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Lycoming TEO-540-A1A User Manual

Lycoming TEO-540-A1A
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© 2018 Avco Corporation. All Rights Reserved
Engine Installation and Operation Manual
TEO-540-A1A Engine
October 2018
Part No. IOM-TEO-540-A1A

Table of Contents

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Lycoming TEO-540-A1A Specifications

General IconGeneral
Rated Speed2700 rpm
Compression Ratio8.7:1
Fuel TypeAvGas 100LL
Oil SystemWet sump
Cooling SystemAir cooled
Redline2700 rpm
Displacement540 cu in (8.8 L)
Bore5.125 in (130.2 mm)
Stroke4.375 in (111.1 mm)
Ignition SystemDual magnetos
Fuel SystemFuel injection
Fuel Grade100LL
TypeHorizontally Opposed, 6-Cylinder, 4-Stroke

Summary

Record of Revisions

Service Document List

List of Figures

List of Tables

Abbreviations and Acronyms

Introduction

Engine Model Nomenclature

Defines the letters and numbers in the engine model nomenclature.

Scope of this Manual

Details the manual's content and purpose for Lycoming engines.

Service Bulletins, Service Instructions, and Service Letters

Explains how Lycoming provides timely updates via SBs, SIs, and SLs.

Compliance Requirements

Compliance Requirements

Emphasizes operating the engine according to manual specs and other service documents.

Warning, Cautions, and Notices

Explains the importance of safety advisories and their definitions.

System Description

TEO-540-A1A Engine

Describes the TEO-540-A1A engine as a turbocharged, electronically-controlled, six-cylinder unit.

Electronic Engine Control System (EECS)

Explains the EECS as a microprocessor system for monitoring and adjusting engine parameters.

EECS Architecture

Details the primary components (ECU, Power Box, ADL) and secondary components of the EECS.

Field Service Tool (FST)

Describes the FST as diagnostic software for identifying fault codes and monitoring ECU operation.

EECS Operation

Explains how the EECS controls actuators, spark plugs, fuel flow, and engine speed.

Electrical Interface

Details the EECS input power requirements and airframe interface connection.

Wiring Harnesses

Describes the two types of wiring harnesses: engine-to-firewall and airframe interface.

Sensors

Lists sensors connected to harnesses that measure engine parameters for ECU input.

Cylinders

Describes the components within each of the six engine cylinders.

Crankcase

Details the construction of the crankcase and its role in housing components and oil passages.

Propeller Drive

Describes the flange-type propeller shaft and its attachment to the crankshaft.

Fuel System

Explains the engine fuel system components including pump, filter, injectors, and manifold.

Electronic Ignition System

Details the ignition system, including harness, coils, spark plugs, and power sources.

Air Induction System

Describes the air induction system, its components, and requirements for air cleaners.

Turbocharger System

Explains the function of the two turbochargers and the EECS control.

Accessory Housing/Accessory Drive Pads

Describes the accessory housing and the types of accessory drive pads.

Lubrication System

Lists the components of the wet sump pressurized lubrication system.

Engine Mounting

Discusses the engine mounting brackets and rear Dynafocal mounting.

Cylinder Number Designations

Illustrates cylinder numbering and the engine firing order.

Theory of Operation

EECS Operation

Details the EECS functions including performance increase, fuel adjustment, and fault detection.

Engine Control Sequence

Explains the sequence of events for EECS to start and operate the engine.

Engine Synchronization

Defines engine synchronization as the calculation of crankshaft and camshaft speed.

Fuel Control

Describes how the EECS controls fuel injection and air/fuel ratio.

Ignition Control

Explains how the EECS electronically controls ignition timing and spark plug operation.

Load Sensing

Details the redundant methods the EECS uses to calculate engine airflow.

Inoperative Cylinder Detection

Explains how the EECS identifies and disables non-operational cylinders.

Cylinder Head Temperature Control

Describes EECS monitoring and adjustment of Cylinder Head Temperature (CHT).

Turbocharger Turbine Inlet Temperature Control

Explains EECS adjustment of fuel to control turbocharger turbine inlet temperature.

Turbocharger Control

Details EECS control of the exhaust bypass valve and manifold pressure.

