LIMBACH L 2400 EF, L 2400ET, L 2400DF, L 2400DT, L 2400DX Operating And Maintenance Manual
...
Operating and Maintenance Manual
Limbach L 2400 EF/DF
ET/DT
DX/DS
Engine for Powered Gliders and
Very Light Aircraft
Edition: 20.06.2018
This manual is approved in accordance with the procedures of the EASA approved development organization No. EASA.21J.270.
Approval and translation has been done by best knowledge and judgement. - In any
case the original text (P/N 250.253.500.000) in german language is authoritative.
Limbach Flugmotoren GmbH
Kotthausener Str. 5
53639 Königswinter, Germany
Tel. ++49-2244-9201-0
Fax ++49-2244-9201-30
www.limflug.de
© Limbach Flugmotoren GmbH 250.253.501.000
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Edition: 20.06.2018
Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.50
1.000
Table of Contents
1.1 Change Index ............................................................................................................................................... 4
1.2 Release ........................................................................................................................................................ 4
2 Introduction .................................................................................................................................................... 5
3 Engine Description ......................................................................................................................................... 6
3.1 Model Designation ....................................................................................................................................... 6
3.2 Cylinder Designation .................................................................................................................................... 7
4 Technical Data ............................................................................................................................................... 8
4.1 LIMBACH L 2400 EF/DF ............................................................................................................................. 8
4.2 LIMBACH L 2400 ET/DT ........................................................................................................................... 10
4.3 LIMBACH L 2400 DX ................................................................................................................................ 12
4.4 LIMBACH L 2400 DS ................................................................................................................................ 14
5 Performance ................................................................................................................................................ 16
5.1 Performance Graph LIMBACH L 2400 EF/DF .......................................................................................... 16
5.1.1 Performance Data L 2400 EF/DF .............................................................................................................. 17
5.2 Performance Graph LIMBACH L 2400 ET/DT .......................................................................................... 18
5.2.1 Performance Data L 2400 ET/DT .............................................................................................................. 19
5.3 Performance Graph LIMBACH L 2400 DX ............................................................................................... 20
5.3.1 Performance Data L 2400 DX .................................................................................................................... 21
5.4 Performance Graph LIMBACH L 2400 DS ............................................................................................... 22
5.4.1 Performance Data L 2400 DS .................................................................................................................... 23
6 Operating Instructions .................................................................................................................................. 24
6.1 Before Starting ........................................................................................................................................... 24
6.2 Engine Start-Up .......................................................................................................................................... 24
6.3 Runup, Performance Check ....................................................................................................................... 25
6.3.1 Performance Check ................................................................................................................................... 25
6.3.2 Ignition Check L 2400 DF/DT/DX/DS......................................................................................................... 25
6.4 Hot Engine Start-Up ................................................................................................................................... 25
6.5 Take-Off ..................................................................................................................................................... 26
6.6 Engine Shut-Down ..................................................................................................................................... 26
6.7 Inflight Shut-Down and Restarting ............................................................................................................. 26
6.8 Emergency Procedures ............................................................................................................................. 27
6.8.1 Version with engine Emergency Switch ..................................................................................................... 27
6.8.2 Version with electronic engine display ....................................................................................................... 28
7 Maintenenance Schedule ............................................................................................................................ 29
7.1 Daily Check ................................................................................................................................................ 29
7.2 Periodical Checks ...................................................................................................................................... 29
7.2.1 If the Engine is not Operated for more than 3 Months ............................................................................... 29
7.2.2 Every 2 Years ............................................................................................................................................. 29
7.2.3 Every 5 Years after New or Main Overhaul ............................................................................................... 29
7.3 Operating Time related Inspections ........................................................................................................... 30
7.3.1 After the first 5 Operating Hours ................................................................................................................ 30
7.3.2 After the first 25 Operating Hours .............................................................................................................. 30
7.3.3 Every 50 Operating Hours ......................................................................................................................... 30
7.3.4 Every 100 Operating Hours ....................................................................................................................... 31
7.3.5 Every 200 Operating Hours ....................................................................................................................... 31
7.3.6 Every 500 Operating Hours ....................................................................................................................... 31
8 Maintenance Instructions ............................................................................................................................. 32
8.1 Oil Change ................................................................................................................................................. 32
8.2 Cleaning of Air Filter................................................................................................................................... 33
8.3 Adjust Idling Speed .................................................................................................................................... 33
8.4 Fuel Filter Cleaning .................................................................................................................................... 33
8.5 Fuel, Lubrication and Cooling System Check ............................................................................................ 33
8.6 Crankcase Ventilation Check ..................................................................................................................... 33
8.7 Compression Check ................................................................................................................................... 34
8.8 Check and Setting of Valve Clearance ...................................................................................................... 34
8.9 Check of Valve Shaft Projecting Length .................................................................................................... 35
8.10 Cleaning, Check and Setting of Spark Plugs ............................................................................................. 35
8.11 Drive Belt Check, Tensioning and Replacement ....................................................................................... 37
8.12 Exhaust System Check .............................................................................................................................. 37
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8.13 Turbocharger Check L 2400 ET/DT/DX ..................................................................................................... 38
8.14 Bowden Cable Check................................................................................................................................. 38
8.15 Emergency Battery and Harness Check .................................................................................................... 38
8.16 Check of Bolted Connections ..................................................................................................................... 38
8.17 Engine Test Run ........................................................................................................................................ 38
8.18 Engine Preservation ................................................................................................................................... 39
8.18.1 Compliance ................................................................................................................................................ 39
8.19 Operation at low ambient Temperatures ................................................................................................... 40
8.20 Operation in Tropical Conditions ................................................................................................................ 41
8.21 Miscellaneous ............................................................................................................................................ 41
9 Overhaul ...................................................................................................................................................... 42
9.1 Major Overhaul ........................................................................................................................................... 42
9.2 Major Repair ............................................................................................................................................... 42
10 Lubricants, Coolants, Fuels ......................................................................................................................... 43
10.1 List of Lubricants ........................................................................................................................................ 43
10.2 Coolant ....................................................................................................................................................... 44
10.3 Fuels .......................................................................................................................................................... 44
11 Recommended Nut Torques........................................................................................................................ 45
12 Trouble Shooting ......................................................................................................................................... 46
12.1 Engine Starting Trouble ............................................................................................................................. 46
12.2 Engine Operating Trouble .......................................................................................................................... 48
12.2.1 Fuel Supply ................................................................................................................................................ 48
12.2.2 Ignition ........................................................................................................................................................ 49
12.2.3 Cooling ....................................................................................................................................................... 49
12.2.4 Lubrication .................................................................................................................................................. 50
12.3 Exhaust / Turbocharger System L 2400 ET/DT/DX ................................................................................... 51
12.4 Mechanical System .................................................................................................................................... 52
12.5 Engine Operating Trouble in Normal Mode, no Trouble in Emergency Mode ........................................... 53
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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.50
1.000
1.1 Change Index
This Edition replaces the Operating and Maintenance Manual from 19.02.2016
This manual has 53 pages and is issued per 20.06.2018
This edition replaces:
Date
Description
02/98
New edition
04.03.2001
Replaces edition from 02/98
01.12.2005
Replaces edition from 04.03.2001
15.01.2014
Replaces edition from 01.12.2005
19.02.2016
Replaces edition from 15.01.2014
20.06.2018
Replaces edition from 19.02.2016
1.2 Release
Relased and approved on: 20.06.2018
Dipl.-Ing. P. Stolinski
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Operating Manual
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2 Introduction
This manual is meant to instruction for proper operation and maintenance of the aircraft engine.
