Lycoming Vo-540 series User manual

Operators Manual

Lycoming

VO-540, IVO-540,

TIVO-540 Series

Approved by FAA

2nd Edition Part No. 60297-17

652 Oliver Street

Williamsport, PA. 17701 U.S.A.

570/323-6181

May 2008

VO-540, IVO-540, TIVO-540 Series Operators Manual

Lycoming Part Number: 60297-17

Lycoming and Powered by Lycoming are trademarks or registered trademarks of

Lycoming.

All brand and product names referenced in this publication are trademarks or registered

trademarks of their respective companies.

For additional information:

Mailing address:

Lycoming Engines

652 Oliver Street

Williamsport, PA 17701 U.S.A.

Phone:

Factory: 570-323-6181

Sales Department: 570-327-7268

Fax: 570-327-7101

Lycomings regular business hours are Monday through Friday from 8:00 AM

through 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 on

how to operate and maintain it. Such maintenance procedures that may be required in conjunction with

periodic inspections are also included. This manual is intended for use by owners, pilots and maintenance

personnel responsible for care of Lycoming powered aircraft. Modifications and repair procedures are

contained 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 result

in poor engine performance and power loss. Also, if power and speed limitations specified in this manual

are exceeded, for any reason, damage to the engine and personal injury can happen. Consult your local

FAA 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 to

keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters

which are available from all Lycoming distributors or from the factory by subscription. Consult the latest

revision of Service Letter No. L114 for subscription information.

SPECIAL NOTE

The illustrations, pictures and drawings shown in this publication are typical of the subject matter they

portray; in no instance are they to be interpreted as examples of any specific engine, equipment or part

thereof.

iii

LYCOMING OPERATORS MANUAL

IMPORTANT SAFETY NOTICE

Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The

service 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 tools

must be used when and as recommended.

It is important to note that most Lycoming publications contain various Warnings and Cautions which

must be carefully read in order to minimize the risk of personal injury or the use of improper service

methods 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 could

not possibly know, evaluate or advise the service trade of all conceivable ways in which service might be

done or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses a

service procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will be

jeopardized by the service procedure they select.

LYCOMING OPERATORS MANUAL

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

LYCOMING OPERATORS MANUAL

¾ Left Side View  VO-540-B1A

¾ Left Rear View  VO-540-C1A

LYCOMING OPERATORS MANUAL

SECTION 1

DESCRIPTION

Page

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

Cylinders....................................................................................................................................................... 1-1

Valve Operating Mechanism ...................................................................................................................... 1-1

Crankcase ..................................................................................................................................................... 1-1

Crankcase Cover.......................................................................................................................................... 1-1

Crankshaft .................................................................................................................................................... 1-1

Connecting Rods .......................................................................................................................................... 1-1

Pistons ........................................................................................................................................................... 1-1

Accessory Housing ....................................................................................................................................... 1-2

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

Induction System.......................................................................................................................................... 1-2

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

Lubricating System...................................................................................................................................... 1-2

Priming System ............................................................................................................................................ 1-3

Ignition System............................................................................................................................................. 1-3

Table of Models ............................................................................................................................................ 1-3

This Page Intentionally Left Blank.

LYCOMING OPERATORS MANUAL SECTION 1

VO, IVO & TIVO-540 SERIES DESCRIPTION

SECTION 1

DESCRIPTION

Lycoming VO-540, IVO-540 and TIVO-540 series engines are six cylinder, horizontally opposed, dry

sump, air cooled models designed for installation in rotor driven aircraft.

In referring to the location of various engine components, the parts will be described in their relationship

to the engine as installed in the airframe. Thus the power take-off section is considered the top and the

accessory drive section the bottom. The section where the shroud tubes are located is the front and the

opposite section the rear. References to the left and right side of the engine are made with the observer

standing at the rear and facing front. The cylinders are numbered from top to bottom; odd numbered

cylinders on the left, even numbered cylinders on the right.

The direction of rotation of the crankshaft is clockwise viewed from the bottom of the engine. For all

accessory drives, the direction of rotation is determined when facing the drive pad.

Cylinders  The cylinders are of conventional air cooled construction with the two major parts, head and

barrel, screwed and shrunk together. The heads are made from an aluminum alloy casting with a fully

machined combustion chamber. Rocker shaft bearing supports are cast integral with the head along with

housings to form the rocker boxes for both valve rockers. The cylinder barrels, which are machined from

chrome nickel molybdenum steel forgings, have deep integral cooling fins and the inside of the barrels are

ground and honed to a specified finish.