Propeller Pitch Control

Explains EECS automatic control of propeller pitch for hydraulic constant-speed propellers.

Engine Overhaul vs. Engine Rebuild

Differentiates between engine overhaul and factory rebuild processes.

Timekeeping

Explains how the EECS records operating time and that it cannot be reset.

Pilot Controls and Annunciators

Pilot Controls

Identifies pilot controls for the TEO-540-A1A engine and shows cockpit controls.

Warning Indication Annunciators

Describes EECS hardwired warning annunciators and their pilot actions.

Engine Reception and Lift

Uncrate Procedure for a New, Rebuilt, or Overhauled Engine

Provides steps for safely removing the engine from its shipping container.

Acceptance Check

Outlines the steps for verifying the engine serial and model numbers upon receipt.

Engine Preservative Oil Removal

Refers to procedures for removing preservative oil from cylinders and crankcase.

Lift the Engine

Provides instructions and cautions for safely lifting the engine using straps.

Requirements for Engine Installation

Overview

Provides an overview of installation requirements and refers to an ICD.

Step 1. Prepare the Engine

Details the preparation steps for new, overhauled, rebuilt, or stored engines.

Prepare a New, Rebuilt, or Overhauled Engine for Installation

Outlines the depreservation procedure for engines prior to installation.

Prepare a Stored Engine for Installation

Instructions for preparing an engine that has been in storage for installation.

Step 2. Supply Interface Items

Lists items the airframe manufacturer must supply for initial engine installation.

Step 3. Remove Components

Procedure for temporarily removing components to facilitate engine installation.

Step 4. Install Engine Mounting Brackets

Instructions for installing engine mounting brackets, including inspection.

Engine Installation

Engine Installation Overview

Refers to Table 1 for steps and section references for engine installation.

Step 1. Install the ECU

Details the procedure for installing the Engine Control Unit (ECU) with correct serial numbers.

Step 2. Install the Power Box

Describes the installation of the Power Box, including its configuration and mounting.

Step 3. Install the Engine on Mounts

Provides instructions for aligning and securing the engine to the airframe mounts.

Step 4. Connect the Wiring Harnesses

Guides the connection of engine and airframe wiring harnesses, checking for damage.

Step 5. Connect the Power Control Linkage

Instructions for connecting the cable to the engine's power control linkage.

Step 6. Install External Accessories

Instructions for installing external accessories onto the engine's accessory drive pads.

Step 7. Install the Alternators

Details the installation of alternators and alternator belts as per maintenance manual.

Step 8. Install the Propeller

Instructions for installing the propeller according to manufacturer specifications.

Step 9. Connect the Fuel Hoses

Guides the connection of fuel hoses, emphasizing cleanliness and proper routing.

Step 10. Connect the Oil Hoses

Provides instructions for connecting oil hoses, ensuring smooth routing and proper torque.

Step 11. Attach Ground Straps

Details the installation of ground straps for EECS operation and lightning protection.

Step 12. Install Components That Had Been Removed Before Engine Installation and Any Additional Ship Loose Components

Instructions for reinstalling removed components and any loose parts shipped with the engine.

Step 13. Make Remaining Engine Connections

Guides the final engine connections for wiring, accessories, ducts, and pipes.

Step 14. Install Baffling

Instructions for installing baffling around the engine compartment.

Step 15 Add Oil

Details the procedure for adding the correct quantity and viscosity of oil to the engine.

Step 16. Engine Pre-Oil Procedure

Explains the critical pre-oil procedure to circulate oil and ensure pressure before starting.

Step 17. Add Fuel

Instructions for adding the specified fuel to the aircraft.

Step 18. Make RPM Measurements

Notes the absence of a mechanical tachometer drive and the need for airframe calibration.

Step 19. Final Installation Inspection

Directs the user to complete the Engine Installation Checklist.

Step 20. Close Engine Compartment

Instructions for closing the engine compartment, ensuring no tools are left behind.

Engine Installation Checklist

A checklist to ensure all engine installation steps have been completed correctly.

Field Run-In

Preparation for Ground Operational Test with Engine Installed in Aircraft

Steps for preparing the aircraft and engine for a ground operational test.