Modifications to the engine are only permitted with the approval of our development department.
Caution:
The specially identifies safety notes must be observed to prevent accidents with personal
injuries and to prevent damage to the engine.
Please also observe the instructions of the aircraft manufacturer. They are specially adapted for operation of the engine in the aircraft.
Caution:
Familiarize yourself with the layout oft he engine controls in your aircraft according tot he
instructions oft he aircraft manufacturer. Pay special attention to those controls needed to
master an emergency situation.
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3 Engine Description
• Horizontally Opposed 4-Cylinder 4-Stroke Reciprocating Engine
• Combined Liquid Cooling for the Cylinder Heads
• Ram Air Cooling for the Cylinders
• Wet Sump Forced Lubrication
• Single Electronic Engine Management System Providing Spark and Fuel
• Direct Propeller Drive
• Electrical Starter
• Alternator
3.1 Model Designation
L
2400
E F 1 . X X 1.
2.
3.
4.
5. 6.
7.
1. LIMBACH (Manufacturer)
2. Displacement Class in cm3
3. (E) Single Ignition
(D) Dual Ignition
4. Equipment - Basic Type of Construction
F = Tractor Propeller
Electronic engine management
Liquid cooling for cylinder heads
Ram air cooling for cylinders
Generator rear
Starter rear
T/X = Tractor Propeller
Turbocharger, Intercooler
Electronic engine management
Liquid cooling for cylinder heads
Ram air cooling for cylinders
Generator rear
Starter rear
5. Type of Propeller Flange
1 = Flange for Variable-Pitch Propeller
2 = Flange for Fixed-Pitch Propeller
3 = Flange for Fixed-Pitch Propeller (SAE 1)
6 + 7. Installation
Type Differences with regard to installation related changes
X = Experimental Engine without Certification
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3.2 Cylinder Designation
I = top II = left III = bottom
IV
=
right V = rear = accessory mounting side
VI
=
front = propeller side
1 =
cylinder 1
2 =
cylinder 2
3 =
cylinder 3
4 =
cylinder 4
arrow
=
crankshaft rotation
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4 Technical Data
4.1 LIMBACH L 2400 EF/DF
Dimensions
Bore
97 mm
Stroke
82 mm
Displacement per Cyl.
606 cm³
Total Displacement
2424 cm³
Compression Ratio
9.5 : 1
Crankshaft Rotation
counterclockwise
Ignition Timing
variable mapped
Firing Order
1-3-2-4
Equipment
Engine management system
Weber Alpha PI 38
Weber Alpha PI 48
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BOSCH 14V-33A
BOSCH 14V-55A
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
74 kW / 100 HP at 3000 rpm
30 inHg
Max. Continuous Power
62 kW / 84.5 HP at 3000 rpm
28 inHg
Engine Rotational Speeds
Max. permissible speed
3200 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2400 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001
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Pressures and Temperatures
Fuel Pressure
2.5 bar / 14.6 psi
(measured relative to the manifold pressure)
Engine Oil Pressure max.
7 bar / 101.5 psi
min.
1 bar / 14.5 psi at 2500 rpm
Engine Oil Temperature max.*)
120 °C
Schmieröltemperatur min
50 °C (indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatuopt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.
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4.2 LIMBACH L 2400 ET/DT
Dimensions
Bore
97 mm
Stroke
82 mm
Displacement per Cyl.
606 cm³
Total Displacement
2424 cm³
Compression Ratio
8.0 : 1
Crankshaft Rotation
counterclockwise
Ignition Timing
variable mapped
Firing Order
1-3-2-4
Equipment
Engine management system
Weber Alpha PI 38
Weber Alpha PI 48
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BOSCH 14V-33A
BOSCH 14V-55A
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Turbocharger
250.173.100
250.173.105
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
96 kW / 130 HP at 3000 rpm
40 inHg***)
41 inHg****)
Max. Continuous Power
85 kW / 115 HP at 3000 rpm
38 inHg***)
39 inHg****)
Engine Rotational Speeds
Max. permissible speed
3200 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2400 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001
***)
With turbocharger 250.173.100
****)
With turbocharger 250.173.105
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Pressures and Temperatures
Fuel Pressure
2.5 bar / 14.6 psi
(measured relative to the manifold pressure)
Engine Oil Pressure max.
7 bar / 101.5 psi
min.
1 bar / 14.5 psi at 2500 rpm
Engine Oil Temperature max.*)
120 °C
Schmieröltemperatur min.
50 °C ((indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatu opt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.
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4.3 LIMBACH L 2400 DX
Dimensions
Bore
97 mm
Stroke
82 mm
Displacement per Cyl.
606 cm³
Total Displacement
2424 cm³
Compression Ratio
8.0 : 1
Crankshaft Rotation
counterclockwise
Ignition Timing
variable mapped
Firing Order
1-3-2-4
Equipment
Engine management system
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Turbocharger
250.173.105
Propeller Flange
250.031.304*)
Engine Ratings
Max. Take-Off Power
118 kW / 160 HP at 3000 rpm
48 inHg
Max. Continuous Power
103 kW / 140 HP at 3000 rpm
44 inHg
Engine Rotational Speeds
Max. permissible speed
3100 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2200 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 250.031.013
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Pressures and Temperatures
Fuel Pressure
2.5 bar / 14.6 psi
(measured relative to the manifold pressure)
Engine Oil Pressure max.
7 bar / 101.5 psi
min.
1 bar / 14.5 psi at 2500 rpm
Engine Oil Temperature max.*)
120 °C
Schmieröltemperatur min.
50 °C ((indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatu opt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.
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4.4 LIMBACH L 2400 DS
Dimensions
Bore
97 mm
Stroke
82 mm
Displacement per Cyl.
606 cm³
Total Displacement
2424 cm³
Compression Ratio
9.5 : 1
Crankshaft Rotation
counterclockwise
Ignition Timing
variable mapped
Firing Order
1-3-2-4
Equipment
Engine management system
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
85 kW / 116 HP at 3400 rpm
29 inHg
Max. Continuous Power
78 kW / 106 HP at 3400 rpm
28 inHg
Engine Rotational Speeds
Max. permissible speed
3400 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2300 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001
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Pressures and Temperatures
Fuel Pressure
2.5 bar / 14.6 psi
(measured relative to the manifold pressure)
Engine Oil Pressure max.
7 bar / 101.5 psi
min.
