tio-540-ae2a series - lycoming.com operator... · operator’s manual lycoming tio-540-ae2a series...

Operator’s Manual

Lycoming

TIO-540-AE2A Series

Approved by FAA

2nd Edition Part No. 60297-27

652 Oliver Street

November 2006Williamsport, PA. 17701 U.S.A.570/323-6181

deggle01

Rectangle

TIO-540-AE2A Series Operator’s ManualLycoming Part Number: 60297-27

©2006 by Lycoming. All rights reserved.Lycoming and “Powered by Lycoming” are trademarks or registered trademarks ofLycoming.

All brand and product names referenced in this publication are trademarks or registeredtrademarks of their respective companies.

For additional information:

Mailing address:

Lycoming Engines652 Oliver StreetWilliamsport, PA 17701 U.S.A.

Phone:

Factory: 570-323-6181Sales Department: 570-327-7268Fax: 570-327-7101

Lycoming’s regular business hours are Monday through Friday from 8:00 AMthrough 5:00 PM Eastern Time (-5 GMT)

Visit us on the World Wide Web at:http://www.lycoming.com

LYCOMING OPERATOR’S MANUAL

ATTENTION

OWNERS, OPERATORS AND MAINTENANCE PERSONNEL

This operator’s manual contains a description of the engine, its specifications, and detailed information onhow to operate and maintain it. Such maintenance procedures that may be required in conjunction withperiodic inspections are also included. This manual is intended for use by owners, pilots and maintenancepersonnel responsible for care of Lycoming powered aircraft. Modifications and repair procedures arecontained in Lycoming overhaul manuals; maintenance personnel should refer to these for such procedures.

SAFETY WARNING

Neglecting to follow the operating instructions and to carry out periodic maintenance procedures can resultin poor engine performance and power loss. Also, if power and speed limitations specified in this manualare exceeded, for any reason, damage to the engine and personal injury can happen. Consult your localFAA 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 tokeep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letterswhich are available from all Lycoming distributors or from the factory by subscription. Consult the latestrevision of Service Letter No. L114 for subscription information.

SPECIAL NOTE

The illustrations, pictures and drawings shown in this publication are typical of the subject matter theyportray; in no instance are they to be interpreted as examples of any specific engine, equipment or partthereof.

iii


IMPORTANT SAFETY NOTICE

Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. Theservice procedures recommended by Lycoming are effective methods for performing service operations.Some of these service operations require the use of tools specially designed for the task. These special toolsmust be used when and as recommended.

It is important to note that most Lycoming publications contain various Warnings and Cautions whichmust be carefully read in order to minimize the risk of personal injury or the use of improper servicemethods 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 couldnot possibly know, evaluate or advise the service trade of all conceivable ways in which service might bedone or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses aservice procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will bejeopardized by the service procedure they select.

Iv


TABLE OF CONTENTS

Page

SECTION 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

v


Left Side View – TIO-540-AE2A

WARNING

THIS ENGINE IS EQUIPPED WITH DYNAMIC COUNTERWEIGHTS. AVOID HIGHENGINE SPEEDS AND LOW MANIFOLD PRESSURES. OPERATE THE THROTTLESMOOTHLY; DO NOT OPEN AND CLOSE IT RAPIDLY. IF THIS WARNING IS NOTHEEDED, SEVERE DAMAGE COULD OCCUR TO THE COUNTERWEIGHTS, ROLLERSAND BUSHINGS.

vi


SECTION 1DESCRIPTION

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 ....................................................................................................................................... 1-2

Oil Sump and Induction Assembly............................................................................................................. 1-2

Lubrication System...................................................................................................................................... 1-2

Cooling System............................................................................................................................................. 1-2

Fuel Injection System .................................................................................................................................. 1-2

Turbocharger System .................................................................................................................................. 1-2

Ignition System............................................................................................................................................. 1-2

This Page Intentionally Left Blank.

LYCOMING OPERATOR’S MANUAL SECTION 1TIO-540-AE2A DESCRIPTION

SECTION 1

DESCRIPTION

The TIO-540-AE2A is a direct drive, six cylinder, fuel injected, horizontally opposed, turbocharged, air-cooled engine with down exhaust and two induction air coolers. This engine is supplied with an automotivetype starter and two (2) alternators. Drives for two (2) AN type accessories and a propeller governor aresupplied as standard equipment. A v-belt drive and mounting bracket are also supplied as standardequipment for mounting a Freon compressor.

In referring to the location of the various engine components, the parts are described in their relationshipto the engine as installed in the airframe. Thus the power take-off end is considered the front and theaccessory drive end the rear. The sump section is considered the bottom and the opposite side of the enginewhere the shroud tubes are located is the top. Reference to the left and right side is made with the observerfacing the rear of the engine. The cylinders are numbered from front to rear, odd numbers on the right, evennumbers on the left. The direction of rotation for accessory drives is determined with the observer facing thedrive pad.

Cylinders – The cylinders are of conventional air-cooled construction with the two major parts, head andbarrel, screwed and shrunk together. The heads are made from an aluminum alloy casting with a fullymachined combustion chamber. Rocker shaft bearing supports are integral with the head along withhousings to form the rocker boxes for both valve rockers. The cylinder barrels, which are machined fromchrome nickel molybdenum steel forgings, have deep integral cooling fins and the inside of the barrels areground and honed to a specified finish.

Baffles are provided to build up a pressure and force the air through the cylinder fins. The air is thenexhausted to the atmosphere through openings located at the rear of the cowling.

Valve Operating Mechanism – A conventional type camshaft is located above and parallel to the crankshaft.The camshaft actuates hydraulic tappets which operate the valves through push rods and valve rockers. Thevalve rockers are supported on full floating steel shafts. The valve springs bear against hardened steel seatsand are retained on the valve stems by means of split keys.

Crankcase – The crankcase assembly consists of two reinforced aluminum alloy castings, fastened togetherby means of studs, bolts, and nuts. The mating surfaces of the two castings are joined without the use of agasket, and the main bearing bores are machined for use by precision type main bearing inserts. Internalpiston cooling is provided by six nozzles, one for each piston, located in the crankcase.

Crankshaft – The crankshaft is made from a chrome nickel molybdenum steel forging. All bearing journalsurfaces are nitrided. Freedom from torsional vibration is assured by a system of pendulum-type dynamiccounterweights.

Connecting Rods – The connecting rods are made in the form of “H” sections from alloy steel forgings.They have replaceable bearing inserts in the crankshaft ends and bronze bushings in the piston ends. Thebearing caps on the crankshaft ends are retained by two bolts and nuts through each cap.

Pistons – The pistons are machined from an aluminum alloy forging. The piston pin is a full floating typewith a plug located in each end of the pin. The pistons are machined for three rings and may employ eitherhalf-wedge or full-wedge rings. Consult the latest revision of Service Instruction No. 1037 for proper pistonand ring combinations.

1-1

SECTION 1 LYCOMING OPERATOR’S MANUALDESCRIPTION TIO-540-AE2A

Accessory Housing – The accessory housing is made from an aluminum casting fastened to the rear of thecrankcase and the top rear of the sump. It forms a housing for the oil pump and the various accessory drives.

A thermometer well with a .4375-20 NF-3 thread is provided in the accessory housing for the installationof an MS28034-3 or equivalent standard type thermometer bulb for measurement of oil temperature.

Oil Sump and Induction Assembly – This assembly consists of the oil sump bolted to a mated covercontaining intake pipe extensions for the induction system. When bolted together they form a mounting padfor the air inlet housing. Fuel drain plugs are provided in the cover, and the sump incorporates oil drainplugs and an oil suction screen.

Lubrication System – A full flow oil filter, oil cooler, and thermostatic bypass valve are remote mounted.

Cooling System – This engine is designed to be cooled by air pressure actuated by the forward speed of theaircraft. Baffles are provided to build up pressure and force the air through the cylinder fins. The air is thenexhausted to the atmosphere through exits at the rear of the cowling.

Fuel Injection System – This engine is equipped with a Bendix servo regulator continuous flow type RSA-10ED1 fuel injector. This fuel injector meters fuel to the nozzles at each individual cylinder intake port inproportion to induction airflow. Manual mixture control and idle cutoff are provided.

The engine is equipped with a fuel pump as part of the fuel system. External fuel filter requirements are150 micron maximum.

Turbocharger System – This engine has two integrally mounted turbochargers, one on each side. Anautomatic control system monitors compressor outlet pressure from sea level to critical altitude byregulating the amount of exhaust gases fed to the turbine wheel.

The automatic control system comprises the variable pressure controller and the exhaust bypass valve, orwastegate. Exhaust gas flow to the turbine wheel is regulated by the wastegate, which is dependent on theoil pressure metered to it from the variable pressure controller.

An absolute pressure relief valve, installed at the fuel injector inlet, protects the engine from excessivesurges of manifold pressure.

