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Lycoming TIO-540-A2A Operator's Manual

Angle valve cylinder heads
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NOTE
In order to accommodate clearer type, larger charts and graphs, and more
detailed illustrations, this edition of the TIO-540 Operator's Manual,
Lycoming Part Number 60297-23A is presented in an 8-1/2 x 11 inch
format. This edition is a complete manual of all TIO-540 model engines
that employ angle valve cylinder heads. These Lycoming 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 level, the
date of the revision, and the pages revised, added or deleted. All revisions
will be supplied in the 8-1/2 x 11 inch format.

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Summary of Contents for Lycoming TIO-540-A2A

  • Page 1 In order to accommodate clearer type, larger charts and graphs, and more detailed illustrations, this edition of the TIO-540 Operator’s Manual, Lycoming Part Number 60297-23A is presented in an 8-1/2 x 11 inch format. This edition is a complete manual of all TIO-540 model engines that employ angle valve cylinder heads.
  • Page 3 Operator’s Manual Lycoming TIO-540 Series Angle Valve Cylinder Heads Approved by FAA Edition Part No. 60297-23A November 2005 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
  • Page 4 TIO-540 Series Angle Valve Cylinder Heads Operator’s Manual Lycoming Part Number: 60297-23A ©2005 by Lycoming. All rights reserved. Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of Lycoming. All brand and product names referenced in this publication are trademarks or registered trademarks of their respective companies.
  • Page 5 The page(s) in this revision replace, add to, or delete current pages in the operator’s manual. PREVIOUS REVISION CURRENT REVISION August 2006 January 2013 3-3, 3-4 May 2008 2-3; 3-55, 3-56, 3-57 ©2013 Avco Corporation, All Rights Reserved Lycoming Engines is a division of Avco Corporation...
  • Page 7 LYCOMING OPERATOR’S MANUAL ATTENTION OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL SAFETY WARNING NEGLECTING TO FOLLOW THE OPERATING INSTRUCTIONS AND TO CARRY OUT PERIODIC MAINTENANCE PROCEDURES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER LOSS. ALSO, IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED, FOR ANY REASON;...
  • Page 8 LYCOMING OPERATOR’S MANUAL IMPORTANT SAFETY NOTICE...
  • Page 9 LYCOMING OPERATOR’S MANUAL...
  • Page 10 This Page Intentionally Left Blank.
  • Page 11 LYCOMING OPERATOR’S MANUAL SECTION 1 DESCRIPTION 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...
  • Page 12 This Page Intentionally Left Blank.
  • Page 13 LYCOMING OPERATOR’S MANUAL SECTION 1 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS DESCRIPTION SECTION 1 DESCRIPTION Cylinders Valve Operating Mechanism – Crankcase – Crankshaft Connecting Rods Pistons Accessory Housing...
  • Page 14 SECTION 1 LYCOMING OPERATOR’S MANUAL DESCRIPTION TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS Oil Sump and Induction Assembly – Cooling System Induction System Turbocharger System NOTE The letter “L” in the model prefix denotes the reverse rotation of the basic model. Example –...
  • Page 15 LYCOMING OPERATOR’S MANUAL SECTION 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...
  • Page 16 This Page Intentionally Left Blank.
  • Page 17 LYCOMING OPERATOR’S MANUAL SECTION 2 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS SPECIFICATIONS SECTION 2 SPECIFICATIONS TIO-540-A1A, -A1B, -A2A, -A2B, -A2C TIO-540-F2BD TIO-540-J2B, -J2BD, -N2BD...
  • Page 18 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS SPECIFICATIONS (CONT.) TIO-540-R2AD* TIO-540-S1AD TIO-540-U2A...

  • Page 20: Tio-540-Aj1A

    SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS SPECIFICATIONS (CONT.) TIO-540-AJ1A 1. STANDARD ENGINE, DRY WEIGHT.
  • Page 21 LYCOMING OPERATOR’S MANUAL SECTION 2 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS SPECIFICATIONS 1. STANDARD ENGINE, DRY WEIGHT (CONT.)
  • Page 22 This Page Intentionally Left Blank.

  • Page 23: Table Of Contents

    LYCOMING OPERATOR’S MANUAL SECTION 3 OPERATING INSTRUCTIONS Page General................................3-1 Prestarting 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 ..........................
  • Page 24 This Page Intentionally Left Blank.

  • Page 25: General

    LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS SECTION 3 OPERATING INSTRUCTIONS 1. GENERAL. NOTE YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THE FRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIED FUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS.

