Lycoming TEO-540-A1A, Installation And Operation Manual

Page 1: ... 2018 Avco Corporation All Rights Reserved Engine Installation and Operation Manual TEO 540 A1A Engine October 2018 Part No IOM TEO 540 A1A ...

Page 2: ...ycoming com 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 NOTE Lycoming recommends that owners of this manual sign up for email notification on the Technical Publications page of our website https www lycoming com contact knowledge base publications By submitting your email address you will receive notific...

Page 3: ...d of Revisions October 2018 Page i TEO 540 A1A Engine Installation and Operation Manual RECORD OF REVISIONS Revision Revision Date Revised By Revision Description Original Original Release of Installation and Operation Manual Part No IOM TEO 540 A1A ...

Page 4: ...Record of Revisions 2018 Avco Corporation All Rights Reserved Page ii October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 5: ...creen Content Inspection S B 533 10 18 Recommended Action for Sudden Engine Stoppage Propeller Rotor Strike or Loss of Propeller Rotor Blade or Tip S I 1011 10 18 Table of Current Tappet Bodies Plunger Assemblies and Hydraulic Lifter Assemblies S I 1014 10 18 Lubricating Oil Recommendations S I 1070 10 18 Specified Fuels S I 1241 10 18 Pre oil the Engine Prior to Initial Start S I 1304 10 18 Engin...

Page 6: ...Service Document List 2018 Avco Corporation All Rights Reserved Page iv October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 7: ...bbreviations and Acronyms xiii Introduction xvii System Description________________________________________________________________ System Description 1 Electronic Engine Control System EECS 2 EECS Architecture 3 Field Service Tool FST 4 EECS Operation 5 Electrical Interface 6 Wiring Harnesses 6 Sensors 7 Cylinders 8 Crankcase 8 Propeller Drive 9 Fuel System 9 Electronic Ignition System 10 Air Ind...

Page 8: ...harger Control 17 Propeller Pitch Control 17 Engine Overhaul vs Engine Rebuild 18 Timekeeping 18 Pilot Controls ____________________________________________________________________ Pilot Controls 19 Warning Indication Annunciators 20 Engine Reception and Lift__________________________________________________________ Uncrate Procedure for New Rebuilt or Overhauled Engines 21 Acceptance Check 21 Eng...

Page 9: ... Step 11 Attach Ground Straps 38 Step 12 Install Components That Had Been Removed Before Engine Installation and Any Additional Ship Loose Components 39 Step 13 Make Remaining Engine Connections 39 Step 14 Install Baffling 39 Step 15 Add Oil 39 Step 16 Engine Pre Oil Procedure 40 Step 17 Add Fuel 41 Step 18 Make RPM Measurements 41 Step 19 Final Installation Inspection 41 Step 20 Close Engine Comp...

Page 10: ...7 Step 6 Engine Stop 68 Engine Conditions ________________________________________________________________ Fault Isolation Use of the Field Service Tool 69 Faults 69 Required Action for Engine Conditions 69 Apply Heat to a Cold Engine 73 Cold Weather Engine Start 74 Engine Operation in Hot Weather 74 Volcanic Ash 75 Overspeed 75 Low Oil Pressure During Flight 76 Engine Preservation and Storage ___...

Page 11: ... Section 1 Example of Engine Box Crate 21 2 Engine Data Plate 21 3 Engine Lift 22 Requirements for Engine Installation Section 1 Oil Sump Drain Plugs and Oil Suction Screen 26 2 Plug in the Induction System 27 3 Fuel Drain Valve Adapter Assembly Installed in the Induction System 27 4 Engine Mounts 32 Engine Installation 1 Engine Wiring Harness Installed on TEO 540 A1A Engine 35 2 Red Colored Band ...

Page 12: ...List of Figures 2018 Avco Corporation All Rights Reserved Page x October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 13: ...for Engine Installation 25 Engine Installation Section 1 Engine Installation Steps and References 33 Engine Initiation 1 Engine Initiation Procedures for All Lycoming Engines 47 Engine Operation 1 Prerequisite Requirements for Engine Operation 61 Engine Conditions 1 Action for Engine Conditions 69 Appendix A Engine Specifications and Operating Limits A 1 TEO 540 A1A Engine Specifications 81 A 2 Ta...

Page 14: ...List of Tables 2018 Avco Corporation All Rights Reserved Page xii October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 15: ...eed Sensor CAN Controller Area Network CHT Cylinder Head Temperature CIP P Primary Compressor Inlet Pressure CIP S Secondary Compressor Inlet Pressure cm Centimeter CRANK Crankshaft Speed Sensor D DC Direct Current DECK P P Primary Induction Air Deck Pressure DECK P S Secondary Induction Air Deck Pressure DECK T Induction Air Deck Temperature DPS Delta Pressure Sensor E ECU Engine Control Unit EEC...

Page 16: ...Field Service Tool Ft lb Foot Pound torque FUEL P Fuel Rail Pressure Sensor FUEL T Fuel Temperature Sensor H Hg Mercury HIRF High Intensity Radiated Field I ICAs Instructions for Continued Airworthiness ICD Interface Control Document in Inch inches in lb Inch Pound torque In Hg Inches of Mercury K KNOCK Knock Sensor kPa Kilopascals L lb Pound LL Low Lead fuel M MAP Manifold Air Pressure MAT P Prim...