Intercoolers, one for each turbocharger, cool the compressed air before it enters the fuel injector.

Two sonic nozzles are also incorporated in the turbocharger system to provide air for cabin pressurization.

Ignition System – This engine is equipped with two Slick pressurized magnetos. The left magneto has afixed retard and long duration boosted spark for starting. A DC power source and a starting vibrator arerequired for operation. The magnetos incorporate an integral, feed through capacitor. An engine equippedwith one retard breaker magneto must have the plain magneto grounded during the starting cycle.

It is recommended that the magneto manufacturer be contacted for information on the various vibrator andswitching arrangements available.

This engine is equipped with radio shielded, all weather, long reach spark plugs, in accordance with thelatest revision of Lycoming Service Instruction No. 1042.

An all weather shielded harness, braid on wire type, is part of the ignition system.

1-2


SECTION 2SPECIFICATIONS

Page

Basic Engine Specifications......................................................................................................................... 2-1

External Dimensions.................................................................................................................................... 2-1

Standard Engine Dry Weight ..................................................................................................................... 2-1

Accessory Drives .......................................................................................................................................... 2-1

LYCOMING OPERATOR’S MANUAL SECTION 2TIO-540-AE2A SPECIFICATIONS

SECTION 2

SPECIFICATIONS

FAA Type Certificate ..............................................................................................................................E14EARated horsepower...........................................................................................................................................350Rated speed RPM.........................................................................................................................................2500Bore, inches.................................................................................................................................................5.125Stroke, inches..............................................................................................................................................4.375Displacement cubic inches..........................................................................................................................541.5Compression ratio ....................................................................................................................................... 7.3:1Firing order .......................................................................................................................................1-4-5-2-3-6Spark occurs, degrees BTC............................................................................................................................20°Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080Prop. Drive Ratio ........................................................................................................................................... 1:1Prop. Drive Rotation ...........................................................................................................................Clockwise

External Dimensions (inches):

Height.......................................................................................................................................................27.75Length ......................................................................................................................................................46.52Width........................................................................................................................................................42.02

Standard Engine, Dry Weight ......................................................................................................595 lbs. (±2%)

Accessory Drive Drive Ratio Direction of Rotation

Starter 16.556:1 CounterclockwiseAlternator (2) 3.800:1 ClockwiseTachometer*Propeller Governor .947:1 ClockwiseMagneto Drives 1.500:1 ClockwiseFuel Pump – AN 1.000:1 CounterclockwiseFreon Compressor Drive 1.462:1 ClockwiseAccessory Drive #1 1.300:1 CounterclockwiseAccessory Drive #2 1.385:1 Clockwise

* - The tachometer is an electronically operated component supplied by the airframe manufacturer.

2-1


SECTION 3OPERATING 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 ...................................................................................................................................... 3-4

Leaning Procedure.................................................................................................................................... 3-4

Engine Flight Chart .................................................................................................................................. 3-6

Operating Conditions ............................................................................................................................... 3-6

Engine Shut-Down Procedure .................................................................................................................... 3-7

Performance Curves .................................................................................................................................... 3-8

LYCOMING OPERATOR’S MANUAL SECTION 3TIO-540-AE2A OPERATING INSTRUCTIONS

SECTION 3

OPERATING INSTRUCTIONS

1. General. Close adherence to these instructions will greatly contribute to long life, economy andsatisfactory operation of the engine.

NOTE

YOUR ATTENTION IS DIRECTED TO THE WARRANTIES THAT APPEAR IN THEFRONT OF THIS MANUAL REGARDING ENGINE SPEED, THE USE OF SPECIFIEDFUELS AND LUBRICANTS, REPAIRS AND ALTERATIONS. PERHAPS NO OTHER ITEMOF ENGINE OPERATION AND MAINTENANCE CONTRIBUTES QUITE SO MUCH TOSATISFACTORY PERFORMANCE AND LONG LIFE AS THE CONSTANT USE OFCORRECT GRADES OF FUEL AND OIL, CORRECT ENGINE TIMING, AND FLYINGTHE AIRCRAFT AT ALL TIMES WITHIN THE SPEED AND POWER RANGE SPECIFIEDFOR THE ENGINE. DO NOT FORGET THAT VIOLATION OF THE OPERATION ANDMAINTENANCE SPECIFICATIONS FOR YOUR ENGINE WILL NOT ONLY VOID YOURWARRANTY BUT WILL SHORTEN THE LIFE OF YOUR ENGINE AFTER ITS WARRANTYPERIOD HAS PASSED.

New engines have been carefully run-in by Lycoming; therefore, no further break-in is necessary insofaras operation is concerned. New or newly overhauled engines should be operated using only the lubricatingoils 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 oroil consumption has stabilized. This is to insure proper seating of the rings and is applicableto new engines, and engines in service following cylinder replacement or top overhaul of oneor more cylinders.

The minimum fuel octane rating is listed in the Flight Chart, Part 8 of this section. Under nocircumstances should fuel of a lower octane rating or automotive fuel (regardless of octane rating) be used.

2. PRESTARTING ITEMS OF MAINTENANCE. Before starting the aircraft engine for the first flight of theday, there are several items of maintenance inspection that should be performed. These are described inSection 4 under Daily Pre-Flight inspection. They must be observed before the engine is started.

3. STARTING PROCEDURES.

The following starting procedures are recommended; however, the starting characteristics of variousinstallations will necessitate some variation from these procedures.

NOTE

Cranking periods should be limited to ten (10) to twelve (12) seconds with five (5) minutesrest between cranking periods.

3-1

SECTION 3 LYCOMING OPERATOR’S MANUALOPERATING INSTRUCTIONS TIO-540-AE2A

a. Cold Engine.

(1) Perform pre-flight inspection.

(2) Set propeller governor in “Full RPM”.

(3) Turn fuel valve to “on” position.

(4) Open throttle approximately ¼ travel.

(5) Turn boost pump on and move mixture control to “Full Rich” position until a slight but steadyflow is indicated.

(6) Return mixture control to “Idle Cut-Off” position.

(7) Set magneto, selector switch. Consult airframe manufacturer’s handbook for correct position.

(8) Engage starter.

(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 thirtyseconds, stop the engine and determine trouble.

NOTE

If engine fails to achieve a normal start, assume it to be flooded. Use standard clearingprocedure of cranking engine over with throttle wide open and ignition off.

b. Hot Engine – Because fuel percolates, the system must be cleared of vapor; it is recommended that thesame procedure, as outlined above, be used for starting a hot engine.

4. COLD WEATHER STARTING. During extreme cold weather, it may be necessary to preheat the engineand oil before starting.

5. GROUND RUNNING AND WARM-UP. Subject engines are air pressure cooled and depend on theforward movement of the aircraft to maintain proper cooling. Particular care is necessary, therefore, whenoperating these engines on the ground. To prevent overheating, it is recommended that the followingprecautions be observed.

NOTE

Any ground check that requires full throttle operation must be limited to three minutes or lessif indicated cylinder head temperature should exceed the maximum stated in this manual.

3-2


a. Head the aircraft into the wind.

b. Leave the mixture in “Full Rich”.

c. Operate the engine on the ground only with the propeller in minimum blade angle setting.

d. Warm up at approximately 1000-1200 RPM. Avoid prolonged idling and do not exceed 2200 RPM onthe ground.

e. Engine is warm enough for take-off when the throttle can be opened without the engine faltering. Ifindicated lubricating oil pressure is above maximum due to cold temperature, do not take off with aturbocharged engine. Excessive oil pressure can cause over boost and consequent engine damage.

6. GROUND CHECK.

a. Warm up as directed above.

b. Check that both oil pressure and oil temperature are within prescribed limits.

c. Leave mixture in “Full Rich”.

d. Move the propeller control through its complete range to check operation and return to full low pitchposition. Full feathering check on the ground is not recommended but the feathering action can bechecked by running the engine between 1000-1500 RPM; then momentarily pulling the propellercontrol into the feathering position. Do not allow the RPM to drop more than 500 RPM.

e. A proper magneto check is important. Additional factors, other than the ignition system, affectmagneto drop-off. They are load-power output, propeller pitch and mixture strength. The importantthing is that the engine runs smoothly because magneto drop-off is affected by the variables listedabove. Make the magneto check in accordance with the following procedures.

(1) With propeller in minimum pitch angle, set the engine to produce 50-65% power as indicated bythe manifold pressure gage unless specified in the aircraft manufacturer’s manual. Set the mixturecontrol to the full rich position. At these settings, the ignition system and spark plugs must workharder because of the greater pressure within the cylinders. Therefore, any weakness in theignition system will be more apparent. Magneto checks at low power settings will only indicatefuel-air distribution quality.

