Rotax 4-stroke Aircraft Engine Troubleshooting
Contents
1. 102 psi Minimum temperature 50 C 120 F 50 C 120 F 50 C 120 F Normal temperature 90 110 C 195 230 F 90 110 C 195 230 F 90 110 C 195 230 F Cylinder heads Outside air Maximum temperature 140 C 285 F 130 C 265 F 130 C 265 F Maximum consumption 0 06 L h 0 13 pt h 0 06 L h 0 13 pt h 0 06 L h 0 13 pt h Maximum temperature 150 C 300 F 150 C 300 F 150 C 300 F Minimum temperature 25 C 13 F 25 C 13 F 25 C 13 F Maximum temperature 50 C 120 F 50 C 120 F 50 C 120 F Minimum pressure 0 15 bar 2 2 psi 0 15 bar 2 2 psi Airbox 0 15 bar 2 2 psi Normal pressure Airbox 0 25 bar 3 6 psi Maximum pressure 0 4 bar 5 8 psi 0 4 bar 5 8 psi Airbox 0 35 bar 5 1 psi Maximum pressure sustained power 1200 hPa 35 4 in Hg AUSTA Maximum pressure take off 1350 hPa 39 9 in Hg Intake manifold Intervention temperature 72 C 160 F 88 C 190 F B Normal temperature 800 C 1472 F 800 C 1472 F 900 C 1650 F SEIS FERAT Maximum temperature sustained 850 C 1562 F 850 C 1562 F 950 C 1740 F Maximum temperature take off 880 C 1620 F 880 C 1620 F A 914 F gt 4 420 085 914 UL 24 417 665 Maximum take off power should only be used for a maximum of 5 minutes B 914 F gt 4 420 200 914 UL 24 42. Starting Can the starter turn the engine NO Loose or oxidized battery terminals Inadequate discharged or faulty battery Wiring resistance too high short circuit or bad contact Faulty starter solenoid or switch Starter turns without cranking engine faulty starter sprag clutch The engine turns but does it start NO Faulty fuel intake1 Water or ice contamination in fuel4 Faulty ignition system Fuel air mixture too rich Fuel air mixture too lean1 Engine mount problem Ignition switch is off Faulty carburetor Insufficient gearbox preload 0 Chokes out of synch or deactivated 1 Revolution too low Is the engine difficult to start in cold weather NO OPNDIBWNE BROMNDTAWNE TRWNE Excessive propeller load13 Inadequate starting jet Chokes out of synch or deactivated Throttle open above idle Revolution too low Too high voltage drop discharged battery Engine too cold Inadequate oil viscosity grade Too much resistance in oil return circuit signalled by too high an oil pressure Is the engine difficult to start when warm NO WHR Faulty fuel intake Obstructed air filtere Carburetor too hot Does the engine stop immediately after it has started Operation ORWE Faulty fuel intake Intake air infiltration11 Faulty carburetor diaphragm Idle speed too low Faulty exhaust system Does the engine vibrate excessively at idle N
3. interior 4 Excessive rotor tolerances Does the oil pressure fluctuate us 1 Resistance in oil pump intake circuit we 2 Worn bypass valve Is the oil leaking YES Determine the source of the leak 1 Gaskets NO 2 Cracks in crankcase 3 Excessive crankcase pressure 4 Insufficient cylinder head nuts tightening torque Cooling system Is there a cylinder heat temperature CHT 1 Instrument or connection problem reading a 2 Probe melted after overheating Is the engine overheating Eg 1 Inadequate air circulation i 2 Insufficient cooling liquid level in expansion tank NO 3 Trapped air bubbles in liquid cooling system 4 Overflow bottle of insufficient capacity or inadequate installation 5 Inadequate cooling liquid mix 6 Dirty or corroded radiator Ignition system Is there an excessive RPM drop when testing ignition systems independently AWON BF ol Check carburetors first Activate choke If there is a change sus pect the carburetors Clean grounding terminals Check pick up coil gaps Swap the position of the red charging coil wires to the electronic modules If the problem remains on the same mag the charging system is OK If it shifts the stator coil its wiring or its grounding are faulty Swap positions of the pick up coil connectors If the problem shifts there is a faulty pick up 6 Install new spark plugs inspect spark plug caps and measure their resistance and the secondary coil s r
4. 17 598
