MW Fly B22 AeroPower Operation Manual Download

Page: 4 / 93

Applicable to: B22 and B25 (a ll versions)

Revision 1.3 – 02/24/ 2015

Manual B – Operations

B.5.4.6. B25H

B.5.4.7. B25L

B.5.4.8. B25R

B.5.4.9. Performance Variation

B.5.5. Ratio Power/Weight

B.5.6. Fuel Consumption

B.5.7. Propeller speed

B.5.8. Direction of the Rotation of the Propeller

B.6. DESCRIPTION OF THE SYSTEMS

B.6.1. Cooling system

B.6.2. Lubricant system

B.6.3. Fuel system

B.6.4. Electric system

B.6.4.1. ES-m Instrumentation

B25L Consumption @ constant MAP

Summary of Contents for B22 AeroPower

Page 1: ...Applicable to B22 and B25 all versions Revision 1 3 02 24 2015 Manual B Operations 1 B22 AeroPower B25 AeroPower Manual B OPERATIONS MANUAL ...

Page 2: ...tions and technical data contained in this manual has been upgraded before printing MW Fly reserves the right to modify correct or upgrade general data at any time without any obligation or prior consent from third parties Publication of any part of this document without written consent of MW Fly is strictly prohibited This Manual forms part of the engine and must be kept safe It must accompany th...

Page 3: ...r Expansion Tank 15 B 3 3 4 Air Filter 15 B 3 3 5 ECU 15 B 3 3 6 Head Cover 15 B 3 3 7 Reduction Gear Box 15 B 3 3 8 Governor 16 B 3 3 9 Water Circuit Arrows 16 B 3 3 10 Fuel Circuit Arrows 16 B 3 4 Modifications and Accessories 17 B 3 4 1 Original Accessories 17 B 3 5 Use of the Technical Documentation 18 B 4 ENGINE DESCRIPTION 19 B 4 1 General Characteristics 19 B 4 2 Engine Models 19 B 4 3 Cyli...

Page 4: ...B22L 47 B 5 6 4 B22R 49 B 5 6 5 B25D 51 B 5 6 6 B25H 53 B 5 6 7 B25L 54 B 5 6 8 B25R 56 B 5 7 Propeller speed 58 B 5 8 Direction of the Rotation of the Propeller 58 B 6 DESCRIPTION OF THE SYSTEMS 60 B 6 1 Cooling system 60 B 6 2 Lubricant system 61 B 6 3 Fuel system 62 B 6 4 Electric system 63 B 6 4 1 ES m Instrumentation 64 5 10 15 20 25 30 35 40 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 ...

Page 5: ...72 B 7 3 2 Start Operation 75 B 7 3 3 Engine Warm Up 76 B 7 3 4 Before Take Off 77 B 7 3 5 Take Off 78 B 7 3 6 Cruise 78 B 7 3 7 Landing 78 B 7 3 8 Engine Switch off 79 B 7 3 9 Use of the Engine in Winter Season 79 B 7 4 Behavior in Case of Emergency 81 B 7 4 1 Accidental Engine Stop Start During Flight 81 B 7 4 2 Over Rev 81 B 7 4 3 Exceeding the Maximum Coolant Temperature 81 B 7 4 4 Exceeding t...

Page 6: ...ter from Service for Extended Period of Time 86 B 8 3 Return to Service After Long Inactivity 86 B 8 4 Engine Protection When Used in Cold Climates 87 B 9 MALFUNCTION RESOLUTION 88 B 9 1 Operation Malfunctions and Their Resolution 88 B 9 2 Anomalies to the Injection and Ignition Systems 89 B 9 3 Signal Engine Malfunction 90 B 10 AUTHORIZED DISTRIBUTOR 92 B 11 MANUAL UPDATE LIST 93 ...

Page 7: ...ommencing to operate the engine it is crucial to read and understand the contents of this document If any part of this manual is unclear or there are any doubts on the interpretation contact an MW Fly service center For additional or more detailed information consult the Maintenance Manual and the Additional Maintenance Manual It is fundamental to integrate the information of this manual with the ...

Page 8: ... 4 in the table the measurement units are indicated between square brackets A 3D Cartesian coordinate right hand is used in the present manual The axis origin is on the propeller shaft In the intersection with the propeller level on the propeller flange the x axis positive direction is towards the engine see picture B 2 2 1 P the y axis positive direction is towards side 1 the z axis points up RAM...