(2) Switch from both magnetos to one and note drop-off, return to both until engine regains speed andswitch to the other magneto and note drop-off, then return to both. Drop-off must not exceed 175RPM and must not exceed 50 RPM between magnetos. A smooth drop-off past the normalspecification of 175 RPM is usually a sign of a too lean or too rich mixture.

(3) If the RPM drop exceeds 175 RPM, slowly lean the mixture until the RPM peaks. Then return thethrottle to the RPM specified in step e. (1) for the magneto check and repeat the check. If the drop-off does not exceed 175 RPM, the difference between the magnetos does not exceed 50 RPM, andthe engine is running smoothly, then the ignition system is operating properly. Return the mixtureto full rich.

3-3


f. Do not operate on a single magneto for too long a period; a few seconds is usually sufficient to checkdrop-off and will minimize plug fouling.

7. OPERATING IN FLIGHT.

a. Subject engines are equipped with a dynamic counterweight system and must be operated accordingly.Use a smooth, steady movement (avoid rapid opening and closing) of the throttle.

b. See airframe manufacturer’s instructions for recommended power settings.

c. Fuel Mixture Leaning Procedure.

Improper fuel/air mixture during flight is responsible for many engine problems, particularly duringtake-off and climb power settings. The procedures described in this manual provide proper fuel/airmixture when leaning Lycoming engines; they have proven to be both economical and practical byeliminating excessive fuel consumption and reducing damaged parts replacement. It is thereforerecommended that operators of all Lycoming aircraft power plants, utilize the instructions in thispublication any time the fuel/air mixture is adjusted during flight.

Manual leaning may be monitored by exhaust gas temperature indication, fuel flow indication, andby observation of engine speed and/or air speed. However, whatever instruments are used in leaningthe mixture, the following general rules need to be observed by the operator of Lycoming aircraftengines.

GENERAL RULES

Never exceed the maximum red line cylinder head temperature limits of 500°F (260°C).

All take-offs are to be made with the mixture controls in the full rich position regardless of field elevation.Turbocharging permits the engine to develop rated power regardless of field elevation. However, it may benecessary to manually lean the engine for ground operation at idle or off idle engine speeds.

Leaning during climb, usually 85% of rated power, is permitted only to the limits described in the aircraftoperator’s handbook. Engine temperature instruments must be monitored and temperatures must bemaintained within the prescribed limits.

During let-down flight operations it may be necessary to manually lean engine to obtain smoothoperation.

On turbocharged engines never exceed 1750°F turbine inlet temperature (TIT).

A. Leaning to Turbine Inlet Temperature or Exhaust Gas Temperature Gage.

1. Best Economy Cruise – Lean to peak turbine inlet temperature (TIT) or 1750°F, whichever occursfirst.

2. Maximum Power Cruise – The engine must always be operated on the rich side of peak TIT. Beforeleaning to obtain maximum power mixture it is necessary to establish a reference point. This isaccomplished as follows:

3-4


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+

3-5


(a) Establish a peak TIT for best economy operation at the highest economy cruise power withoutexceeding 1750°F. This is the same value previously determined in step A(1).

(b) Deduct 125°F from this temperature and thus establish the temperature reference point for usewhen operating at maximum power mixture.

(c) Return mixture control to full rich and adjust the RPM and manifold pressure for desiredperformance cruise operation.

(d) Lean out mixture until TIT is the value established in Step b. This sets the mixture at bestpower.

B. Leaning to Flowmeter.

Lean to applicable fuel flow tables or lean to indicator marked for correct fuel flow for each powersetting.

8. ENGINE FLIGHT CHART.

Fuel ................................................................................100/100LL octane, minimum (*Aviation Grade Fuel)

* - Refer to latest revision of Service Instruction No. 1070.

*Recommended Grade OilMIL-L-22851

Average Ambient MIL-L-6082B Ashless DispersantTemperature SAE Grade SAE Grades

All Temperatures --- 15W-50 or 20W-50Above 80°F 60 60Above 60°F 50 40 or 5030°F to 90°F 40 40

0°F to 70°F 30 30, 40 or 20W-40Below 10°F 20 30 or 20W-30

* - Refer to latest revision of Service Instruction No. 1014.

Oil Sump Capacity......................................................................................................... 12 U.S. Qts. Maximum

OPERATING CONDITIONS

Average *Oil Inlet TemperatureAmbient Air Desired Maximum

Above 60°F 180°F (82°C) 245°F (118°C)30°F to 90°F 180°F (82°C) 245°F (118°C)

0°F to 70°F 170°F (77°C) 245°F (118°C)Below 10°F 160°F (71°C) 245°F (118°C)

* - Engine oil temperature should not be below 140°F (60°C) during continuous operation.

3-6


OPERATING CONDITIONS (CONT.)

Oil Pressure, psi Maximum Minimum Idling Start and Warm-Up(Normal Operation)

95 55 25 115

Fuel Pressure, psi MIN. MAX IDLE MIN.

Inlet to fuel pump -2 65Inlet to fuel injector 29 65 12

Fuel Max. *Max.Cons. Oil Cons. Cyl. Head

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

Normal Rated 2500 350 38.5 1.16 500°F (260°C)Performance Cruise

(75% Rated) 2400 260 22.0 0.86 500°F (260°C)Economy Cruise

(60% Rated) 2200 210 15.0 0.70 500°F (260°C)

* - Maximum permissible cylinder head temperature, as measured with a bayonet type AN5541thermocouple. For maximum engine life the cylinder head temperature should not exceed 475°F above85% power, and 435°F at 85% power and below in level flight cruise conditions.

Fuel Injector Air Inlet Temperature.............................................................................................400°F (204°C)

Maximum Turbine Inlet Temperature .......................................................................................1750°F (953°C)

Engine Restart: Engine restarts should not be attempted above 23,000 feet.

9. ENGINE SHUT-DOWN PROCEDURE.

a. Set propeller at minimum blade angle.

b. Idle until there is a decided decrease in cylinder head temperature.

c. Increase throttle to 1000 RPM. Maintain speed for approximately 20-30 seconds to insure adequatescavenging of turbocharger oil system.

d. Move mixture control to “Idle Cut-Off”.

e. When engine stops, turn ignition switch off.

3-7


Figure 3-2. Maximum Manifold Pressure vs. Altitude

3-8


Figure 3-3. Fuel Flow vs Percent Rated Power

3-9


USING CURVE TO FIND ACTUAL HORSEPOWER

The Sea Level and Altitude Performance Curves, Figures 3-4 through 3-6 are used todetermine actual horsepower delivered by the engine for a given altitude, RPM, manifoldpressure, and inlet air temperature.

STANDARD ALTITUDE TEMPERATURES IN DEGREES F

PRESSURE ALTITUDE(Thousands)

STANDARD ALTITUDE(Temperature °F)

SL24681012141618202224

5952453831231692-5

-12-19-27

Correct power approximately 1% for each 10° variation in air inlet temperature fromstandard altitude temperature. Add correction for temperature below standard; subtractcorrection for temperatures above standard.

3-10


Figure 3-4. Sea Level/Altitude Performance Curve –(Sheet 1 of 3)

3-11



3-12



3-13


SECTION 4PERIODIC INSPECTIONS

Page

General.......................................................................................................................................................... 4-1

Pre-Starting Inspection ............................................................................................................................... 4-1

Daily Pre-Flight – Engine............................................................................................................................ 4-2

Daily Pre-Flight – Turbochargers .............................................................................................................. 4-2

25-Hour Inspection – Engine ...................................................................................................................... 4-2

50-Hour Inspection – Engine ...................................................................................................................... 4-2

100-Hour Inspection .................................................................................................................................... 4-3

400-Hour Inspection .................................................................................................................................... 4-4

Non-Scheduled Inspections ......................................................................................................................... 4-5

LYCOMING OPERATOR’S MANUAL SECTION 4TIO-540-AE2A PERIODIC INSPECTIONS

SECTION 4

PERIODIC INSPECTIONS

NOTE

Perhaps no other factor is quite so important to safety and durability of the aircraft and itscomponents as faithful and diligent attention to regular checks for minor troubles andprompt repair when they are found.

The operator should bear in mind that the items listed in the following pages does not constitute acomplete aircraft inspection, but are meant for the engine only. Consult the airframe manufacturer’shandbook for additional instructions.

Pre-Starting Inspection – The daily pre-flight inspection is a check of the aircraft prior to the first flight ofthe 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 prove severalhundred accidents occur yearly directly responsible to poor pre-flight inspections.

Among the major causes of poor pre-flight inspection are lack of concentration, reluctance toacknowledge the need for a check list, carelessness bread by familiarity and haste.