1 bar / 14.5 psi at 2500 rpm
Engine Oil Temperature max.*)
120 °C
Schmieröltemperatur min
50 °C (indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatuopt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.
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5 Performance
5.1 Performance Graph LIMBACH L 2400 EF/DF
RPM (1/min)
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5.1.1 Performance Data L 2400 EF/DF
Power values in kW (HP values in parentheses)
Manifold
Pressure
(inHg)
2400 rpm
2500 rpm
2600 rpm
2700 rpm
2800 rpm
2900 rpm
3000 rpm
20
28 (38)
21
33 (45)
22
34 (46)
37.5 (51)
23
38 (52)
42 (57)
24
42.5 (58)
46 (63)
25
44 (60)
48 (65)
55 (75)
26
48.5 (66)
53 (72)
27
54.5 (74)
58 (79)
28
60 (82)
62.5 (85)
29 67 (91)
30
56 (76)
60 (81)
64 (87)
68 (92)
70 (95)
72 (98)
74 (100)
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5.2 Performance Graph LIMBACH L 2400 ET/DT
RPM (1/min)
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5.2.1 Performance Data L 2400 ET/DT
Power values in kW (HP values in parentheses)
Manifold Pressure (inHg)
2200 rpm
2400 rpm
2600 rpm
2800 rpm
3000 rpm
*)
**)
23
24
29 (40)
34.5 (47)
37 (50)
40 (54)
42 (57)
24
25
31.5 (43)
37 (50)
39 (53)
42 (57)
44 (60)
25
26
34 (46)
38 (52)
40.5 (55)
44 (60)
46 (63)
26
27
36 (49)
40 (54)
42 (57)
46 (63)
48.5 (66)
27
28
38 (52)
42 (57)
43.5 (59)
49 (67)
51.5 (70)
28
29
40.5 (55)
44 (60)
45.5 (62)
51.5 (70)
54.5 (74)
29
30
42 (57)
45.5 (62)
49 (67)
53.5 (73)
57.5 (78)
30
31
44 (60)
48 (65)
53 (72)
57 (77)
61 (83)
31
32
45.5 (62)
50 (68)
57 (77)
60 (81)
64 (87)
32
33
48.5 (66)
52 (71)
60 (82)
63 (86)
67 (91)
33
34
51 (69)
55 (75)
62 (84)
67 (91)
51 (96)
34
35
53 (72)
57.5 (78)
63 (87)
69 (94)
73.5 (100)
35
36
55 (75)
60 (81)
66 (90)
71.5 (97)
76 (103)
36
37
57.5 (78)
62.5 (85)
68.5 (93)
74 (101)
79.5 (108)
37
38
60 (82)
65.5 (89)
71 (97)
78 (106)
82.5 (112)
38
39
62.5 (85)
69 (94)
75 (102)
82 (111)
86 (117)
39
40
73 (99)
79 (107)
85 (116)
90 (122)
40
41
84 (114)
90.5 (123)
96 (131)
*)
Applies to turbocharger 250.173.100
**)
Applies to turbocharger 250.173.105
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5.3 Performance Graph LIMBACH L 2400 DX
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5.3.1 Performance Data L 2400 DX
Power values in kW (HP values in parentheses)
Manifold
Pressure
2000 min-1
2200 min-1
2400 min-1
2600 min-1
2800 min-1
3000 min-1
(inHg)
24
23 (31)
24 (33)
28 (38)
30 (41)
32,5 (44)
37,5 (51)
26
28 (38)
30 (41)
33 (45)
35.5 (48)
37.5 (51)
41 (56)
28
31.5 (43)
34 (46)
37 (50)
41 (56)
43.5 (59)
48 (65)
30
35.5 (48)
38.5 (52)
42.5 (58)
46.5 (63)
50 (68)
55 (75)
32
38 (52)
44 (60)
48.5 (66)
51.5 (70)
58 (79)
63 (86)
34
42 (57)
48 (65)
53.5 (73)
59 (80)
64 (87)
70 (95)
36
46.5 (63)
52 (71)
58 (79)
65 (88)
72 (98)
77.5 (105)
38
50 (68)
58 (79)
63.5 (86)
70.5 (96)
77.5 (105)
83 (113)
40
54.5 (74)
62 (84)
68.5 (93)
76.5 (104)
84 (114)
89 (121)
42
60.5 (82)
68.5 (93)
76 (103)
82.5 (112)
91 (124)
96.5 (131)
44
75 (102)
82.5 (112)
89 (121)
97 (132)
104.5 (142)
46
94 (128)
103 (140)
110.5 (150)
48
109 (148)
119 (162)
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5.4 Performance Graph LIMBACH L 2400 DS
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5.4.1 Performance Data L 2400 DS
Power values in kW (HP values in parentheses)
Manifold
Pres-
sure
2000 min-1
2200 min-1
2400 min-1
2600 min-1
2800 min-1
3000 min-1
3200 min-1
3400 min-1
(inHg)
22
30 (41)
32 (43)
33 (45)
34,5 (47)
35 (48)
38 (52)
23
31 (42)
32,5 (44)
33 (45)
34,5 (47)
38 (52)
42 (57)
45,5 (62)
54,5 (74)
24
31 (42)
34,5 (47)
36 (49)
39 (53)
42 (57)
45,5 (62)
50 (68)
60 (82)
25
33 (45)
37 (50)
39 (53)
43,5 (59)
45,5 (62)
48 (65)
54,5 (74)
63 (86)
26
35 (48)
39 (53)
42 (57)
48 (65)
52 (71)
56 (76)
59 (80)
69 (94)
27
39 (53)
43,5 (59)
46 (63)
55 (75)
59 (80)
63 (86)
68 (92)
73 (99)
28
42 (57)
48 (65)
52 (71)
59 (80)
63 (86)
68,5 (93)
73,5 (100)
78,5 (107)
29
42,5 (58)
50 (68)
56 (76)
63 (86)
69 (94)
76 (103)
81,5 (111)
85 (116)
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6 Operating Instructions
Strict adherence to the information contained in this operating manual is the basis for undisturbed operation of your engine.
6.1 Before Starting
Perform daily check (see section 7.1)
Move throttle lever to the full power position.
Check freedom of movement.
Check that the throttle lever on the throttle body reaches both the full power and idle position.
Switch ignition to „Off“
Disconnect the spark plug connectors.
Turn propeller a few times by hand.
Check for unnormal noises and indication of stiff movement.
Reinstall spark plug connectors.
Note:
Engines that are equipped with a vacuum pump may never be turned against the normal sense
of engine rotation. Damage to the vacuum pump may occur.
Caution:
The propeller may only be turned by hand with the spark plug connectors removed.
6.2 Engine Start-Up
Caution:
When starting the engine, the propeller area must be clear. No persons may be present in the propeller area.
Open fuel shutoff valve.
Turn master switch and engine electrical system on.
Fuel pump starts and turns itself off after approximately 10 seconds.
Turn ignition off.
Turn emergency switch to emergency mode.
Turn ignition on.
• Fuel pump starts to operate and stops automatically after approx. 10 seconds*).
