Textron Lycoming IO-540 Series Operator'S Manual Download Page 41

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Summary of Contents for Lycoming IO-540 Series

Page 1: ...ges in the operator s manual PREVIOUS REVISION January 1997 Section 2 Index 2 2 2 3 2 4 Added pages 2 5 2 6 2 7 2 8 Section 3 Index 3 10 3 11 3 12 Added page 3 12A B 3 13 3 17 3 18 Added page 3 18A B...

Page 2: ...MANAUAL TEXTRON Lycoming O 540 IO 540 SERIES AIRCRAFT ENGINES 4 th EDITION October 1999 Approved by F AA TEXTRON Lycoming 652 OliverStreet Williamsport PA17701U S A 570 323 6181 PartNo 60297 10 Printe...

Page 3: ...ce procedures can result in poor engine performance and power loss Also if power and speed limitations specified in this manual are ex ceeded for any reason damage to the engine and personal injury ca...

Page 4: ...con tain various Warnings and Cautions which must be carefully read in order to minimize the risk of personal injury or the use of improper ser vice methods that may damage the engine or render it uns...

Page 5: ...that engine replacementis required Textron Lycoming s obligation during dieprorationperiod extendsto major partsof theengine whichare limited to crankcase crankshaft camshaft cylinders connectingrods...

Page 6: ...CE ON THE PART OF TEXTRON LYCOMING AND TEXTRON LYCOMING S LIABILITY ON SUCH CLAIMSHALL INNO CASE EXCEED THE PRICEALLO CABLETO THE ENGINEORPARTWHICHGIVESRISETO THE CLAIM LIMITATIONOFLIABILITY IN NOEVEN...

Page 7: ...Theobligationson the part of TextronLycomingset forthaboveare your exclusiveremedyand theexclusiveliabilityof Textron Lycoming This warrantyallocatesthe riskof product failurebetweenyou and TextronLyc...

Page 8: ...MAGES INCLUDINGBUT NOT LIMITED TO LOSSOF PROFITSOR REVENUES LOSSOF USE OFTHE ENGINEORCOSTOF AREPLACEMENT No agreement varying this warranty or Textron Lycoming s obligations under it will be binding u...

Page 9: ...ormal maiutenanceexpensesor consunmable items The obligationson the partof Textron Lycomingset forthabove areyourexclusive remedyand dieexclusiveliabilityof Textron Lycoming This warrantyallocates the...

Page 10: ...AGES INCLUDINGBUTNOT LIMITED TO LOSSOPPROFITS OR REVENUES LOSSOFUSE OFTHE ENGINEORCOSTOF AREPLACEMENT No agreement varying this warranty or Textron Lycoming s obligations under it will be binding upon...

Page 11: ...SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 DESCRIPTION SPECIFICATIONS OPERATING INSTRUCTIONS PERIODIC INSPECTIONS MAINTENANCE PROCEDURES TROUBLE SHOOTING INSTALLATIONAND STORAGE TABLE...

Page 12: ...TEXTRON LYCOMING OPERATOR S MANUAL 3 4 Right Front View Typical IO 540 B...

Page 13: ...unterweight system and must be operated accordingly avoid high engine speed low manifold pressure operation Use a smooth steady movement of the throttle avoid rapid opening and closing If this warning...

Page 14: ...IPTION Page General 1 1 Cylinders 1 1 Valve Operating Mechanism 1 1 Crankcase 1 1 Crankshaft 1 2 Connecting Rods 1 2 Pistons 1 2 Accessory Housing 1 2 Oil Sump 1 2 Oil Sump and Induction Assembly 1 2...

Page 15: ...nd barrel screwed and shrunk together The heads are made from an aluminumalloycasting with a fullymachined com bustion chamber Rocker shaft bearing supports are cast integral with the head along with...

Page 16: ...roper piston and ring combinations Accessory Housing The accessory housing is made from an aluminum casting and is fastened to the rear of the crankcase and the top rear of the sump It forms a housing...

