LIMBACH L 2400 EF, Operating And Maintenance Manual

Page 1: ...ures of the EASA approved develop ment 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 ...

Page 2: ... 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 Opera...

Page 3: ...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 Lubricatio...

Page 4: ...anual 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 ...

Page 5: ...on 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 opera tion 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 ai...

Page 6: ...r 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...

Page 7: ... Manual L 2400 EF DF ET DT DX DS 250 253 501 000 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 ...

Page 8: ...ition 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 ...

Page 9: ...e 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 op...

Page 10: ...ator 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 cr...

Page 11: ...e 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 o...

Page 12: ...CH 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 m...

Page 13: ...e 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 o...

Page 14: ... 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 maintainan...

Page 15: ...e 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 op...

Page 16: ...Page 16 53 Edition 20 06 2018 Operating Manual L 2400 EF DF ET DT DX DS 250 253 501 000 5 Performance 5 1 Performance Graph LIMBACH L 2400 EF DF RPM 1 min ...

Page 17: ... 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 ...

Page 18: ...Page 18 53 Edition 20 06 2018 Operating Manual L 2400 EF DF ET DT DX DS 250 253 501 000 5 2 Performance Graph LIMBACH L 2400 ET DT RPM 1 min ...

Page 19: ...2 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 6...

Page 20: ...Page 20 53 Edition 20 06 2018 Operating Manual L 2400 EF DF ET DT DX DS 250 253 501 000 5 3 Performance Graph LIMBACH L 2400 DX ...

Page 21: ... 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 9...

Page 22: ...Page 22 53 Edition 20 06 2018 Operating Manual L 2400 EF DF ET DT DX DS 250 253 501 000 5 4 Performance Graph LIMBACH L 2400 DS ...

Page 23: ... 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...

Page 24: ...ote 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 pre sent in the propeller area Open fuel shutoff valve Turn...

Page 25: ...nce 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 engi...

Page 26: ...fter 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 ...

Page 27: ...tween 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 c...

Page 28: ...sturbed The operating time for the engine is limited Check the flight manual for the time re maining to fly Take course to the next possible landing site Adjust your flight attitude to a maxi mum 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 alti tude Note The voltage of...

Page 29: ...heck 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 Ch...

Page 30: ...nd 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 actu...

Page 31: ...d 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 ...

Page 32: ...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 inboa...

Page 33: ...ilter 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 ...

Page 34: ...move 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...

Page 35: ...semble 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 cy...

Page 36: ...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 co...

Page 37: ...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 bo...

Page 38: ...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...

Page 39: ... 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 cm 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 ...

Page 40: ...ke 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 extre...

Page 41: ...utinely 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 eng...

Page 42: ...ations 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 obsta...

Page 43: ...gher 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 Su...

Page 44: ... 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 U...

Page 45: ...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 ...

Page 46: ... insufficient contact Clean connectors Connect or replace wire Ground wire to engine not connected defec tive 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 Faste...

Page 47: ...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 ...

Page 48: ...nd 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 an...

Page 49: ...ive Check wiring and switch and replace as necessary Fuse in MCU defective Replace fuse determine cause short cir cuit 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 inst...

Page 50: ... 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 re...

Page 51: ...d 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...

Page 52: ...posite materials have been proven to be in compatible with the fuel thus causing the tank material to dissolve In such cases the complete fuel system pumps filters lines in jectors 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 blad...

Page 53: ...nce to pickup pins on the flywheel Throttle potentiometer loose maladjusted disconnected or defective Check poteniometer fastening adjust if nec essary 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 re place if necessary Replace potentiometer if necessary Coolant temperature sensor defective Chec...