• At the same time the yellow indicating light in the engine emergency switch illuminates.
In case of an electronic engine display the word “Emergency” is displayed.
*)
Listen for operation noise.
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Turn emergency switch to normal mode
The emergency indication disappears.
Move the throttle lever to 5-10 % power.
Check propeller clearance
Start engine.
When the engine is firing, release starter button and set engine speed to
appr. 1300 rpm by means of the throttle lever.
Check oil pressure (must increase within 10 sec.).
6.3 Runup, Performance Check
Run the engine for approx. 2 min. at 1300 rpm. Then increase speed to 1500 rpm until oil
temperature is 50 °C.
Due to the sluggish action of the indication, there will be sufficient effective operating
temperature at 50 °C already.
6.3.1 Performance Check
Move throttle lever to full-throttle stop. Engine has to reach the full-throttle static speed
published in the flight and maintenance manual of the aircraft manufacturer. Return
throttle lever to idle.
6.3.2 Ignition Check L 2400 DF/DT/DX/DS
Using the throttle lever set the engine speed to 2000 rpm.
Check function of both ignition circuits starting from position „Ignition circuit 1+2“.
The engine must operate without misfiring in all operating modes of the ignition switch.
The engine speed may not drop more than 100 rpm using the position “Ignition circuit 1+2”
as a reference.
Set the ignition switch to position “Iginition circuit 1+2”
Caution:
If full-throttle ground runs are made for a longer period, overheating
of the engine is possible!
6.4 Hot Engine Start-Up
Hot engine starting is performed as described in Chapter 6.2, but without checking the
emergency switch.
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6.5 Take-Off
Increase engine speed steadily to full throttle and perform first part of climb
with this setting, then reduce power.
Observe coolant, oil temperature and pressure. The limits may not be exceeded.
Caution:
With increasing ambient temperatures the engine power and the lift up of the wings
will be reduced. This applies especially to situations in which the runway has been
heated up by sunlight.
6.6 Engine Shut-Down
Shut engine down by switching ignition off.
Caution:
After taxiing for an extended period or at high power, run the engine at
approx. 1300 rpm for 2 to 3 min.
Close fuel shutoff valve.
6.7 Inflight Shut-Down and Restarting
Set throttle to idle, let engine cool down and switch off ignition.
To avoid windmilling bring propeller into feathered position.
Starting engine is the same as on the ground.
It is not necessary to check emergency operation.
If the engine is cold, perfom warm-up.
At low ambient temperatures and after prolonged soarings:
• the engine oil may have cooled so much,
that the engine cannot be started anymore,
• the capacity of the starting battery may be reduced
(see section 8.19)
Caution:
Make sure that you have sufficient altitude to restart the engine, especially
at low ambient temperatures and prolonged soaring.
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6.8 Emergency Procedures
If engine operation is disturbed, the emergency switch (S) should be set to emergency mode.
When in emergency mode some engines sensors are deactivated resp. replaced with reserve
sensors. Also a reserve fuel pump is selected.
6.8.1 Version with engine Emergency Switch
After activating Emergency Mode the yellow indicator (1) turns on.
During emergency operation the exhaust gas
temperature (EGT) must be monitored.
Adjust the power lever such that the exhaust
gas temperature is in a range between 600 and
750 °C, depending on rpm. If the exhaust gas
temperature exceeds the limit, the power must
be reduced until the temperature comes between limits again. At low power settings the
exhaust gas temperatures may be lower than
stated. In such cases the power lever should be
adjusted such that the engine runs as smooth
as possible.
Note:
The engine may be restarted in emergency mode as long as the main battery is functional and the
master switch is in the “ON” position.
If the red warning light (1) on the status indicator
“Discharge” comes on, consider the following:
• The electrical system is disturbed.
• The operating time for the engine is limited.
(Check the flight manual for the time remaining to fly).
• Take course to the next possible landing
site. Adjust your flight attitude to a maximum range (climb at elevated speed),
check the flight manual.
• The engine may not be restarted with the
electric starter (Starting only possible by
windmilling and considerable loss of altitude).
Caution:
If the lamp “Emergency Battery Discharge” comes on, the time availa-ble to operate
the engine is limited.
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6.8.2 Version with electronic engine display
After activating the emergency mode the message „Emergency“ comes on.
Note:
The engine may be restarted in emergency mode as long as the main battery is functional and the
master switch is in the “ON” position.
If the red warning light (1) on the status indicator
“Discharge” comes on, consider the following:
• The electrical system is disturbed.
• The operating time for the engine is limited.
(Check the flight manual for the time remaining to fly).
• Take course to the next possible landing
site. Adjust your flight attitude to a maximum range (climb at elevated speed),
check the flight manual.
• The engine may not be restarted with the
electric starter (Starting only possible by
windmilling and considerable loss of altitude).
Note:
The voltage of the emergency battery „NBatt“.
Caution:
If the red indicatator (1) lamp “Emergency Battery Discharge” comes on, the time
available to operate the engine is limited. When the indicator is on an acoustic
signal is issued. It may be turned off by pressing the alarm switch.
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7 Maintenenance Schedule
Maintenance at Limbach aircraft engines is to be performed after fixed time periods or when reaching a
certain interval of operating hours. In addition, a “daily check” has to be performed before each flight.
Note:
On turbocharged engines ET/DT/DX models the exhaust collector (pipes running from the engine
to the turbocharger) are part of the engine.
7.1 Daily Check
• Remove engine cowling.
• Check bolted connections for obviously loose or missing fasteners.
• Check baffle assembly.
• Check all coolers and radiators for free passage of air – clean if necessary.
• Check harness.
• Check condition of drive belt.
• Check cowling for cracks and correct attachment.
• Check clearance of throttle pushrods and bowden cables.
• Check engine oil level and refill as necessary. Volume difference between
max. and min. markings: 0.75 Ltr.
• Check coolant level and refill as necessary.*)
• Check oil, fuel and cooling system for leakage.
• Check acid level of batteries and refill as necessary.
• Perform test run (see section 8.17).
7.2 Periodical Checks
7.2.1 If the Engine is not Operated for more than 3 Months
Check capacity of emergency battery with a battery tester.
7.2.2 Every 2 Years
Replacement of emergency battery recommended (depending on battery type).
7.2.3 Every 5 Years after New or Main Overhaul
Replace oil and fuel hoses (mounted to the engine). The oil and fuel hoses mounted
to the engine are signed with an expiration date, e.g. 5.01 - i.e. to be replaced not later
than May 2001.
*)
After refilling the glycol content may have to be reestablished.
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7.3 Operating Time related Inspections
section
7.3.1
7.3.3
7.3.4
7.3.5
7.3.6
After 5 Operating hours
X
After 25 Operating hours
X
Every 50 Operating hours
X
Every 100 Operating hours
X X
Every 200 Operating hours
X X X
Every 500 Operating hours
X X X
7.3.1 After the first 5 Operating Hours
• Check valve clearance, replace cylinder head cover gasket as necessary.