Page 17: ...sor P PFT Pre Flight Test button PMA Permanent Magnet Alternator P N Part Number POH Pilot s Operating Handbook psi Pounds per square inch R RCA Radio Corporation of America rpm Revolutions per Minute S SAE Society of Automotive Engineers oil viscosity SB Service Bulletin SI Service Instruction T TIT Turbine Inlet Temperature Sensor TLO Time Limited Operation TPS Throttle Position Sensor U UL Unle...

Page 18: ...Abbreviations and Acronyms 2018 Avco Corporation All Rights Reserved Page xvi October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 19: ...fault isolation guidelines and procedures to replace components and to disassemble and assemble the engine refer to the TEO 540 A1A Engine Maintenance Manual For spare parts information refer to the TEO 540 A1A Illustrated Parts Catalog Refer to the latest revision of the Service Table of Limits SSP 1776 for dimensions clearances measurements and torque values Service Bulletins Service Instruction...

Page 20: ...o supply the best guidance and recommended practices for safe operation of its engines The table below defines the four types of safety advisory message used in this manual as 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...

Page 21: ...yrighted work All rights reserved by Lycoming Engines Content in this manual cannot be changed or released as a reprint electronic media output or web communiqué without written permission from Lycoming Engines Environmental Compliance Lycoming Engines recommends that engine owners and service personnel be in compliance with all federal state and local environmental regulations when solvents paint...

Page 22: ...Introduction 2018 Avco Corporation All Rights Reserved Page xx October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 23: ...trol an optional electronic propeller governor can be used down exhaust and induction air coolers As standard equipment this engine has an automotive type starter two alternator drives and three AN type accessory drives two standard and one high speed The engine has an Electronic Engine Control System EECS which is a microprocessor The EECS continuously monitors and automatically adjusts operating...

Page 24: ...lled system that continuously monitors and adjusts ignition timing fuel injection timing and fuel mixture based on operating conditions The EECS eliminates the need for magnetos and manual fuel air mixture Figure 2 shows the EECS integrated controls The EECS connects engine hardware with electronic controls to replace mechanical control systems and enables single lever engine control Figure 2 EECS...

Page 25: ...Alternator PMA mounted on the engine accessory drive supplies power to the power box o Data Logger ADL a single channel unit that records data received from the ACU via the CAN bus communication Figure 3 EECS Primary Components Secondary components o Engine harness o Sensors o Actuators The ECU and Power Box are connected by two wiring harnesses the engine to firewall harness Figure 4 and the airf...

Page 26: ... fault codes from the ECU Upload fault codes from the ECU Monitor ECU operation Upload data from the data logger if needed The EECS collects internal fault log data and external fault log data Maintenance personnel use this data for diagnostic and continuous airworthiness Access to this tool is through a laptop where the software is installed and through an established link with the EECS for the e...

Page 27: ... activate all 12 spark plugs The channel in control sends output to the fuel injectors exhaust bypass valve propeller governor and its six ignition coils The other channel sends output to its six ignition coils These outputs control fuel flow induction manifold pressure engine speed and ignition timing The ECU transmits output data through two CAN buses CAN2 and CAN3 and one RS232 bus Figure 6 The...

Page 28: ... sources simultaneously Airframe power only is used under the following conditions During engine start When the engine speed is below approximately 1000 rpm When the PMA has failed Each Power Box Channel has a dedicated ground connected to a common airframe ground Electrical Interface Table 1 identifies elements of the electrical interface for the engine Table 1 Engine Electrical Interface Element...

Page 29: ...he temperature of air before the throttle Primary Induction Air Manifold Temperature Sensor MAT P 1 Redundantly measures the MAT Secondary Induction Air Manifold Temperature Sensor MAT S 1 Redundantly measures the MAT Fuel Temperature Sensor FUEL T 1 Measures the temperature of the fuel in the fuel rail Cylinder Head Temperature Sensor CHT 1 6 6 Measures the Cylinder Head Temperature CHT Exhaust G...

Page 30: ...Refer to Appendix A for the cylinder cooling airflow and pressure differential curve Crankcase The crankcase is made up of two reinforced castings divided at the centerline of the engine The castings are attached by a series of thru studs bolts and nuts The mating surfaces of the two castings are joined without a gasket The crankcase forms the bearings for the camshaft The camshaft operates the ro...

Page 31: ...ller governor drive is on the left front half of the crankcase Fuel System The fuel system Figure 7 can support continued engine operation throughout its flow and pressure range The engine fuel system is made up of a three position engine driven fuel pump in line fuel filter fuel hoses fuel rails six electronic fuel injectors fuel manifold and fuel regulator adapter manifold assembly Figure 7 TEO ...

Page 32: ...el injector based on the measured airflow rate The fuel injectors supply atomized fuel into the intake port of each cylinder sequentially The electronic fuel system supplies priming fuel for engine start Electronic Ignition System The Electronic Ignition System Figure 8 has an all weather shielded braided wire type ignition harness and coil box with 12 electronic ignition coils connected to 12 rad...

Page 33: ...e and transmits the control signal to the electronic two way solenoid valve The electronic two way solenoid valve controls oil pressure to the exhaust bypass valve s hydraulic actuator The exhaust bypass valve controls exhaust gas flow to the turbine wheels Intercoolers one for each turbocharger decrease the temperature of the compressed air before it enters the throttle body The turbocharger outl...