Page 9: ...ons for installation or maintenance B 2 3 Identification Data The Engine serial number is located on the upper side of crank case near oil dip stick It is composed of ten alpha numeric codes where the third and fourth symbol indicate Model and Version the following four are the serial number and the last two are the year of manufacturing Identification code and version is illustrated in chart B 4 ...

Page 10: ...portant to understand all the safety aspects and to distinguish the two different safety types active and passive B 3 2 1 Passive Safety Passive safety concerns the engine design and the engine installation criteria The following is a list of the main engine features designed to increase passive safety CRANK SHAFT ON BALL BEARINGS This reduces the risk of engine stoppage in case of lubricant syste...

Page 11: ...oids the complicated setting of cooling that an air cooled engine needs With the liquid cool engine the real performance of the engine is close to the theoretical performance because engine temperature does not depend at all on external and flight conditions COOLING CIRCUIT IN STAINLESS STEEL This solution has been designed to avoid any risk of wear or loosening of the coolant circuit hoses PRE IN...

Page 12: ... the situations or behaviors that could create a dangerous situation Check often the engine attachment the aircraft command the fuel line electrical wiring harness and the filters Never fill the fuel supply with the risk of spilling on hot parts of the engine Always use approved fuel containers using extreme caution in transportation Never pour fuel in an enclosed area or where fumes may reach the...

Page 13: ...dden to use a propeller with a polar moment of inertia higher than the maximum prescribed that will release MW fly from any liability The engine has not received any certification for aeronautical use It must be used exclusively on experimental aircraft where an engine failure will not compromise flight safety Its use in certified aircraft is strictly prohibited The user is informed about the risk...

Page 14: ... need to be done prior to flight as well as other information concerning engine characteristics and operation All labels are in English The following is a list of the labels their position and meaning B 3 3 1 Engine Oil Filler Cup B 3 3 1 P CAPACITY 2 8 L API SG OR HIGHER this identifies the oil specification as indicated by the American Petroleum Institute API ENGINE OIL engine oil SAE 15W 50 oil...

Page 15: ... pressurized filler cap B 3 3 4 Air Filter B 3 3 4 P KEEP CLEAN AND DRY RAM INTAKE EFFECT the intake manifold is designed to take advantage of the ram effect B 3 3 5 ECU This label is placed on the rear side of the ECU s bracket B 3 3 5 P FULL AUTHORITY DIGITAL ENGINE CONTROL F A D E C OPERATING ELECTRICAL VOLTAGE 9 18V MAX OPERATING TEMPERATURE 85 C CHECK WIRING LOOM BEFORE FLIGHT PROTECT BEFORE ...

Page 16: ...LY INTEGRATED ELECTRO HYDRAULIC B 3 3 9 Water Circuit Arrows B 3 3 9 P The arrows are place in correspondence to the in and out water pump manifold and indicate the direction of the water flow The lower manifold is the output line from the engine to the radiator and the upper manifold is the inlet line from the radiator to the engine B 3 3 10 Fuel Circuit Arrows B 3 3 10 P The arrows are placed on...

Page 17: ...oesn t interfere with the throttle command or with the propeller For no reason modify the engine wiring harness Do not modify the engine map of the ECUs Avoid installing any accessory that can block the normal coolant flow Always check that the total electrical absorption of all the electronic components installed on the aircraft is not greater than the power supplied by the generator It is mandat...

Page 18: ...ncludes all the necessary information to correctly execute the planned maintenance program of the engine D Heavy Maintenance Manual includes all the information to correctly execute any unplanned maintenance as the result of an engine failure E Illustrated Parts Catalogue includes the list of all of the spare parts and accessories F Overhaul Manual includes all necessary information to carry out a...

Page 19: ...from the engine oil it has a helical gear and monolithic propeller shaft and it is designed for an oil pump for the hydraulic constant speed governor ADC Automatic Damping Control to control the torsional vibration up to 2500 rpm Electric starter motor and start relay pre installed on the engine Oil cooled alternator and voltage regulator pre installed on the engine B 4 2 Engine Models The followi...

Page 20: ...2 are on side 1 and cylinder 3 and 4 are on side 2 ULL U THORITY IGITAL NGINE ONTROL FLY BY MAX OPERATING TEMPERATURE 85 C CHECK WIRING LOOM BEFORE FLIGHT OPERATING ELECTRIC VOLTAGE 9 18V PROTECT BEFORE WASHING RESERVOIR PR ESS UR IZE D N E V E R O P E N W H E N O T H C A P A C I T 0 Y 7 L US E E T H Y L E N E E C H A N G E C O O L A N T V E R Y 2 Y E A R S E C E A H C O C K I L O N S T E L D N O ...