7.3.2 After the first 25 Operating Hours
• Work as specified in section 7.3.3
7.3.3 Every 50 Operating Hours
• Check fuel, lubrication and cooling system for leaks.
• Clean engine.
• Check all coolers and radiators for free passage of air – clean if necessary.
• Check crankcase ventilation.
• Check routing oft he turbocharger*) drain line (see section 8.13)
• Clean induction air filter or replace, if necessary.
• Check valve clearance, replace cylinder head cover gasket as necessary.
• Check compression.
• Clean and check spark plugs.
• Check drive belt tension of generator and coolant pump.
• Check the control cable and actuator rod for both the throttle and the boost limiter*) on the
turbocharger for freedom of movement, range of travel – lubricate.
• Check emergency operation.
• Check seating of electrical connectors and wire boots.
• Check engine wiring for damage and proper routing.
• Check condition of emergency battery (see section 8.15)
• Check bolts, nuts, safety pins, and engine mounting frame for tight fit and proper condition.
• Perform engine test run.
*)
L 2400 ET/DT/DX only
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7.3.4 Every 100 Operating Hours
• Change oil and replace oil filter.
• Change fuel filter.
• Work as specified in section 7.3.3
7.3.5 Every 200 Operating Hours
• Replace spark plugs
• Work as specified in section 7.3.3
• Work as specified in section 7.3.4
7.3.6 Every 500 Operating Hours
• Check valve shaft projecting length.
• Work as specified in section 7.3.3
• Work as specified in section 7.3.4
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8 Maintenance Instructions
This chapter describes the performance of maintenance work. In addition, the preservation of engines as
well as winter and tropical operation is covered.
Caution:
Disconnect spark plug connectors before performing any work on the engine.
Caution:
When starting the engine, the propeller area must be clear. Secure the aircraft from
rolling. No persons may be present in the propeller area.
Note:
Vacuum pump equipped aircraft engines must never be turned opposite to the engine rotation
because the vacuum pump might be damaged.
Check with your airworthiness inspector if inspection is mandatory before starting work.
It is recommended to mark the position of parts to be removed before commencing disassembly
work in order to facilitate assembly later on.
This is only applicable to parts which might be installed in different positions. During assembly,
pay attention to markings provided by the manufacturer.
The spark plug connectors are marked with the cylinder numbers.
It is not important whether they are attached to the out- or inboard spark plugs.
8.1 Oil Change
Warm up engine.
Drain oil.
Remove drain plug. After all oil is drained, install drain plug with a new gasket.
Change oil filter.
Remove oil filter. Slightly oil the rubber seal of the new filter before mounting
and tighten filter manually.
Refill engine oil.
The oil charge is 3.5 l. Check oil level by means of the oil-measuring stick. The MAX marking
must not be exceeded. The engine must be horizontally orientated. This is especially important
for so called “taildragger” Aircraft.
See section 10.1 for oil specifications
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8.2 Cleaning of Air Filter
Remove air filter.
Clean air filter, using compressed air, blowing from inside outwards.
Special filters are to be cleaned according to the aircraft manufacturer’s instructions.
8.3 Adjust Idling Speed
The idling speed may be adjusted via the adjusting screw on the throttle body. The speed
should be adjusted to 800 ±100 rpm. Turning the screw clockwise increases idling speed.
Turning the screw counterclockwise reduces the idling speed.
8.4 Fuel Filter Cleaning
Draining and cleaning of fuel filter.
Refer to flight and maintenance manual of aircraft manufacturer.
8.5 Fuel, Lubrication and Cooling System Check
Check all hoses, hose connections, fittings, related equipment and engine casing joints for
leaks, damage, proper attachment, installation and replacement periods. Check liquid levels.
Coolant and oil level should be between MIN and MAX markings.
Check the radiator, oil cooler and intercooler for obstruction, foreign objects and dirt.
Clean if neccessary.
8.6 Crankcase Ventilation Check
Check visually for damages and clean breather line as necessary. Check suitability and
installation of breather line - it has to be stable at engine operating temperatures (danger
of buckling) and must be installed properly (no bucklings, no reduction in cross-sectional
area, no suction effects at the end of the line).
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8.7 Compression Check
Compression checks should be performed when the engine is “warm to touch”.
Remove spark plugs and the connectors from the injectors.
Measure compression by means of a compression pressure recorder.
Perform measurement with throttle full open. Record compression pressure at
starting rpm for every cylinder until the pressure indicated on the recorder does
nor rise anymore.
Wear limit: 6 bar / 87 psi.
Permitted pressure difference: 2 bar / 29 psi
Reinstall spark plugs and injector connectors.
8.8 Check and Setting of Valve Clearance
Valve clearance must be checked or set only on a cold engine (ambient temperature).
Caution:
Remove spark plug connectors before starting to work.
Remove valve cover.
Valve clearance check.
Turn propeller according to engine rotation until the valves of the second cylinder
are overlapping. Now, the valve clearance of the first cylinder may be checked (see
cylinder designation at page 3.2).
Move thickness gauge between valve shaft and setscrew. The thickness gauge must be
movable slightly “sucking”. It must not jam.
Valve clearance setting.
Untighten nut of setscrew and turn setscrew until thickness gauge can be moved slightly “sucking”.
Tighten nut and check valve clearance again, readjust, if necessary.
Order of adjustment
The order of adjustment is: 1 - 3 - 2 - 4, i.e. the propeller has to be turned by 180° after the first cylinder
has been set, in order to check the valve clearance of the third cylinder. After another 180° turn according to the engine rotation, the valve clearance of the second cylinder may be checked, etc.
Valve clearance:
Intake Valve 0.20 mm
Exhaust Valve 0.20 mm
Check cylinder head cover gaskets and replace, if necessary.
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8.9 Check of Valve Shaft Projecting Length
Remove cylinder head covers.
Dismount rocker arm shafts.
Measurement of valve shaft projecting length by means of measuring device P/N: 803.001.130.
If the projecting length is less than 24 mm for the intake and exhaust valve the cylinder heads
have to be replaced by new ones.
Caution:
If the measurement is within limits, however the valve measured is less than 24.5
mm, the projecting length of the valve shafts has to be checked every 100 hours.
Install rocker arm shafts.
• Position rocker arm shaft assemblies on the studs in the cylinder head.
• Seat the pushrods in the sockets of the rocker arms.
• Pre-assemble spring washers and M8 nuts (strength class 10)
• Ensure that the pushrods are also seated in the camshaft followers.
• Torque nuts to 25 Nm
Note:
Turning the pushrods while tightening the bolts will prevent the pushrods from becoming
unseated at the cam followers.
Caution:
An unseated pushrod may cause power loss and/or subsequent
engine damage.
Check valve clearance and readjust, if necessary.
Mount cylinder head cover.
Check gaskets and replace as necessary.
8.10 Cleaning, Check and Setting of Spark Plugs
Removal of spark plugs.
Disconnect spark plug connectors.
Caution:
Do not unscrew spark plugs when the engine is hot.
Cleaning of spark plugs.
