Textron Lycoming IO-540 Series User manual

rVlT
1:n Lycoming
OPERATOR'S MANUAL
REVISION
REVISION
NO. PUBLICATION
0,10-540 Series
60297-10-4 Operator's Manual
PUBLICATION PUBLICATION
NO. DATE
60297-10 March1991
The page(s) in this revision replace, add to, or delete current pages in
the operator's manual.
PREVIOUS REVISION
January 1997
Section 2 Index, 2-2, 2-3, 2-4,
Added pages 2-5, 2-6, 2-7, 2-8;
Section 3 Index, 3-10, 3-11,
3-12, Added page 3-12A/B;
3-13, 3-17, 3-18, Added page
3-18A/B; 3-41,3-42,3-42, Add-
ed page 3-45
January 1999
Section 2 Index, 2-6, 2-7; 3-10,
3-11, 3-13, 3-18, Added pages
3-46,3-47; Section 4 Index,4-2,
Added page 4-2A/B; 5-9, 5-10,
5-11, 5-12March 1999
4-2
CURRENT REVISION
April 1999
3-12,3-12A/B, 3-13

OPERATOR'S
MANAUAL
TEXTRON Lycoming
O-540 & IO-540 SERIES
AIRCRAFT ENGINES
4th EDITION October, 1999
Approved by F.AA.
TEXTRON Lycoming
652 OliverStreet
Williamsport,
PA17701U.S.A.
570/323-6181
PartNo. 60297-10
Printed in U.S.A.

TEXTRON LYCOMING OPERATOR'S MANUAL
ATTENTION
OWNERS, OPERATORS, AND
MAINTENANCE PERSONNEL
This operator's manualcontainsadescription of the engine, its specifica-
tions, and detailed information on how to operate and maintain it. Such
maintenanceprocedures that may be required in conjunctionwith periodic
inspections are also included. This manualis intended for use,by owners,
pilotsand maintenance personnel responsible for care of Textron Lycom-
ingpoweredaircraft.Modificationsand repair procedures are contained in
TextronLycoming
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 ex-
ceeded, for any reason, damage to the engine and personal injury can hap-
pen. Consult your local FAA approved maintenance facility.
SERVICE BULLETINS, INSTRUCTIONS, AND LETTERS
Althoughthe informationcontained in this manualis up-to-date at time
ofpublication,
users are urged to keep abreast oflater information
through
TextronLycoming
Service Bulletins,
Instructions and Service Letters which
are available
fromallTextron Lycoming
distributors or fromthe factory by
subscription. Consult the latest edition of Service Letter No. L114for
subscription information.
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.

TEXTRON
LYCOMINGOPERATOR'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 Textron 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 Textron Lycoming publications con-
tain various Warnings and Cautions which must be carefully read in
order to minimize the risk of personal injury or the use of improper ser-
vice 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. Textron Lycoming could not possibly know,
evaluate or advise the service trade of all conceivable ways in which ser-
vice might be done or of the possible hazardous consequences that may
be involved. Acordingly, anyone who uses a service procedure must first
satisfy themselves thoroughly that neither their safety nor aircraft safe-
ty will be jeopardized by the service procedure they select.