Page 21: ...ibed maintenance time table It is not possible to extend the guarantee condition for different uses of the engine MW Fly declines any responsibility for damage or bodily injury due to the improper end use of the engine An improper end use of the engine will cause an immediate suspension of the guarantee and will release MW fly from any liability The engine life cannot exceed the TBO limit see tabl...

Page 22: ...Applicable to B22 and B25 all versions Revision 1 3 02 24 2015 Manual B Operations 22 B 5 2 Dimension B 5 2 1 P ...

Page 23: ... R A E Y C U P T O 2 N 2 T 3 379 C A P A L 2 8 E O I L O I L SA E 15W 50 A PI SG OR H IG H ER E N G I N E E N G I N E T F G L F E R I O H C K B C E H C I Y T CHECK WI RI NG LOOM B EFORE FLIGHT PROTECT BEFORE WASHING PROTECT B EFORE WASHING M AX OPERATI NG TEM PERATURE 85 C OPERATI NG ELECTRI C VOLTAGE 9 18V FLY ON TROL N GI NE BY I GI TAL U TH ORITY U LL 0 209 Dim ensional w it h gear box 68 0 247...

Page 24: ...ng air filter Only the radiator coolant and exhaust system are not included in the weight shown in the table Weight Kg Dry With lubricants B22D B25D 79 5 82 3 B22H B25H 78 7 81 5 B22L B25L 83 6 86 6 B22R B25R 83 6 86 6 B 5 3 1 C Model without reduction gear box with the reduction gear box the weight is 83 6 and 86 6 B 5 3 1 Optional Accessory Weight Adapter for bed mount 4 pieces 0 37 Kg Exhaust s...

Page 25: ...AP and RPM the limit at high RPM is due to the thermodynamics the limit at low RPM is to avoid overload on the reduction gear box During flight the preferred power is set with high RPM and low MAP The use of the engine at maximum continuous power for a long period can seriously damage the engine and can cause a sudden stoppage of the engine In the following paragraph there is the performance graph...

Page 26: ...nual B Operations 26 Graph POWER MAP with constant RPM each graph indicates the power output in reference to the different values of RPM in function of MAP The bold indicates the maximum continuous power in function of the MAP 5 difference from the graph is permitted ...

Page 27: ...5 4 3 C B 5 4 4 C 20 3400 95 3400 12 14 16 18 20 22 24 26 30 40 50 60 70 80 90 100 2000 2250 2500 2750 3000 3250 HP Kgm RPM B22D Performance full throttle Power Torque 0 10 20 30 40 50 60 70 80 90 100 2000 2250 2500 2750 3000 3250 HP RPM Range of use B22D Available power Necessary power Max cont power ...

Page 28: ...s 28 B 5 4 5 C B 5 4 6 C 20 30 40 50 60 70 80 90 100 2000 2250 2500 2750 3000 3250 3500 HP RPM B22D Power constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 20 30 40 50 60 70 80 90 100 22 23 24 25 26 27 28 29 30 HP inHg B22D Power constantRPM 3400 3250 3000 2750 2500 2250 2000 max cont ...

Page 29: ... 7 C B 5 4 8 C 131 5 4300 22 4200 14 16 18 20 22 24 26 28 30 32 50 60 70 80 90 100 110 120 130 140 2250 2500 2750 3000 3250 3500 3750 4000 4250 HP Kgm RPM B22H performace full throttle Power Torque Max cont 112 5 27 8inHg 60 70 80 90 100 110 120 130 140 22 23 24 25 26 27 28 29 HP inHg B22H Power 4300 giri ...

Page 30: ... C B 5 4 10 C 20 8 3950 114 7 3950 14 16 18 20 22 24 26 28 50 60 70 80 90 100 110 120 2250 2500 2750 3000 3250 3500 3750 4000 HP Kgm RPM B22LPerformance full throttle Power Torque 0 20 40 60 80 100 120 2500 2750 3000 3250 3500 3750 4000 HP RPM B22LRange of use Available power Necessary power Max cont power ...

Page 31: ...B 5 4 11 C B 5 4 12 C 30 40 50 60 70 80 90 100 110 120 2750 3000 3250 3500 3750 4000 4250 HP RPM B22LPower constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 30 40 50 60 70 80 90 100 110 120 22 23 24 25 26 27 28 29 30 HP inHg B22LPower constantRPM 4200 4000 3750 3500 3250 3000 2750 max cont ...

