAINTENANCE PROCEDURES TIO 540 SERIES ANGLE VALVE CYLINDER HEADS Figure 5 8 Density Control Full Throttle Setting Limits TIO 540 F2BD 5 14 ...

Page 115: ...LYCOMING OPERATOR S MANUAL SECTION 5 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES Figure 5 9 Density Control Full Throttle Setting Limits TIO 540 J2B J2BD N2BD 5 15 ...

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Page 117: ...ilure of Engine to Develop Full Power 6 3 Rough Engine 6 3 Low Oil Pressure 6 3 High Oil Temperature 6 4 Excessive Oil Consumption 6 4 High Fuel Flow Indicated on Fuel Gage 6 4 TROUBLE SHOOTING TURBOCHARGER Excessive Noise or Vibration 6 4 Engine Will Not Deliver Rated Power 6 5 Critical Altitude Lower Than Specified 6 6 Engine Surges or Smokes 6 6 High Deck Pressure 6 6 ...

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Page 119: ...s Fill fuel tank Clean dirty lines strainers or fuel valves Overpriming Leave ignition off and mixture control in Idle Cut Off open throttle and unload engine by cranking for a few seconds Turn ignition switch on and proceed to start in a normal manner Defective spark plug Clean and adjust or replace spark plugs Defective ignition wire Check with electric tester and replace any defective wires Def...

Page 120: ...ne necessary Plugged fuel injector nozzle Clean or replace nozzle Flow divider fitting plugged Clean fitting Low Power and Uneven Mixture too rich indicated by Readjustment of fuel injector Running sluggish engine operation red or carburetors by authorized exhaust flame at night Extreme personnel is indicated cases indicated by black smoke from exhaust Mixture too lean indicated by Check fuel line...

Page 121: ...proper fuel flow Check strainer gage and flow at the fuel line Restriction in air scoop Examine air scoop and remove restrictions Improper fuel Drain and refill tank with recommended fuel Faulty ignition Tighten all connections Check system with tester Check ignition timing Rough Engine Cracked engine mount Replace or repair mounting Defective mounting bushings Install new mounting bushings Uneven...

Page 122: ... by Usually caused by worn or stuck rings Failing or failed bearing Examine sump for metal parti cles If found overhaul of en gine is indicated Defective temperature gage Replace gage Excessive oil consumption Low grade of oil Fill tank with oil conforming to specification Failing or failed bearings Check sump for metal particles Worn piston rings Install new rings Incorrect installation of piston...

Page 123: ...n material lodged in com Disassemble and clean pressor impeller or turbine Excessive dirt build up in com Thoroughly clean compressor pressor assembly Service air cleaner and check for leakage Leak in engine intake or exhaust Tighten loose connections or replace manifold gaskets as necessary Rotating assembly bearing Overhaul turbocharger seizure Restriction in return lines from Remove and clean l...

Page 124: ...r metering valve in Replace controller controller holding it open Metering jet in actuator plugged Remove actuator and clean jet Actuator piston seal failed and If there is oil leakage at actuator leaking excessively drain clean cylinder and replace piston seal Exhaust bypass valve sticking Clean and free action Engine Surges or Smokes Air in oil lines or actuator Bleed system Controller metering ...

Page 125: ...ss actuator inlet If pressure on outlet side of actuator is too high have ex haust bypass controller adjusted Exhaust bypass valve actuator Remove and disassemble actu piston locked in full closed ator check condition of piston position usually accompanied and packing or replace actuator by oil leakage at actuator drain assembly line NOTE Exhaust bypass normally closed in idle and low power condit...

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Page 127: ...ORAGE Page Preparation of Engine for Installation 7 1 General 7 1 Inspection of Engine Mounting 7 1 Attaching Engine to Mounts 7 1 Oil and Fuel Line Connections 7 1 Propeller Installation 7 2 Corrosion Prevention in Engines Installed in Inactive Aircraft 7 2 ...