Valve Operating Mechanism  A conventional type camshaft is located in front of and parallel to the

crankshaft. The camshaft actuates hydraulic tappets which operate the valves through push rods and valve

rockers. The valve rockers are supported on full floating steel shafts. The valve springs bear against

hardened steel seats and are retained on the valve stems by means of split keys.

Crankcase  The crankcase assembly consists of two reinforced aluminum alloy castings fastened together

by means of studs, bolts and nuts. The mating surfaces of the two castings are joined without the use of a

gasket and the main bearing bores are machined for use of precision type main bearing inserts.

Crankcase Cover  The crankcase cover is made from a magnesium alloy casting and is fastened to the rear

of the crankcase. An integral cast chamber incorporates a mounting pad for the carburetor or fuel injector

and serves as a center distributing zone for the fuel  air mixture on carbureted engines.

Crankshaft  The crankshaft is made from a chrome nickel molybdenum steel forging. All bearing journal

surfaces are nitrided.

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. The

bearing caps on the crankshaft ends are retained by means of two bolts and nuts through each cap.

Pistons  The pistons are machined from an aluminum alloy forging. The piston pin is of the full floating

type with a plug located at each end. Depending on the cylinder assembly, pistons may be machined for

either three or five rings and employ half wedge rings. Consult the latest revision of Service Instruction No.

1037 for proper piston and ring assemblies.

1-1

SECTION 1 LYCOMING OPERATORS MANUAL

DESCRIPTION VO, IVO & TIVO-540 SERIES

Accessory Housing  The accessory housing and accessory housing cover are made from magnesium alloy

castings and are fastened to the bottom of the crankcase. This assembly forms a housing for the oil pump

and the various accessory drives. A scavenge oil sump is fastened to the bottom of the accessory housing.

Cooling System  The engine is designed to be cooled by air pressure built up on one side of the cylinder

and discharged, with an accompanying drop in pressure, through cylinder finning. This cooling air on rotor-

driven aircraft is supplied by an external fan installed by the airframe manufacturer. Close fitting baffles

direct the flow of air around the cylinder fins and the discharge air is exhausted to the atmosphere.

Induction System (Carbureted Engines)  These engines are equipped with either single or dual MA-6-AA

carburetors (see Table of Models for model application). This carburetor incorporates an automatic mixture

control and idle-cut-off. The fuel  air mixture, after passing from the carburetor to the center distributing

zone is distributed to the cylinders through individual intake pipes.

Induction System (Fuel Injected Engines)  (See Table of Models for model application.) Either a Bendix

RS system or RSA system is used on subject engines.

The RS system operates by measuring the air flow through the throttle body of the servo valve regulator

controls, and uses this measurement to operate a servo valve within the control. The regulated pressure

established by the servo valve is used to control the fuel distributor valve assembly, which then establishes

fuel flow in proportion to air flow and fuel vaporization takes place at the individual intake port.

The RSA system is based on the principle of measuring air flow and using the air flow signal in a stem

type regulator to convert the air force into a fuel force. This fuel force (fuel pressure differential) when

applied across the fuel metering section makes fuel flow proportional to air flow. Vaporization takes place

at individual intake ports.

Turbocharger System (TIVO-540)  A turbocharger is supplied as an integral part of the TIVO-540 model.

The function of the turbocharger is to provide constant air density to the fuel injector inlet from sea level to

critical altitude. Regulating the amount of exhaust gas fed to the turbine wheel controls the output which

determines engine power. This factor is regulated by the control system which has two components, namely

the density controller and the exhaust bypass valve (waste gate). The position of the waste gate is

determined by oil pressure acting on a piston which is connected to the butterfly valve by linkage.

Increasing oil pressure on the piston closes the waste gate valve and increases power; decreasing oil

pressure opens the valve and decreases power. The bleed oil required to activate the piston is controlled by

the density controller. The density controller action is automatic and modulating to continue and reverse the

process as engine power, speed and altitude change.