Page 17: ...off The Marvel Schebler HA 6 is a horizontal mounted carburetor equip ped with a manual mixture control and idle cut off The Bendix RS type fuel injection system operates by measuring the air flow thr...

Page 18: ...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 Drive...

Page 19: ...cker clearance hydraulictappets collapsed 028 080 028 080 028 080 Prop drive ratio 1 1 1 1 1 1 Prop driven rotation Clockwise Clockwise Clockwise 0 540 SERIES J L F FAAType Certificate 295 295 Rated h...

Page 20: ...1 1 Prop drivenrotation Clockwise V SERIES IO 540 D N R T V SERIES FAATypeCertificate 1E4 Rated horsepower 260 Rated speed RPM 2700 Bore inches 5 125 Stroke inches 4 375 Displacement cubic inches 541...

Page 21: ...1 1 Prop driven rotation Clockwise 10 540 J SERIES FAAType Certificate 1E4 Rated horsepower 250 Rated speed RPM 2575 Bore inches 5 125 Stroke inches 4 375 Displacement cubic inches 541 5 Compression r...

Page 22: ...5 GA5 447 00 IO 540 G1E5 448 00 IO 540 G F5 449 00 IO 540 G1B5 453 00 IO 540 G1C5 GD5 454 00 IO 540 P1A5 455 00 IO 540 K1E5D 466 00 IO 540 M1A5 M1B5D 467 00 IO 540 K1G5 K1H5 K1J5D L1A5D 468 00 IO 540...

Page 23: ...rs degrees BTC 20 Valverocker clearance hydraulic tappets collapsed 028 080 Prop drive ratio 1 1 Prop driven rotation Clockwise IO 540 AB SERIES FAAType Certificate 1E4 Rated horsepower 230 Rated spee...

Page 24: ...pets collapsed 028 080 Prop drive ratio 1 1 Prop drivenrotation Clockwise 1 STANDARDENGINE DRY WEIGHT MODEL LBS 0 540 L3C5D 387 00 O 540 J1A5D J2A5D J1B5D J2B5D 387 00 O 540 J3A5D J3C5D 388 00 0 540 B...

Page 25: ...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 G1D...

Page 26: ...Mag Fuel Pump Plunger Operated DriveRatio 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 Directionof Rotation Counter Clockwise Clockwise Cloc...

Page 27: ...2 Starting Procedures 3 2 Ground Running and Warm Up 3 4 Ground Check 3 4 Operating in Flight Leaning Procedure 3 7 Use of Carburetor Heat 3 7 Engine Flight Chart 3 10 Operating Conditions 3 12 Engin...

Page 28: ...NCE SPECIFICATIONS FOR YOUR ENGINE WILL NOT ONLY VOID YOUR WARRANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS PASSED New engines have been carefully run in by Textron Lyco...

Page 29: ...ion from these procedures NOTE Cranking periods should be limited from ten 10 to twelve 12 seconds with 5 minutes rest between cranking periods a 0 540 Series 1 Perform pre flight inspection 2 Set car...

Page 30: ...and move mixture control to Full Rich position until a slight but steady flow is indicated 6 Return mixture control to Idle Cut off position 7 Set magneto selector switch Consult airframe manufacture...

Page 31: ...ese engines on the ground To prevent overheating it isrecom mended that the followingprecautions be observed NOTE Anyground checkthatrequiresfull throttleoperationmust belimited tothree minutes orless...

Page 32: ...pressure gage Mixture control shouldbe inthe fullrich posi tion Atthese settings the ignitionsystem and spark plugsmust work harder because of the greater pressure within the cylinders Under these con...

Page 33: ...e mixture the followinggeneral rules should be observed by the operator of Textron Lycomingaircraft engines GENERAL RULES Never exceedthe maximum red line cylinder head temperaturelimit For maximum se...