  • Page 26: Cold Weather Starting

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS a. TIO-540 Series (Cold Engine). NOTE If engine fails to achieve a normal start, assume it to be flooded and use standard clearing procedure. Then repeat above procedure.

  • Page 27: Ground Check

    LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS a. Head the aircraft into the wind. b. Leave mixture in “Full Rich”. c. Operate the engine on the ground only with the propeller in minimum blade angle setting.

  • Page 28: Operating In Flight

    The procedures described in this manual provide proper fuel/air mixture when leaning Lycoming 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.

  • Page 29: Engine Flight Chart

    LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS (1) Best Economy Cruise – Lean to peak turbine inlet temperature (TIT) or 1650°F, whichever occurs first. (2) Maximum Power Cruise – The engine must always be operated on the rich side of peak TIT.
  • Page 30 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...

  • Page 31: Operating Conditions

    LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS OPERATING CONDITIONS...
  • Page 32 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING CONDITIONS (CONT.) *TIO-540-A1A, -A1B, -A2A, -A2B, -A2C *TIO-540-F2BD *TIO-540-J2B, -J2BD, -N2BD *TIO-540-R2AD...
  • Page 33 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS OPERATING CONDITIONS (CONT.) *TIO-540-S1AD *TIO-540-U2A *TIO-540-V2AD *TIO-540-W2A...

  • Page 34: Engine Shut-Down Procedure

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING CONDITIONS (CONT.) *TIO-540-AH1A *TIO-540-AJ1A e. Engine Shut-Down Procedure.
  • Page 35 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 36 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 37 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 38 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 39 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 40 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 41 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 42 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 43 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 44 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 45 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 46 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 47 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 48 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 49 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 50 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 51 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 52 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 53 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 54 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 55 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 56 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 57 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 58 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 59 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 60 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 61 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 62 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 63 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 64 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 65 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 66 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 67 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 68 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 69 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 70 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 71 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 72 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 73 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 74 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 75 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 76 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 77 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 78 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 82 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 83 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 84 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 85 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 86 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 87 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
  • Page 88 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 89 LYCOMING OPERATOR’S MANUAL SECTION 3 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS OPERATING INSTRUCTIONS...
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  • Page 91 LYCOMING OPERATOR’S MANUAL SECTION 4 PERIODIC INSPECTIONS Page General................................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 ............................
  • Page 92 This Page Intentionally Left Blank...
  • Page 93 LYCOMING OPERATOR’S MANUAL SECTION 4 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS PERIODIC INSPECTIONS SECTION 4 PERIODIC INSPECTIONS NOTE Perhaps no other factor is quite so important to safety and durability of the aircraft and its components as faithful and diligent attention to regular checks for minor troubles and prompt repair when they are made.
  • Page 94 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS 1. DAILY PRE-FLIGHT (ENGINE). 2. DAILY PRE-FLIGHT (TURBOCHARGER). 3. 10-HOUR INSPECTION (ENGINE). 4. 25-HOUR INSPECTION (ENGINE). NOTE If an engine does not have a full-flow oil filter, change oil every 25 hours; also, inspect oil pressure and suction screens for metal contamination, and clean thoroughly before reinstallation.
  • Page 95 LYCOMING OPERATOR’S MANUAL SECTION 4 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS PERIODIC INSPECTIONS a. Ignition System – b. Fuel and Induction System – c. Lubrication System – d. Exhaust System e. Cooling System f. Cylinders g. Turbocharger –...
  • Page 96 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS 6. 100-HOUR INSPECTION. a. Electrical System – b. Lubrication System – c. Magnetos NOTE Engines equipped with pressurized ignition system should be checked using the Bendix Model 11-10090 airflow tester as described in latest revision of Service Instruction No.
  • Page 97 LYCOMING OPERATOR’S MANUAL SECTION 4 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS PERIODIC INSPECTIONS CAUTION DO NOT OPERATE THE TURBOCHARGER IF LEAKS EXIST IN THE DUCTING, OR IF AIR CLEANER IS NOT FILTERING EFFICIENTLY. DUST LEAKING INTO AIR DUCTING CAN DAMAGE TURBOCHARGER AND ENGINE.
  • Page 98 This Page Intentionally Left Blank...
  • Page 99 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 .......................
  • Page 100 This Page Intentionally Left Blank...