Page 34: ...mp one on each side A threaded oil plug is on the left side of the oil sump for removal of the suction screen Six oil nozzles one at each piston supply positive internal piston cooling An airframe supplied oil cooler is necessary Oil is supplied to and returned from the oil cooler by ports in the accessory housing An oil cooler bypass valve in the accessory housing controls oil flow to the cooler ...

Page 35: ...tappets and camshaft bearings 9 Oil flows into the tappet through indexing holes and through the hollow push rods to the valve mechanism The oil lubricates the valve rocker bearings and valve stems 10 Oil continues to flow through isolated drilled openings to the main bearings of the crankshaft Angular holes go through the main bearings to the rod journals 11 Oil flows through the accessory housin...

Page 36: ...ler is at the front of the engine and the accessories are at the rear of the engine Refer to Figure 10 for cylinder number designations Cylinders 1 and 2 are at the front of the engine In a top view of the engine the left side cylinders are 2 4 6 and the cylinders on the right are 1 3 5 The firing order of the cylinders is 1 4 5 2 3 6 Figure 10 Cylinder Number Designations ...

Page 37: ...on Enables more stable engine operation thru automatic adjustments with changing environmental conditions such as changes in altitude temperature or changes in engine load Supplies more detailed feedback about engine operating conditions and history Automatically does engine pre flight tests Automatically uses redundant features when necessary Supplies integrated functionality such as propeller co...

Page 38: ...es the crankshaft and camshaft speed sensors to calculate engine speed and position Although the engine can operate with full functionality with either sensor position data from the camshaft sensor is necessary for full sequential fuel injection Fuel Control The fuel system supplies a mixture of fuel and air to the cylinders under all conditions of operation The fuel system will keep the correct f...

Page 39: ...S controls the exhaust bypass valve during engine operation Although each channel of the ECU can control the exhaust bypass valve actuator only the ECU channel currently in control of the fuel has control of the exhaust bypass valve actuator The EECS prevents the pressure ratio across the turbocharger compressor from going above a maximum value set in the software The EECS controls the induction a...

Page 40: ...ned to service and the engine operating hours continue without interruption as recorded in the engine logbook 2 Engine rebuild The engine is completely disassembled and assembled with parts and components that have been inspected to new limits An engine rebuild is only completed at the Lycoming Engines factory After an engine rebuild the engine is issued a zero time logbook Timekeeping The EECS re...

Page 41: ...tion switch ON EECS enables fuel and spark to the engine Ignition switch OFF EECS disables fuel and spark to the engine Ignition switch START Enables power to the starter Pre Flight Test PFT switch Starts the pre flight test sequence or sends an acknowledgement and stops the pre flight test Fuel Pump Switch ON Turns the aircraft fuel boost pump ON continuously Fuel Pump Switch AUTO Enables control...

Page 42: ...sing the FST correct the condition s and clear the fault s If the NTO annunciator illuminates during flight and stays illuminated constantly land as soon as safely possible Although the engine will continue to operate operation will be in a degraded mode which requires a prompt safe landing Identify the fault s using the FST correct the condition s and clear the fault s before further flight TLO T...

Page 43: ... A Remove the staples at the bottom perimeter around the box B Remove a few top slats of the crate CAUTION DO NOT TURN THE CRANKSHAFT OF AN ENGINE WITH PRESERVATIVE OIL BEFORE REMOVAL OF THE PLUGS FROM THE SPARK PLUG HOLES OTHERWISE ENGINE DAMAGE CAUSED BY HYDRAULIC LOCK CAN OCCUR C Look for any fluid oil or fuel on the skid or below the engine If fluid is found identify the source Figure 1 Exampl...

Page 44: ...hapter in this manual 5 Refer to the section Lift the Engine in this chapter and lift the engine Engine Preservative Oil Removal The engine is sent with preservative oil in the cylinders and preservative oil in the crankcase Refer to the Prepare a New Rebuilt or Overhauled Engine for Installation section in the Requirements for Engine Installation chapter in this manual Lift the Engine CAUTION USE...

Page 45: ...CTS TO PREVENT DAMAGE TO THE ENGINE OR ITS COMPONENTS 2 Remove the bolts that attach the shipping brackets to the front and rear of the engine 3 Lift the engine slowly and vertically 4 When the engine has preservative oil complete the preservative oil removal procedure now while the engine is lifted Refer to the section Prepare a New Rebuilt or Overhauled Engine for Installation section or Prepare...

Page 46: ...Engine Reception and Lift 2018 Avco Corporation All Rights Reserved Page 24 October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 47: ...for Engine Installation Step Section References in This Chapter 1 Prepare the Engine 2 Supply Interface Items 3 Remove Components 4 Install Engine Mounting Brackets Step 1 Prepare the Engine To prepare a new overhauled or rebuilt engine Refer to the section Prepare a New Rebuilt or Overhauled Engine for Installation in this chapter To prepare an engine that has been in storage Refer to the section...

Page 48: ...he upper spark plugs holes F Turn the crankshaft completely three or four complete revolutions to remove the cylinder preservative oil from the cylinders G Collect the cylinder preservative oil as it drains out of the lower spark plug holes H Tilt the engine to one side until the spark plug holes on that side are vertical I Turn the crankshaft two revolutions and let the oil drain out through the ...

