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Lycoming O-540 Series Operator's Manual

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Operator's Manual
Lycoming
O-540, IO-540 Series
Approved by FAA
th
4
Edition
Part No. 60297-10
June 2006
652 Oliver Street
Williamsport, PA. 17701 U.S.A.
570/323-6181

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  • Page 1 Operator’s Manual Lycoming O-540, IO-540 Series Approved by FAA Edition Part No. 60297-10 June 2006 652 Oliver Street Williamsport, PA. 17701 U.S.A. 570/323-6181...
  • Page 2 O-540, IO-540 Series Operator’s Manual Lycoming Part Number: 60297-10 ©2006 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 3 The page(s) in this revision replace, add to, or delete current pages in the operator’s manual. PREVIOUS REVISION CURRENT REVISION August 2006 March 2009 September 2008 3-7, 3-8; Added page 3-8A/B ©2009 by Lycoming “All Rights Reserved” Lycoming Engines, a division of AVCO Corporation, a wholly owned subsidiary of Textron Inc.

  • Page 5: Safety Warning

    Although the information contained in this manual is up-to-date at time of publication, users are urged to keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters which are available from all Lycoming distributors or from the factory by subscription. Consult the latest revision of Service Letter No. L114 for subscription information.

  • Page 6: Important Safety Notice

    It is also important to understand that these Warnings and Cautions are not all inclusive. Lycoming could not possibly know, evaluate or advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences that may be involved.

  • Page 7: Table Of Contents

    LYCOMING OPERATOR’S MANUAL TABLE OF CONTENTS Page SECTION 1 DESCRIPTION SECTION 2 SPECIFICATIONS SECTION 3 OPERATING INSTRUCTIONS SECTION 4 PERIODIC INSPECTIONS SECTION 5 MAINTENANCE PROCEDURES SECTION 6 TROUBLE-SHOOTING SECTION 7 INSTALLATION AND STORAGE SECTION 8 TABLES...
  • Page 8 LYCOMING OPERATOR’S MANUAL ¾ Right Front View – Typical IO-540-B ¾ Right Rear View – Typical IO-540-C...
  • Page 9 LYCOMING OPERATOR’S MANUAL WARNING THESE ENGINES ARE EQUIPPED WITH A DYNAMIC COUNTERWEIGHT 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 IS NOT HEEDED, THERE COULD BE SEVERE DAMAGE TO THE COUNTERWEIGHTS, ROLLER AND BUSHINGS.
  • Page 10 This Page Intentionally Left Blank.

  • Page 11: Section 1 Description

    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 ............................... 1-2 Oil Sump and Induction System......................... 1-2 Cooling System .............................
  • Page 12 This Page Intentionally Left Blank.
  • Page 13 LYCOMING OPERATOR’S MANUAL SECTION 1 O-540, IO-540 SERIES DESCRIPTION SECTION 1 DESCRIPTION The O-540 and IO-540 series are six cylinder, direct drive, horizontally opposed, air cooled engines. In referring to the location of the various engine components, the parts are described in their relationship to the engine as installed in the airframe.
  • Page 14 Lycoming IO-540 series engines are equipped with either a Bendix type RS or RSA fuel injector. The fuel injection system schedules fuel flow in proportion to air flow and fuel vaporization takes place at the intake ports.

  • Page 15: Specifications

    LYCOMING OPERATOR’S MANUAL SECTION 2 SPECIFICATIONS Page O-540-A, -B, -E, -G, -H Series........................2-1 O-540-F, -J, -L Series; IO-540-A, -B, -E, -G, -P Series................2-2 IO-540-C, -D, -J, -N, -R, -T, -V Series......................2-3 IO-540-K, -L, -M, -S, -W, -AA Series......................2-4 IO-540-AB, -AC, -AE Series ........................
  • Page 16 This Page Intentionally Left Blank.
  • Page 17 LYCOMING OPERATOR’S MANUAL SECTION 2 O-540, IO-540 SERIES SPECIFICATIONS SECTION 2 SPECIFICATIONS O-540-A* SERIES FAA Type Certificate ............................295 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 occurs, degrees BTC..........................25 Valve rocker clearance (hydraulic tappets collapsed) .................