WARRANTY
(LIMITED)
NEWAND
REMANUFACTURED
RECIPROCATING
AIRCRAFT
ENGINE
WHAT
TEXTRON
LYCOMING
PROMISES
YOU
> Textron Lycoming warrants eachnew and remanufactured reciprocating
enginesold by itto be freefrom
defectsin
> materialand workmanshipappearing
within one (1) year from
the date of first
operation exchlding
necessaryaircraft
> acceptance esting.The date of first operationmust not exceed two(2) years from thedate ofshipment fromTextron
Lycoming.
Textron Lycoming's obligationunder this warrantyshallbe limited to its choiceof repair
or replacement,on an ex-
change
basis,of theengine oranypartof theegine, whenTextron Lycoming
hasdetermined
thattheengineisdefective
in
materialor workmanship.
Suchrepair or replacementwillbemade byTextron Lycoming
at nocharge to you.Textron
Lycoming will also bear the cost for labor in connection with the repair or replacement as provided in Textron
Lycoming's
thencurrent Removaland Installation
LaborAllowanceGuidebook.
Inaddition,if Texton Lycoming
determinestha the engineproves tobe defectivein materialorwornanship during
the period untiltheexpirationofTextron Lycoming'srecommended Time Between
Overhaul(TBO), or two(2) years
fromthedate offirst operation,
whichever
occurs first,Texon Lycomiugwillreimburseyou for apro rataportionof the
charge forthe repair or replacement
(at its
choice) with TextronLycoming parts,
ofparts requiredto be repairedor re-
placed, or a replacementengine,if it determines thatengine replacementis required. Textron Lycoming's obligation
during dieproration
period extendsto major partsof theengine, which
are limited to crankcase, crankshaft,
camshaft,
cylinders,connecting
rods, pistons,sump,accessoryhousingand gears. The proration
policydoes not extendto laboror
toaccessories,includingbut
not limitedto magnetos, carburetors
or fuel injectors, fuelpumps,starters,alternatorsand
turbochargers
and theircontrolers.
Any
engineor part sorepairedor replacedwill beentitledto warranty
forthe remainder
ofthe original
warrantyperiod.
YOUR OBLIGATIONS
The enginemusthave received
normal use andservice. Youmust applyfor warranty with an authorized Textron
Lycoming
distributorwithin30 daysofdie appearance
ofthe defectin materialor workmanship
TextronLycoming'swarranty does not cover normal maintenance
expenses
orconsumableitems Theobligations
on
the pan of Textron Lycoming
set forthaboveae yourexclusive
remedyand theexclusiveliability
ofTextron
Lycoming.
Tlis warrantyallocatestheriskofproductfailurebetween youandTextronLycoming,
aspermitted by applicablelaw.
TextronLycoming reserves
the rightto
deny any warranty
claim ifit reasonably
determinesthatthe engine
orpart has
been subjectto accident or used,adjusted, altered, handled,maintained
orstored otherthanasdirectedin youroperator's
manual, orif non-genuineTextronLycoming parts areinstalledin or onthe engineand aredetermined tobe a possible
causeof die incidentfor which
diewarrantyapplicaton isfiled.
TextronLycomingmay change dieconstructionof enginesatany time without
incurringanyobligationtoincorporate
suchalterations
in enginesor partspreviouslysold.

> THIS LIMITED WARRANTY
IS EXCLUSIVE
AND IN LIEU
OF ALL OTHER
WARRANTIES ANDREPRESEN-
> TATIONS,EXPRESS
OR IMPLIED ORSTATUTORY.
WHETHER
WRITTEN OR ORAL, INCLUDINGBUT
NOT
LIMITED TOANY WARRANTY
OF MERCHANTABILITY
OR FITNESS FOR ANY PARTICULAR
PURPOSE.
) ANDANY IMPLIEDWARRANTY ARISING FROM ANY COUBSE OF PERFORMANCEOR DEALING OR
TRADEUSAGE.
THIS WARRANTY
IS ALSO IN LIEUOF ANYOTHER
OBLIGATION, LIABILITY,
RIGHT OR
> CLAIM, WHETHER IN CONTRACT OR IN TORT, INCLUDING ANY RIGHT IN STRICT LIABILITY IN
TORT OR ANY RIGHT ARISING FROM NEGLIGENCEON THE PART OF TEXTRON LYCOMING, AND
> TEXTRON LYCOMING'S LIABILITY ON SUCHCLAIMSHALL, INNO CASE EXCEED THE PRICE
ALLO-
> CABLE
TOTHE ENGINEORPARTWHICHGIVES
RISE
TOTHE CLAIM.
LIMITATION
OFLIABILITY
IN NO
EVENT,
WHETHER AS A RESULT
OF
A BREACH
OF WARRANTY,CONTRACT OR ALLEGED
NEG-
LIGENCE,
SHALLTEXTRON
LYCOMING BE
LIABLEFOR
SPECIALOR CONSEQUENTIAL
ORANY OTHER
DAMAGES,INCLUDINGBUTNOT LIMITED TOLOSSOFPROFITSORREVENUES, LOSSOFUSE OFTHE
ENGINEORCOSTOF
A REPLACEMENT.
No agreementvarying this warranty orTextron Lycoming's obligations under it will be binding upon Textron
Lycoming
unlessin writingsigned
bya duly authorized
representative
ofTextron
Lycoming.
Effective October 1, 1995 Revision "J"
TextronLycoming
Williamsport,Pennsylvania