Lubricating System  The dry sump, fuel pressure lubrication system is actuated by an impeller type oil

pump enclosed within the accessory housing. This pump incorporates a pressure pump and a scavenge pump

driven by a common drive shaft. The pressure pump draws oil from the externally mounted supply tank and

forces it through drilled passages to the oil filter. From the filter the oil is directed through a check valve to

the oil pressure regulating valve. The check valve prevents gravity oil from draining into the crankcase

when the engine is shut down and the oil pressure valve maintains the oil pressure within limits and

discharges excess oil back to the inlet side of the pump. After completing its passage through the engine the

oil is conducted to the scavenge pump in the accessory housing and returned to the external tank.

1-2

LYCOMING OPERATORS MANUAL SECTION 1

VO, IVO & TIVO-540 SERIES DESCRIPTION

Priming System  Provision for a priming system is provided on all carbureted engines. Fuel injected

engines do not require a priming system.

Ignition System  Dual ignition is furnished by magnetos assembled on each side of the accessory housing.

Consult Table of Models for model application.

TABLE OF MODELS

MODEL APPLICATION

Model* Left Right Carburetor Fuel Injector

VO-540-B1A, -B2A

VO-540-B1B, -B1F

VO-540-B1C, -B2C

VO-540-B1D, -B2D

VO-540-B1E, -B2E

VO-540-B2G

VO-540-B1B3

VO-540-B1H3

VO-540-C1A, -C2A

VO-540-C1B, -C2B

VO-540-C2C

VO-540-C1C3

IVO-540-A1A

TIVO-540-A2A

S6LN-20

S6LN-204

S6LN-20

S6LN-1209

S6LN-204

S6LN-1209

S6LN-204

S6LN-20

S6LN-1209

S6LN-204

S6RN-21

S6RN-200

S6RN-21

S6RN-1208

S6RN-200

S6RN-1208

S6RN-200

S6RN-21

S6RN-1208

S6RN-200

MA-6AA

MA-6AA(2)

MA-6AA

MA-6AA(2)

RSA-10AD1

RS-5BD2

* - Models with number 2 in suffix incorporate spring coupling drives. Models with

number 3 in suffix incorporate counterweighted crankshaft.

1-3

This Page Intentionally Left Blank.

LYCOMING OPERATORS MANUAL

SECTION 2

SPECIFICATIONS

Page

Specifications  VO-540-B Series ............................................................................................................... 2-1

Specifications  VO-540-C Series ............................................................................................................... 2-1

Specifications  IVO-540 Series.................................................................................................................. 2-2

Specifications  TIVO-540 Series ............................................................................................................... 2-2

Accessory Drives .......................................................................................................................................... 2-3

Detail Weights .............................................................................................................................................. 2-3

This Page Intentionally Left Blank.

LYCOMING OPERATORS MANUAL SECTION 2

VO, IVO & TIVO-540 SERIES SPECIFICATIONS

SECTION 2

SPECIFICATIONS

VO-540-B SERIES

FAA Type Certificate ....................................................................................................................................304

Rated horsepower...........................................................................................................................................305

Rated speed, RPM........................................................................................................................................3200

Bore, inches.................................................................................................................................................5.125

Stroke, inches..............................................................................................................................................4.375

Displacement, cubic inches.........................................................................................................................541.5

Compression ratio ....................................................................................................................................... 7.3:1

Firing order .......................................................................................................................................1-4-5-2-3-6

Spark occurs, degrees BTC..............................................................................................................................25

Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080

Crankshaft drive ratio .................................................................................................................................... 1:1

Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise

VO-540-C SERIES

FAA Type Certificate ....................................................................................................................................304

Rated horsepower...........................................................................................................................................305

Rated speed, RPM........................................................................................................................................3200

Bore, inches.................................................................................................................................................5.125

Stroke, inches..............................................................................................................................................4.375

Displacement, cubic inches.........................................................................................................................541.5

Compression ratio ....................................................................................................................................... 8.7:1

Firing order .......................................................................................................................................1-4-5-2-3-6

Spark occurs, degrees BTC..............................................................................................................................25

Valve rocker clearance (hydraulic tappets collapsed) ......................................................................... .028-.080

Crankshaft drive ratio .................................................................................................................................... 1:1

Crankshaft rotation (viewed from bottom) .........................................................................................Clockwise

2-1

SECTION 2 LYCOMING OPERATORS MANUAL

SPECIFICATIONS VO, IVO & TIVO-540 SERIES

SPECIFICATIONS

IVO-540 SERIES

FAA Type Certificate ..............................................................................................................................E11EA