Page 34: ...nue leaning until engine roughness is noted 3 Enrich until engine runs smoothly and power is regained 8 USE OF CARBURETOR HEAT CONTROL Under certain moist atmospheric conditions at temperature of 200...

Page 35: ...ANUAL 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 R...

Page 36: ...rol should be left in the cold position during normal flight operations On damp cloudy foggy or hazy days regardless of outside temperature keep a sharp lookout for loss in manifold pressure or RPM or...

Page 37: ...ee the air craft flight manual for specific instructions 9 ENGINE FLIGHT CHART FuelRequirements 0 540 MODELS AviationGrade Fuel B Series A3D5 E Series A G H Series F J LSeries 80 87 Octane Minimum 91...

Page 38: ...40 Below 10 F 12 22 C SAE 20 SAE 30 20W30 Refer to the latestedition of Service Instruction No 1014 Oil Sump Capacity 0 540 MODELS All Series ExceptBelow 12 U S Qts Minimum safe quantity insump 2 3 4...

Page 39: ...een 165 F 73 8 C and 200 F 93 3 C in level flight cruiseconditions OPERATINGCONDITIONS FUEL PRESSURE PSI MIN MAX IDLE MIN 0 540 Series Except L3C5D 0 5 8 0 L3C5D 3 30 IO 540 AB1A5 C1B5 C1C5 C4B5 C4B5D...

Page 40: ...l injector IO 540 K1A5 1A 1A5D K1B5 K1B5D K1F5D K1K5 K2A5 M1A5 M1C5 Inlet to fuel pump Inlet to fuel injector MIN MAX IDLE MIN 2 40 18 55 2 18 45 45 12 12 12 2 55 18 55 IO 540 AC1A5 Inlet to fuel pump...

Page 41: ...N MAX IDLE MIN IO 540 AA1A5 AA1B5 Inlet to fuel pump 4 55 Inlet to fuel injector 18 55 12 10 540 A1A5 B1A5 B1C5 E1A5 E1B5 G1A5 G1E5 G1F5 K1C5 K1E5 K1E5D Inlet to fuel injector 20 26 NOTE All IO 540Mod...

Page 42: ...5 Rated Economy Cruise 65 Rated 2575 2350 2200 2575 2350 2200 2700 2450 2350 2800 2800 2800 0 540 A Series 250 190 16 3 150 12 5 0 540 B Series 235 175 15 5 140 12 2 0 540 E G H 260 195 19 0 155 14 0...

Page 43: ...e maintain cylinder head temperature between 150 F and 435 F during continuous operation Model 0 540 JEngines manual leaning to best economy is permit ted at cruise conditions up to 75 power resulting...

Page 44: ...260 C IO 540 D N R T V Series Normal Rated Performance Cruise 75 Rated Economy Cruise 60 Rated 2700 260 2450 195 0 87 500 F 260 C 15 0 0 65 500 F 260 C 2350 155 12 0 0 52 500 F 260 C IO 540 K L M S S...

Page 45: ...Normal Rated 2400 Performance Cruise 75 Rated 2200 Economy Cruise 60 Rated 2000 O 540 W Series 235 0 78 175 12 5 0 58 140 10 1 0 47 IO 540 AA Series 250 0 83 190 14 5 0 63 150 11 5 0 50 IO 540 ABSerie...

Page 46: ...700 300 23 7 0 98 480 F 249 C Performance Cruise 75 Rated 2400 225 19 0 0 73 480 F 249 C Economy Cruise 60 Rated 2200 180 12 6 0 58 480 F 249 C e Engine Shut Down 1 Set propeller at minimum blade angl...

Page 47: ...CH OPERATNG CONDITIONS STDSEALEVEL FUELGRADE MININUM 91 96 21 20 RPM 17 PERCENT 7 15 POWER 70 TEXTRONLYCOMINGOPERATOR S MANUAL SECTION 3 E NO 11800 NOTE TOOBTAIN FUELCONSUPTION Al ALTITUDE ENTER THIS...