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Page 129: ...ion the lubricating oil should be drained while the engine is hot This will remove any residual preservative oil that may have been present CAUTION DO NOT ROTATE THE CRANKSHAFT OF AN ENGINE CONTAINING PRESERVATIVE OIL BEFORE REMOVING THE SPARK PLUGS BECAUSE IF THE CYLINDERS CONTAIN ANY APPRECIABLE AMOUNT OF THE MIXTURE THE RESULTING ACTION KNOWN AS HYDRAULICING WILL CAUSE DAMAGE TO THE ENGINE ALSO...

Page 130: ...on preventive oil while cranking the engine about five 5 revolutions with the starter The spray gun nozzle may be placed in either of the spark plug holes NOTE Spraying should be accomplished using an airless spray gun Spraying Systems Co Gunjet Model 24A 8395 or equivalent In the event an airless spray gun is not available personnel should install a moisture trap in the air line of a conventional...

Page 131: ...ANAUL SECTION 8 TABLES Page Table of Limits 8 1 Ground Run After Top Overhaul 8 2 Flight Test After Top Overhaul 8 3 Full Throttle HP at Altitude 8 4 Centigrade Fahrenheit Conversion Table 8 5 Inch Fractions Conversions 8 6 ...

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Page 133: ...RECOMMENDATIONS AND INFORMATION CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN LYCOMING AIRCRAFT ENIGINES CONSULT LATEST REVISION OF SPECIAL SERVICE PUBLICATION NO SSP1776 CONSULT LATEST REVISION OF SERVICE INSTRUCTION NO 1029 AND NO 1150 FOR INFORMATION PERTINENT TO CORRECTLY INSTALLING CYLINDER ASSEMBLY 8 1 ...

Page 134: ...SECTION 8 LYCOMING OPERATOR S MANUAL TABLES TIO 540 SERIES ANGLE VALVE CYLINDER HEADS 8 2 ...

Page 135: ...LYCOMING OPERATOR S MANUAL SECTION 8 TIO 540 SERIES ANGLE VALVE CYLINDER HEADS TABLES 8 3 ...

Page 136: ...0 90 5 15 000 58 7 22 000 44 0 4 000 87 5 16 000 56 5 22 500 43 3 5 000 84 6 17 000 54 3 23 000 42 2 6 000 81 7 17 500 53 1 23 500 41 4 7 000 78 9 18 000 52 1 24 000 40 3 8 000 76 2 18 500 51 4 24 500 39 5 9 000 73 5 19 000 50 0 25 000 38 5 TABLE OF SPEED EQUIVALENTS Sec Mi M P H Sec Mi M P H Sec Mi M P H 72 0 50 24 0 150 14 4 250 60 0 60 22 5 160 13 8 260 51 4 70 21 2 170 13 3 270 45 0 80 20 0 18...

Page 137: ...8 0 23 3 10 14 0 137 78 280 536 0 17 8 0 32 0 143 33 290 554 0 12 22 10 50 0 148 89 300 572 0 6 67 20 68 0 154 44 310 590 0 1 11 30 86 0 160 00 320 608 0 4 44 40 104 0 165 56 330 626 0 10 00 50 122 0 171 11 340 644 0 15 56 60 140 0 176 67 350 662 0 21 11 70 158 0 182 22 360 680 0 26 67 80 176 0 187 78 370 698 0 32 22 90 194 0 193 33 380 716 0 37 78 100 212 0 198 89 390 734 0 43 33 110 230 0 204 44...

Page 138: ... 1562 0192 3 969 21 32 6562 3382 16 669 11 64 1719 0232 4 366 43 64 6719 3545 17 065 3 16 1875 0276 4 762 11 16 6875 3712 17 462 7 32 2187 0376 5 556 23 32 7187 4057 18 256 15 64 2344 0431 5 593 47 64 7344 4235 18 653 1 4 25 0491 6 350 3 4 75 4418 19 050 9 32 2812 0621 7 144 25 32 7812 4794 19 844 19 64 2969 0692 7 540 51 64 7969 4986 20 241 5 16 3125 0767 7 937 13 16 8125 5185 20 637 11 32 3437 0...

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