  • Page 18: Section 2 Specifications

    SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-540, IO-540 SERIES SPECIFICATIONS (CONT.) O-540-J, -L SERIES FAA Type Certificate ............................295 Rated horsepower............................235 Rated speed RPM............................2400 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) .................
  • Page 19 LYCOMING OPERATOR’S MANUAL SECTION 2 O-540, IO-540 SERIES SPECIFICATIONS SPECIFICATIONS (CONT.) IO-540-D, -N, -R, -T*, -V SERIES FAA Type Certificate ........................... 1E4 Rated horsepower............................260 Rated speed RPM............................2700 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..........................25...
  • Page 20 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-540, IO-540 SERIES SPECIFICATIONS (CONT.) IO-540-K*, -L, -M, -S* SERIES FAA Type Certificate ........................... 1E4 Rated horsepower............................300 Rated speed RPM............................2700 Bore, inches..............................5.125 Stroke, inches..............................4.375 Displacement, cubic inches.........................541.5 Compression ratio ............................8.7:1 Firing order ............................1-4-5-2-3-6 Spark occurs, degrees BTC..........................20...
  • Page 21 LYCOMING OPERATOR’S MANUAL SECTION 2 O-540, IO-540 SERIES SPECIFICATIONS SPECIFICATIONS (CONT.) IO-540-AB SERIES FAA Type Certificate ........................... 1E4 Rated horsepower............................230 Rated speed RPM............................2400 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) ................
  • Page 22 SECTION 2 LYCOMING OPERATOR’S MANUAL SPECIFICATIONS O-540, IO-540 SERIES 1. STANDARD ENGINE, DRY WEIGHT MODEL LBS. O-540-L3C5D ............................387.00 O-540-J1A5D, -J2A5D, -J1B5D, -J2B5D ....................387.00 O-540-J3A5D, -J3C5D ..........................388.00 O-540-B1A5, -B2A5, -B4A5........................395.00 O-540-B1B5, -B2B5, -B4B5, -J3A5......................395.00 O-540-A2B, -B1D5...........................396.00 O-540-F1B5 ..............................400.00 O-540-B2C5, -E4A5 ..........................402.00 O-540-E4B5..............................403.00...

  • Page 23: Accessory Drives

    LYCOMING OPERATOR’S MANUAL SECTION 2 O-540, IO-540 SERIES SPECIFICATIONS 1. STANDARD ENGINE DRY WEIGHT (CONT.) MODEL LBS. IO-540-L1C5, -L1B5D ..........................471.00 IO-540-K1J5 .............................472.00 IO-540-K1D5, -K1F5 ..........................473.00 IO-540-S1A5.............................475.00 IO-540-AA1A5, -AA1B5 .........................479.00 1. ACCESSORY DRIVES *Accessory Drive Drive Ratio **Direction of Rotation Starter 16.556:1...
  • Page 24 This Page Intentionally Left Blank.

  • Page 25: Operating Instructions

    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 .............................. 3-2 Operating in Flight ............................3-4 Use of Carburetor Heat Control.........................
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  • Page 27: Prestarting Items Of Maintenance

    WARRANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTY PERIOD HAS PASSED. New engines have been carefully run-in by Lycoming and therefore, no further break-in is necessary insofar as operation is concerned; however, new or newly overhauled engines should be operated using only the lubricating oils recommended in the latest revision of Service Instruction No.

  • Page 28: Section 3 Operating Instructions

    SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES a. O-540 Series (1) Perform pre-flight inspection. (2) Set carburetor heat control in “cold” position. (3) Set propeller governor (if applicable) in “Full RPM” position. (4) Turn fuel valve to “on” position.

  • Page 29: Cold Weather Starting

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS (9) When engine starts, place magneto selector switch in “Both” position. (10) Move mixture control slowly and smoothly to “Full Rich”. (11) Check oil pressure gage for indicated pressure. If oil pressure is not indicated within thirty seconds, stop the engine and determine trouble.

  • Page 30: 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 31: General Rules

    Manual leaning may be monitored by exhaust gas temperature indication, fuel flow indication, and by observation of engine speed and/or airspeed. However, whatever instruments are used in leaning the mixture, the following general rules should be observed by the operator of Lycoming aircraft engines.
  • Page 32 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-1. 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...