Clean spark plugs by means of a plastic brush in a degreasing solution. Do not use a
steel or brass brush for cleaning. Do not sandblast spark plugs.
Check electrode gap and adjust, if necessary.
Check electrode gap by means of a thickness gauge and adjust it by bending the
ground electrode.
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The electrode gap is 0.7 mm.
Reinstall spark plugs and connect spark plug connectors.
Grease spark plug thread with graphite grease P/N: 170.210.010.
Torque to 20 Nm.
Caution:
Electrodes must always be free from graphite grease! Do not use copper paste.
Use the following spark plugs:
NGK DCPR 7 E
P/N: 250.123.101
Change spark plugs every 200 operating hours.
Note:
The condition of the spark plugs removed from the engine discloses the following
information:
Light grey:
Spark plug and engine adjustment o.k.
Velvet black:
Electrode gap too big
Mixture too rich
Lack of air (induction air filter contaminated)
Engine does not reach required temperature
Oillike glossy:
Interrupted spark plug operation
Excess oil in combustion chamber
Cylinder or piston rings worn out
Pearl formation:
Wrong spark plug
Loose spark plug
Mixture too lean (“false air”)
Valves do not close properly
Induction air temperature too high
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8.11 Drive Belt Check, Tensioning and Replacement
Drive belt check.
Check for wear, cracks and oil traces.
Drive belt tension check.
It must be possible to push the drive belt through with a strong thumb load
by 5 to 10 mm.
Tensioning of drive belt.
Generator:
Unfasten mounting bolt of clamp at the accessory housing. Unfasten mounting
nut of alternator with locking at the clamp. Tension drive belt by moving the alternator.
Tighten and lock all bolts and nuts.
Coolant Pump:
Loosen fastening bolts of tensioner, tension belt and retorque bolts.
Replacement of drive belt.
Generator:
Unfasten mounting bolts of clamp and detach drive belt from pulley of alternator.
Detach drive belt from crankshaft drive pulley. Attach new drive belt to crankshaft
and alternator pulley and tension drive belt. Tighten all mounting bolts.
Coolant pump:
Remove propeller and propeller adapter. Loosen belt tensioner and remove belt.
Install new belt, tension and tighten tensioner bolts. Mark all bolts with safety laquer
after tightening. Install propeller adapter and propeller. Check propeller blade track.
Caution:
After propeller installation airworthiness inspection is mandatory.
New drive belts stretch more during the first time of operation. A check is required after
10 operating hours. Set belt tension as necessary.
8.12 Exhaust System Check
Check for damages, leaks and condition. Refer to flight and maintenance manual of
aircraft manufacturer.
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8.13 Turbocharger Check L 2400 ET/DT/DX
Check turbocharger for secure mounting. Check hose to boost pressure limiter for fit, tightness
and damage. Check routing of turbocharger drain line (it must be routed with a constant
declination towards the valve cover and have no bucklings, no reduction in cross-sectional area).
8.14 Bowden Cable Check
Check for condition, ease of motion and proper attachment. Refer to flight and maintenance
manual of aircraft manufacturer.
8.15 Emergency Battery and Harness Check
Check emergency battery and warning lights. To do so disconnect the generator connector.
Start engine and turn off the main switch. The engine must continue to run and the red light
“Discharge” must be blinking. If installed the red generator warning lamp must be on.
Disconnect leads from the emergency battery and test loading capacity with a battery tester
(similar to HAZET 4650-5). Reconnect leads.
Check proper installation, attachment and tight fit of electrical connections and terminals.
Vibration of harness during operation must be avoided. Check connectors for corrosion.
Check grounding leads.
8.16 Check of Bolted Connections
Check all accessible bolts and nuts for tight fit and check existing locks visualy.
8.17 Engine Test Run
Check of starting performance.
At normal conditions (temperature, maintenance condition) the engine starts easily. If this is
not the case check fuel supply and ignition system.
Caution:
Do not operate the starter a prolonged period of time (Risk of overheating).
Warming up.
Run the engine for approx. 2 min. at 1300 rpm. Then increase speed to 1500 rpm
until the oil temperature is 50 °C.
Temperatures and pressures
See “Technical Data”.
Check of throttle response.
Move power lever steadily to full throttle. Engine must show immediate response,
engine speed must increase steadily.
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Engine performance check
Move throttle lever to full-throttle stop. Engine has to reach the full-throttle static speed
(refer to flight and maintenance manual of aircraft manufacturer). Set variable-pitch
propellers to Take-off pitch.
8.18 Engine Preservation
Engines that are taken out of operation for more than 6 months shall be preserved.
Note:
At high humidity, it is recommended to close the exhaust muffler exit.
8.18.1 Compliance
Installed engine:
• Warm up engine and drain engine oil after engine shut-down. Change oil filter.
• Clean engine thoroughly.
• In any case, corrosion protection has to be performed by using fresh engine oil.
• Charge 3.5 l of engine oil and run engine for approx. half a minute with increased idle speed.
• Remove air filter and spray 25 to 30 cm³ of engine oil slowly into the intake opening of the
running engine. Stop engine during spraying.
• Wet throttle linkage and boost pressure limiter linkage with engine oil.
Caution:
After corrosion protection, the engine must not run any more as this would disable
corrosion protection.
Removed engine:
• Remove spark plugs and spray engine oil into the combustion chambers so that the
upper part of the cylinder barrel is wetted, too.
• Crank engine manually or with starter for a few turns.
• Spray spark plugs with engine oil and install them again.
• Wet all linkages with engine oil.
• Close all openings to avoid entry of dirt or moisture
• Spray engine surface with engine oil. Take care of not exposing rubber parts and
electrical connectors to engine oil.
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8.19 Operation at low ambient Temperatures
In general, engine maintenance should be performed before the beginning of the cold season.
Furthermore, the following hints for operation at extremely low ambient temperatures should
be observed:
Electrical system
At low ambient temperatures, the capacity of the starting battery is reduced. This may
lead to starting problems.
Check all wiring connections in the ignition system and clean as necessary, oxidized
terminals cause voltage drops and thus starting problems.
Crankcase ventilation
At low ambient temperatures and high humidity, saponification of vent dome and breather
line is possible. Make sure by means of special inspections that this cannot happen - a total
lock might cause the engine oil to leak through the sealings due to overpressure.
This would lead to high oil losses and possibly to the destruction of the engine.
Engine oil
For prolonged soaring (with stopped engine) please note that the viscosity of the engine
oil increases extremely with the cooling down of the engine. In extreme cases the viscosity
may have increased so much, that the starter cannot turn the engine anymore.
When planning your flight, consider prolonged soaring and fill engine with appropriate oil.
Eventually you should start the engine in between to warm up the engine oil again.
Coolant
For prolonged soaring (with stopped engine) take care that the coolant does not freeze.
A content up to a maximum of 60% of anti-freeze and corrosion protection is necessary in
any case. Eventually the radiator may have to be masked by suitable means.
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8.20 Operation in Tropical Conditions
The following measures are necessary to protect the engine against heat and dust:
Air filter
If the engine is operated in areas of high dust accumulation install larger air filter
(contact your aircraft manufacturer for details).