Page 49: ... OVER TIME CAUSE ENGINE FAILURE G Safety cable the oil sump drain plugs and oil suction screen plug in accordance with the standard practices per the latest revision of AC43 13 1B or per the latest revision of Service Instruction No SI 1566 6 Drain the fuel pump A Put a collection container underneath the fuel pump B Remove the shipping caps installed on the fuel pump C Let any preservative fluid ...

Page 50: ...gines be operated with ashless dispersant oil during and after break in the first 50 hours of engine operation or until oil consumption has stabilized 14 Add ashless dispersant oil to a new overhauled or rebuilt engine 15 Refer to Appendix A for the oil capacity Refer to the Add Oil procedure in the Engine Installation chapter in this manual 16 Use the correct disposal procedure for collected oil ...

Page 51: ... Manual 8 Complete the preservative oil removal procedure as follows A Put a container under the engine to collect the cylinder preservative oil B Turn the crankshaft completely three or four revolutions to remove the cylinder preservative oil from the cylinders C Collect the cylinder preservative oil as it drains out of the lower spark plug holes D Tilt the engine to one side until the spark plug...

Page 52: ...No SI 1566 12 Remove the oil filter and install a new oil filter Refer to Chapter 12 10 in the TEO 540 A1A Engine Maintenance Manual 13 If the front expansion plug is installed and a constant speed propeller is to be used remove the expansion plug per instructions in the Crankshaft Disassembly section of Chapter 72 20 in the TEO 540 A1A Engine Maintenance Manual 14 Refer to Chapter 74 20 in the TE...

Page 53: ...warnings and cautions from the system o No Take Off NTO Primary annunciator o NTO Secondary annunciator o Time Limited Operation TLO annunciator o Fault Found FFL annunciator Pre Flight Test PFT pushbutton pushbutton with illumination capability or pushbutton with separate illumination Ignition dual pole single throw switches Aircraft battery used as an EECS backup Starter wiring and controls Two ...

Page 54: ...e engine installation The component s will be re installed after the engine is installed Step 4 Install Engine Mounting Brackets If not already done install the four engine mounting brackets on the engine If the engine mounting brackets were removed from a previously installed engine examine the brackets per the Engine Mount Inspection section in Chapter 72 00 of the TEO 540 A1A Engine Maintenance...

Page 55: ...tep Section References in This Chapter 1 Install the ECU 2 Install the Power Box 3 Install the Engine on Mounts 4 Connect the Wiring Harnesses 5 Connect the Power Control Linkage 6 Install External Accessories 7 Install the Alternators 8 Install the Propeller 9 Connect the Fuel Hoses 10 Connect the Oil Hoses 11 Attach Ground Straps 12 Install Components That Had Been Removed Before Engine Installa...

Page 56: ...stall the Power Box with the correct serial number on the airframe in its designated location in accordance with the wiring diagram Refer to Appendix B of the TEO 540 A1A Engine Maintenance Manual for additional details NOTICE Mounting the ECU to the Power Box requires four 1 4 20 bolts with a maximum length of 1 2 inch 2 The Power Box can be installed in a stacked configuration CAUTION THERE MUST...

Page 57: ...Connect the Wiring Harnesses 1 Examine the airframe receptacles for the airframe interface and airframe power Look closely at the pins and sockets If a receptacle is damaged repair or replace the receptacle as per the airframe manufacturer s instructions 2 Appendix B of the TEO 540 A1A Engine Maintenance Manual identifies harness leads and plugs on the wiring harness Examine the plugs on the engin...

Page 58: ... BY LYCOMING ENGINES NOTICE All the plugs on the wiring harness are uniquely keyed and must be in the correct orientation for the plug to install correctly in the receptacle 8 Connect the two harness plugs primary and secondary identified as CIP P and CIP S to the compressor inlet pressure sensors installed in the induction system between the airframe induction air filter and the turbocharger comp...

Page 59: ...p 8 Install the Propeller Install the propeller in accordance with the propeller and airframe manufacturer s instructions Step 9 Connect the Fuel Hoses 1 Remove unwanted material from the aircraft fuel strainer Let a minimum of 1 gallon 3 8 liters of fuel flow through the strainer aircraft fuel filter and fuel supply line WARNING REMOVE ANY CONTAMINATION FROM AIRCRAFT FUEL TANKS AND FUEL HOSES FAI...

Page 60: ...ENDS OR KINKS IN THE OIL HOSE ROUTING TO PREVENT INTERRUPTIONS TO OIL FLOW DO NOT ROUTE OIL HOSES CLOSE TO HEAT SOURCES 1 Connect the oil hose from the oil sump to the wastegate 2 Connect the oil hoses from the airframe supplied oil cooler 3 Clean each oil hose section and install it in the respective areas Make sure the oil hose routing is smooth without sharp bends kinks or helical twists 4 When...

Page 61: ...nect EECS wiring harness to airframe adapter interface wiring harness 2 Make engine connections to accessories 3 Make engine connections to wires and cables 4 Make engine connections to ducts and cowling 5 Make engine connections to breather hoses and pipes 6 Connect alternator blast tubes to a source of cooling air sufficient to prevent the alternator temperature from increasing above maximum lim...