  • Page 36: Operating Conditions

    165°F (73.8°C) and 200°F (93.3°C) in level flight cruise conditions. OPERATING CONDITIONS FUEL PRESSURE (PSI) MIN. MAX. IDLE MIN. O-540 Series (Except –L3C5D) ------ -L3C5D* ------ * - Above compressor outlet pressure. IO-540-AB1A5, -C1B5, -C1C5, -C4B5, -C4B5D, -C4D5, -C4D5D, -D4A5, -D4B5,...
  • Page 37 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES OPERATING CONDITIONS (CONT.) FUEL PRESSURE (PSI) MIN. MAX. IDLE MIN. IO-540-A1A5, -B1A5, -B1C5, -E1A5, -E1B5, -G1A5, -G1E5, -G1F5, -K1C5, -K1E5, -K1E5D Inlet to fuel injector ------ IO-540-AA1A5, -AA1B5 Inlet to fuel pump...

  • Page 38: Performance Curves

    LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS OPERATING CONDITIONS (CONT.) Fuel Max. *Max. Cons. Oil Cons. Cyl. Head Operation Gal/Hr. Qts./Hr. Temp. O-540-F Series Normal Rated 2800 ----- 0.78 500°F (260°C) Performance Cruise (75% Rated) 2800 15.0 0.58...
  • Page 39 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES OPERATING CONDITIONS (CONT.) Fuel Max. *Max. Cons. Oil Cons. Cyl. Head Operation Gal./Hr. Qts./Hr. Temp. IO-540-A, -B, -E, -G, -P Series Normal Rated 2575 ----- 0.97 500°F (260°C) Performance Cruise...
  • Page 40 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS OPERATING CONDIITONS (CONT.) Fuel Max. *Max. Cons. Oil Cons. Cyl. Head Operation Gal./Hr. Qts./Hr. Temp. IO-540-AA Series Normal Rated 2425 ----- 0.83 500°F (260°C) Performance Cruise (75% Rated) 2200 14.5 0.63...
  • Page 41 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-2. Part Throttle Fuel Consumption Curve – O-540-A 3-14...
  • Page 42 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-3. Sea Level Power Curve – O-540-A 3-15...
  • Page 43 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SEREIS Figure 3-4. Sea Level and Altitude Performance Curve – O-540-A 3-16...
  • Page 44 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-5. Part Throttle Fuel Consumption Curve – O-540-B 3-17...
  • Page 45 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-6. Sea Level Power Curve – O-540-B 3-18...
  • Page 46 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-7. Sea Level and Altitude Performance Curve – O-540-B 3-19...
  • Page 47 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-8. Part Throttle Fuel Consumption Curve – O-540-E, -G, -H 3-20...
  • Page 48 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-9. Sea Level and Altitude Performance Curve – O-540-E, -G, -H 3-21...
  • Page 49 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-10. Part Throttle Fuel Consumption Curve – O-540-F Series 3-22...
  • Page 50 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-11. Sea Level and Altitude Performance Curve – O-540-F Series 3-23...
  • Page 51 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-12. Sea Level and Altitude Performance Curve – O-540-J, -L 3-24...
  • Page 52 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-13. Part Throttle Fuel Consumption – IO-540-A, -B, -E, -G, -P 3-25...
  • Page 53 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-14. Sea Level and Altitude Performance Curve – IO-540-A, -G, -P 3-26...
  • Page 54 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-15. Sea Level and Altitude Performance Curve – IO-540-B, -E 3-27...
  • Page 55 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-16. Part Throttle Fuel Consumption Curve – IO-540-C 3-28...
  • Page 56 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-17. Sea Level and Altitude Performance Curve – IO-540-C 3-29...
  • Page 57 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-18. Part Throttle Fuel Consumption Curve – IO-540-D, -N, -R, -T, -V 3-30...
  • Page 58 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-19. Sea Level and Altitude Performance Curve – IO-540-D, -N, -R, -T, -V 3-31...
  • Page 59 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-20. Normally Aspirated Fuel Consumption Curve – IO-540-J 3-32...
  • Page 60 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-21. Sea Level and Altitude Performance Curve – IO-540-J 3-33...
  • Page 61 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-22. Part Throttle Fuel Consumption Curve – IO-540-K, -L, -M, -S 3-34...
  • Page 62 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-23. Sea Level and Altitude Performance Curve – IO-540-K, -L, -M, -S 3-35...
  • Page 63 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-24. Fuel Flow vs Percent Rated Power Curve – IO-540-W Series 3-36...
  • Page 64 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-25. Sea Level and Altitude Performance Curve – IO-540-W Series 3-37...
  • Page 65 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-26. Fuel Flow vs Percent Rated Power – IO-540-AA1A5 3-38...
  • Page 66 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-27. Sea Level and Altitude Performance Curve – IO-540-AA1A5 3-39...
  • Page 67 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-28. Sea Level and Altitude Performance Curve – IO-540-AB Series 3-40...
  • Page 68 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-29. Fuel Flow vs Percent Rated Power – IO-540-AC Series 3-41...
  • Page 69 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SERIES Figure 3-30. Sea Level and Altitude Performance Curve – IO-540-AC Series 3-42...
  • Page 70 LYCOMING OPERATOR’S MANUAL SECTION 3 O-540, IO-540 SERIES OPERATING INSTRUCTIONS Figure 3-30. Fuel Flow vs Percent Rated Power – IO-540-AE Series 3-43...
  • Page 71 SECTION 3 LYCOMING OPERATOR’S MANUAL OPERATING INSTRUCTIONS O-540, IO-540 SEIES Sea Level and Altitude Performance Curve – IO-540-AE Series 3-44...