4-1

SECTION 4 LYCOMING OPERATOR’S MANUALPERIODIC INSPECTIONS TIO-540-AE2A

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. See that fuel tanks are full.

e. Check fuel and oil line connections, note minor indications for repair at 50-hour inspection. Repairany leaks before aircraft is flown.

f. Open the fuel drain to remove any accumulation of water and sediment.

g. Make sure all shields and cowling are in place and secure. If any are missing or damaged, repair orreplacement should be made before the aircraft is flown.

h. Check controls for general condition, travel, and freedom of operation.

i. Induction system air filter should be inspected and serviced in accordance with the airframemanufacturer’s recommendations.

2. DAILY PRE-FLIGHT (TURBOCHARGERS).

a. Inspect mounting and connections of turbochargers for security, oil leakage and air or exhaust gasleakage.

b. Check engine crankcase breather for restrictions to breather.

3. 25-HOUR INSPECTION (ENGINE). After twenty-five (25) hours of operating time since the firstinspection, new, rebuilt or newly overhauled engines should undergo a 50-hour inspection includingdraining and renewing lubricating oil.

4. 50-HOUR INSPECTION (ENGINE). In addition to the items listed for daily pre-flight inspection, thefollowing maintenance checks should be made after every 50 hours of operation.

a. Ignition System –

(1) If fouling of spark plugs has been apparent, rotate bottom plugs to upper position.

(2) Examine spark plug leads of cable and ceramics for corrosion and deposits. This condition isevidence of either leaking spark plugs, improper cleaning of the spark plug walls or connectorends. Where this condition is found, clean the cable ends, spark plug walls and ceramics with adry, clean cloth or a clean cloth moistened with methyl-ethyl-ketone. All parts should be clean anddry before reassembly.

(3) Check ignition harness for security of mounting clamps and be sure connections are tight at sparkplug and magneto terminals.

4-2


b. Fuel and Induction System – Remove and clean the fuel inlet strainers. Check the mixture control andthrottle linkage for travel, freedom of movement, security of the clamps and lubricate if necessary.Check the air intake ducts for leaks, security, filter damage; evidence of dust or other solid material inthe ducts is indicative of inadequate filter care or damaged filter. Check vent lines for evidence of fuelor oil seepage; if present, fuel pump may require replacement.

c. Lubrication System –

(1) Check oil lines for leaks, particularly at connections; for security of anchorage and for wear due torubbing or vibration, for dents and cracks.

(2) Replace elements on external full flow oil filters. Before disposing of used element check interiorfolds for traces of metal particles that might be evidence of internal engine damage. Drain andrenew lubricating oil.

d. Exhaust System – Check attaching flanges at exhaust ports on cylinders for evidence of leakage. Ifthey are loose, they must be removed and machined flat before they are reassembled and tightened.Examine exhaust manifolds for general condition.

e. Cooling System – Check cowling and baffles for damage and secure anchorage. Any damaged ormissing part of the cooling system must be repaired or replaced before the aircraft resumes operation.

f. Cylinders – Check rocker box covers for evidence of oil leaks. If found, replace gasket and tightenscrews to specified torque (50 in.-lbs.).

Check cylinders for evidence of excessive heat which is indicated by burned paint on the cylinder.This condition is indicative of internal damage to the cylinder and, if found, its cause must bedetermined and corrected before the aircraft resumes operation.

Heavy discoloration and appearance of seepage at cylinder head and barrel attachment area isusually due to emission of thread lubricant used during assembly of the barrel at the factory, or byslight gas leakage which stops after the cylinder has been in service for awhile. This condition isneither harmful nor detrimental to engine performance and operation. If it can be proven that leakageexceeds these conditions, the cylinder should be replaced.

g. Turbochargers – All fluid power lines and mounting brackets incorporated in turbocharger systemshould be checked for leaks, tightness and any damage that may cause a restriction.

Check for accumulation of dirt or other interference with the linkage between the bypass valve andthe actuator which may impair operation of turbocharger. Clean or correct cause for interference.

The vent line from the actuator should be checked for oil leakage. Any constant oil leakage is causefor replacement of piston seal.

Check alternate air valve to be sure it swings free and seals tightly.

5. 100-HOUR INSPECTION. In addition to the items listed for daily pre-flight and 50-hour inspection, thefollowing maintenance checks should be made after every one hundred hours of operation.

a. Electrical System –

4-3

SECTION 4 LYCOMING OPERATOR’S MANUALPERIODIC INSPECTIONS TIO-540-AE2A

(1) Check all wiring connected to the engine or accessories. Any shielded cables that are damagedshould be replaced. Replace clamps or loose wires and check terminals for security andcleanliness.

(2) Remove spark plugs; test, clean and regap. Replace if necessary.

b. Lubrication System – Drain and renew lubricating oil.

c. Magnetos – Check breaker points for pitting and minimum gap. Check for excessive oil in the breakercompartment, if found, wipe dry with a clean lintless cloth. The felt located at the breaker pointsshould be lubricated in accordance with the magneto manufacturer’s instructions. Check magneto toengine timing. Timing procedure is described in Section 5, 1, b of this manual.

NOTE

The pressurized ignition system should be checked using the Bendix model 11-10090 airflowtester as described in latest revision of Service Instruction No. 1308.

d. Engine Accessories – Engine mounted accessories such as pumps, temperature and pressure sensingunits should be checked for secure mounting, tight connections.

e. Cylinders – Check cylinders visually for cracked or broken fins.

f. Engine Mounts – Check engine mounting bolts and bushings for security and excessive wear. Replaceany bushings that are excessively worn.

g. Fuel Injector Nozzles and Lines – Check fuel injector nozzles for looseness. Tighten to 60 in.-lbs.torque. Check fuel line for dye stains at connections (indicating leakage) and security of lines. Repairor replacement must be accomplished before aircraft resumes operation.

h. Turbochargers – Inspect all air ducting and connections in turbocharger system for leaks. Makeinspection both with engine shut down and with engine running. Check at manifold connections toturbine inlet and at engine exhaust manifold gasket, for possible air leakage.

CAUTION

DUST LEAKING INTO AIR DUCTING CAN DAMAGE TURBOCHARGER AND ENGINE.

Check for dirt or dust build-up within the turbochargers. Check for uneven deposits on theimpellers. Consult AiResearch Industrial Div. Manual TP-21 for method to remove all such foreignmatter.

Check the condition of the flexible hoses in the turbocharger system. Stiffness of the hose isindicative of deterioration and if this condition is noted the hose should be replaced before furtherflight.

6. 400-HOUR INSPECTION. In addition to the items listed for daily pre-flight, 50-hour and 100-hourinspections, the following maintenance check should be made after every 400 hours of operation.

4-4


Valve Inspection – Remove rocker box covers and check for freedom of valve rockers when valves areclosed. 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 beremoved (including the piston and connecting rod assembly) and inspected for further damage. Replace anyparts that do not conform with limits shown in the latest revision of Special Service Publication No. SSP-1776.

7. NON-SCHEDULED INSPECTIONS. Occasionally, service bulletins, or service instructions are issued byLycoming that require inspection procedures that are not listed in this manual. Such publications, usuallyare limited to specified engine models and become obsolete after correction modification has beenaccomplished. All such publications are available from Lycoming distributors, or from the factory bysubscription. Consult the latest revision of Service Letter No. L114 for subscription information.Maintenance facilities should have an up-to-date file of these publications available at all times.

4-5


SECTION 5MAINTENANCE PROCEDURES

Page

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

Ignition and Electrical System

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

Timing Magnetos to Engine ..................................................................................................................... 5-1

Fuel System

Repair of Fuel Leaks................................................................................................................................. 5-4

Fuel Injector Inlet Screen Assembly ....................................................................................................... 5-4

Fuel Grades and Limitations ................................................................................................................... 5-4

Air Intake Ducts and Filter...................................................................................................................... 5-4

Lubrication System

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

Oil Suction Screen..................................................................................................................................... 5-5

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

Cylinders

Removal of Cylinder Assembly................................................................................................................ 5-5

Removal of Piston from Connecting Rod ............................................................................................... 5-6

Removal of Hydraulic Tappet Sockets and Plunger Assemblies.......................................................... 5-6

Assembly of Hydraulic Tappet Plunger Assemblies.............................................................................. 5-6

Assembly of Cylinder and Related Parts ................................................................................................ 5-6

Turbocharger ............................................................................................................................................... 5-8

Alternator and Compressor Belt Tension.................................................................................................. 5-8

LYCOMING OPERATOR’S MANUAL SECTION 5TIO-540-AE2A MAINTENANCE PROCEDURES

SECTION 5

MAINTENANCE PROCEDURES

The procedures described in this section are provided to guide and instruct personnel in performing suchmaintenance operations that may be required in conjunction with the periodic inspections listed in thepreceding section. No attempt is made to include repair and replacement operations that will be found in theapplicable Lycoming Overhaul Manual.

