540 Series This beast handles any burden. The Lycoming O -5 -540 40 series engines are six-cylinder, six-cylinder, direct-drive, horizontally opposed, air-cooled models. The cylinders are of conventional air-cooled construction with heads made from an aluminum-alloy casting and a fully machined combustion chamber. Rocker-shaft bearing supports are cast integral with the head, along with housings to form the rocker boxes. The cylinder barrels have deep integral cooling fins, and the inside of the barrels are ground and honed to a specified finish. The IO-5 IO -540 40 and TIO-5 TIO -540 40 (turbocharged) series engines are equipped with a fuel-injection system, which schedules fuel flow in proportion to airflow. Fuel vaporization takes place at the intake ports. A turbocharger(s) is mounted as an integral part of the TIO-5 TIO -540 40 series. Automatic waste-gate waste-gate control of the turbocharger provides constant air density to the fuel-injector inlet from sea level to critical altitude. CHROMIUM-MODIFIED NI-RESIST IRON EXHAUST-VALVE GUIDES, RESULTING IN BETTER WEAR CHARACTERISTICS
FORGED-STEEL CONNECTING RODS
FORGED-STEEL CAMSHAFTS
OPTIONAL CH CHROME KI KIT
NITRIDE-HARDENED ST STEEL ALLOY CYLINDER BARRELS
FORGED-STEEL CRANKSHAFTS
AVAILABLE OPTIONS: – Lightw Lightweight eight starter starterss – Electr Electronic onic igniti ignition on – Spin-o Spin-onn or remote remote oil filter filter – Air conditioning conditioning provisio provisions ns – Factory chrom chromee kits: kits: Triple-plated rocker-box covers, intake pipes and shroud tubes – Optio Optional nal magne magnetos tos – Fixed-p Fixed-pitch itch or constant-sp constant-speed eed propeller applications
This current production model data is provided for engine selection, and is subject to change without notice. The Lycoming Sales Department should be contacted prior to starting detailed installation layouts. Engine weights may vary according to specific engine model configuration.
540 CUBIC INCH ENGINE SERIES
MODEL
COMPRESSION RATIO HP
O-540-A O-540-B O-540-E O-540-G O-540-J O-540-L IO-540-A IO-540-C IO-540-D IO-540-K IO-540-S IO-540-V IO-540-AA IO-540-T4B5 IO-540-W1A5 TIO-540-A TIO-540-C L/TIO-540-F L/TIO-540-J TIO-540-S L/TIO-540-U L/TIO-540-W TIO-540-AB1AD TIO-540-AF1B TIO-540-AA1AD TIO-540-AE2A
8.50:1 7.20:1 8.50:1 8.50:1 8.50:1 8.50:1 8.70:1 8.50:1 8.50:1 8.70:1 8.70:1 8.50:1 7.30:1 8.50:1 8.50:1 7.30:1 7.20:1 7.30:1 7.30:1 7.30:1 7.30:1 7.30:1 8.00:1 8.00:1 8.00:1 7.30:1
250 235 260 260 235 235 290 250 260 300 300 260 270 260 235 310 250 325 350 300 350 350 250 270 270 350
RPM
2,575 2,575 2,700 2,700 2,400 2,400 2,575 2,575 2,700 2,700 2,700 2,700 2,700 2,700 2,400 2,575 2,575 2,575 2,575 2,700 2,500 2,600 2,575 2,575 2,575 2,500
HEIGHT (IN)
TBO
2,000 24.56 2,000 24.56 2,000 24.56 2,000 24.56 2,000 20.43-24.56 2,000 20.43 1,400 19.60 2,000 24.46 2,000 24.46 2,000 19.60-20.86 1,800 19.60 2,000 19.35 1,800 19.60 2,000 21.50 2,000 19.35 1,800 22.71 2,000 30.33 1,800 22.42 1,800 22.56 1,800 26.28 1,800 22.62 2,000 23.33 2,000 30.06 2,000 28.62 2,000 21.48 2,000 27.75
WIDTH (IN)
LENGTH (IN)
DRY WT (LBS)
REMARKS
33.37 33.37 33.37 33.37 33.37 33.37 34.25 33.37 33.37 34.25 34.25 33.37 34.25 33.37 33.37 34.25 33.37 34.25 34.25 36.02 34.25 34.80 33.37 33.38 33.37 46.52
37.22-38.42 37.22-39.34 37.22-39.34 39.34 38.93 38.93 38.62 37.22-38.42 38.42-39.34 38.62-39.34 39.34 38.93 39.24 38.93 38.93 51.34 40.38 51.34 51.50 39.56 51.93 54.19 39.36 40.24 48.57 42.02
405-406 395-397 397-399 415 387-388 387 443 402-404 410-412 466-474 475 414-420 479 418 400 540 483 542 548 533 580 567 474 493 466 595
Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts Dynafocal Mounts
TIO-540 ENGINE LABELING LEGEND:
1
2
1 PREFIXES:
AE – Aerobatic (wet sump) H – Horizontal Helicopte r I – Fuel Injected L – Left Hand Rotation Crankshaft O – Opposed Cylinders T – Turbocharged
2 CYLINDER CUBIC INCH
DISPLACEMENT: Number of Cylinders
Cubic Inch Displacement
4 6 8
235, 320, 360 540, 580 720
ENGINE MOUNT CONFIGURATIONS: Conical –
Straight mounts parallel to crankshaft.
Dynafocal –
Mounts set at a specified angle to the crankshaft with Type 1 (30˚) and Type 2 (18˚).
Bed –
Bed mounting available on select engine models. © 2004 Lycoming. Lycoming is a division of AVCO Corp., a Textron subsidiary.
LYCOMING OPERATOR’S MANUAL O-540, IO-540 SERIES
SECTION 3 OPERATING INSTRUCTIONS
Figure 3-29. Fuel Flow vs Percent Rated Power – IO-540-AC Series
SECTION 3 OPERATING INSTRUCTIONS
LYCOMING OPERATOR’S MANUAL O-540, IO-540 SERIES
Figure 3-30. Sea Level and Altitude Performance Curve – IO-540-AC Series 3-42