Page 62: ...oil procedure 1 Make sure that the Ignition switch the Auxiliary Fuel Pump switch and the Fuel Selector are all in the OFF position 2 Disconnect the oil supply hose from the top of the turbocharger 3 Disconnect the engine air duct from the compressor housing inlet 4 Fill the turbocharger oil inlet port with clean ashless dispersant engine oil and manually turn the compressor wheel several revoluti...

Page 63: ...ressure is not stable or drops suddenly stop pre oiling and contact Lycoming Engines NOTICE A new spark plug gasket must be installed whether a new or acceptable re used spark plug is to be installed 13 Once the minimum oil pressure of 20 psi 138 kPa is shown on the oil pressure gauge re install the spark plugs each with a new gasket and connect the ignition leads to all spark plugs per instructio...

Page 64: ...all wiring harnesses and wiring connections have been made Make sure the wiring harness and sensors are attached to the engine Make sure the ECU and Power Box are installed Make sure baffles have been installed Make sure fuel hoses and oil hoses are connected and that there are no leaks Make sure clamps are securely installed on the fuel hoses Make sure oil has been added to engine and the oil qua...

Page 65: ...brated to ensure accuracy CAUTION MAKE SURE THAT ALL VENT AND BREATHER LINES ARE INSTALLED CORRECTLY AND ARE SECURELY IN PLACE IN ACCORDANCE WITH THE AIRFRAME MAINTENANCE MANUAL B Install engine intercylinder baffles airframe baffles seals and cowling All baffles and seals must be in new or good condition to ensure sufficient cooling airflow differential across the engine C For optimum cooling dur...

Page 66: ...that speed for 15 minutes J Make sure the cylinder head temperature oil temperature and oil pressure are within the specified limits in Appendix A of this manual NOTICE Extended ground operation can cause excessively high cylinder head and or oil temperatures If any malfunction occurs stop the engine and let it cool Identify and correct the cause before continuation of the ground operational test ...

Page 67: ... to the engine per the latest revision of Service Instruction No SI 1014 and Appendix A of this manual WARNING IF DURING AN OPERATIONAL TEST OR ENGINE IDLE ANNUNCIATORS ILLUMINATE OR ANY OPERATIONAL PROBLEMS OCCUR IDENTIFY THE FAULT S USING THE FST CORRECT THE CONDITION S AND CLEAR THE FAULT S OR CONTACT LYCOMING ENGINES 3 Proceed to the Engine Initiation chapter for the remaining procedures to pu...

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Page 69: ...s for All Lycoming Engines Step Section References in This Chapter 1 Pre Flight Inspection for Engine Initiation 2 Daily Pre Start Inspection 3 Engine Start 4 Complete the Operational Test 5 Engine Run Up 6 Complete the Pre Flight Test 7 Engine Stop 8 Break In Flight Test 50 Hour Operation 9 Required Inspections During Break In Warranty Requirement WARNING AS ONE OF THE CONDITIONS FOR THE ENGINE W...

Page 70: ...ified in Appendix A Measure the engine oil level before every flight to make sure there is sufficient oil in the engine If the oil level is too low after adding oil look for any oil leaks Identify and correct the cause of any oil leak Complete an oil level check per Chapter 12 10 in the TEO 540 A1A Engine Maintenance Manual Make sure that the engine crankcase breather is attached tightly and that ...

Page 71: ...EAT SOURCES HEAT CAN DAMAGE THE FUEL AND OIL HOSES AND CAUSE A LEAK WHICH COULD LEAD TO CATASTROPHIC ENGINE FAILURE Examine fuel and lubrication lines A Make sure that each fuel hose and oil hose is intact not bent or damaged and does not have any kinks or dents B Make sure that the fuel hoses and oil hoses are securely connected C Make sure the clamps are tightly attached to support the fuel and ...

Page 72: ...ended start procedure follow the aircraft manufacturer s procedure 1 If the engine is newly installed or is to be put back into service after long term storage make sure the pre oil procedure was done Refer to section Step 17 Engine Pre Oil Procedure in the Engine Installation chapter in this manual 2 Complete specified steps and settings for engine start recommended by the aircraft POH or aircraf...

Page 73: ...START AND WARM UP ENGINE DAMAGE CAN OCCUR IF THE OIL TEMPERATURE OR OIL PRESSURE IS NOT AT THE SPECIFIED MINIMUM LEVELS 13 Monitor engine instrumentation for indicated oil pressure If there is no oil pressure indication within 10 seconds stop the engine Contact Lycoming Engines NOTICE Unstable oil pressure or oil pressure less than 25 psi 172 kPa could be an indication of obstructed or interrupted...

Page 74: ...l temperature If low or no oil pressure is noted stop the engine and identify the cause 5 Operate the engine at 750 rpm for 1 minute slowly increase the speed to 1000 rpm in 3 minutes 6 Let the engine operate at 1000 rpm for approximately 3 minutes 7 Look for any illuminated caution or warning lights in the cockpit 8 If oil pressure is sufficient operate the engine at 1000 RPM until the oil temper...