1. IGNITION AND ELECTRICAL SYSTEM.

a. Ignition Harness and Wire Replacement – In the event that an ignition harness or an individual lead isto be replaced, consult the wiring diagram to be sure harness is correctly installed. Mark location ofclamps and clips to be certain the replacement is clamped at correct locations.

b. Timing Magnetos to Engine –

(1) Remove a spark plug from No. 1 cylinder and place a thumb over the spark plug hole. Rotate thecrankshaft in direction of normal rotation until the compression stroke is reached; this is indicatedby a positive pressure inside the cylinder tending to push the thumb off the spark plug hole.Continue rotating the crankshaft until the advance timing mark on the front face of the starter ringgear is in alignment with the small hole located at the two o’clock position on the front face of thestarter housing. (Ring gear is marked at 20°.) At this point, the engine is ready for assembly of themagnetos.

(2) Remove the ignition harness from the left (retard breaker) magneto, if installed. Insert the Slick T-118 timing pin in the hole marked “L” on the face of the distributor block. Apply a slight inwardpressure to the pin and slowly rotate the magneto drive shaft clockwise until the shoulder of thepin seats against the distributor block. When properly engaged, the timing pin will be inserted 7/8inch into the distributor block.

NOTE

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

CAUTION

DO NOT ROTATE THE MAGNETO ROTOR SHAFT WITH THE TIMING PIN INSERTEDINTO THE DISTRIBUTOR BLOCK. THIS COULD DAMAGE THE INTERNALCOMPONENTS OF THE MAGNETO.

5-1

SECTION 5 LYCOMING OPERATOR’S MANUALMAINTENANCE PROCEDURES TIO-540-AE2A

Figure 5-1. Ignition Wiring Diagram

(3) Inspect the left magneto accessory housing mounting pad to ensure the magneto drive dampers,adapter, and gaskets are there and installed properly. Position the magneto on its side with the topof the magneto located outboard away from the accessory housing vertical centerline. Install themagneto onto the mounting pad. Be sure the drive dampers remain in place when the magnetodrive is inserted into the drive gear. Secure the magneto to the accessory housing with the properclamps, washers, and nuts. Tighten nuts only finger tight.

CAUTION

DO NOT ROTATE THE MAGNETO OR ENGINE WITH THE TIMING PIN INSERTEDINTO THE MAGNETO DISTRIBUTOR BLOCK. THIS COULD CAUSE DAMAGE TO THEINTERNAL COMPONENTS OF THE MAGNETO.

(4) Remove the timing pin from the distributor block.

(5) Repeat steps (2), (3), (4) for the right (plain) magneto.

5-2


WARNING

DO NOT ATTACH HARNESS SPARK PLUG ENDS TO THE SPARK PLUGS UNTIL ALLMAGNETO-TO-ENGINE TIMING PROCEDURES AND MAGNETO-TO-SWITCHCONNECTIONS ARE ENTIRELY COMPLETED.

(6) Attach a timing light to the magneto condenser stud according to the timing light manufacturer’sinstructions.

(7) Rotate the magneto assembly in the direction of rotor rotation until the timing light comes on. Ifthe light is on initially, rotation of the magneto is not required. This indicates the breaker pointsare closed.

(8) Slowly rotate the magneto assembly in the opposite direction until the light goes out or the breakerpoints open.

(9) Alternately tighten the magneto mounting nut clamps to 8 ft.-lbs. torque. Continue to tighten bothnuts alternately, in several steps, to 17 ft.-lbs. torque.

(10) Repeat steps (6) thru (9) for the second magneto.

(11) Rotate the engine approximately 10° opposite to the normal rotational direction. The timing lightsshould light. Slowly (bump) rotate the engine in the normal direction until the timing lights go out.Both lights should go out within ± 1° of the 20° timing mark on ring gear with the dot on thestarter housing as referenced in step (1).

(12) Repeat steps (6) thru (10) until the condition described in step (11) is satisfied.

(13) If magneto position (± 15° from the mounting pad horizontal centerline allowed) interference isencountered, which is unlikely, the magneto must be removed and the drive gear in the accessoryhousing repositioned. Care must be taken not to drop the dampers into the engine during therepositioning of the drive gear.

(14) Remove timing light leads from the magnetos.

(15) Attach the appropriate switch or P-Leads to the condenser terminal of each magneto using a lockwasher and nut. Torque nut to 13-15 in.-lbs.

(16) Retard Breaker – Attach one positive lead of the timing light to retard breaker terminal and thenegative lead to ground. Set the engine 20° before top center on the compression stroke of thenumber 1 cylinder. The timing light should be on, indicating the retard breaker points are closed.Slowly rotate the engine in the normal direction until the timing light goes out indicating thepoints opened. The TC #1 timing mark on the ring gear should be aligned with the dot on thestarter housing within ± 3°. If the timing of these points is incorrect, refer to the Slick MaintenanceManual for the procedure and proper adjustment of the contact points.

(17) Attach the switch retard breaker lead to the retard post on the magneto (left magneto only) using alock washer and nut. Torque nut to 13-15 in.-lbs.

5-3


(18) Install ignition harness assemblies on the magnetos. The left magneto harness is marked “left” andright magneto harness is marked “right”. Check for proper installation of “o” ring seal in the wirecap. Torque cap mounting screws to 18-20 in.-lbs.

NOTE

Some timing lights operate in the reverse manner as described. The light comes on when thebreaker points open. Check your timing light instructions.

c. Alternator Output – The alternator should be checked to determine that the specified voltage andcurrent are being obtained.

2. FUEL SYSTEM.

a. Repair of Fuel Leaks – In the event a line or fitting in the fuel system is replaced, only a fuel solublelubricant, such as clean engine oil or Loctite Hydraulic Sealant may be used. Do not use any otherform of thread compound.

b. Fuel Injector Inlet Screen Assembly – Remove the assembly and check the screen for distortion oropenings in the strainer. Replace for either of these conditions. Clean screen assembly in solvent anddry with compressed air. To install the screen assembly, place the gasket on the screen assembly andinstall the assembly in the throttle body and tighten to 60-70 in.-lbs. torque.

c. Fuel Grades and Limitations – See recommended fuel grades in Section 3.

In the event that the specified fuel is not available at some locations, it is permissible to use higheroctane fuel. Fuel of a lower octane than specified is not to be used. Under no circumstances shouldautomotive fuel be used (regardless of octane rating).

NOTE

It is recommended that personnel be familiar with the latest revision of Service InstructionNo. 1070 regarding specified fuel for Lycoming engines.

d. Air Intake Ducts and Filter – Check all air intake ducts for dirt or restrictions. Inspect and service airfilters as instructed in the airframe manufacturer’s handbook.

e. Idle Speed and Mixture Adjustment -

(1) Start the engine and warm up in the usual manner until oil and cylinder head temperatures arenormal.

(2) Check magnetos. If the “mag-drop” is normal, proceed with idle adjustment.

(3) Set throttle stop screw so that the engine idles at the airframe manufacturer’s recommended idlingRPM. If the RPM changes appreciably after making idle mixture adjustment during thesucceeding steps, readjust the idle speed to the desired RPM.

(4) When the idling speed has been stabilized, move the cockpit mixture control lever with a smooth,steady pull toward the “Idle Cut-Off” position and observe the tachometer for any change duringthe leaning process. Caution must be exercised to return the mixture control to the “Full Rich”position before the RPM can drop to a point where the engine cuts out. An increase of more than50 RPM while “leaning out” indicates an excessively rich idle mixture. An immediate decrease inRPM (if not preceded by a momentary increase) indicates the mixture is too lean.

5-4


If the above indicates that the idle adjustment is too rich or too lean, turn the idle mixtureadjustment in the direction required for correction, and check this new position by repeating theabove procedure. Make additional adjustments as necessary until a check results in a momentarypick-up of approximately 50 RPM. Each time the adjustment is changed, the engine should be runup to 2000 RPM to clear the engine before proceeding with the RPM check. Make finaladjustment of the idle speed adjustment to obtain the desired idling RPM with closed throttle. Theabove method aims at a setting that will obtain maximum RPM with minimum manifold pressure.In case the setting does not remain stable, check the idle linkage; any looseness in this linkagewould cause erratic idling. In all cases, allowance should be made for the effect of weatherconditions and field altitude upon idling adjustment.

3. LUBRICATION SYSTEM.

a. Oil Grades and Limitations – Service the engine in accordance with the recommendations shown inSection 3.

b. Oil Suction Screen – At each oil change, remove and inspect for metal particles; clean and reinstall.

c. Oil Relief Valve – The adjustable oil relief valve enables the operator to maintain engine oil pressurewithin the specified limits. If the pressure under normal operating conditions should consistentlyexceed the maximum or minimum specified limits, adjust the valve as follows:

With the engine warmed up and running at approximately 2000 RPM, observe the reading on the oilpressure gage. If the pressure is above maximum or below minimum specified limits, stop engine andscrew the adjusting screw out to decrease pressure and in to increase pressure. Depending oninstallation, the adjusting screw may have only a screw driver slot and is turned with a screw driver;or may have the screw driver slot plus a pinned .375-24 castellated nut and may be turned with eithera screw driver or a box wrench.