Page 32: ...4200 130 3 4550 14 16 18 20 22 24 26 28 30 32 50 60 70 80 90 100 110 120 130 140 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 HP Kgm RPM B22R Performace fullthrottle Power Torque 0 20 40 60 80 100 120 140 2500 2750 3000 3250 3500 3750 4000 4250 4500 HP RPM B22R Range of use Available Power Necessary Power Max cont Power ...

Page 33: ... 16 C 30 40 50 60 70 80 90 100 110 120 130 140 2750 3000 3250 3500 3750 4000 4250 4500 4750 HP RPM B22R Power constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 30 40 50 60 70 80 90 100 110 120 130 140 22 23 24 25 26 27 28 29 30 HP inHg B22R Power constantRPM 4700 4500 4250 4000 3750 3500 3250 3000 max cont ...

Page 34: ...17 C B 5 4 18 C 23 2 3400 110 3400 12 14 16 18 20 22 24 26 28 30 30 40 50 60 70 80 90 100 110 120 2000 2250 2500 2750 3000 3250 HP Kgm RPM B25D Performance full throttle Power Torque 0 20 40 60 80 100 120 2000 2250 2500 2750 3000 3250 HP RPM B25D Range of use Available power Necessary power Max cont power ...

Page 35: ...4 19 C B 5 4 20 C 20 30 40 50 60 70 80 90 100 110 120 2000 2250 2500 2750 3000 3250 3500 HP RPM B25D Power constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 20 30 40 50 60 70 80 90 100 110 120 22 23 24 25 26 27 28 29 30 CV inHg B25D Power constantRPM 3400 3250 3000 2750 2500 2250 2000 max cont ...

Page 36: ...5 4 22 C 156 4300 26 1 4200 16 18 20 22 24 26 28 30 32 34 36 60 70 80 90 100 110 120 130 140 150 160 2250 2500 2750 3000 3250 3500 3750 4000 4250 HP Kgm RPM B25H Performance full throttle Power Torque Max cont 133 5 27 8inHg 60 70 80 90 100 110 120 130 140 150 160 22 23 24 25 26 27 28 29 HP inHg B25H at 4300 RPM ...

Page 37: ...5 4 24 C 24 1 3950 133 1 3950 16 18 20 22 24 26 28 30 32 60 70 80 90 100 110 120 130 140 2250 2500 2750 3000 3250 3500 3750 4000 HP Kgm RPM B25LPerformance full throttle Power Torque 0 20 40 60 80 100 120 140 2500 2750 3000 3250 3500 3750 4000 HP RPM B25LRange of use Available power Necessary power Max cont power ...

Page 38: ... C B 5 4 26 C 30 40 50 60 70 80 90 100 110 120 130 140 2750 3000 3250 3500 3750 4000 4250 HP RPM B25LPower constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 30 40 50 60 70 80 90 100 110 120 130 140 22 23 24 25 26 27 28 29 30 HP inHg B25LPower constantRPM 4200 4000 3750 3500 3250 3000 2750 max cont ...

Page 39: ...54 2 4550 16 18 20 22 24 26 28 30 32 34 36 60 70 80 90 100 110 120 130 140 150 160 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 HP Kgm RPM B25R Performance full throttle Power Torque 0 20 40 60 80 100 120 140 160 2500 2750 3000 3250 3500 3750 4000 4250 4500 HP RPM B25R Range of use Available power Necessary power Max cont power ...

Page 40: ... 40 50 60 70 80 90 100 110 120 130 140 150 160 2750 3000 3250 3500 3750 4000 4250 4500 4750 HP RPM B25R Power constantMAP 29 9 28 5 27 25 5 24 22 5 max cont 30 40 50 60 70 80 90 100 110 120 130 140 150 160 22 23 24 25 26 27 28 29 30 HP inHg B25R Power constantRPM 4700 4500 4250 4000 3750 3500 3250 3000 max cont ...

Page 41: ...ormance based height B 5 4 31 C The variation of the engine performance not in the standard ISA conditions can be calculated with the following formula Q Q ISA 288 T K Where Q is the power calculated Q ISA is the power in standard ISA condition and T K is the temperature in Kelvin degree T K T C 273 The graph B 5 4 19 C shows the power variation based on air temperature B 5 4 32 C 50 60 70 80 90 1...