Page 48: ...EL POWER CURVE LYCOMING 0 540 A SERIES COMPRESSION RATIO 8 50 1 SPARKADVANCE 25 BTC CARBURETOR MARVEL SCHEBLER MA 4 5 FUEL GRADE MINIMUM 91 96 MIXTURESETTING FULL RICH OPERATING CONDITIONS STD SEA LEV...

Page 49: ...HPT 60 ACTU ___ HEATERUSED z APPROIMATELR 1 CORRECTION FR p _ 1 EAC AL VRIATIA R M H5L PS L T TTE IT TE__ _ MP ANOW ACTUALINLETA TEMP 0 Figure 3 4 Sea Level and Altitude Performance Curve 0 540 A...

Page 50: ...CONDITIONS STD SEA LEVEL FUEL GRADE MINIMUM 80 87 TEXTRONLYCOMING OPERATOR SMANUAL ON 3 23 21 20 19 I 18 ENGINE RFM 16 15 14 NOTE TO OBTAINFUEL CONSUMPTION AT ALTITUDE ENTERTHISCURVE WITH EQUIVALENT...

Page 51: ...TEXTRONLYCOMING OPERATOR SMANUAL SECTION 3 0 540 10 540SERIES CURVE NO 10821 B POWER POWER Figure 3 6 Sea Level Power Curve 0 540 B 3 22...

Page 52: ...ROM ALTITUDE R PM MANIFOLDPRESSURE AND AIR INLET TEMPERATURE LLOCATE AN FULLTHROTTLE ALTITUDE CURVEFOR GIVENRPMMANIFOLD PRESS 2 LOCATES ON SEALEVELCURVE 0 m m n w m 0 r m Figure 3 7 Sea Level and Alti...

Page 53: ...n step 2 to altitude performance curve Example Point C 4 Connect point A and point C with a straight line 5 Read horsepower on line CA for given altitude Example At 1500 feet with a power setting of 2...

Page 54: ...GINE PERFORMANCE DATA MAXIMUMPOWERMIXTURE UNLESSOTHERWISE NOTE ENGINE MODEL O 540 B SE ES COMPRESSON RATIO 7 2 CARBURETOR MARVEL SCHEBLER MA 4 5 FUEL GRADE MINIMUM 80 87 NOEXTERNAL MIXTURE HEATER USED...

Page 55: ...COMING 0 540 E G H COMPRESSION RATIO 8 50 1 SPARKTIMING 25 BTC CARBURETOR MARVELSCHEBLER MA 4 5 MIXTURE SETTING FULL RICH OPERATING CONDITIONS STD SEA LEVEL FUEL GRADE MINIMUM 91 96 24 23 12 45 PERFOR...

Page 56: ...RfEA HO O WERATGIVEN TITUE 0 8 oruY RMACKiT r D RWIARTO V T j 260 TLITU RE TERTUe o APIEMIX IIATIT I C RT RC FMR 240 E ACI0 F ATIOR T T ErHalUI 220 e z e vrl Ters Frr xs 200 A t t X cURVENO 12ss O AL...

Page 57: ...UMPTION TOLERANCE 0 540F SERIES MA 4 5 100 100LL 8501 25 BTC 4 FUELCONSUMPTION U S G PH 20 22 24 26 ABSOLUTE MANIFOLD PRESSURE IN HG SPECIFIC FUELCONSUMPTION 6 28 NOTE TOOBTAIN FUELCONSUMPTION ATALTIT...

Page 58: ...m z m z 19 20 21 22 23 24 25 26 27 28 29 ABSOLUTE MANIFOLDPRESSURE IN HG Figure 3 12 Sea Level and Altitude Performance Curve 0 540 F Series...