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

a. Removal of Cylinder Assembly –

(1) Remove exhaust manifold.

(2) Remove rocker box drain tube, intake pipe, baffle and any clips that might interfere with theremoval of the cylinder.

(3) Disconnect ignition cables and remove the bottom spark plug.

(4) Remove rocker box cover and rotate crankshaft until piston is approximately at top center of thecompression stroke. This is indicated by a positive pressure inside of cylinder tending to pushthumb off of bottom spark plug hole.

(5) Slide valve rocker shafts from cylinder head and remove the valve rockers. Valve rocker shaftscan be removed when the cylinder is removed from the engine. Remove rotator cap from exhaustvalve stem.

5-5


(6) Remove push rod by grasping ball end and pulling rod out of shroud tube. Detach shroud tubespring and lock plate and remove shroud tubes from cylinder head.

NOTE

The hydraulic tappets, push rods, rocker arms and valves must be assembled in the samelocation from which they were removed.

(7) Remove cylinder base nuts, then remove cylinder by pulling directly away from crankcase. Becareful not to allow the piston to drop against the crankcase, as the piston leaves the cylinder.

b. Removal of Piston from Connecting Rod – Remove the piston pin plugs. Insert piston pin pullerthrough piston pin, assemble puller nut; then proceed to remove piston pin. Do not allow connectingrod 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 Assemblies – It will be necessary to remove andbleed the hydraulic tappet plunger assembly so that dry tappet clearance can be checked when thecylinder assembly is reinstalled. This is accomplished in the following manner:

(1) Remove the hydraulic tappet push rod socket by inserting the forefinger into the concave end ofthe socket and withdrawing. If the socket cannot be removed in this manner, it may be removed bygrasping the edge of the socket with a pair of needle nose pliers. However, care must be exercisedto avoid scratching the socket.

(2) To remove the hydraulic tappet plunger assembly, use the special Lycoming service tool. In theevent that the tool is not available, the hydraulic tappet plunger assembly may be removed by ahook in the end of a short piece of lock wire, inserting the wire so that the hook engages the springof the plunger assembly. Draw the plunger assembly out of the tappet body by gently pulling thewire.

CAUTION

NEVER USE A MAGNET TO REMOVE HYDRUALIC PLUNGER ASSEMBLIES FROMTHE CRANKCASE. THIS CAN CAUSE THE CHECK BALL TO REMAIN OFF ITS SEAT,RENDERING THE UNIT INOPERATIVE.

d. Assembly of Hydraulic Tappet Plunger Assemblies – To assemble the unit, unseat the ball by insertinga thin clean wire through the oil inlet hole. With the ball off its seat, insert the plunger and twistclockwise so that the spring catches. All oil must be removed before the plunger is inserted.

e. Assembly of Cylinder and Related Parts – Rotate the crankshaft so that the connecting rod of thecylinder being assembled is at the top center of the compression stroke. This can be checked byplacing two fingers on the intake and exhaust tappet bodies. Rock crankshaft back and forth over topcenter. If the tappet 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 ofplunger assembly.

5-6


(2) Assemble piston with rings so that the number stamped on the piston pin boss is toward the frontof the engine. The piston pin should be of a hand push fit. If difficulty is experienced in insertingthe piston pin, it is probably caused by carbon or burrs in the piston pin hole. During assembly,always use a generous quantity of oil, both in the piston pin hole and on the piston pin.

(3) Assemble one piston pin plug at each end of the piston pin and place a new rubber oil seal ringaround the cylinder skirt. Coat piston and rings and the inside of the cylinder generously with oil.

(4) Using a piston ring compressor, assemble the cylinder over the piston so that the intake port is atthe bottom of the engine. Push the cylinder all of the way on, catching the ring compressor as it ispushed off.

NOTE

Before installing cylinder hold-down nuts, lubricate crankcase thru-stud threads with anyone of the following lubricants, or combination of lubricants.1. 90% SAE 50W engine oil and 10% STP.2. Parker Thread Lube.3. 60% SAE 30 engine oil and 40% Parker Thread Lube.

NOTE

At any time a cylinder is replaced, it is necessary to retorque the thru-studs on the cylinderon the opposite side of the engine.

(a) Tighten ½ inch cylinder base nuts to 300 in.-lbs. (25 ft.-lbs.) torque, using the sequence shownin Figure 5-2.

(b) Using the same sequence, tighten the ½ inch cylinder base nuts, to 600 in.-lbs. (50 ft.-lbs.)torque.

Figure 5-2. Sequence of Tightening Cylinder Base Hold-Down Nuts

5-7


(c) Tighten the 3/8 inch hold down nuts to 300 in.-lbs. (25 ft.-lbs.) torque. Sequence of tighteningis optional.

(d) As a final check, hold the torque wrench on each nut for about five seconds. If the nut does notturn, it may be presumed to be tightened to correct torque.

CAUTION

AFTER ALL CYLINDER BASE NUTS HAVE BEEN TIGHTENED, REMOVE ANY NICKS INTHE CYLINDER FINS BY FILING OR BURRING.

(5) Install new shroud tube oil seals on both ends of shroud tube. Install shroud tube and lock in placeas required for type of cylinder.

(6) Assemble each push rod in its respective shroud tube, and assemble each rocker in its respectiveposition by placing rocker between bosses and sliding valve rocker shaft in place to retain rockers.Before installing exhaust valve rocker, place rotator cap over end of exhaust valve stem.

(7) Be sure that the piston is at top center of compression stroke and that both valves are closed.Check clearance between the valve stem tip and the valve rocker. In order to check this clearance,place the thumb of one hand on the valve rocker directly over the end of the push rod and pushdown so as to compress the hydraulic tappet spring. While holding the spring compressed, thevalve clearance should be between .028 and .080 inch. If clearance does not come within theselimits, remove the push rod and insert a longer or shorter push rod, as required to correctclearance.

NOTE

Inserting a longer push rod will decrease the valve clearance.

(8) Install intercylinder baffles, rocker box covers, intake pipes, rocker box drain tubes and exhaustmanifold.

5. TURBOCHARGER..

a. Variable Pressure Controller – Refer to latest revision of Lycoming Service Instruction No. 1431 foradjustment procedure.

6. ALTERNATOR AND COMPRESSOR DRIVE BELT TENSION.

Check the tension of new belts 25 hours are installation. Refer to latest revision of Service Instruction No.1129 for methods of checking tension of drive belts.

5-8


SECTION 6TROUBLE-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.......................................................................................................................................... 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....................................................................................................................... 6-5

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

LYCOMING OPERATOR’S MANUAL SECTION 6TIO-540-AE2A TROUBLE-SHOOTING

SECTION 6

TROUBLE-SHOOTING

Experience has proven that the best method of trouble-shooting is to decide on the various causes of agiven trouble and then to eliminate causes one by one, beginning with the most probable. The followingcharts list some of the more common troubles, which may be encountered in maintaining engines andturbochargers; their probable causes and remedies.

1. TROUBLE-SHOOTING – ENGINE.

TROUBLE PROBABLE CAUSE REMEDY

Failure of Engine to Start Lack of fuel. Check fuel system for leaks. Fillfuel tank. Clean dirty lines,strainers or fuel valves.

Overpriming. Leave ignition “off” and mixturecontrol in “Idle Cut-Off”, openthrottle and “unload” engine bycranking for a few seconds. Turnignition switch on and proceed tostart in a normal manner.

Defective spark plugs. Clean and adjust or replace sparkplugs.

Defective ignition wiring. Check with electric tester, andreplace any defective wires.

Defective battery. Replace with charged battery.

Improper operation of magnetobreaker.

Clean points. Check internaltiming of magnetos.

Lack of sufficient fuel flow. Disconnect fuel line and checkfuel flow.

Water in fuel injector. Drain fuel injector and fuel lines.

Internal failure. Check suction screen for metalparticles. If found, completeoverhaul of the engine may beindicated.

6-1

SECTION 6 LYCOMING OPERATOR’S MANUALTROUBLE-SHOOTING TIO-540-AE2A


Failure of Engine to Idle Properly Incorrect idle mixture. Adjust mixture.

Leak in induction system. Tighten all connections in theinduction system. Replace anyparts that are defective.

Incorrect idle adjustment. Adjust throttle stop to obtaincorrect idle.

Uneven cylinder compression. Check condition of piston ringsand valve seats.

Faulty ignition system. Check entire ignition system.

Insufficient fuel pressure. Adjust fuel pressure.

Leak in air bleed nozzle balanceline.

Check connection and replace ifnecessary.

Plugged fuel injector nozzle. Clean or replace nozzle.