Oil-measuring stick
Seal oil-measuring stick by inserting a felt washer below the oil stick cap.
To achieve a tight fit of the oil stick in its guiding tube, bend stick as necessary.
Liquid cooling
If the engine is operated routinely at high ambient temperatures, a larger Radiator
may be necessary (contact your aircraft manufacturer or the design organization).
The content of anti-freeze and corrosion protection may be reduced to 40 % to
improve cooling performance
Dust protection of engines out of operation
Close exhaust pipe, crankcase ventilation, and induction air filter with a
dustproof sealing.
Corrosion protection of engines out of operation
See section 8.18 for instructions.
Maintenance hints:
Air filter: Check daily and clean or replace as necessary.
Drive belts: Check drive belt tension daily. If wear is evident, replace drive belt.
Radiators: Check daily for erosion wear.
8.21 Miscellaneous
For further advice on maintenance and repair, refer to our maintenance instructions
and technical bulletins.
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9 Overhaul
9.1 Major Overhaul
Major overhaul must be performed by the manufacturer or overhaul shops, authorized by the
manufacturer. Therefore, the engine has to be forwarded to the manufacturer or an authorized
overhaul shop, after the operating time limit has been reached.
The permissible operating time (TBO) is determined by the latest issue of Technical Bulletin No. 9.
9.2 Major Repair
Major repair and major modifications must be performed only by the manufacturer or licensed
fixed base operators, authorized by the manufacturer.
After ground or obstacle contact of the propeller, the engine has to be disassembled in any
case and the crankshaft has to be checked outside the engine. Eccentricity measurement of
crankshaft or propeller flange at installed conditions is inaccurate and not acceptable.
If ground or obstacle contact of the propeller has not been mentioned when ordering repair or
major overhaul of an aero-engine, the liability of the owner for sequential damages will continue
even after repair or major overhaul has been performed.
A change of the propeller hub has to be considered a major repair in any case.
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10 Lubricants, Coolants, Fuels
10.1 List of Lubricants
Do not use ash less dispersant or straight mineral aircraft engine oils!
Do not use fully synthetic oils!
Use only brand name oils according to spezification API-SG, or higher. (eg. API-SH, SI, SJ, S…)
as well as one of Volkswagen-specs VW 500 00, VW 501 01 or VW 502 00.
As the temperature ranges of adjacent SAE classes are overlapping, there is no need to
change the oil for short time temperature variations.
See also information in the section 8.18
If low viscosity oils are used, the oil pressure may go below the lower limit at continuously
high engine speeds and high loads. Such operating conditions should be avoided.
Lubricant additives - no matter what type - must not be added to the oil.
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10.2 Coolant
The cooling system is filled with a mixture of water and anti-freeze and corrosion
protection for all seasons. The amount of coolant is approximately 3.5 ltrs.
The mixing ratio may be varied between the following limits:
Frost protection
down to
Percentage anti-freeze
corrosion protection
Percentage water
-25 °C
40 % min.
60 %
-35 °C
50 %
50 %
-45 °C
60 % max.
40 %
Nitrite less and silicate less anti-freeze and corrosion protection may not be mixed with each other Antifreeze and corrosion protection fluid should comply with VW specification TL VW 774 C or TL VW 744 D
for coolant additives. Nitrite less coolant additives are available in different colors. Silicate less coolant
additives are usually red colored. A brownish color of the coolant may indicate mixing. When changing
the coolant, rinse the engine and radiator with clear water.
10.3 Fuels
Following fuels are factory approved:
• Super Plus 98 fuel according to DIN EN 228,
• AVGAS 100 LL,
• or other unleaded fuels with a minimum octane rating of 98 RON and 87 MON.
Notes:
• Fuel hoses and lines must be suitable for fuel.*)
• Use fresh, brand name fuels only. Storage time for fuel is limited. If stored too long in ventilated con-
tainers, volatile components of the fuel may evaporate. That can change the properties of the fuel
(reduced octane number). Also the fuel properties depend on the calendar season.
• Use of fuel additives is not permitted.
• Mixing of leaded and unleaded fuels is not recommended. Use mixed fuel only in case of need.
Caution:
Use of other fuels is not approved by the manufacturer.
*)
Fuels may contain alcohol. Please consult the instructions of your aircraft manufacturer.
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11 Recommended Nut Torques
Oil drainage screw to crankcase
20 Nm
Crankcase ventilation to case
10 Nm
Spark plug to cylinder head
20 Nm
Nut of valve clearance setscrew
15 Nm
Clamp to alternator (M6)
10 Nm
Clamp to alternator (M8)
20 Nm
Clamp to case
20 Nm
Alternator to case
45 Nm
Exhaust flange to cylinder head
20 Nm
Engine mount to case (M10)
45 Nm
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12 Trouble Shooting
“Small”, apparently negligible causes are often responsible for a “big” effect, i.e. disturbance
of engine operation. Detection of the causes is not always easy. The hints to possible trouble
causes and their correction contained in this section serve as a guideline for the engine user,
listing the most frequent faults. This list of causes, however, does not claim for completeness.
Repair work must be done only by persons authorized to perform the specific task.
12.1 Engine Starting Trouble
Possible Cause:
Remedy:
Battery discharged or defective.
Charge or replace battery.
Battery wiring not connected to starter motor
or defective or possibly insufficient contact.
Clean connectors. Connect or replace wire.
Ground wire to engine not connected, defective, possibly insufficient contact.
Clean connectors. Connect or replace
ground wire.
Starter motor defective.
Repair or replace starter motor.
Starter relay defective.
Replace starter relay.
Engine electrics not swiched on.
Turn on engine electrics.
Ignition harness disengaged, mixed up or
damaged.
Fasten ignition lead(s) or replace. Observe
firing sequence 1-3-2-4. Check markings of
connectors.
Fuse blown in relay box (MCU).
Check fuse, replace if necessary
Wiring harness or connector loose or defective, wire broken in wiring harness.
Check wiring harness and connectors,
repair if necessary.
Throttle potentiometer defective.
Check throttle potentiometer. Replace if
necessary. Try to run engine in emergency
mode.
RPM sensor defective or not connected.
Check rpm sensor. Replace if necessary.
Try to run engine in emergency mode.
ECU defective.
Replace ECU.
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Possible Cause:
Remedy:
Ignition module defective.
Check ignition module(s). Replace if necessary.
Ignition coil defective.
Check ignition coil(s). Replace if necessary.
Spark plugs wet due to excess fuel.
Remove spark plugs, clean and dry. Determine and eliminate cause of excess fuel.
Electrode gap of spark plug too wide.
Correct electrode gap to 0.7 mm or replace
spark plugs.
Fuel tank empty (faulty indication of fuel
gauge).
Refuel, replace fuel gauge.
Fuel valve closed or filter blocked.
Open fuel valve, clean or replace filter.
Fuel line defective or not connected. Leaks
in fuel system.
Replace or connect fuel line. Repair leaks.