TEXTRONLycoming
WARRANTY
(LIMITED)
REPLACEMENT
PART - RECIPROCATING
AIRCRAFTENGINE
WHAT
TEXTRON
LYCOMING
PROMISES
YOU
TextronLycoming
warrants each new reciprocatingaircraftengine
replacementpartsoldbyit tobe freefrom defects
in material and workmanshipappearing within one (1) year from its date of first operation.The dateof firstopera-
tion. must not
exceed two(2)years fromthe date ofshipmentfrom TextronLycoming.
Textron Lycoming'sobligationunder thiswarrantyshallhe limited to
its choiceof repairor replacement, on an ex-
changebasis, of thereplacement part,when TextronLycoming
has determined thatthepart isdefective in
materialor
workmanship.TextronLycomingwill also reimburseyoufor thecostsforlaborinconnectionwith therepairor replace-
mentas providedinTextronLycoming's thencurrentRemoval
and Installation
LaborAllowanceGuidebook.
Any partsorepaired orreplacedwillbe wanrranted
for theremainder
ofthe original warrantyperiod.
YOUROBLIGATIONS
Theengine
in which thereplacement
partis installedmust have receivednormal use and service.Youmust
applyfor
warranty
with anauthorizedTextron Lycoming distributorwithin 30daysof theappearance ofthedefect inmaterialor
workmanship.
TextronLycoming'swarranty doesnot cover normalmaintenanceexpensesor consumableitems. Theobligations
on
the part ofTextronLycomingset forthaboveare your exclusive
remedyand theexclusive
liabilityofTextron Lycoming.
This warrantyallocatesthe riskof product failurebetween
youand Textron
Lycoming,as permitted
byapplicable
law.
TextronLycoming reserves
the rightto deny
any warrantyclaimifit reasonably
determinesthat theengineor part has
been subjecttoaccident orused, adjusted,
altered, handled,maintained
or storedotherthanasdirectedin youroperator's
manual, orif non-genuineTextron
Lycoming partsareinstalledin oron theengine
and aredetermined tobe apossible
causeof theincidentfor whichthe warranty
application
isfiled.
TextronLycoming maychangetheconstructionofenginesatany time withoutincurringanyobligationto incorporate
suchalterations
in enginesor parts previously
sold.
THIS LIMITEDWARRANTY
IS EXCLUSIVE
AND INLIEU OFALL OTHERWARRANTIESANDREPRESEN-
TATIONS.EXPRESSOR IMPLIEDOR STATUTORY,
WHETHER
WRITTENOR ORAL, INCLUDINGBUT
NOT
LIMITEDTOANY WARRANTY
OF MERCHANTABILITY
OR FITNESS FOR
ANY PARTICULAR
PURPOSE.
ANDANY IMPLIED WARRANTY ARISING FROM ANY COURSE OF PERFORMANCEOR DEALING OR
TRADEUSAGE THIS WARRANTY
ISALSO IN LIEU
OF ANYOTHEROBLIGATION.LIABILITY,
RIGHT OR
CLAIM. WHETHER IN CONTRACT OR IN TORT, INCLUDING ANY RIGHT IN STRICT LIABILITY IN
TORT OR ANY RIGHT ARISING FROM NEGLIGENCE ON THE PART OF TEXTRON LYCOMING. AND
TEXTRON LYCOMING'S LIABILITY ON SUCH CLAIMSHALL IN NO CASE EXCEED THE PRICEALLO-
CABLETOTHE ENGINEOR PARTWHICHGIVES
RISETOTHE CLAIM