5. O Faulty fuel intake Faulty ignition system Fuel air mixture too rich Engine mount problem12 Excessive propeller load13 Choke still on Carburetors out of synch Insufficient gearbox preload Insufficient exhaust system pressure Does the engine miss at idle ONE OONOAAKWYE Bad fuel quality Water or ice contamination in fuel4 Faulty ignition system Does the engine miss at takeoff and cruise speeds NO Bad fuel quality Faulty ignition system Spark plug problem Fuel air mixture too lean1 Carburetor too hot Is the engine lacking power and having diffi culty reaching maximum RPM NO WME JAWNE Bad fuel quality Excessive propeller load13 Faulty exhaust system Operation continued Do the engine and prop seem to work against each other at shutdown Does the engine WNE Idle speed too high Insufficient gearbox preload No 4 keep turning over after shutdown iEngine overheating Does the engine detonate and preignite YES 1 Bad fuel quality 2 Spark plug problem 8 NO 3 Intake air infiltration41 4 Carburetors out of synch Oil Does the oil level rise EJ 1 oil stays too cold through operation 2 If oil has a distinct smell of fuel No Faulty float valve operation Does the oil level drop YES 1 Oil return to tank obstructed i 2 Inadequate tension of the bypass valve spring dirt or wear on ball No or seat 3 Eroded pump cover
6. esistance 7 Swap ignition module A with module B measure their primary coil resistance on new style modules the ground goes through the connector If the problem moves there is a faulty ignition module Copyright 2003 Aero Propulsion Technologies All rights reserved 4 45 TROUBLESHOOTING Faulty fuel intake Closed fuel circuit valve Empty fuel tank eooop tors carburetor intake Insufficient or obstructed fuel tank vent Defective fuel pump Air infiltration in fuel circuit2 ump capacity ir infiltration in fuel circuit Leak at connections in hoses in filter Faulty primer pump lost its sealing Bad fuel quality Fuel degraded over time Insufficient octane ratin Water or ice contamination in fuel Water or ice in system Water or ice in tank Gascolator full of water Faulty float valve operation Worn float valve Dirt on valve sealing surface Blocked floats Permeable floats low floatation Obstructed air filter Obstructed by dirt or debris Soaked with water or fuel Excessive oiling Faulty ignition system Faulty connection in circuit Inadequate trigger coil gap Defective ignition coils eoorseeeMeeeegece he ewe en OPERATING PARAMETERS Obstruction in fuel circuit hoses filter pump fittings selec Fuel circuit installation length height restrictions overwhelms Shorted or damaged ignition cable Faulty spark plug cap Spark plug problem Faulty switch or wiring Spark plug prob
7. lem nadequate electrode gap Contact between electrodes Fouled spark plug Broken or wet insulating porcelain Worn or defective spark plug nadequate spark plug range too cold hot Fuel air mixture too rich Needle adjusted too high Float level too high Faulty float valve operation gt Obstructed air filter 0 Fuel air mixture too lean Needle adjusted too low Float level too low Air infiltration in fuel circuit2 Intake air infiltration11 Fuel foaming caused by violent vibration of the carburetors 1 Intake air infiltration Leak at compensation tube and its connections Leak at o rings e Cracked or worn carburetor rubber socket 12 Engine mount problem e Worn or untightened rubber mounts e Inadequate rubber mount selection e Faulty engine mount design 13 Excessive propeller loa e Excessive pitch diameter or number of blades e Excessive moment of inertia e opeeeeepeeeewmeeeeeemesee CP VAAUE EPR YAUR YAU KJ ii 914 F UL Minimum idle 1400 RPM 1400 RPM 1400 RPM Maximum sustained 5500 RPM 5500 RPM 5500 RPM Maximum take off 5800 RPM 5800 RPM 5800 RPM Minimum pressure lt 3500 RPM 0 8 bar 12 psi 0 8 bar 12 psi 1 5 bar 22 psi A 0 8 bar 12 psi Normal pressure gt 3500 RPM 2 5 bar 29 73 psi 2 5 bar 29 73 psi 4 5 5 bar 22 73 psi A 2 5 bar 29 73 psi Maximum pressure for a short period at cold start 7 bar 102 psi 7 bar 102 psi 7 bar
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