Lycoming TEO-540 Series User manual

© 2022 Avco Corporation. All Rights Reserved.
Field Service Tool User Manual
& Troubleshooting Guide
TEO-540 Series Engine Models
August 2022
Part No. SSP-122

Field Service Tool User Manual
& Troubleshooting Guide
Lycoming Part Number: SSP-122
Contact Us:
Mailing Address:
Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 USA
Phone:
Factory
U.S. and Canada Toll Free:
Direct:
[phone]
[phone]
• [phone] (Toll Free)
• [phone]
• Email Technicals[email protected]
Lycoming’s regular business hours are Monday through Friday from 8:00AM through 5:00PM
Eastern Time (-5 GMT).
Visit us Online: www.lycoming.com
The information in this User Manual and Troubleshooting Guide is intended for general use of the
FST as a diagnostic tool for TEO-540-Series engines. If available, refer to the model specific
engine maintenance manual when identifying faults for your engine. There could be differences in
the troubleshooting steps for some faults.

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© 2022 Avco Corporation. All Rights Reserved Record of Revisions
August 2022 Page i
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RECORD OF REVISIONS
Revision
Revision
Date
Revision Description
Original
Original Release of Field Service Tool User Manual & Troubleshooting
Guide - SSP-122

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© 2022 Avco Corporation. All Rights Reserved Service Document List
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SERVICE DOCUMENT LIST
NOTICE: The following is a list of service documents referenced in or incorporated into the
information in this publication. Always refer to the latest revision of any service
document for changes or additional information. Supplements to a service document
contain information relevant to the service document but not yet added to the service
document.
The latest revision of all service documents in this list can be downloaded from our
website https://www.lycoming.com/contact/knowledge-base/publications.
To narrow the search parameters and limit the number of returns, enter only the
numerical portion of the service document number in the Search box on the website.
For example, if you are looking for Service Letter L114BJ, just type in "114".
Number
Incorporation
Date
Subject
S.I. 1573
8/22
Lycoming TEO-540 Engine Series Engine Control Unit
(ECU) Assembly Cross-References
S.L. L114
8/22
Reciprocating Engine and Accessory Maintenance
Publications

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TEO-540-C1A Engine Maintenance Manual
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TABLE OF CONTENTS
Section Page
Frontal __________________________________________________________________________
Record of Revisions .............................................................................................................................. i
Service Document List ....................................................................................................................... iii
Table of Contents ................................................................................................................................ v
Introduction ....................................................................................................................................... xii
Field Service Tool User Manual
—Field Service Tool Abbreviations and Acronyms ....................................................................... 1
—System Requirements .................................................................................................................. 3
—Software Installation ................................................................................................................... 5
—ECU to FST Connection ........................................................................................................... 13
—Access the Field Service Tool ................................................................................................... 15
— Start the FST Program .......................................................................................................... 15
— Home Tab ............................................................................................................................. 15
— Displaying ECU Active Data ............................................................................................... 17
— Uploading Fault History....................................................................................................... 18
— Clearing a Fault .................................................................................................................... 19
— Retrieving Data Logger Unit Information ........................................................................... 20
— Data Graphing ...................................................................................................................... 21
— Close the FST Program ........................................................................................................ 24
— Disconnect the ECU and FST .............................................................................................. 24
—Sending Data to Lycoming Technical Support ......................................................................... 25
—Sending Data ........................................................................................................................ 25
—Field Service Tool - Software Problems ................................................................................... 27
— Table 1 - Corrective Action Guide ....................................................................................... 27