LIMITATION
OF LIABILITY
IN NO EVENT, WHETHER ASA RESULTOFA BREACHOF WARRANTY,CONTRACT OR ALLEGED
NEG-
LIGENCE,SHALLTEXTRONLYCOMINGBE LIABLEFORSPECIALOR CONSEQUENTIAL
ORANY OTHER
DAMAGES,INCLUDINGBUT NOT LIMITED TOLOSS
OF PROFITS
OR REVENUES, LOSS
OF USE OFTHE
ENGINE
ORCOSTOF AREPLACEMENT.
No agreementvarying this warranty or Textron Lycoming's obligations under it will be binding upon Textron
Lycoming
unlessinwriting signed by a dulyauthorized representative
ofTextron Lycoming.
Effective October1,1995 Revision 'J"
Textron
Lycoming
Williamsport,Pennsylvania <

Lycoming
WARRANTY
(LIMITED)
OVERHAULED
RECIPROCATINGAIRCRAFTENGINE
WHATTEXTRON
LYCOMINGPROMISES
YOU
Textron Lycoming warrantseach overhauledreciprocating enginesold byit to be freefrom defects in materialand
workmanshipappearing withinone (1) year from the dale offirst operation,excluding necessary aircraft acceptance
testing. The dateof first operationmust not exceed two(2) yearsfrom thedateofshipmentfrom TextronLycoming
Textron Lycoming'sobligationunder thiswarrantyshallbe limited to its choiceof repairorreplacement, on an ex-
changebasis,of the engineorany partof theengine,when Textron Lycominghas determinedthat theengine isdefective
in materialor workmanship.Suchrepairor rep acementwill bemade by TextronLycomingat nocharge to you.Textron
Lycoming will also bear the cost for labor in connection with the repair or replacement as providedin Textron
Lycoming'sthencurrent Removaland installationLaborAllowanceGuidebook.
Anyengine orpartso repairedor replaced willbe entitledto warrantyforthe remainderof theoriginalwarrantyperiod.
YOUR OBLIGATIONS
The enginemusthave receivednormaluse andservice. Youmust applyfor warranty with all authorizedTextron
Lycomingdistributorwithin30 daysofthe appearanceof the defectin materialor workmanship
TextronLycoming'swarranty doesnot cover normal maiutenance
expensesorconsunmableitems.The obligations
on
the partofTextronLycomingset forthabove areyourexclusive remedyand dieexclusiveliabilityof TextronLycoming.
This warrantyallocatestheriskofproductfailure betweenyouand TextronLycoming,aspermittedby applicablelaw.
TextronLycoming reservestherighttodenyanywarranty clainifit reasonably
determinesthatthe engineor part has
been subjectto accident or used, adjusted,altered, handled,maintainedorstoredotherthanas directedin youroperator's
manual, or if non-genuineTexron Lycoming pas areinstalledin oron tlieegine andare determinedto bea possible
causeof the incidentfor whichthewarrantyapplicationisfiled.
TextronLycoming maychangetheconstructionofenginesat any
time withoutincurringanyobligationto incorporate
suchalterationsin enginesorpartspreviouslysold.
THISLIMITED WARRANTYIS EXCLUSIVEAND IN LIEUOF ALL OTHER WARRANTIESANDREPRESEN-
TATIONS,EXPRESSOR IMPLIED ORSTATUTORY,WHETHERWRITTEN ORORAL, INCLUDINGBUTNOT
LIMITED TO ANY WARRANTY
OF MERCHANTABILITYOR FITNESS FOR
ANY PARTICULARPURPOSE,
ANDANY IMPLIED WARRANTY ARISING FROM ANY COURSE OF PERFORMANCEOR DEALING OR
TRADEUSAGE.THIS WARRANTYISALO IN LIEUOF ANYOTHEROBLIGATION, LIABILITY,RIGHT OR
CLAIM, WHETHER IN CONTRACT OR IN TORT, INCLUDINGANY RIGHT IN STRICT LIABILITY IN
TORT OR ANY RIGHT ARISING FROM NEGLIGENCE ON THE PART OF TEXTRON LYCOMING, AND
TEXTRON LYCOMING'S LIABILITY ON SUCH CLAIMSHALL INNO CASE EXCEED THE PRICEALLO.
CABLETOTHE ENGINEORPARTWHICHGIVESRISE TOTHECLAIM.