  • Page 72: Section 4 Periodic Inspections

    LYCOMING OPERATOR’S MANUAL SECTION 4 PERIODIC INSPECTIONS 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 ............................4-2 100-Hour Inspection ............................ 4-3 400-Hour Inspection ............................ 4-4 Non-Scheduled Inspections ......................... 4-4...
  • Page 73 This Page Intentionally Left Blank...
  • Page 74 LYCOMING OPERATOR’S MANUAL SECTION 4 O-540, IO-540 SERIES 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 found.
  • Page 75 SECTION 4 LYCOMING OPERATOR’S MANUAL PERIODIC INSPECTIONS O-540, IO-540 SERIES 1. DAILY PRE-FLIGHT (ENGINE). a. Be sure all switches are in the “Off” position. b. Be sure magneto ground wires are connected. c. Check oil level. d. Check fuel level.
  • Page 76 LYCOMING OPERATOR’S MANUAL SECTION 4 O-540, IO-540 SERIES PERIODIC INSPECTIONS b. Fuel Line and Induction System – Check the primer lines for leaks and security of the clamps. Remove and clean the fuel inlet strainers. Check the mixture control and throttle linkage for travel, freedom of movement, security of the clamps and lubricate if necessary.
  • Page 77 7. NON-SCHEDULED INSPECTIONS. Occasionally, service bulletins or service instructions are issued by Lycoming that require inspection procedures that are not listed in this manual. Such publications, usually are limited to specified engine models and become obsolete after corrective modification has been accomplished.

  • Page 78: Section 5 Maintenance Procedures

    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........................5-1 Generator or Alternator Output ......................5-7 Fuel System Repair of Fuel Leaks..........................5-7 Carburetor or Fuel Injector Inlet Screen Assembly................5-7 Fuel Grades and Limitations ........................
  • Page 79 This Page Intentionally Left Blank...

  • Page 80: Ignition And Electrical System

    No attempt is made to include repair and replacement operations that will be found in the applicable Lycoming Overhaul Manual. 1. IGNITION AND ELECTRICAL SYSTEM.
  • Page 81 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-540, IO-540 SERIES Figure 5-1. Ignition Wiring Diagram Figure 5-2. Timing Marks – 6 Cylinder –1200 Series...
  • Page 82 LYCOMING OPERATOR’S MANUAL SECTION 5 O-540, IO-540 SERIES MAINTENANCE PROCEDURES 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. (7) To remove engine-to-magneto drive gear train backlash, turn engine magneto drive as far as possible in direction opposite to normal rotation;...
  • Page 83 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-540, IO-540 SERIES Figure 5-3. Ignition Wiring Diagram – Dual Magneto...
  • Page 84 LYCOMING OPERATOR’S MANUAL SECTION 5 O-540, IO-540 SERIES MAINTENANCE PROCEDURES 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 rotation until the compression stroke is reached; this is indicated by a positive pressure inside the cylinder tending to push the thumb off the spark plug hole.
  • Page 85 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-540, IO-540 SERIES (6) Attach a timing light to the magneto condenser stud according to the timing light manufacturer’s instructions. (7) Rotate the magneto assembly in the direction of rotor rotation until the timing light comes on. If the light is on initially, rotation of the magneto is not required.