Page 59: ...NG 20 BTC FUELINJECTOR BENDIXRS IO MIXTURE CONTROL MANUALTO BEST ECONOMY OR BEST POWER ASINDICATED FUELGRADE MINIMUM 100 100LL 22 21 20 19 18 17 16 15 14 13 12 11 10 PERCENT RATED POWER 85 NOTE FUELCO...

Page 60: ...Figure 3 14 Sea Leveland Altitude Performance Curve 10 540 A G P...

Page 61: ...fr i gIX4D ALI Tnl Lra _2LI FI2o 1 Figure3 15 Sea Level and AltitudePerformanceCurve IO 540 B E...

Page 62: ...MPRESSION RATIO 8 50 I SPARKTIMING 25 BTC FUELINJECTOR BENDIX MODEL RSA 5ADI FUEL GRADE MINIMUM 91 96 MIXTURE CONTROL MANUAL TOBESTECONOMY ORBEST POWER ASINDICATED aX I i n z IL 0 IC 15 14 13 12 II 10...

Page 63: ...CORRECT FOR DIFFERENCE BETWEEN STD I z w m z Figure 3 17 Sea Level and Altitude Performance Curve IO 540 C...

Page 64: ...ESSION RATIO 8 50 1 SPARK TIMING 25SBTC FUEL INJECTOR BENDIX MODEL RSASAD1 MIXTURE CONTROL MANUAL TOBEST ECONOMY ORBEST POWER INDICATED FUEL GRADE MINIMUM 0 N V 91 95 P T WIuLL 71 PERCENT RATED POITER...

Page 65: ...z 0 Figure 3 19 Sea Level and Altitude Performance Curve IO 540 D N R T m...

Page 66: ...MPRESSION RATIO 8 50 1 SPARK TIMING 25 BTC FUELINJECTOR BENDIX MODEL RSA 5ADI FUEL GRADE MINIMUM 100 100LL MIXTURE CONTROL MANUAL TOBESTECONOMY ORBEST POWER ASINDICATED 20 19 18 17 16 15 12 10 9 PERCE...

Page 67: ...z Z PRESSURE ALTITUDE INTHOUSANDS OFFEET 18 19 20 21 22 23 24 25 26 27 28 29 ABSOLUTE MANIFOLD PRESSURE IN HG Figure 3 21 Sea Level and Altitude Performance Curve IO 540 J...

Page 68: ...704 SPARK TIMING 20 BTC FUEL NJECTOR BEIOIXMODEL RSA IOADI MIXTURE CONTROL MAMIAL TOBESTECONOMY ORBEST POWER ASINICATED FUELGRADE MINMUM 10010LL _z I I iI MI cf z 0 I LL wD Ijn za 22 21 20 19 17 IE 1...

Page 69: ......

Page 70: ...IES SECTION 3 CURVE No 13386 FUELFLOWvsPERCENT RATEDPOWER LYCOMING 10 540 AAIA5 NORMALLYASPIRATED 22 20 18 16 14 12 10 50 60 70 80 90 100 PERCENT RATED POWER Figure 3 24 Fuel Flow vs Percent Rated Pow...

Page 71: ...Figure 3 25 Sea Level Altitude Performanc Curve IO 540 AA Series...

Page 72: ...ING IO 540 W SERIES TEXTRON LYCOMINGOPERATOR S MANUAL 0 540 10 540 SERIES SECTION 3 CURVE No 13383 50 60 70 80 90 100 PERCENTRATEDPOWER I I I I I Figure 3 26 Fuel Flow vs Percent Rated Power IO 540 W...

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Page 74: ...TEXTRON LYCOMING OPERATOR S MANUAL 0 540 10 540 SERIES SECTION 3 I I 4d N it e W E rl 11 K a in i V i s ii e 111 2 r o O w a X _____ iI I It 1 Added January 1997 3 45...