Page 42: ...o the model without reduction gear box B 5 6 Fuel Consumption The fuel consumption is a function of the power output and the fluid dynamic conditions All consumption data indicated in the manual refers to the engine running with the Power mode engine fuel map Power With the engine running in Economy mode the fuel consumption is 10 less than the value indicated The following table indicates the con...

Page 43: ...e position The following paragraph indicates the fuel consumption of each engine model Graph CONSUMPTION PER H RPM with constant MAP each curve refers to a value of MAP indicated in inches of mercury inHg and it is the fuel consumption in liters per hour in function of the RPM Graph CONSUMPTION PER H MAP constant speed each curve refers to a regime of rotation of the motor and returns the hourly c...

Page 44: ...5 6 1 B22D B 5 6 3 C B 5 6 4 C 5 7 9 11 13 15 17 19 21 23 25 2000 2250 2500 2750 3000 3250 3500 L h RPM B22D Consumption constant MAP 29 9 28 5 27 25 5 24 22 5 5 7 9 11 13 15 17 19 21 23 25 22 23 24 25 26 27 28 29 30 L h inHg B22D consumption constantRPM 3400 3250 3000 2750 2500 2250 2000 ...

Page 45: ...C 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2000 2250 2500 2750 3000 3250 L h RPM B22D consumption constantpower 90 85 80 75 70 65 60 55 50 45 40 35 30 170 180 190 200 210 220 230 240 250 260 22 23 24 25 26 27 28 29 30 gHP h inHg B22D specificconsumption constantRPM 3400 3250 3000 2750 2500 2250 2000 ...

Page 46: ...ision 1 3 02 24 2015 Manual B Operations 46 B 5 6 2 B22H B 5 6 7 C B 5 6 8 C 5 10 15 20 25 30 35 22 23 24 25 26 27 28 29 L h inHg B22H consumption 4300 RPM 160 170 180 190 200 22 23 24 25 26 27 28 29 gHP h inHg B22H specificconsumption 4300 RPM ...

Page 47: ...7 B 5 6 3 B22L B 5 6 9 C B 5 6 10 C 5 10 15 20 25 30 35 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 L h RPM B22Lconsumption constantMAP 29 9 28 5 27 25 5 24 22 5 5 10 15 20 25 30 35 22 23 24 25 26 27 28 29 30 L h inHg B22Lconsumption constantRPM 4200 4000 3750 3500 3250 3000 2750 ...

Page 48: ...12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2750 3000 3250 3500 3750 4000 4250 L h RPM B22Lconsumption constantpower 110 105 100 95 90 85 80 75 70 65 60 55 50 170 180 190 200 210 220 230 22 23 24 25 26 27 28 29 30 gHP h inHg B22Lspecific consumption constantRPM 4200 4000 3750 3500 3250 3000 2750 ...

Page 49: ...5 6 4 B22R B 5 6 13 C B 5 6 14 C 5 10 15 20 25 30 35 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 L h RPM B22R Consumption constantMAP 29 9 28 5 27 25 5 24 22 5 5 10 15 20 25 30 35 22 23 24 25 26 27 28 29 30 L h inHg B22R consumption constantRPM 4700 4500 4250 4000 3750 3500 3250 3000 ...

Page 50: ...8 19 20 21 22 23 24 25 26 27 28 29 30 31 32 2750 3000 3250 3500 3750 4000 4250 4500 4750 L h RPM B22R Consumption constantpower 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 50 170 180 190 200 210 220 230 22 23 24 25 26 27 28 29 30 gHP h inHg B22R specificconsumption constantRPM 4500 4700 4000 4250 3750 3500 3250 3000 2750 ...

Page 51: ...rations 51 B 5 6 5 B25D B 5 6 17 C B 5 6 18 C 5 10 15 20 25 30 2000 2250 2500 2750 3000 3250 3500 L h RPM B25D Consumption constantMAP 29 9 28 5 27 25 5 24 22 5 5 10 15 20 25 30 22 23 24 25 26 27 28 29 30 L h inHg B25D Consumption constantRMP 3400 3250 3000 2750 2500 2250 2000 ...

Page 52: ...0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 2000 2250 2500 2750 3000 3250 L h RPM B25D Consumption constantpower 105 100 95 90 85 80 75 70 65 60 55 50 45 170 180 190 200 210 220 230 240 250 260 22 23 24 25 26 27 28 29 30 gCv h inHg B25D Specific consuption constant RPM 3400 3250 3000 2750 2500 2250 2000 ...