LIMITATION
OFLIABILITY
IN NO EVENT,WHETHER ASA RESULT
OFA BREACH
OF WARRANTY, CONTRACTOR ALLEGED
NEG-
LIGENCE,SHALLTEXTRONLYCOMING BELIABLEFORSPECIALOR CONSEQUENTIALORANYOTHER
DAMAGES, INCLUDINGBUTNOT LIMITED TO LOSSOPPROFITS OR REVENUES, LOSSOFUSE OFTHE
ENGINEORCOSTOF AREPLACEMENT.
No agreementvarying this warranty or Textron Lycoming's obligations under it will be binding upon Textron
Lycomingunless
in writing signed bya duly authorizedrepresentative
ofTextron Lycoming.
Effective October1, 1995 Revision "J"
Textron
Lycoming
Williamsport,Pennsylvania
(

TABLE OF CONTENTS
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
SECTION 7
SECTION 8
DESCRIPTION
SPECIFICATIONS
OPERATING INSTRUCTIONS
PERIODIC INSPECTIONS
MAINTENANCE PROCEDURES
TROUBLE-SHOOTING
INSTALLATIONAND STORAGE
TABLES
Page
1-1
2-1
3-1
4-1
5-1
6-1
7-1
8-1

TEXTRON LYCOMING OPERATOR’S MANUAL
3/4 Right Front View - Typical IO-540-B

TEXTRONLYCOMIING
OPERATOR'S
MANUAL
WARNING
These engines are equipped with a dynamic counterweight system and
must be operated accordingly; avoid high engine speed, low manifold
pressure operation. Use a smooth, steady movement of the throttle (avoid
rapid opening and closing). If this warning is not heeded, there could be
severe damage to the counterweights, roller and bushings.

TEXTRON LYCOMING OPERATOR'S MANUAL
DESCRIPTION
Page
General................................................. 1-1
Cylinders ................................................ 1-1
Valve Operating Mechanism ......... .. ............... 1-1
Crankcase ............................................... 1-1
Crankshaft ............................................. 1-2
Connecting Rods ......................................... 1-2
Pistons .................................................. 1-2
Accessory Housing ............................... ....... 1-2
Oil Sump ............................................... 1-2
Oil Sump and Induction Assembly ........................ 1-2
Cooling System .......................................... 1-2
Induction System ........................................ 1-3

TEXTRON LYCOMING OPERATOR'S MANUAL
0-540 & 10-540 SERIES SECTION1
DESCRIPTION
The 0-540 and 10-540 series are six cylinder,direct drive, horizontally
opposed, air cooled engines.
In referring to the locationof the various engine components, the parts
are described intheir relationship to the engine as installedin the airframe.
Thus the power take-off end is considered the front; the accessory drive
end, the rear. The sump section is considered the bottom and the opposite
side ofthe engine where the shroud tubes are located the top. Reference
to the left and right side is made with the observer facingthe rear of the
engine. The cylinders are numbered from front to rear, odd numbers on
the right, even numbers on the left. The direction of rotation for accessory
drives is determined with the observer facing the drive pad.
Cylinders - The cylinders are ofconventionalair cooled construction with
the two major parts, head and barrel, screwed and shrunk together. The
heads are made from analuminumalloycasting with afullymachined com-
bustion chamber. Rocker shaft bearing supports are cast integral with the
head alongwith housings to form the rocker boxes for both valverockers.
The cylinder barrels, whichare machined fromchrome nickelmolybdenum
steel forgings, have deep integralcooling fins and the inside ofthe barrels
are ground and honed to a specified finish.
ValveOperating
Mechanism - A conventional
type camshaft is located above
andparallelto the crankshaft. The camshaft actuates hydraulic
tappets which
operate the valves through push rods andvalverockers. The valverockers
are supported on full-floatingsteel shafts. The valve springs bear against
hardened steel seats and are retained on the valvestems by means ofsplit
keys.
Crankcase -The crankcase assembly consists of two reinforced aluminum
alloycastings, fastened together by means of studs, bolts and nuts. The
mating surfaces ofthe 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.
1-1