Page 75: ...SERIES SECTION 3 MINIMUM FUELFLOWVERSUS PERCENT RATEDPOWER TEXTRON LYCOMING10 540 AC1A Curve No 13544 160 150 90 80 70 60 50 60 70 80 90 PERCENT RATED POWER 100 Figure 3 29 Fuel Flow vs Percent Rated...

Page 76: ...NGINE MODEL 10 540 AC COMPRESSION RATIO 8 7 1 3 CONNECT A C BYA STRAIGHT FUEL INJECTOR PACRSA 10 LINE ANDREAD HORSEPOWER FUEL GRADE MIN 100 LL ATGIVENALTITUDED 4 MODIFY HORSEPOWER AT D FORVARIATION OF...

Page 77: ...ION Page General 4 1 Pre Starting Inspection 4 1 Daily Pre Flight Inspection 4 2 10 Hour Inspection 4 2 25 Hour Inspection 4 2 50 Hour Inspection 4 2A B 100 Hour Inspection 4 4 400 Hour Inspection 4 5...

Page 78: ...t for the engine only Consult the airframe manufacturer s handbook for addi tional instructions Pre Starting Inspection The daily pre flight inspection is a check of the aircraft prior to the first fl...

Page 79: ...em airfilter shouldbe inspected andserviced inaccor dance with the airframe manufacturer s recommendations 2 10 HOURINSPECTION ENGINE Within ten 10 hours of operat ing time for new remanufactured or n...

Page 80: ...AL 0 540 10 540 SERIES SECTION 4 3 50HOUR INSPECTION ENGINE In addition to the items listed for daily pre flight inspection the following maintenancechecks should be made after every 50 hours of opera...

Page 81: ...xture control and throttle linkage for travel freedom of move ment security of the clamps and lubricate if necessary Check the air intake ducts forleaks security filter damage evidence of dust or othe...

Page 82: ...or awhile This condiiton is neither harmful nor detrimental to engine performance and operation If it can be proven that leakage exceeds these conditions the cylinder should be replaced 4 100 HOUR INS...

Page 83: ...followingmaintenance check should be made after every 400 hours of operation ValveInspection Removerocker box covers and check for freedom of valve rockers when valves are closed Look for evidence of...

Page 84: ...lternator Output 5 8 Fuel System Repair of Fuel Leaks 5 9 Carburetor or Fuel Injector Inlet Screen Assembly 5 9 Fuel Grades and Limitations 5 9 Air Intake Ducts and Filter 5 9 Idle Speed and Mixture A...

Page 85: ...mpression stroke is reached which is indicated by a positive pressure inside the cylinder tending to push the thumb offthe spark plughole Continue rotating the crankshaft until the ad vance timingmark...

Page 86: ...TEXTRONLYCOMING OPERATOR SMANUAL SECTION 5 0 540 10 540SERIES Figure 5 1 Ignition Wiring Diagram Figure 5 2 Timing Marks 6 cyl 1200 Series 5 2...

Page 87: ...posi tion as directed in paragraph lb 1 6 Install the magneto to engine gasket on the magneto flange WARNING Do not attach harness spark plug ends to the spark plugs until all magneto to engine timin...

Page 88: ...TEXTRON LYCOMING OPERATOR SMANUAL SECTION 5 0 540 10 540SERIES Figure 5 3 Ignition Wiring Diagram Dual Magneto 5 4...

Page 89: ...off indicating left main breaker has opened Then evenly tighten the magneto mounting clamps 15 Back the engine up approximately 10 and then carefully bump the engine forward at tie same time observing...

Page 90: ...lock Apply a slight inward 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 pi...

Page 91: ...n until the timing light comes on If the light is on initially rotation of the magneto is not required This indicates the breaker points are closed 8 Slowly rotate the magneto assembly in the opposite...

Page 92: ...ed Slowlyrotate the engine in the normal direction until the timing light goes out in dicating the points opened The TC 1 timing mark on the ring gear should be aligned with the dot on the starter hou...