Fuel pump defective or electrical connection
to fuel pump interrupted.
Investigate electrical system and repair if
neccessary. Replace fuel pump. Try to run
engine in emergency mode.
Fuel pressure regulator defective.
Check fuel pressure, replace if necessary.
Note:
Warning Light „Fuel Pressure“ is on.
Coolant temperature sensor defective.
Check sensor, replace if necessary.
Induction system leakage.
Check induction system for leakage and replace, if necessary, tighten joints.
Throttle fully closed.
Check throttle lever, check idle speed adjusting screw.
Insufficient compression (no valve clearance, leaky valves, engine
overheated).
Adjust valve clearance, repair cylinder head,
tighten cylinder heads according to specification. Investigate and remove cause of
overheating.
Engine defective (blocked or worn out).
Overhaul engine.
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12.2 Engine Operating Trouble
The following phenomena are considered to be engine operating trouble:
• uneven and irregular engine run
• temporary interruptions
• low power
• engine overheat
• rough engine run
Consider reasons as per section 12.1 besides the ones listed below.
12.2.1 Fuel Supply
Possible Cause:
Remedy:
Insufficient fuel flow (Fuel ventilation locked,
lines blocked or defective, filter or screens
blocked).
Check tank ventilation, lines, filter and
screens and replace as necessary.
Insufficient fuel pump pressure.
Check fuel pump pressure and correct, if
necessary.
Fuel injector defective.
Replace fuel injector.
Fuel pump defective.
Repair or replace fuel pump.
Fuel pressure regulator defective.
Check fuel pressure, replace if necessary.
Coolant temperature sensor defective.
Check sensor, replace if necessary.
Pressure sensor plugged, defective.
Check and clean hose to sensor, replace
sensor if neccessary.
Wrong idling speed.
Adjust idling speed.
Throttle does not open fully.
Repair throttle control.
Air filter dirty or blocked.
Clean or replace air filter.
Induction system leaking.
Check induction system for leaks and seal
system if necessary.
Wrong fuel.
Refill fuel tank with specified fuel.
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12.2.2 Ignition
Possible Cause:
Remedy:
Ignition module defective.
Check ignition module, replace if necessary.
Ignition coil defective.
Check ignition coil, replace if necessary.
Spark plug defective.
Replace spark plug.
Wrong spark plugs.
Use specified spark plugs.
Ignition harness disengaged or damaged.
Fasten ignition lead(s) or replace.
Connector on ignition coils mixed.
Check markings, change over if necessary.
Wiring harness or connector loose or defective wire broken in wiring harness.
Check wiring harness and connectors, repair
if necessary.
Ignition switch defective.
Check wiring and switch and replace as
necessary.
Fuse in MCU defective.
Replace fuse, determine cause (short circuit) and repair.
12.2.3 Cooling
Possible Cause:
Remedy:
Not enough coolant.
Fill coolant up to “MAX” marking, check for
cause and repair if necessary.
Coolant system leaking.
Seal cooling system.
Coolant pump leaking, defective or drive belt
missing.
Check coolant pump, replace if necessary
or install drive belt.
Insufficient or damaged baffling and/or cooling system ducts.
Repair or complete baffling and ducts. Seal
leakages.
Cooling air inlet disturbance (missing spinner, cross section too small).
Install spinner, check air inlets in cowling for
foreign objects.
Fresh air and heating system ducts defective.
Replace ducts.
Cooling air outlet disturbance (Cross
section too small or cowlflap does not
open sufficiently).
Increase air outlet in cowling.
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12.2.4 Lubrication
Possible Cause:
Remedy:
Bad engine oil quality.
Change oil. Use specified oil.
Oil filter or cooler blocked.
Change oil filter. Clean oil cooler, replace if
necessary.
Note:
At low ambient temperatures the oil may be
overcooled in the oil cooler, thus causing
blockage and high oil pressures. Mask oil
cooler by suitable means to raise oil temperature.
Oil thermostat or thermostat spring
defective.
Check thermostat block, repair or replace if
necessary.
Oil temperature sensor or indicator
defective.
Check temperature sensor and indicator
and replace as necessary.
Lack of oil in the oil sump.
Check oil level and refill oil as necessary.
Note:
If the engine was accidently operated without
engine oil after performing an oil change –
expect severe engine damage. A teardown
inspection and repair ist strongly recommended for safe operation.
Oil pump defective.
Repair or replace oil pump.
Oil pressure regulating piston or spring
defective.
Replace regulating piston or spring.
Oil loss due to blocked crankcase
ventilation.
Clean ventilation, replace and properly install breather line (no bucklings or contractions).
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12.3 Exhaust / Turbocharger System L 2400 ET/DT/DX
Possible Cause:
Remedy:
Induction system leaking.
Check seals, rubber boots and hose
clamps, replace if neccessary.
Intercooler leaking.
Replace intercooler.
Exhaust system leaking.
Check joints, replace springs if neccessary.
Leaking exhaust gasket
Replace seal.
Thermal isolation missing around exhaust.
Repair /replace
Turbocharger defective.
Replace turbocharger.
Boost pressure limiter not working correctly.
Check linkage for corrosion, boost pressure
hose for damage or leakage, replace if neccsary.
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12.4 Mechanical System
Possible Cause:
Remedy:
No valve clearance.
Set valve clearance.
Note:
This symptom may be indication of an overheating engine, check cooling system, injection and ignition.
Leaking or sticking valve.
Repair cylinder head.
Note:
In some cases, fuel tanks made out of composite materials have been proven to be incompatible with the fuel, thus causing the
tank material to dissolve. In such cases, the
complete fuel system, pumps, filters, lines, injectors, fuel pressure regulator etc. must be
cleaned or even be re placed.
Strong accumulation of deposit in the
combustion chamber.
Demount cylinder heads, remove deposits.
Propeller unbalance.
Balance propeller. Check propeller blade
track.
Engine suspension defective.
Replace engine suspension.
Excessive gas leakage at the piston.
Repair engine.
Bearing defective.
Repair engine.
Engine defective.
Repair engine.
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12.5 Engine Operating Trouble in Normal Mode, no Trouble in Emergency Mode
The following phenomena are considered to be engine operating trouble:
• uneven and irregular engine run
• temporary interruptions
• low power
• engine overheat
• rough engine run
Possible Cause:
Remedy:
Speed sensor B1 (top mounted) defective.
Replace speed sensor, restore gap distance
to pickup-pins on the flywheel.
Throttle potentiometer loose, maladjusted,
disconnected or defective.
Check poteniometer fastening, adjust if necessary.
Note:
To adjust the throttle poteniometer a special
tool is necessary P/N 803.002.015.000 (only
for Weber Alpha).
Check wiring and/or connector repair or replace if necessary. Replace potentiometer if
necessary.
Coolant temperature sensor defective.
Check sensor, replace if necessary.
Air temperature sensor defective.
Check sensor, replace if necessary.
Wiring harness or connector loose or defective, wire broken in wiring harness.
Check wiring harness and connectors, repair if necessary.
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