Maintenance instruction for the engine SOLO 2 350 after 5 years of
Contents
1. ignition coil Check of the wiring A visual check has to be made to all wires If there are visible breaks of the isolation especially on the ignition cables they have to be replaced Inside the ignition coil and the spark plug cap there are threads For this reason the cables can simply be dismantled by turning the cable in counterclockwise direction The new cables can be mounted by turning the cable clockwise The cables have to be secured with a heat shrink sleeve against damages Check of the rubber isolaters of the engine mounting The rubber isolater have to be checked visually They may not show cracks damages or excessive swelling Functional check with test run A test run on the ground is not advisable It is safer to accomplish the functional check during a flight with engine on over the airfield The engine performance can simply be judged over the RPM indication green LED showing correct RPM must light up Pay attention on possible uneven run or unusual vibrations solo Maintenance instruction for the Page no 8 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Edition 1 Postfach 600152 x operation June 19 2001 D71050 Sindelfingen Germany If the test run has to be made on the ground the airplane must be mounted and fixed completely Fuel valve open Ignition and electric fuel pump on if available or operate manual pump Use a piece of safety wire to slightly press on the diaphragms in the carburet2. D71050 Sindelfingen operation June 19 2001 Germany 5 Carburettor check From serial number 1 to 338 parts of the manufacturer Tillotson were used Starting from serial number 339 and higher parts of the manufacturer Walbro were used This can be recognized by the fact that on the Walbro system the metering unit is cast on to the intake manifold 05 10 841 p Dichtung 05 10 842 Stevermodul 05 10 843 AP Dichtung ae 4 05 10 844 T Membrane A l OD t eaxs 05 10 845 E f F l Deckel 00 30 168 Unterlagscheibe 00 10 239 M3X16 DIN84 Picture 5 Structure of the metering unit from Tillotson serial numbers 1 to 338 20 32677 Dusenstock eingepreBbt Hauptduse 23 00 690 Stevermodul 05 10 597 MEMBRANE REGEL 95 526 WB 05 10 879 DECKEL 21 3063 WB O00 18 388 la ee s M3x16 TT 05 10 881 DIC 92 257 WB 05 10 594 DICHTUNG 92 146 WB Picture 6 structure of the metering unit from Walbro from serial number 339 and higher Remove the fuel hoses Remove the 4 screws 3 screws on Tillotsen on the covers Remove the metering module and clean it with compressed air To do this you have to press the small lever 1 against the spring Then you can blow air to the valve seat 2 Reassemble the metering module in the order as shown in the picture above All seals and diaphragms have to be replaced Check the controle module for correct sealing To do this you have to use a manometer Pictu
3. e same time During turning the engine slowly there must be a noticeably compression After exceeding the top dead center of each piston movement there must be a noticeable acceleration The reason of missing compression is usually caused by leaking cylinder head gaskets If one or both of the cylinder head gaskets are defect the engine has to be removed and the gaskets part number 20 61 407 have to be replaced Torque values for nuts and bolts see above If the suspicion on defective piston rings exists these can be examined after disassembly of the exhaust system Turn the engine in such a way that the rings are visible through the exhaust port The piston rings as well as the pistons should not have deep scratches With a small screwdriver the rings can be examined for free movement in their grooves Push on each ring They must be able to move free and move back into their original position If one or more of the piston rings are defect the engine has to be sent to the manufacturer The instruction for the replacement of the engine can be found in the service manual of the airplane manufacturer Picture 4 Piston ring check Attention During all work on the engine with dismantled parts make shure that no parts and no dirt can enter the engine These parts can lead to the destruction of the engine solo Maintenance instruction for the Page no 4 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Edition 1 Postfach 600152