Page 93: ...fuel injector c Fuel Grades and Limitations See recommended fuel grades on I page 3 10 or reference latestedition of Service Instruction No 1070 In the event that the specified fuel is not available a...

Page 94: ...oo rich or too lean turn the idle mixture adjustment in the direction required for correction and check this new position by repeating the above procedure Make additionaladjustments as necessary until...

Page 95: ...ted d Oil Relief Valve Adjustable The adjustableoil relief valve en ablesthe operatorto maintainengineoil pressure within the specified limits If the pressureunder normaloperatingconditions shouldcon...

Page 96: ...e and pull shroud tubes through holes in cylinder head NOTE Thehydraulic tappets push rods rockerarms and valvesmust be assembled in the same locationfrom which they were re moved 7 Remove cylinder ba...

Page 97: ...embly of Hydraulic Tappet Plunger Assemblies To assemble the unit unseat the ball by inserting a thin clean wire through the oil inlet hole With the ball off its seat insert the plunger and twist cloc...

Page 98: ...rings and the inside of the cylinder generously with oil Cylinder hold down plate Shim 4 req d percylinder 010IN thickX 50 70 INwide During initialtightening use twoshims between each plate andthebarr...

Page 99: ...nuts and tighten as directed in the following steps NOTE At any time a cylinder is replaced it is necessary to retorque the thru studs on the cylinder on the opposite side of the engine a Engines usin...

Page 100: ...sed Check clearance between the valve stem tipand the valverocker In order to check this clearance place the thumb of one hand on the valverocker directly over the end of the push rod and push down so...

Page 101: ...ailure of Engine to Start 6 1 Failure of Engine to Idle Properly 6 2 Low Power and Uneven Running 6 3 Failure of Engine to Develop Full Power 6 4 Rough Engine 6 4 Low Oil Pressure 6 5 High Oil Tempera...

Page 102: ...emedies 1 TROUBLE SHOOTING ENGINE TROUBLE PROBABLE CAUSE REMEDY Failure of Engine to Start Lack of fuel Overpriming Defective spark plugs Defective ignition wire Defective battery Check if fuel valve...

Page 103: ...ck oil screens for metal particles If found complete overhaul of the engine may be indicated Failure of Engine to Idle Properly Incorrect idle mixture Adjust mixture Leak in induction system Incorrect...

Page 104: ...el injector or carburetors by authorized personnel is indicated Mixture too lean indicated by over heating or backfiring Leaks in induction system Defective spark plugs Improper fuel Magneto breaker p...

Page 105: ...in air scoop Improper fuel Faulty ignition Cracked engine mount Defective mounting bushings Uneven compression REMEDY Replace connectors on spark plug wire Clean or replace nozzle Tighten all connect...

Page 106: ...ppage in oil pump intake passage Remove and clean oil pressure relief valve Check gasket between accessory housing and crankcase See High Oil Temp erature in Trouble column Check line for obstruction...

Page 107: ...f engine is indicated Fill tank with oil conform ing to specification Failing or failed bearings Worn piston rings Incorrect installation of piston rings Failure of rings to seat new nitrided cylinder...

Page 108: ...2 Inspection of Engine Mounting 7 2 Attaching Engine to Mounts 7 2 Oil and Fuel Line Connections 7 2 Propeller Installation 7 2 Preparation of Carburetors and Fuel Injectors for Installation Carbureto...

Page 109: ...is not possible heat the cylinders with heat lamps before attempting to drain the engine After the oilsump has been drained the plug shouldbe replaced safety wired and the sump refilledwith lubricatin...

Page 110: ...he enginemount isnot bent or damaged by distortion or misalignmentas this canproduce abnormalstresses within the engine Attaching Engine to Mounts See airframe manufacturer s recommenda tion for metho...

Page 111: ...her shelter where the preservation process is to be performed b Removesufficientcowlingto gainaccess to the sparkplugsand remove both spark plugs from each cylinder c Spray the interior of each cylind...