Page 75: ...ENTIFY THE FAULT S USING THE FST CORRECT THE CONDITION S AND CLEAR THE FAULT S OR CONTACT LYCOMING ENGINES NOTICE After the first 25 hours of operation change the oil Examine the oil filter and oil suction screen Refer to Chapter 12 10 in the TEO 540 A1A Engine Maintenance Manual Examine the air filters every other flight for dirt and be prepared to clean or replace them if necessary If the aircra...

Page 76: ...ete the PFT The rpm must be set to 1800 Average CHT between 140ºF and 425ºF 60ºC and 218ºC Before the PFT the EECS activates Built In Tests BITs The BITs are sequences that are pre programmed in the EECS software to look for unacceptable conditions in the engine After all BITs are acceptable the EECS enables the PFT NOTICE Complete the pre flight test when the aircraft is still on the ground To st...

Page 77: ... air fuel ratio B The EECS enables and disables each pre flight test in sequence through calibration The EECS continues the pre flight test to completion even if the expected system response does not occur NOTICE Allow sufficient time for the pre flight test to complete as shown by the PFT annunciator before making any power control changes Otherwise the pre flight test could be inadvertently canc...

Page 78: ...nd illuminates the NTO PRI and or NTO SEC annunciators identify the fault s using the FST correct the condition s and clear the fault s 7 Once the pre flight test is completed the PFT annunciator goes out If either the NTO PRI or NTO SEC annunciator remains illuminated there is a condition that prevents flight and must be corrected Such conditions can be a fault that exceeds set limits or the syst...

Page 79: ...ngine Stop 1 Before engine shutdown operate the engine between 1000 and 1200 rpm for at least 5 minutes to allow turbocharger cool down 2 When operating temperatures are stable and the EGT drops below 1100 F 593 C increase engine speed to 1800 rpm for 15 to 20 seconds Then decrease engine speed to between 1000 and 1200 rpm before engine shutdown 3 After the temperatures are stable set the Ignition...

Page 80: ...e release of the aircraft for service WARNING REPLACE ENGINE TEST CLUBS WITH APPROVED FLIGHT PROPELLERS BEFORE THE FLIGHT TEST DO NOT TAKE OFF IF ANY OF THE FOLLOWING CONDITIONS ARE FOUND Engine roughness High or low fuel flow Low high or surging rpm or fluctuations High manifold pressure High low or fluctuating oil pressure Low battery charge 1 Start the engine and complete a pre flight run up in...

Page 81: ... consumption value is above the limits in Appendix A identify and correct the cause Complete this flight test again up to and including this step before releasing the aircraft for service 12 Refer to the Chapter 12 10 of the TEO 540 A1A Series Engines Maintenance Manual to complete the Oil Change Procedure drain the ashless dispersant oil and add new ashless dispersant oil up to the specified oil ...

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Page 83: ... this manual for dashboard controls Step 2 Engine Start WARNING MAKE SURE THAT THE AREA IN THE ROTATIONAL ARC RADIUS OF THE PROPELLER IS CLEAR OF PERSONNEL OR ANY OBSTRUCTION BEFORE STARTING THE ENGINE NOTICE If the engine is to be started in an environment at temperatures less than 10 F 12 C refer to the section Apply Heat to a Cold Engine in the Engine Conditions chapter in this manual This engi...

Page 84: ...VER 10 SECONDS LET THE STARTER COOL FOR 30 SECONDS AFTER EACH ENERGIZATION DO NOT TRY MORE THAN FIVE ENGINE STARTS WITHIN A 2 MINUTE PERIOD IF THE STARTER FAILS TO ENERGIZE AFTER TWO ATTEMPTS IDENTIFY AND CORRECT THE CAUSE 10 Energize the starter not to exceed 10 seconds until the engine starts 11 If an electronic governor is installed increase rpm to 1800 Do not exceed oil pressure of 115 psi 793...

Page 85: ...T THE CAUSE OF THE PROBLEM AND REPEAT THIS RUN UP Complete the engine run up as follows 1 Start the engine 2 Make sure the oil temperature is above the specified minimum WARNING IF THE ENGINE IS OPERATED AT LOW OIL PRESSURE OR LOW OIL LEVEL THE ENGINE CAN MALFUNCTION OR STOP 3 Make sure the oil pressure and oil temperatures are within operating range Appendix A 4 Increase the power control to 1200...

Page 86: ... following criteria must be met to enable the pre flight test to start when the PFT button is pressed in the next step Engine speed is 1800 rpm Oil pressure in green Oil temperature in green NOTICE If the PFT button is pressed and held down the pre flight test will not begin because the EEC system will assume the PFT button is stuck 5 Momentarily press and release the PFT button Do not press the P...

Page 87: ...ct engine speed and ensure average CHT is within limits before pressing the PFT button again D Once the pre flight test starts it will abort if any of the following occur Power control changes more than 5 from where it was at the start of the sequence Engine speed goes below 1000 rpm Engine speed goes above 2300 rpm Engine load goes below 15 Average CHT goes below 140º 60ºC Average CHT goes above ...

Page 88: ...nnunciator illuminated NOTICE If problems are found that go beyond field maintenance contact Lycoming Engines Technical Support 9 The engine is ready for take off when the oil temperature is greater than 140 F 60 C and there are no faults or items that need corrective action 10 Use smooth transitions of the power control FULL CLOSED to FULL OPEN in no less than 2 seconds during power control shift...