  • Page 86: Fuel System

    LYCOMING OPERATOR’S MANUAL SECTION 5 O-540, IO-540 SERIES MAINTENANCE PROCEDURES NOTE Some timing lights operate in the reverse manner as described. The light comes on when the breaker points open. Check your timing light instructions. c. Generator or Alternator Output – Check the generator or alternator (whichever is applicable) to determine that the specified voltage and current are being obtained.

  • Page 87: Lubrication System

    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 foreign matter lodged between the ball and seat will result in faulty readings.
  • Page 88 LYCOMING OPERATOR’S MANUAL SECTION 5 O-540, IO-540 SERIES MAINTENANCE PROCEDURES NOTE Check applicable parts catalog for optional size/pressure capacity relief- valve springs. 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.
  • Page 89 MAINTENANCE PROCEDURES O-540, IO-540 SERIES (2) To remove the hydraulic tappet plunger assembly, use the special Lycoming service tool. In the event that the tool is not available, the hydraulic tappet plunger assembly may be removed by a hook in the end of a short piece of lockwire, inserting the wire so that the hook engages the spring of the plunger assembly.
  • Page 90 LYCOMING OPERATOR’S MANUAL SECTION 5 O-540, IO-540 SERIES MAINTENANCE PROCEDURES (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.
  • Page 91 SECTION 5 LYCOMING OPERATOR’S MANUAL MAINTENANCE PROCEDURES O-540, IO-540 SERIES CAUTION AFTER ALL CYLINDER BASE NUTS HAVE BEEN TIGHTENED, REMOVE ANY NICKS IN THE CYLINDER FINS BY FILING OR BURRING. (6) Install new shroud tube oil seals on both ends of shroud tube. Install shroud tube and lock in place as required for type of cylinder.

  • Page 93: Section 6 Trouble-Shooting

    LYCOMING OPERATOR’S MANUAL SECTION 6 TROUBLE-SHOOTING 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............................6-3 High Oil Temperature ..........................
  • Page 94 This Page Intentionally Left Blank...

  • Page 95: Troubleshooting (Engine)

    LYCOMING OPERATOR’S MANUAL SECTION 6 O-540, IO-540 SERIES TROUBLE-SHOOTING SECTION 6 TROUBLE-SHOOTING Experience has proven that the best method of trouble-shooting is to decide on the various causes of a given trouble and then to eliminate causes one by one, beginning with the most probable. The following charts list some of the more common troubles, which may be encountered in maintaining engines;...

  • Page 96: Failure Of Engine To Idle Properly

    SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-540, IO-540 SERIES TROUBLE PROBABLE CAUSE REMEDY Failure of Engine to Idle Incorrect idle mixture Adjust mixture. Properly Leak in induction system Tighten all connections in the induction system. Replace any parts that are defective.

  • Page 97: Low Power And Uneven Running

    LYCOMING OPERATOR’S MANUAL SECTION 6 O-540, IO-540 SERIES TROUBLE-SHOOTING TROUBLE PROBABLE CAUSE REMEDY Low Power and Uneven Running Defective ignition wire Check wire with electric tester. (Cont.) Replace defective wire. Defective spark plug terminal Replace connectors on spark plug connectors wire.

  • Page 98: High Oil Temperature

    SECTION 6 LYCOMING OPERATOR’S MANUAL TROUBLE-SHOOTING O-540, IO-540 SERIES TROUBLE PROBABLE CAUSE REMEDY Low Oil Pressure (Cont.) Leak in suction line or pressure Check gasket between accessory line housing and crankcase. High oil temperature See “High Oil Temperature” in “Trouble” column.