Ground Operational Test

Details the procedure for conducting the ground operational test of the engine.

Engine Initiation

Engine Initiation

Outlines procedures for initiating newly installed or overhauled Lycoming engines.

Warranty Requirement

States warranty conditions requiring adherence to manual specifications and maintenance procedures.

Step 1. Pre-Flight Inspection for Engine Initiation

Guides the completion of a pre-flight inspection checklist for engine initiation.

Step 2. Pre-Start Inspection

Refers to the Pilot’s Operating Handbook for the daily pre-start inspection.

Step 3. Engine Start

Provides a step-by-step procedure for starting the engine safely.

Step 4. Operational Test

Details the procedure for conducting the operational test of the engine.

Step 5. Engine Run-Up

Guides the procedure for running up the engine, checking oil temperature and pressure.

Step 6. Complete the Pre-Flight Test

Explains the pre-flight test (PFT) to ensure correct engine operation and EECS functionality.

Step 7. Engine Stop

Provides the procedure for safely shutting down the engine, including turbocharger cool down.

Step 8. Break-In/Flight Test/50-Hour Operation

Outlines the engine break-in process, including flight tests and 50-hour operations.

Step 9. Required Inspections During Break-In (50-Hour Operation)

Lists required inspections during the first 50 hours of engine operation.

Engine Operation

Prerequisite Requirements for Engine Operation

Lists the prerequisite steps that must be completed before routine engine operation.

Step 1. Pre-Start Check

Refers to the POH for pre-start checks and notes on air filter inspection.

Step 2. Engine Start

Details the engine start procedure, including safety checks and environmental considerations.

Step 3. Engine Run-Up

Guides the procedure for running up the engine, checking oil temperature and pressure.

Step 4. Pre-Flight Test

Explains the pre-flight test (PFT) to ensure correct engine operation and EECS functionality.

Step 5. Engine Operation

Provides instructions for normal engine operation, including take-off and flight recommendations.

Step 6. Engine Stop

Details the procedure for safely shutting down the engine, including turbocharger cool down.

Engine Conditions

Fault Isolation - Use of Field Service Tools

Explains how to use the Field Service Tool (FST) for fault isolation.

Faults

Describes how the EECS collects fault code data for diagnostics.

Required Action for Engine Conditions

Identifies corrective actions for various engine conditions and annunciator states.

Apply Heat to a Cold Engine

Provides procedures for starting an engine in cold weather conditions.

Cold Weather Engine Start

Offers Lycoming's recommended procedure for cold weather engine starts.

Engine Operation in Hot Weather

Provides recommendations for operating the engine in hot weather conditions.

Volcanic Ash

Advises against operating in volcanic ash and outlines standard actions for contamination.

Overspeed

Explains engine overspeed conditions, EECS response, and corrective actions.

Low Oil Pressure During Flight

Discusses causes of low oil pressure and the recommended actions for a safe landing.

Engine Preservation and Storage

Engine Corrosion and Prevention

Explains how to prevent engine corrosion through regular operation and proper storage.

Engine Preservation Guidelines - 31 to 60 Days

Details the procedure for preserving engines installed in aircraft stored for 31 to 60 days.

Extended Engine Preservation for 61 Days or More

Refers to Service Instruction SI-1481 for preserving engines for longer periods.

Fuel Injector Preservation

Refers to fuel injector manufacturer's instructions for preservation.

Appendix A

Table A-1 Engine Specifications

Presents detailed specifications for the TEO-540-A1A engine.

Table A-2 Table of Operating Limits for Engine

Lists the operating limits for engine oil pressure, temperature, and consumption.

Table A-3 Accessory Drives

Shows accessory drives, their types, rotation, and torque specifications.

Appendix B

Table B-1 Physical Environmental Limits

Lists physical environmental limits for EECS components as per DO-160F.

Appendix C

Table C-1 Safety Alert Messages

Displays critical safety alert messages and their corresponding titles and warnings.

Appendix D

NOTICE: For Wiring Harness Leads and Connection Location...

Directs users to Appendix B of the Maintenance Manual for wiring details.

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