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INTRODUCTION
Scope of this Publication
The Field Service Tool (FST) is a diagnostic software loaded on a laptop which is connected by
Controller Area Network (CAN) bus interface to the engine’s Electronic Engine Control System
(EECS). The EECS connects engine hardware with electronic controls to continuously monitor and
automatically adjust operating conditions such as ignition timing, fuel injection timing, and fuel
mixture.
The EECS is made up of:
• Engine Control Unit (ECU) - a dual channel unit which contains system processors, input
signal conditioning, output actuator drive stages, and aircraft communication interfaces. The
ECU monitors and controls engine operation and sends this information to the FST. The ECU
has a unique part number for each engine.
• Power Box - a dual channel unit which supplies regulated primary and secondary power over
to the EECS.
• Data Logger Unit (DLU or ADL) - (optional) a single channel unit that continuously collects
and records engine operating data (data history) and fault codes received from the ECU via
the CAN. The fault codes are used for engine diagnostics. The data history can show trends to
further help with engine diagnostics.
NOTICE: The ECU configuration and part number (P/N) are unique for each engine.
The ECU and POWER BOX are connected by two wiring harnesses, the engine harness and airframe
supplied interface harness. Two channels on the ECU communicate with each other through the
CAN. Each channel has input processing, a microprocessor and output processing which control the
engine independently of each other. Sensors connected to the engine harness send inputs to the ECU
to control the engine through output to the actuators. The actuators also are connected to the ECU by
the same wiring harnesses.
The CAN is the means to transmit data input and output, including fault codes, to and from the ECU
and FST to monitor and control the engine as well as to download data from the optional Data
Logger.
This publication contains instructions to:
• Install the FST software on a computer or laptop (or other display device)
• Operate the FST and associated navigation conventions for using the FST
• Access and display engine data
• Access, display, read, export, and clear engine fault codes
• Reset Time Limited Operation (TLO) and No Take-Off (NTO) indicators in the cockpit
avionics
• Download run time data, trip data, and data history from the Data Logger
• Display runtime data and active data logged by the field service tool
The “Troubleshooting Guide” found in the maintenance manual for each specific engine model,
contains recommended corrective action for the fault codes to remove the root cause which will
ultimately enable the fault code to be cleared. In some instances, multiple related fault codes can
display if they have a common or associated root cause. In these cases, a logic fault tree is given to
help isolate the root cause.
NOTICE: The FST is to be used only during servicing and maintenance and NOT during flight.

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Warning, Cautions, and Notices
Be sure to read and obey the Warnings, Cautions and Notices in this publication and in service
documents. Although Lycoming cannot know all possible hazards or damages, it makes a reasonable
effort to supply the best possible guidance and recommended practices for safe operation and
maintenance of its engines.
The table below defines the four types of safety advisory messages used in this publication per the
American National Standard and ANSI Z535-6-2006.
Safety Advisory Conventions
Advisory Word
Definition
DANGER:
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury. This signal word is to be limited to the
most extreme situations.
WARNING
Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury. It can also be used without
the safety alert symbol as an alternative to "NOTICE."
NOTICE:
The preferred signal word to address practices not related to
personal injury.
Simplified Technical English
The text in the publication is written in the form of Simplified Technical English in compliance with
FAA requirements and to make translation into other languages easier.
Figures
Figures in this publication are for conceptual illustrative purposes only. Figures always start as
Figure 1 in each chapter.
Copyright
This publication is a copyrighted work. All rights reserved by Lycoming Engines. Content in this
publication cannot be changed or released as a reprint, electronic media output, or web communiqué
without written permission from Lycoming Engines.
Supplemental Service Information
Refer to the latest revision of Service Letter No. L114 for a list of Lycoming publications available
for purchase.
Feedback
To supply comments, suggestions, or corrections to this publication, either call Lycoming Engines
Customer Service at the phone number in the front of this publication or use the Lycoming.com
website.
Publication Revisions
Lycoming Engines constantly examines our publications to provide our customers the most complete
and up-to-date information for operating and maintaining our engines. Revisions to this publication
will be published as necessary.

TEO-540-C1A Engine Maintenance Manual
© 2022 Avco Corporation. All Rights Reserved Abbreviations and Acronyms
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FIELD SERVICE TOOL USER MANUAL
FIELD SERVICE TOOL USER MANUAL ABBREVIATIONS AND ACRONYMS
A
ADL
Data Logger
AFR
Air-Fuel Ratio
C
CAN
Controller Area Network
CHT
Cylinder Head Temperature
CID
Cylinder Identification (camshaft position sensor)
CPS
Crankshaft Position Sensor
CRC
Cyclic Redundancy Check
CTC
Cylinder Temperature Control
D
DC
Direct Current
DLU
Data Logger Unit
E
ECU
Engine Control Unit
(physical box consisting of a primary and a secondary channel)
EECS
Electronic Engine Control System
EGT
Exhaust Gas Temperature
EPA
Environmental Protection Agency
ETC
Electronic Throttle Control
F
FAA
Federal Aviation Administration
FAR
Federal Aviation Regulations
FAR
Fuel Air Ratio
FFL
Fault Found Lamp
FHA
Functional Hazard Assessment
FRT
Fuel Rail Temperature
FSM
Finite State Machine
FST
Field Service Tool
K
KAM
Keep Alive Memory
M
MAT
Manifold Air Temperature