Page 89: ...ommended power settings B Until oil consumption has stabilized after the first 50 hours of flight cruising is to be done at not less than 65 power to ensure correct seating of the rings 4 Recommendations to Prevent Spark Plug Fouling Lead deposits can collect on the spark plug electrodes when the engine operates at lower than specified temperatures with fuel rich mixtures fuel rich mixtures do not...

Page 90: ... turn the Fuel Selector to the OFF position WARNING DO NOT TURN THE PROPELLER ON A HOT ENGINE EVEN THOUGH THE IGNITION SWITCH IS IN THE OFF POSITION THE ENGINE COULD KICK BACK AS A RESULT OF AUTO IGNITION CAUSED BY A SMALL AMOUNT OF FUEL REMAINING IN THE CYLINDERS AUTO IGNITION COULD RESTART THE ENGINE AND CAUSE SERIOUS BODILY INJURY OR DEATH NOTICE An independent fuel shut off valve is supplied b...

Page 91: ...ic components failure Required Action for Engine Conditions Table 1 identifies corrective action for engine conditions prior to and during flight Detailed fault isolation is included in the TEO 540 A1A Engine Maintenance Manual Table 1 Action for Engine Conditions Engine Condition Explanation Corrective Action Displays Engine indicating data not available Do not take off until Maintenance identifi...

Page 92: ... possible PFT in Progress indication is cleared while the PFT is in progress The PFT annunciator will flash as an indication that the pre flight test was not completed The pilot must push and then let go of the PFT button to clear this condition and then re start the pre flight test Engine Operation Engine roughness Complete a safe landing and speak to Maintenance Engine hesitates misses Complete ...

Page 93: ...iable operation There could be some select points where Lean of Peak operation is advantageous Ascent to target altitude leveled off fuel flow increased with power control input On hot days during steep climbs or in other situations in which the engine could operate at high temperatures the EECS automatically prevents overheating Higher fuel flow can be observed as the EECS uses more fuel to preve...

Page 94: ...n Engine stall Make sure the Fuel Selector is set to the correct fuel tank Make sure that the auxiliary fuel pump is ON Cycle the Ignition switch to OFF then ON Set the power control to maintain a manifold pressure of 8 in Hg 3 9 psi or more Make sure that the Ignition switch is set to ON If the propeller has stopped turning engage the starter If the engine restart procedure during flight is not s...

Page 95: ...t difficult NOTICE Pre heat application will help the engine start during cold weather and is necessary when the engine has been in sub freezing temperature 10º F 12ºC Do not use small electric heaters which install in the cowling opening to warm up an engine because they do not apply sufficient heat Do not use a heated dipstick to apply heat because heat will be concentrated and not applied throu...

Page 96: ...ay cold If no leaks or damage are found complete the pre heat application again before engine start 2 Let the engine warm up at 1000 rpm until oil pressure and temperature are stable within operating limits identified in Appendix A 3 Complete a ground check in accordance with the aircraft manufacturer s POH 4 Complete a cycle of the propeller control position in accordance with the aircraft and pr...

Page 97: ...ng smoothly in flight make a safe landing of the aircraft as soon as possible and isolate faults on the engine CAUTION DO NOT TOUCH THE VOLCANIC ASH WITH BARE HANDS DO NOT USE WATER TO REMOVE THE VOLCANIC ASH 3 Additional measures could be necessary under specific operating conditions Refer to the TEO 540 A1A Engine Maintenance Manual for corrective action Overspeed In engine overspeed the engine ...

Page 98: ...il pressure loss or engine operation with oil below the recommended minimum operating level identified in Table A 1 in Appendix A the most conservative action is to remove the engine disassemble and completely examine all engine components per instructions in the TEO 540 A1A Engine Maintenance Manual NOTICE Very often a sudden loss of oil pressure also shows a sudden increase in oil temperature An...

Page 99: ...ine cannot be operated at the recommended oil temperatures speak with the aircraft manufacturer about the use of oil cooler winterization plates Because climate conditions are different in various geographic areas Lycoming Engines only can give general recommendations for corrosion prevention The owner and operator must take into account the following factors for setting a rust and corrosion preve...

Page 100: ...udes a spray application of preservative oil to the walls of each engine cylinder You will need the following items from industrial suppliers to complete this procedure Engine preservation oil mixture made up of 24 MIL C 6529 71 SAE J1966 Grade 1065 or MIL PRF 21260 Grade 30 5 Cortec M 529 Airless spray gun or garden sprayer Clay desiccant bags NOTICE Start this preservation procedure at the end o...

Page 101: ...r instructions in Chapter 72 80 in the TEO 540 A1A Engine Maintenance Manual remove the exhaust system per the airframe manufacturer s manual B Install bags of clay desiccant in the exhaust and intake ports C Install the intake pipes per instructions in Chapter 72 80 in the TEO 540 A1A Engine Maintenance Manual install the exhaust system per the airframe manufacturer s manual D Attach red cloth st...

Page 102: ...er 2018 TEO 540 A1A Engine Installation and Operation Manual Extended Engine Preservation for 61 Days or More Refer to the latest revision of Service Instruction No SI 1481 Fuel Injector Preservation Refer to the fuel injector manufacturer s instructions for preservation of fuel injectors ...