Page 112: ...specification MIL L6529 Type 1 heated to 200 F 220 F 930C 1040C spray nozzle temperature NOTE Oilsofthe typementionedare tobeused in TextronLycomingaircraftengines for corrosionpreventiononly and not...

Page 113: ...OIL LEVEL GAGE TEXTRONLYCOMING OPERATOR SMANUAL 0 540 10 540 SERIES SECTION7 Figure 7 1 Installation Drawing Left Side View 0 540 Series Figure 7 2 Installation Drawing Rear View 0 540 Series 7 5...

Page 114: ...ENTER OF GRAVITY OILDRAIN FULL RICH POSITION IDLE CUT OFF POSITION Figure 7 3 Installation Drawing Left Side View IO 540 C D J N TACHOMETER CONN BREATHER FITTNG OIL TEMPERATURE CONN OIL FROM COOLER VA...

Page 115: ...R PAD OILFROM COOLER OILPRESSURE SCREEN HSG TEXTRONLYCOMING OPERATOR SMANUAL 0 540 10 540 SERIES SECTION7 Figure 7 5 Installation Drawing Left Side View IO 540 B E Figure 7 6 Installation Drawing Rear...

Page 116: ...7 0 540 10 540SERIES FUELMANFOLD PRESSURE OIL LEVEL GAGE FUEL DRAIN Figure 7 7 Installation Drawing Left Side View IO 540 A G P S TEMPERATURE CONN VACM PUMP PAD OILPRESS GAGE CANN Figure 7 8 Installat...

Page 117: ...ANUAL 0 540 10 540 SERIES SECTION7 MAN PRESS CONN CENTER OFGRAVITY OILSUCTION SCREEN OILDRAIN PLUGS Figure 7 9 Installation Drawing Left Side View I0 540 K CENTER OFGRAVITY Figure 7 10 Installation Dr...

Page 118: ...TION7 0 540 10 540 SERIES FUEL INLET STRAINER FUEL PRESSURE CONNECTION MIXTURE CONTROLLEVER THROTTLE LEVER BOWL DRAIN PLUG Figure 7 11 Installation Drawing Alternate Oil Line Connections Magnetos and...

Page 119: ...ABLES 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 Table of Speed Equivalents 8 4 Centigrade Fahrenheit Conversion 8 5...

Page 120: ...ND INFOR MATION CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN TEXTRON LYCOMING AIRCRAFT ENGINES CONSULTTHE LATESTEDITION OF SPECIALSERVICE PUBLICATIONNO SSP1776 CONSULTLATESTEDITIONO...

Page 121: ...llCDl PrmX11151SsoS t TEXTRON LYCOMING OPERATOR S MANUAL _ F C id e r i IV i a I a a rl wU t w 9B en rll i SX I1 I 91 I 0 540 10 540 SERIES 0 0 m 0 0 0 a 0 D 5 _s 0 o C C z z 0 Ci o d o m I z r t M 0...

Page 122: ...during climb and cruise Tested by m FLIGHT TEST RECORD Z C Temperature Pressure Temperature FuelFlow Time RPM MAP L oil R oil L cyl R cyl L oil R oil L fuelR fuel L carb R carb Amb AirLeft Right Climb...

Page 123: ...00 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...

Page 124: ...20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 94 0 76 0 58 0 40 0 22 0 4 0 14 0 32 0 50 0 68 0 86 0 104 0 122 0 140 0 158 0 176 0 194 0 212 0 230 0 248 0 266 0 284 0 302 0 3...

Page 125: ...4219 1398 4375 1503 397 1 2 794 17 32 1 191 35 64 1 587 9 16 2 381 19 32 2 778 39 64 3 175 5 8 3 969 21 32 4 366 43 64 4 762 11 16 5 556 23 32 5 593 47 64 6 350 3 4 7 144 25 32 7 540 51 64 7 937 13 16...

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