4. ews apply a screwdriver and strike on it with a hammer check roller bearing for corrosion rust or discoloration blue caused by overheating visual check If there is any damage recognizable the engine has to be sent to the manufacturer Reassemble and secure the screws with Loctite 243 Picture 10 Check of the rear bearing solo Maintenance instruction for the Page no 7 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Postfach 600152 D71050 Sindelfingen Edition 1 operation June 19 2001 Germany 11 12 13 14 Examine the air gap between the ignition coils and the flywheel Check the distance between the magnet and the ignition coils with a gage The distance should be between 0 2mm and 0 4mm In no case the flywheel should contact the ignition coils If the gap must be corrected the bolts holding the ignition coil must be loosened Then put a gage 0 4 mm between the flywheel and the ignition coil Press the ignition coil against the flywheel and tighten the bolts Make sure that the flywheel is positioned in such a way that the magnet machined surface of the flywheel is showing towards the ignition coil which has to be adjusted Tighten the bolts with a torque of 2Nm Pull out the gage and check the distance again When the distance is within the indicated range 0 2 to 0 4mm the screws must be secured with the nuts on the backside of the holding plate Picture 11 Check of theair gap at the
5. re 7 Check pressure 0 4 bar Permissible decrease of pressure 0 1 bar min This examination is particularly important because only sealing carburettors ensure a perfect engine run If necessary the control modules have to be replaced part numbers see below S ol O Maintenance instruction for the Page no 5 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of ee Postfach 600152 D71050 Sindelfingen operation June 19 2001 Germany Picture 7 Seal check Picture 8 Cleaning the metering module 6 Replacing the fuel hoses If necessary the supplied fuel hose must be shortened The hose and the metal protection can be cut to correct length with a side cutter Be sure that the hoses are mounted ascending and that there are no breaks Make sure that the hoses are not too far away from the engine in order to prevent a hook when retracting the engine into the fuselage The hoses have to be secured with safety wire on the nipples The metal protection has to be fastened with the hose clamps over the nipples 7 Replace spark plug and spark plug cap Remove the spark plugs and check the color of the spark plug electrode The color should be brown to grey In the case of dark or black colour of the electrodes it can be assumed that the metering module in the carburetors was leaking see check 3 Replace spark plugs Bosch W5AC part number 23 00 500 Replace spark plug cap part number23 00 701 To do this you have to turn the cap co
6. solo Maintenance instruction for the Page no 1 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Edition 1 Postfach 600152 operation June 19 2001 D71050 Sindelfingen Germany Introduction Due to the TM 4603 10 the following change results for the owners of a SOLO 2 350 aircraft engines 1 The overhaul of the engine after a period of operation of 5 years is no longer necessary and is replaced by a special inspection which can be conducted by the manufacturer or a certified maintenance organisation or a certified maintenance person For this purpose the Maintenance instruction for the engine SOLO 2 350 after 5 years of operation was released This instruction also contents a list of the necessary material In principal it is mandatory that if one of the examinations leads to a negative result and cannot be repaired by the implementing person the engine has to be sent to the manufacturer 2 The execution of the inspection has to be documented in the attached finding report All parts necessary for the inspection can be ordered from the manufacturer as a kit To order the kit the serial number of the engine or the correct part number of the suitable kit has to be sent From serial number 1 to 338 order number 05 10 927 from serial number 339 up order number 05 10 928 Up to serial number 338 carburettor parts from Tillotsen were used Later the carburettor parts from Walbro were used Checklist 1 Check the
7. special inspection Engine 2 350 Serial number cceeeeee Neenee O OOOO m r Decompression valves clean and check Pe Pe Pe Replace spark plug and spark plug cap M Pe 7 a fo o F ee mw Pe 13 Functional check on the ground or in flight 14 Visual check after test run Special inspection accomplished by name signature Confirmation of the special inspection by name signature Inspection stamp inspector
8. the decompression valves in the cylinder head torque 20 Nm Pay attention to the bended connecting sheet metal The shorter section must point forward in flight direction To check the correct sealing of the decompression valves turn the propeller No exit of compressed air should be heard If the valves don t seal after the cleaning they must be replaced part no 28 00 272 decompression valve complete 20 31 989 St ssel Deko Veniil 20 31 991 25 Geh use Deko Ventil f 00 55 279 f m bng 5 SI RINGBXO 8 7993RW f 00 70 28 A FEDER 0 9x14x18 DRK f f f m a n i 003158325 j j SCHEIBE6 3x 6x3 1 5 BND 0033356 f H lse 6 2x8x2 5DIST 7 f a A my si f f 003 507 f Scheibe f f f f if eS Ze LS a UU ZA 7 Thermag Mutter M jy f Picture 3 Decompression valve solo Maintenance instruction for the Page no 3 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Edition 1 Postfach 600152 operation June 19 2001 D71050 Sindelfingen Germany 3 Check the sealing of the engine especially the cylinder head gaskets Check the compression of the engine Check if near the cylinder head gasket carbon leaks can be seen Leaky decompression valves can also lead to such findings Turn the engine with the propeller Pay attention if leaks of compressed air can be heard Together this check the function of the piston rings can be examined at th