TEXTRON LYCOMING OPERATOR'SMANUAL
SECTION
1 10-540& 10-540SERIES
Crankshaft -The crankshaft is made from a chrome nickel molybdenum
steel forging. All bearing journal surfaces are nitrided. Freedom from tor-
sional vibration is assured by a system of pendulum type dynamic
counterweights.
Connecting Rods -The connecting rods are made in the form of "H" sec-
tions 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 two bolts and nuts through
each cap.
Pistons - The pistons are machined from an aluminum alloy forging. The
piston pin is a full floating type with a plug located in each end of the pin.
Depending on the cylinder assembly, pistons may be machined for either
three or four rings and may employ either half-wedge or full-wedge rings.
Consult the latest revision ofService Instruction No. 1037for proper piston
and ring combinations.
Accessory Housing -The accessory housing is made from an aluminum
casting and is fastened to the rear of the crankcase and the top rear of
the sump. It forms a housing for the oil pump and the various accessory
drives.
Oil Sump (0-540, IO-540-C, -D, -J, -N, -R) - The sump incorporates an
oildrain plug, oil suction screen, mounting pad for carburetor or fuel injec-
tor, the intake riser and intake pipe connections.
Oil Sump and Induction Assembly (Except 0-540, 10-540-C, -D, -J, -N,
-R) - This assembly consists of the oil sump bolted to a mated cover con-
taining intake pipe extensions for the induction system. When bolted
together they form a mounting pad for the air inlet housing. Fuel drain plugs
are provided in the cover and the sump incorporates oil drain plugs and
an oil suction screen.
Cooling System - These engines are designed to be cooled by air pressure
actuated by the forward speed of the aircraft. Baffles are provided to build
up a pressure and force the air through the cylinder fins. The air is then
exhausted to the atmosphere through gills or augmentor tubes usually
located at the rear of the cowling.

TEXTRON
LYCOMING
OPERATOR'S
MANUAL
0-540 & 10-540 SERIES SECTION
1
Induction System -TextronLycoming0-540 series engines are equipped
with aMarvel-Schebler MA-4-5carburetor. Particularlygood distribution
ofthe fuel-airmixture to each cylinderis obtainedthrough the center zone
induction system, which is integral with the oil sump and is submerged
in oil, insuring a more uniform vaporization of fuel and aiding in cooling
the oil in the sump. From the riser the fuel-air mixture is distributed to
each cylinder by individualintake pipes.
TextronLycoming
10-540series engines are equippedwitheither a Ben-
dixtype RS or RSA
fuelinjector. The fuelinjectionsystem schedules fuel
flow
inproportionto airflow
andfuel vaporization
takes place at the intake
ports.
A brief description of the carburetor and fuel injectors follows:
The Marvel-ScheblerMA-4-5
carburetor is ofthe singlebarrel float
type
and is equipped with a manual mixture control and an idle cut-off.
The Marvel-Schebler HA-6 is a horizontal mounted carburetor equip-
ped with a manual mixture control and idle cut-off.
The Bendix RS type fuel injection system operates by measuring the
air flowthrough the throttle body of the servo valve regulator controls,
and uses this measurement to operate a servo valvewithin the control.
The regulated fuelpressure established by the servo valve
is used to con-
trol the distributor valveassembly, whichthen schedules fuel flowin pro-
portion to air flow.
The Bendix RSA
type fuel injectionsystem is based on the principle of
measuring air flowand using the air flowsignalin a stem type regulator
to convert the air force into a fuelforce. This fuelforce (fuelpressure dif-
ferential) when applied across the fuel metering section (jetting system)
makes fuel flowproportional to air flow.
NOTE
The letter "D" usedas the 4th or 5th character
in the modelsuffix means
thatthe basic
model
configuration
has been
altered
by
theuseofdual magnetos
housed in a single housing. Example - basicmodel10-540-K1A5 becomes
IO-540-K1A5D.
Operational
aspects
of enginesare the same, and performance datafor the
basic modelstill apply.
1-3