Flow divider fitting plugged. Clean fitting.

Low Power and Uneven Running Mixture too rich; indicated bysluggish engine operation, redexhaust flame at night. Extremecases indicated by black smokefrom exhaust.

Readjustment of fuel injector byauthorized personnel is indicated.

Mixture too lean; indicated byoverheating or backfiring.

Check fuel lines for dirt or otherrestrictions. Readjustment of fuelinjector by authorized personnel isindicated.

Leaks in induction system. Tighten all connections. Replacedefective parts.

Defective spark plugs. Clean and gap or replace sparkplugs.

Improper fuel. Fill tank with fuel ofrecommended grade.

6-2



Low Power and Uneven Running(Cont.)

Magneto breaker points notworking properly.

Clean points. Check internaltiming of magnetos.

Defective ignition wire. Check wire with electric tester.Replace defective wire.

Defective spark plug terminalconnectors.

Replace connectors on spark plugwire.


Failure of Engine to Develop FullPower

Leak in induction system Tighten all connections andreplace defective parts.


Throttle lever out of adjustment. Adjust throttle lever.

Improper fuel flow. Check strainer, gage and flow atthe fuel line.

Restriction in air scoop. Examine air scoop and removerestrictions.

Improper fuel. Drain and refill tank withrecommended fuel.

Faulty ignition. Tighten all connections. Checksystem with tester. Check ignitiontiming.

Rough Engine Cracked engine mount. Replace or repair mounting.

Defective mounting bushings. Install new mounting bushings.

Uneven compression. Check compression.


Low Oil Pressure Insufficient oil. Fill sump to proper level withrecommended oil.

Air lock or dirt in relief valve. Remove and clean oil pressurerelief valve.

6-3



Low Oil Pressure (Cont.) Leak in suction line or pressureline.

Check gasket between accessoryhousing and crankcase.

High oil temperature. See “High Oil Temperature” in“Trouble” column.

Defective pressure gage. Replace.

Stoppage in oil pump intakepassage.

Check line for obstruction. Cleansuction strainer.

High Oil Temperature Insufficient oil supply. Fill oil sump to proper level withspecified oil.

Low grade of oil. Replace with oil conforming tospecifications.

Clogged oil lines or strainers. Remove and clean oil strainers.

Excessive blow-by. Usually caused by worn or stuckrings.

Failing or failed bearing. Examine sump for metal particles.If found, overhaul of engine isindicated.

Defective temperature gage. Replace gage.

Excessive Oil Consumption Low grade of oil. Fill tank with oil conforming tospecification.

Failing or failed bearings. Check sump for metal particles.

Worn piston rings. Install new rings.

Incorrect installation of pistonrings.

Install new rings.

Failure of rings to seat (newnitrided cylinders).

Use mineral base oil. Climb tocruise altitude at full power andoperate at 75% cruise powersetting until oil consumptionstabilizes.

High Fuel Flow Indicated on FuelGage


6-4


2. TROUBLE-SHOOTING – TURBOCHARGER.


Excessive Noise or Vibration Improper bearing lubrication. Supply required oil pressure.Clean or replace oil line; clean oilstrainer. If trouble persists,overhaul turbocharger.

Leak in engine intake or exhaustmanifold.

Tighten loose connections orreplace manifold gaskets asnecessary.

Dirty impeller blades. Disassemble and clean.

Engine Will Not Deliver RatedPower

Clogged manifold system. Clear all ducting.

Foreign material lodged incompressor impeller or turbine.

Disassemble and clean.

Excessive dirt build-up incompressor.

Thoroughly clean compressorassembly. Service air cleaner andcheck for leakage.

Leak in engine intake or exhaust. Tighten loose connections orreplace manifold gaskets asnecessary.

Rotating assembly bearingseizure.

Overhaul turbocharger.

Restriction in return lines fromactuator to exhaust bypasscontroller.

Remove and clean lines.

Exhaust bypass controller is inneed of adjustment.

Have exhaust bypass controlleradjusted.

Oil pressure too low. Tighten fittings. Replace lines, orhoses, increase oil pressure todesired pressure.

Inlet orifice to actuator clogged. Remove inlet line at actuator andclean orifice.

Exhaust bypass controllermalfunction.

Replace unit.

6-5



Engines Will Not Deliver RatedPower (Cont.)

Exhaust bypass butterfly notclosing.

Low pressure. Clogged orifice inlet to actuator.

Butterfly shaft binding. Checkbearings.

Turbocharger impeller binding,frozen or fouling housing.

Check bearings. Replaceturbocharger.

Piston seal in actuator leaking.Usually accompanied by oilleakage at drain line.

Remove and replace actuator ordisassemble and replace packing.

Critical Altitude Lower ThanSpecified

Controller not getting enough oilpressure to close the exhaustbypass.

Check pump outlet pressure, oilfilters, external lines for leaks orobstructions.

Chips under metering valve incontroller holding it open

Replace controller.

Metering jet in actuator plugged. Remove actuator and clean jet.

Actuator piston seal failed andleaking excessively.

If there is oil leakage at actuatordrain, clean cylinder and replacepiston seal.

Exhaust bypass valve sticking. Clean and free action.

Engine Surges or Smokes Air in oil lines or actuator. Bleed system.

Controller metering valve stemseal leaking oil into manifold.

Replace controller.

Clogged breather. Check breather for restrictions toair flow.

NOTE

Smoke would be normal if engine has idled for a prolonged period.

High Deck Pressure (CompressorDischarge Pressure)

Controller metering valve notopening, aneroid bellows leaking.

Replace controller assembly orreplace aneroid bellows.

Exhaust bypass sticking closed. Shut off valve in return line notworking.

Butterfly shaft binding. Checkbearings.

6-6



High Deck Pressure (CompressorDischarge Pressure) (Cont.)

Exhaust bypass sticking closed.(Cont.)

Replace exhaust bypass valve orcorrect linkage binding.

Controller return line restricted. Clean or replace line.

Oil pressure too high. Check pressure 75 to 85 psi (80psi desired) at exhaust bypassactuator inlet.

If pressure on outlet side ofactuator is too high, have exhaustbypass controller adjusted.

Exhaust bypass valve actuatorpiston locked in full closedposition. (Usually accompaniedby oil leakage at actuator drainline.) NOTE: Exhaust bypassnormally closed in idle and lowpower conditions. Should openwhen actuator inlet line isdisconnected.

Remove and disassemble actuator,check condition of piston andpacking or replace actuatorassembly.

Exhaust bypass controllermalfunction.

Replace controller.

6-7


SECTION 7INSTALLATION 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

Propeller Installation ................................................................................................................................ 7-1

Preparation of Fuel Injector for Installation............................................................................................. 7-2

Corrosion Prevention in Engines Installed in Inactive Aircraft.............................................................. 7-2

LYCOMING OPERATOR’S MANUAL SECTION 7TIO-540-AE2A INSTALLATION AND STORAGE

SECTION 7

INSTALLATION AND STORAGE

1. PREPARATION OF ENGINE FOR INSTALLATION. Before installing an engine that has been preparedfor storage, remove all dehydrator plugs, bags of desiccant and preservative oil from the engine.Preservative oil can be removed by removing the bottom spark plugs and turning the crankshaft three orfour revolutions by hand. The preservative oil will then drain through the spark plug holes. Draining will befacilitated if the engine is tilted from side to side during the above operation. Preservative oil which hasaccumulated in the sump can be drained by removing the oil sump plug. Engines that have been stored in acold place should be removed to an environment of at least 70°F (21°C) for a period of 24 hours beforepreservative oil is drained from the cylinders. If this is not possible, heat the cylinders with heat lampsbefore attempting to drain the engine.

After the oil sump has been drained, the plug should be replaced, safety-wired, and the sump refilled withlubricating oil. The crankshaft should again be turned several revolutions to saturate the interior of theengine with the clean oil. When installing spark plugs, make sure that they are clean; if not, wash them inclean petroleum solvent. Of course, there will be a small amount of preservative oil remaining in the engine,but this can cause no harm. However, after twenty-five hours of operation, the lubricating oil should bedrained 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 PRESERVATIVEOIL BEFORE REMOVING THE SPARK PLUGS, BECAUSE IF THE CYLINDERSCONTAIN ANY APPRECIABLE AMOUNT OF THE MIXTURE, THE RESULTINGACTION, KNOWN AS HYDRAULIC LOCKING, WILL DAMAGE THE ENGINE. ALSO,ANY CONTACT OF THE PRESERVATIVE OIL WITH PAINTED SURFACES SHOULD BEAVOIDED.