9. torques of all reachable nuts and bolts The values from the current engine manual apply section 5 service instructions Spark plug 20 Nm 14 5 ft Ibs Hub on crankshaft left hand 50 Nm 36 ft Ibs Nuts M6 on cylinder head 13 Nm 9 5 ft Ibs Nuts M8 on cylinder head 20 Nm 14 5 ft Ibs Nuts M8 an cylinder base 13 Nm 9 5 ft Ibs Hex Head bolts and allen M4 3 Nm 12 ft Ibs M6 13 Nm 19 5 ft Ibs M8 23 Nm 16 5 ft Ibs Slotted Screws M3 0 9 Nm 0 6 ft Ibs M4 2 Nm 1 5 ft Ibs M5 4 Nm 3 ft Ibs A suitable torque wrench has to be used solo Maintenance instruction for the Page no 2 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Edition 1 Postfach 600152 operation June 19 2001 D71050 Sindelfingen Germany 2 Decompression valves clean and check Remove the operation lever 1 on the engine mount Remove the decompression valves 2 Clean the valves with fuel Clean the valve seat with a fine wire brush All oil carbon deposit has to be E lie valve must be able to be moved free in the valve body g n T N he m 2 Picture 1 Picture 2 Removing the decompression valves Cleaning of the decompression valves If the valve in the assembled condition cannot be cleaned then it has to be disassembled To do this you have to remove the snap ring Picture 3 part 00 55 279 on the upper end Push the valve out of the housing All parts have to be cleaned completely Reassemble the decompression valve Insert
10. tors hole in the covers of the metering module This is necessary to prime the engine Start the engine with the provided starting belt If the engine has gotten to much fuel press the decompression valves Too much fuel can exit through the decompression valves The RPM on the ground must be at least 4 200 1 min The RPM can be measured on the control panel with a voltmeter which is connected at the pin 10 and ground One volt corresponds to 1 000 1 min 15 Visual check after test run After the test run another visual check has to be made Pay attention in particular to leakages which are recognizable by leaking oil or fuel If the cylinder heads have been removed all nuts on the cylinder head have to be retorqued with the indicated torque Material list Pos pes Partnr Description __ S O 6 1 2700397 Fuelline complete _ S 8 1 0062231 O Ring62x2NBR70SHO _ gt 9 2 0510841 Gasket Tillotson un il s no 338 Z Part number complete kit from serial number 1 to 338 05 10 927 Part number complete kit from serial number 339 and over 05 10 928 Additionally to the parts contained in the kit maybe you need the following parts Pos pes PartNo Description S 28 00 272 Decompression valves complete 20 61 407 Cylinder head gasket pt CT Safety wire For the procedure you need the follwing special tools Torque wrench Carburettor tester No 00 80 314 Manometer Finding report on the
11. unterclockwise off the ignition wire The new cap has to be turned clockwise onto the ignition cable Insert the new spark plugs torque 20Nm and push on the cap firmly Picture 9 Replacing the spark plug cap solo Maintenance instruction for the Page no 6 of 8 KLEINMOTOREN GMBH engine SOLO 2 350 after 5 years of Postfach 600152 D71050 Sindelfingen Edition 1 operation June 19 2001 Germany 10 Visual check of the exhaust system Check the exhaust system if there are any visible cracks These can be found by rests of black carbon deposits on the exhaust If the findings are uncertain then the carbon should be wiped off with gasoline So possible cracks become visible If the exhaust system is removeded for better investigation make sure that new gaskets are used for reassembly Before you reassemble the exhaust the sealing surfaces must be cleaned from rests of the old gaskets Attention During all work on the engine with dismantled parts make shure that no parts and no dirt can enter the engine These parts can lead to the destruction of the engine Check the entire engine particularly the cylinder fins for damages Examine the entire engine for damages and broken off ribs or cracks at the housing If individual cooling fins should have broken off the engine has to be sent to the manufacturer Check of the rear crankshaft bearing on corrosion or overheating Remove the rear cover In order to loosen the 4 scr
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