SPECIFICATIONS
Page
O(-540-A,-B, -E, -F ,-G, -H, -L, -L Series .. ................. 2-
IO-540-A,-B, -E,-, G,-P ,-,-D, -N, -R, -T, -V Series .......... 2-2
IO-540-C,-J Series .................................... 2-3
IO-540-K, -L, -M, -S, -W Series ......................... 2-4
IO-540-AA,-AB Series ................................. 2-5
IO-540-AC Series ...................................... 2-6
Standard Engine Weights ......... ....................... 2-6
Accessory Drives ................. .................... 2-8
Revised January 1999

TEXTRON
LYCOMINGOPERATOR'S
MANUAL
0-540 & 10-540 SERIES SECTION
2
SPECIFICATIONS
0-540 SERIES
-A* -B -E,-G-,H
FAAType Certificate 295 295 295
Rated horsepower 250 235 260
Rated speed RPM 2575 2575 2700
Bore, inches 5.125 5.125 5.125
Stroke, inches 4.375 4.375 4.375
Displacement cubic inches 541.5 541.5 541.5
Compression ratio 8.5:1 7.2:1 8.5:1
Firing order 1-4-5-2-3-6 1-4-5-2-3-6 1-4-5-2-3-6
Spark occurs degrees BTC 250 25 25
Valve
rocker clearance
(hydraulictappets collapsed) .028-.080 .028-.080 .028-.080
Prop. drive ratio 1:1 1:1 1:1
Prop. driven rotation Clockwise Clockwise Clockwise
0-540 SERIES
-J,-L -F
FAAType Certificate 295 295
Rated horsepower 235 235
Rated speed RPM 2400 2800
Bore, inches 5.125 5.125
Stroke, inches 4.375 4.375
Displacement cubic inches 541.5 541.5
Compression ratio 8.5:1 8.5:1
Firing order 1-4-5-2-3-6 1-4-5-2-3-6
Spark occurs degrees BTC 23 250
Valverocker clearance
(hydraulic
tappets collapsed) .028-.080 .028-.080
Prop. drive ratio 1:1 1:1
Prop. driven rotation Clockwise Clockwise
*0-540-A Series alternate hp/rpm rating: 235/2400 (except -A3D5).
2-1

TEXTRON LYCOMING OPERATOR'S MANUAL
SECTION 2 0-540 &10-540 SERIES
SPECIFICATIONS
10-540 -A, -B, -E, -G, -P SERIES
FAATypeCertificate .................................... 1E4
Rated horsepower. ....................................... 290
Ratedspeed, RPM ....................................... 2575
Bore, inches............... ................... ..... 5.125
Stroke,inches.......................................... 4.375
Displacement cubic inches ................................ 541.5
Compressionratio........................................ 8.7:1
Firingorder
........................................... 1-4-5-2-3-6
Spark occurs,degrees BTC ........... .................. 20°
Valverockerclearance (hydraulictappetscollapsed) ........ 028-.080
Prop.driveratio ........................................ 1:1
Prop.drivenrotation ..................................... Clockwise
-V SERIES IO-540-D,-N, -R, -T*, -V SERIES
FAATypeCertificate ......... ... ....... ..... 1E4
Rated horsepower
........................................ 260
Ratedspeed, RPM ......... ........... .... 2700
Bore, inches.............................. 5.125
Stroke, inches
................... ....................... 4.375
Displacement cubic inches ................................ 541.5
Compressionratio
...................................... 8.5:1
Firing
order........................... .................1-4-5-2-3-6
Sparkoccurs, degreesBTC ............................... 25°
Valverockerclearance (hydraulictappets collapsed) ........ 028-.080
Prop.drive ratio........................................ 1:1
Prop.
driven rotation ..................................... Clockwise
*- IO-540-T4B5 model enginehasan alternateratingof 250horsepow-
er at2575 RPM.When operated atalternate rating, all performancedata
pertinent to the IO-540-C series is applicable.
2-2 Revised January 1997