General – Should any of the dehydrator plugs, containing crystals of silica-gel or similar material, be brokenduring their term of storage or upon their removal from the engine, and if any of the contents should fall intothe engine, that portion of the engine must be disassembled and thoroughly cleaned before using the engine.The oil strainers should be removed and cleaned in gasoline or some other hydrocarbon solvent. The fueldrain screen located in the fuel inlet of the fuel injector should also be removed and cleaned in ahydrocarbon solvent. The operator should also note if any valves are sticking. If they are, this condition canbe eliminated by coating the valve stem generously with a mixture of gasoline and lubrication oil.

Inspection of Engine Mounting – If the aircraft is one from which an engine has been removed, make surethat the engine mount is not bent or damaged by distortion or misalignment as this can produce abnormalstresses within the engine.

Attaching Engine to Mounts – See airframe manufacturer’s recommendation for method of mounting theengine.

Oil and Fuel Line Connections – The oil and fuel line connections are called out on the accompanyinginstallation drawings.

Propeller Installation – Consult the airframe manufacturer for information relative to propeller installation.

7-1

SECTION 7 LYCOMING OPERATOR’S MANUALINSTALLATION AND STORAGE TIO-540-AE2A

2. PREPARATION OF FUEL INJECTOR FOR INSTALLATION.

A fuel injector that has been prepared for storage should undergo the following procedure before beingplaced in service.

Fuel Injector (Bendix) – Remove and clean the fuel inlet strainer assembly and reinstall. Inject clean fuelinto the fuel inlet connection with the fuel outlets uncapped until clean fuel flows from the outlets. Do notexceed 15 psi inlet pressure.

CORROSION PREVENTION IN ENGINES INSTALLEDIN INACTIVE AIRCRAFT

Corrosion can occur, especially in new or overhauled engines, on cylinder walls of engines, that will beinoperative for periods as brief as two days. Therefore, the following preservation procedure isrecommended for inactive engines and will be effective in minimizing the corrosion condition for a periodof up to thirty days.

NOTE

Ground running the engine for brief periods of time is not a substitute for the followingprocedure; in fact, the practice of ground running will tend to aggravate rather thanminimize this corrosion condition.

a. As soon as possible after the engine is stopped, move the aircraft into the hangar, or other shelterwhere the preservation process is to be performed.

b. Remove sufficient cowling to gain access to the spark plugs and remove both spark plugs from eachcylinder.

c. Spray the interior of each cylinder with approximately two (2) ounces of corrosion preventive oilwhile cranking the engine about five (5) revolutions with the starter. The spray gun nozzle may beplaced 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 spray gun and becertain oil is hot at the nozzle before spraying cylinders.

d. With the crankshaft stationary, again spray each cylinder through the spark plug holes withapproximately two (2) ounces of corrosion preventive oil. Assemble spark plugs and do not turncrankshaft after cylinders have been sprayed.

The corrosion preventive oil to be used in the foregoing procedure should conform to specification MIL-L-6529, Type 1 heated to 200°F/220°F (93°C/104°C) spray nozzle temperature. It is not necessary to flushpreservative oil from the cylinder prior to flying the aircraft. The small quantity of oil coating the cylinderswill be expelled from the engine during the first few minutes of operation.

7-2


NOTE

Oils of the type mentioned are to be used in Lycoming aircraft engines for corrosionprevention only, and not for lubrication. See the latest revision of Lycoming ServiceInstruction No. 1014 and Service Bulletin No. 318 for recommended lubricating oil.

7-3

SECTION 7 LYCOMING OPERATOR’S MANUALINSTALLATION AND STORAGE TIO-540-AE2A

Figure 7-1. Installation Drawing – Left Side View –TIO-540-AE2A

7-4


Figure 7-2. Installation Drawing – Rear View –TIO-540-AE2A

7-5


SECTION 8TABLES

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

Inch – Fraction Conversion ........................................................................................................................ 8-6

LYCOMING OPERATOR’S MANUAL SECTION 8TIO-540-AE2A TABLES

SECTION 8

TABLES

FOR TIGHTENING TORQUE RECOMMENDATIONS AND INFORMATION

CONCERNING TOLERANCES AND DIMENSIONS THAT MUST BE MAINTAINED

IN LYCOMING AIRCRAFT ENGINES, CONSULT LATEST REVISION OF SPECIAL

SERVICE PUBLICATION NO. SSP-1776.

CONSULT LATEST REVISION OF SERVICE INSTRUCTION NO. 1029 AND NO.

1150 FOR INFORMATION PERTINENT TO CORRECTLY INSTALLING CYLINDER

ASSEMBLY.

8-1

SECTION 8 LYCOMING OPERATOR’S MANUALTABLES TIO-540-AE2A

8-2


8-3


FULL THROTTLE HP AT ALTITUDE(Normally Aspired Engines)

AltitudeFt.

% S.L.H.P.

AltitudeFt.

% S.L.H.P.

AltitudeFt.

% S.L.H.P.

0500

1,0002,0002,5003,0004,0005,0006,0007,0008,0009,000

10098.596.893.692.090.587.584.681.778.976.273.5

10,00011,00012,00013,00014,00015,00016,00017,00017,50018,00018,50019,000

70.868.365.863.461.058.756.554.353.152.151.450.0

19,50020,00020,50021,00021,50022,00022,50023,00023,50024,00024,50025,000

49.148.047.646.045.244.043.342.241.440.339.538.5

TABLE OF SPEED EQUIVALENTS

Sec./Mi. M.P.H. Sec./Mi. M.P.H. Sec./Mi. M.P.H.72.060.051.445.040.036.032.730.027.725.7

5060708090

100110120130140

24.022.521.220.018.918.017.116.415.615.0

150160170180190200210220230240

14.413.813.312.812.412.011.611.210.910.6

250260270280290300310320330340

8-4


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 inthe column (F) to the right. To convert 20°F to Centigrade; find 20 in the center column and read –6.67°C inthe (C) column to the left.

C F-C F C F-C F-56.7-51.1-45.6-40.0-34.0-28.9-23.3-17.8

-12.22-6.67-1.114.44

10.0015.5621.1126.6732.2237.7843.3348.8954.4460.0065.5671.0076.6782.2287.7893.3398.89

-70-60-50-40-30-20-10

0102030405060708090

100110120130140150160170180190200210

-94.0-76.0-58.0-40.0-22.0

-4.014.032.050.068.086.0

104.0122.0140.0158.0176.0194.0212.0230.0248.0266.0284.0302.0320.0338.0356.0374.0392.0410.0

104.44110.00115.56121.11126.67132.22137.78143.33148.89154.44160.00165.56171.11176.67182.22187.78193.33198.89204.44210.00215.56221.11226.67232.22237.78243.33248.89254.44260.00

220230240250260270280290300310320330340350360370380390400410420430440450460470480490500

428.0446.0464.0482.0500.0518.0536.0554.0572.0590.0608.0626.0644.0662.0680.0698.0716.0734.0752.0770.0788.0806.0824.0842.0860.0878.0896.0914.0932.0

8-5

SECTION 8 LYCOMING OPERATOR’S MANUALTABLES TIO-540-AE2A

INCH FRACTION CONVERSIONSDecimals, Area of Circles and Millimeters

InchFraction

DecimalEquiv.

AreaSq. In.

MMEquiv.

InchFraction

DecimalEquiv.

AreaSq. In.

MMEquiv.

1/641/323/641/163/327/641/8

5/3211/643/167/3215/64

1/49/3219/645/1611/3223/64

3/813/3227/647/1615/3231/64

.0156

.0312

.0469

.0625

.0937

.1094.125

.1562

.1719

.1875

.2187

.2344.25

.2812

.2969

.3125

.3437

.3594.375

.4062

.4219

.4375

.4687

.4844

.0002

.0008

.0017

.0031

.0069

.0094

.0123

.0192

.0232

.0276

.0376

.0431

.0491

.0621

.0692

.0767

.0928

.1014

.1105

.1296

.1398

.1503

.1725

.1842

.397

.7941.1911.5872.3812.7783.1753.9694.3664.7625.5565.5936.3507.1447.5407.9378.7319.1289.525

10.31910.71611.11211.90612.303

1/217/3235/649/1619/3239/64

5/821/3243/6411/1623/3247/64

3/425/3251/6413/1627/3255/64

7/829/3259/6415/1631/3263/64

.5.5312.5469.5625.5937.6094.625

.6562

.6719

.6875

.7187

.7344.75

.7812

.7969

.8125

.8437

.8594.875

.9062

.9219

.9375

.9687

.9844

.1964

.2217

.2349

.2485

.2769

.2916

.3068

.3382

.3545

.3712

.4057

.4235

.4418

.4794

.4986

.5185

.5591

.5800

.6013

.6450

.6675

.6903

.7371

.7610

12.70013.49413.89114.28815.08115.47815.87516.66917.06517.46218.25618.65319.05019.84420.24120.63721.43121.82822.22523.01923.41623.81224.60625.003

8-6

tio-540-ae2a series - lycoming.com operator... · operator’s manual lycoming tio-540-ae2a series...

Documents