  • Page 99: Section 7 Installation And Storage

    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 ..........................7-1 Preparation of Carburetors and Fuel Injectors for Installation .............
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  • Page 101 LYCOMING OPERATOR’S MANUAL SECTION 7 O-540, IO-540 SERIES INSTALLATION AND STORAGE SECTION 7 INSTALLATION AND STORAGE 1. PREPARATION OF ENGINE FOR INSTALLATION. Before installing an engine that has been prepared for storage, remove all dehydrator plugs, bags of desiccant and preservative oil from the engine.
  • Page 102 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-540, IO-540 SERIES 2. PREPARATION OF CARBURETORS AND FUEL INJECTORS FOR INSTALLATION. Carburetors and fuel injectors that have been prepared for storage should undergo the following procedure before being placed in service.
  • Page 103 INSTALLATION AND STORAGE 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 104 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-540, IO-540 SERIES Figure 7-1. Installation Drawing – Left Side View – O-540 Series Figure 7-2. Installation Drawing – Rear View – O-540 Series...
  • Page 105 LYCOMING OPERATOR’S MANUAL SECTION 7 O-540, IO-540 SERIES INSTALLATION AND STORAGE Figure 7-3. Installation Drawing – Left Side View – IO-540-C, -D, -J, -N Figure 7-4. Installation Drawing – Rear View – IO-540-C, -D, -J, -N...
  • Page 106 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-540, IO-540 SERIES Figure 7-5. Installation Drawing – Left Side View – IO-540-B, -E Figure 7-6. Installation Drawing – Rear View – IO-540-B, -E...
  • Page 107 LYCOMING OPERATOR’S MANUAL SECTION 7 O-540, IO-540 SERIES INSTALLATION AND STORAGE Figure 7-7. Installation Drawing – Left Side View – IO-540-A, -G, -P, -S Figure 7-8. Installation Drawing – Rear View – IO-540-A, -G, -P, -S...
  • Page 108 SECTION 7 LYCOMING OPERATOR’S MANUAL INSTALLATION AND STORAGE O-540, IO-540 SERIES Figure 7-9. Installation Drawing – Left Side View – IO-540-K Figure 7-10. Installation Drawing – Rear View – IO-540-K...
  • Page 109 LYCOMING OPERATOR’S MANUAL SECTION 7 O-540, IO-540 SERIES INSTALLATION AND STORAGE Figure 7-11. Installation Drawing – Alternate Oil Line Connections, Magnetos and View of Carburetor – O-540 Series...
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  • Page 111: Section 8 Tables

    LYCOMING OPERATOR’S MANUAL 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 Table of Speed Equivalents ......................... 8-4 Centigrade-Fahrenheit Conversion......................8-5...
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  • Page 113: Torque Recommendations

    RECOMMENDATIONS INFORMATION CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED IN LYCOMING AIRCRAFT ENGINES, CONSULT THE LATEST REVISION OF SPECIAL SERVICE PUBLICATION NO. SSP-1776. CONSULT THE LATEST REVISION OF SERVICE INSTRUCTION NO. 1029 AND NO. 1150 FOR INFORMATION PERTINENT TO CORRECTLY INSTALLING...

  • Page 116: Full Throttle Hp At Altitude

    SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-540, IO-540 SERIES FULL THROTTLE HP AT ALTITUDE (Normally Aspirated Engines) Altitude % S.L. Altitude % S.L. Altitude % S.L. H.P. H.P. H.P. 10,000 70.8 19,500 49.1 98.5 11,000 68.3 20,000 48.0 1,000 96.8 12,000 65.8...

  • Page 117: Centigrade-Fahrenheit Conversion Table

    LYCOMNG OPERATOR’S MANUAL SECTION 8 O-540, IO-540 SERIES TABLES CENTIGRADE-FAHRENHEIT CONVERSION TABLE Example: To convert 20°C to Fahrenheit, find 20 in the center column headed (F-C); then read 68.0°F in the column (F) to the right. To convert 20°F to Centigrade; find 20 in the center column and read –6.67°F in the (C) column to the left.
  • Page 118 SECTION 8 LYCOMING OPERATOR’S MANUAL TABLES O-540, IO-540 SERIES INCH FRACTIONS CONVERSIONS Decimals, Area of Circles and Millimeters Inch Decimal Area Inch Decimal Area Fraction Equiv. Sq. In. Equiv. Fraction Equiv. Sq. In. Equiv. 1/64 .0156 .0002 .397 .1964 12.700 1/32 .0312...

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