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Abbreviations and Acronyms © 2022 Avco Corporation. All Rights Reserved
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FIELD SERVICE TOOL USER MANUAL ABBREVIATIONS AND ACRONYMS (CONT.)
N
NTC
Negative Temperature Coefficient type Thermistor
NTO
No Take Off
P
PFT
Pre-Flight Test
PSSA
Preliminary System Safety Assessment
R
RAM
Random Access Memory
ROC
Rate of Change
ROM
Read Only Memory
RTCA
Radio Technical Commission for Aeronautics
RTD
Resistance Temperature Detector
S
SAE
Society of Automotive Engineers
SPF
Single Point Failure
T
TBD
To Be Decided
TBO
Time Between Overhaul
TLO
Time Limited Operation
TIT
Turbine Inlet Temperature
TPS
Throttle Position Sensor
W
WGA
Wastegate Actuator

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SYSTEM REQUIREMENTS
The following hardware is necessary to use the Field Service Tool (FST):
• A laptop using Windows 7 or 10 operating system with an internet connection.
• iE2 Service Cable - ST-528 (Figure 1).
• iE2 Field Service Tool CAN Interface - ST-530 (Figure 2).
NOTICE: ST-528 and ST-530 are available from an Authorized Lycoming Engines
Distributor.
Figure 1
iE2 Service Cable - ST-528
Figure 2
iE2 Field Service Tool CAN Interface - ST-530

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SOFTWARE INSTALLATION
This chapter contains step-by-step instructions for installing the FST software. The following
download procedure pictures are for illustrative and procedural purposes. For best results, Lycoming
recommends installing the latest version of FST software.
1. With the laptop turned on and connected to the internet, navigate to the Lycoming Engines
Home Page www.lycoming.com.
2. Click on the iE2 Portal tab in the ribbon at the top of the page (Figure 1).
Figure 1
iE2 Portal on the Lycoming.com Website
3. If you are not already registered, click on REGISTER (Figure 2) and enter your email
address and name (Figure 3) on the First-Time Registration Page.
Figure 2
Lycoming iE2 Software Portal
Figure 3
First-Time Registration Page

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4. Click Continue on the First-Time
Registration Page and you will be
transferred to the Password Entry
Page to create and confirm a
password (Figure 4).
5. After you have successfully
registered, you will receive a
confirmation email from
Lycoming.
Figure 4
Password Entry Page
6. If you are already registered, click on LOGIN (Figure 5) and go directly to the Log-In page
(Figure 6) to enter your username and password.
Figure 5
Lycoming iE2 Software Portal
Figure 6
Log-In Page

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7. After log-in, navigate to the Shared Folders page (Figure 7) and double-click on the iE2
Software Download.
Figure 7
Shared Folders Page
8. You will be transferred to the iE2 Software Download page (Figure 8). Double-click on the
iE2 Field Service Tool SW icon.
Figure 8
iE2 Software Download Page

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9. Check the box to the left of the “iE2 Field Service Tool SW” icon then click on the
Download button (Figure 9).
Figure 9
File Download Page
10. Click the Save button from the pop-up window at the bottom of the page (Figure 10) and
choose a file folder location for the download from the Save As dialog window, then click
Save.
Figure 10
File Save Page

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11. From the file folder where the download was saved, double-click the “iE2 Field Service Tool
SW” icon (Figure 11) to open the Destination Directory.
Figure 11
Saved File Folder
12. Click the Setup button on the WinZip Self Extractor dialog box (Figure 12).
Figure 12
WinZip Self Extractor Dialog Box

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13. Choose the folder location for the software in the Destination Directory (Figure 13), then
click the Next button.
Figure 13
Destination Directory Dialog Box
14. Read the Lycoming Software License Agreement then choose the “I accept the License
Agreement” button. Click Next on the License Agreement page (Figure 14).
15. Read the National Instruments Software License Agreement then choose the “I accept the
License Agreement” button. Click Next on the License Agreement page (Figure 15).
Figure 14
Lycoming Software License Agreement
Figure 15
Software License Agreement