Page 103: ...gine Specifications Number of Cylinders 6 Cylinder Arrangement Firing Order 1 4 5 2 3 6 Spark Plugs 12 Spark Plug Advance 20º BTC Maximum Rated Continuous HP RPM Altitude 350 HP 2500 rpm 8000 ft 2 438 Meters Takeoff Rated 350 HP 2500 rpm Performance Cruise 75 Rated 262 HP 2400 rpm Economy Cruise 60 Rated 210 HP 2200 rpm Fuel Injection Electronic Fuel Injectors 6 one for each cylinder Engine Back u...

Page 104: ...or possible alternative fuels contact Technical Support at the phone numbers in the front of this manual For optional starters and alternators refer to the TEO 540 A1A Illustrated Parts Catalog or contact Lycoming Engines NOTICE All locations and rotations are as viewed from the accessory housing end back of the engine unless specified differently Table A 2 Table of Operating Limits for Engine Oil...

Page 105: ... C Maximum Manifold Pressure 42 in hg 142 2 kPa Maximum Cylinder Head Temperature 500 F 260 C Cylinder Head Temperature for maximum service life Above 85 power 475 F 246 1 C Cylinder Head Temperature for maximum service life 85 power and below in level flight 435 F 224 C Maximum Alternator Temperature Stator Slot and Stator End Turns 356 F 180 C Maximum Alternator Temperature Drive End Bearing and...

Page 106: ...ter clockwise 16 556 1 450 51 150 17 Alternators 2 SAE Clockwise 3 80 1 60 7 120 14 175 20 Accessory Pad 1 AND20000 Counter clockwise 1 3 1 70 8 800 90 25 3 Accessory Pad 2 AND20000 Clockwise 1 3 1 100 11 800 90 40 5 Accessory Pad 3 AND20000 Clockwise 3 54 1 40 5 300 34 25 3 Prop Gov Pad AND20010 Clockwise Viewing Pad 0 947 1 125 14 2200 249 25 3 Fuel Pump AND20003 Clockwise 1 0 1 25 3 450 51 25 3...

Page 107: ... 2018 Avco Corporation All Rights Reserved Appendix A October 2018 Page 85 TEO 540 A1A Engine Installation and Operation Manual Figure A 1 Cooling Air Requirements ...

Page 108: ...Appendix A 2018 Avco Corporation All Rights Reserved Page 86 October 2018 TEO 540 A1A Engine Installation and Operation Manual Figure A 2 Propeller Governor Oil Transfer Leakage Rate ...

Page 109: ... 2018 Avco Corporation All Rights Reserved Appendix A October 2018 Page 87 TEO 540 A1A Engine Installation and Operation Manual Figure A 3 Sonic Nozzle Airflow ...

Page 110: ...Appendix A 2018 Avco Corporation All Rights Reserved Page 88 October 2018 TEO 540 A1A Engine Installation and Operation Manual Figure A 4 2500 RPM Sea Level and Altitude Performance ...

Page 111: ... 2018 Avco Corporation All Rights Reserved Appendix A October 2018 Page 89 TEO 540 A1A Engine Installation and Operation Manual Figure A 5 2400 RPM Sea Level and Altitude Performance ...

Page 112: ...Appendix A 2018 Avco Corporation All Rights Reserved Page 90 October 2018 TEO 540 A1A Engine Installation and Operation Manual Figure A 6 2200 RPM Sea Level and Altitude Performance ...

Page 113: ... 2018 Avco Corporation All Rights Reserved Appendix A October 2018 Page 91 TEO 540 A1A Engine Installation and Operation Manual Figure A 7 Fuel Flow versus Percent of Rated Power ...

Page 114: ...Appendix A 2018 Avco Corporation All Rights Reserved Page 92 October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 115: ...ECS Sensor and Actuators ECU and Power Box 4 Temperature and Altitude B3 B3 5 Temperature Variation A A 6 Humidity C C 8 Vibration Engine Durability R Curve I 9 Explosive Atmosphere IIE IIE 10 Waterproofness S S 11 Fluid Susceptibility F F 12 Sand and Dust D D 13 Fungus Resistance F F 14 Salt Fog S S 15 Magnetic Effect N A N A 16 Power Input Z Z 17 Voltage Spike A A 18 Audio Frequency Conducted Su...

Page 116: ...Appendix B 2018 Avco Corporation All Rights Reserved Page 94 October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 117: ...n when deciding to command a reset 5 WARNING The NTO indication provides an indication that the ECU along with limited conventional engine hardware is acceptably safe for flight once a proper PFT is conducted The operator must still interrogate conventional engine indications to determine that the conventional engine is also acceptable safe for flight 6 WARNING The operator must properly conduct a...

Page 118: ...Appendix C 2018 Avco Corporation All Rights Reserved Page 96 October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...

Page 119: ...ation and Operation Manual APPENDIX D WIRING DIAGRAMS NOTICE For Wiring Harness Leads and Connection Location Air Frame Wiring Interface Communications Buses Volt Power System Connection System Wiring Diagrams and Communications Bus Data refer to Appendix B in the TEO 540 A1A Engine Maintenance Manual ...

Page 120: ...Appendix D 2018 Avco Corporation All Rights Reserved Page 98 October 2018 TEO 540 A1A Engine Installation and Operation Manual This page intentionally left blank ...