  • Page 101: Ignition And Electrical System

    LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES SECTION 5 MAINTENANCE PROCEDURES 1. IGNITION AND ELECTRICAL SYSTEM. a. Ignition Harness and Wire Replacement – b. Timing Magneto to Engine – Single Magneto Dual Magnetos...
  • Page 102 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS WARNING DO NOT ATTACH HARNESS SPARK PLUG ENDS TO THE SPARK PLUGS UNTIL ALL MAGNETO-TO-ENGINE TIMING PROCEDURES MAGNETO-TO-SWITCH CONNECTIONS ARE ENTIRELY COMPLETED. NOTE Some timing lights operate in the reverse manner as described. The light comes on when the...
  • Page 103 LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES...
  • Page 104 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 105 LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES c. Internal Timing – Dual Magneto – Main Breakers – Retard Breaker –...

  • Page 106: Generator Or Alternator Output

    Fuel Grades and Limitations – 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 – e. Idle Speed and Mixture Adjustment –...

  • Page 107: Lubrication System

    LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES 3. LUBRICATION SYSTEM. a. Oil Grades and Limitations – b. Oil Suction and Oil Pressure Screens – NOTE On installations employing external oil filters, step 3, b is not practical at this time. But should be observed at the 100-hour inspection c.

  • Page 108: Crankcase

    SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS a. Removal of Cylinder Assembly – NOTE The hydraulic tappets, push rods, rocker arms and valves must be assembled in the same location from which they were removed.
  • Page 109 LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES d. Assembly of Hydraulic Tappet Plunger Assemblies – e. Assembly of Cylinder and Related Parts –...
  • Page 110 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS NOTE Before installing cylinder hold-down nuts, lubricate crankcase thru-stud threads with any one of the following lubricants, or combination of lubricants. 1. 90% SAE 50W engine oil and 10% STP.

  • Page 111: Turbocharger

    LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES NOTE Inserting a longer push rod will decrease the valve clearance. 5. TURBOCHARGER. a. Density Controller – EXAMPLE Operating at the stated conditions with a compressor discharge temperature of 120°F, the manifold pressure and compressor discharge pressure should be 38.6 in.
  • Page 112 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 113 LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES...
  • Page 114 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 115 LYCOMING OPERATOR’S MANUAL SECTION 5 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS MAINTENANCE PROCEDURES...
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  • Page 117 LYCOMING OPERATOR’S MANUAL SECTION 6 TROUBLE-SHOOTING – ENGINE Page Failure of Engine to Start..........................6-1 Failure of Engine to Idle Properly......................6-2 Low Power and Uneven Running....................... 6-2 Failure of Engine to Develop Full Power....................6-3 Rough Engine ............................... 6-3 Low Oil Pressure............................
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  • Page 119 LYCOMING OPERATOR’S MANUAL SECTION 6 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING 1. TROUBLE-SHOOTING – ENGINE.
  • Page 120 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 121 LYCOMING OPERATOR’S MANUAL SECTION 6 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TROUBLE-SHOOTING...
  • Page 122 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 123 LYCOMING OPERATOR’S MANUAL SECTION 6 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TROUBLE-SHOOTING 2. TROUBLE-SHOOTING – TURBOCHARGER.
  • Page 124 SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS NOTE Smoke would be normal if engine has idled for a prolonged period.
  • Page 125 LYCOMING OPERATOR’S MANUAL SECTION 6 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TROUBLE-SHOOTING...
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  • Page 127 LYCOMING OPERATOR’S MANUAL SECTION 7 INSTALLATION AND STORAGE 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...
  • Page 128 This Page Intentionally Left Blank...

  • Page 129: Crankshaft

    LYCOMING OPERATOR’S MANUAL SECTION 7 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS INSTALLATION AND STORAGE SECTION 7 INSTALLATION AND STORAGE 1. PREPARATION OF ENGINE FOR INSTALLATION. 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.
  • Page 130 NOTE Oils of the type mentioned are to be used in Lycoming aircraft engines for corrosion prevention only, and not for lubrication. See the latest revision of Lycoming Service Instruction No. 1014 and Service Bulletin No. 318 for recommended lubricating oil.
  • Page 131 LYCOMING OPERATOR’S MANAUL 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 LYCOMING OPERATOR’S MANUAL SECTION 8 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TABLES SECTION 8 TABLES...
  • Page 134 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS...
  • Page 135 LYCOMING OPERATOR’S MANUAL SECTION 8 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TABLES...
  • Page 136 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS FULL THROTTLE HP AT ALTITUDE (Normally Aspirated Engines TABLE OF SPEED EQUIVALENTS...
  • Page 137 LYCOMING OPERATOR’S MANUAL SECTION 8 TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS TABLES CENTIGRADE-FAHRENHEIT CONVERSION TABLE...
  • Page 138 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES TIO-540 SERIES – ANGLE VALVE CYLINDER HEADS INCH FRACTIONS CONVERSIONS Decimals, Area of Circles and Millimeters...

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