Page 53: ...on 1 3 02 24 2015 Manual B Operations 53 B 5 6 6 B25H B 5 6 21 C B 5 6 22 C 5 10 15 20 25 30 35 40 22 23 24 25 26 27 28 29 L h inHg B25H Consumption 4300 RPM 160 170 180 190 200 22 23 24 25 26 27 28 29 gCv h inHg B25H Specific consumption 4300 RPM ...

Page 54: ...5 6 7 B25L B 5 6 23 C B 5 6 24 C 5 10 15 20 25 30 35 40 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 L h RPM B25LConsumption constantMAP 29 9 28 5 27 25 5 24 22 5 5 10 15 20 25 30 35 40 22 23 24 25 26 27 28 29 30 L h inHg B25LConsumption constantRPM 4200 4000 3750 3500 3250 3000 2750 ...

Page 55: ...6 C 12 14 16 18 20 22 24 26 28 30 32 34 2750 3000 3250 3500 3750 4000 4250 L h RPM B25LConsumption constantPower 130 125 120 115 110 105 100 95 90 85 80 75 70 65 60 55 170 180 190 200 210 220 230 22 23 24 25 26 27 28 29 30 gCv h inHg B25LSpecific consumption constantRPM 4200 4000 3750 3500 3250 3000 2750 ...

Page 56: ... 8 B25R B 5 6 27 C B 5 6 28 C 5 10 15 20 25 30 35 40 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 L h RPM B25R Consumption constantMAP 29 9 28 5 27 25 5 24 22 5 5 10 15 20 25 30 35 40 22 23 24 25 26 27 28 29 30 L h inHg B25R Consumption constantRPM 4700 4500 4250 4000 3750 3500 3250 3000 ...

Page 57: ... 24 26 28 30 32 34 36 38 2750 3000 3250 3500 3750 4000 4250 4500 4750 L h RPM B25R Consumption constantpower 150 145 140 135 130 125 120 115 110 105 100 95 90 85 80 75 70 65 60 50 170 180 190 200 210 220 230 22 23 24 25 26 27 28 29 30 gCv h inHg B25R Specificconsumption constantRPM 4500 4700 4000 4250 3750 3500 3250 3000 2750 ...

Page 58: ...plash lubrication occurs with specific oil for the gears contained in the gearbox itself This oil does not participate in the lubrication of any other mechanical parts The shafts of the gear box are made integrally with the gear Each wheel shaft runs on ball bearings of a significant size The gearbox is not equipped with any mechanical damper Torsional vibrations are reduced by an electro hydrauli...

Page 59: ...an damage the automatic timing chain tensioner and also disengage the system on the engine starter For engines with a reduction gear box the counterclockwise rotation of the propeller produces a drift to the right of the aircraft Counter this on the ground with the left pedal and properly balance in flight with aerodynamic surfaces of compensation For versions without a gear box it is the opposite...

Page 60: ...system Optional Supplied standard equipm ent Therm ostate full Over Head Cylinder valve effec t Double Pu m p Cylinder Si d e 1 Head Si d e 2 Radiator T 75 C Vaso espansione Tem perature sensor Tem perature sensor T 75 C Hot c ircuit Cold c ircuit Water tank B 6 1 1 C For a detailed description of the system see the paragraph A 9 1 ...

Page 61: ...d 1 bearings Cam shaft Tappet Start sensor gears Splash lubric ation gears Tim ing Tem erat ure Tim ing c hain 2 Bearings Tappet bearings Cam shaft Head 2 Generat or Dec om pr B 6 2 1 C For a detailed description of the system see the paragraph A 10 1 An oil temperature sensor is mounted on the right rear of the oil sump The data from the sensor is sent to the injection control unit do not remove ...

Page 62: ... Pressure regulator Fuel tank Filter net Filter cylinder 1 2 Injector Fuel valve Fuel tank B 6 3 1 C In case of the use of two tanks it is essential to install a dual flow valve which can act on both the delivery branch and on the return to the tank A valve with these characteristics is available as an accessory with the cod C107 In case a safety valve is installed on the return to the fuel tank i...

Page 63: ... Panel F D U Electric Hub Battery A Battery B Engine Connector Instrum ent Push Button sw itch Engine Cabin E Safe Starter Start GND Engine GND Start A Aux pum p lane B lane Master B 6 4 1 C The engine is equipped with two injection ECUs and electronic ignition mapped with barometric and altimeter compensation and totally independent electrical circuits The ignition system is electronic inductive ...

Page 64: ...ction and ignition system is greater than the current produced by the generator B 6 4 1 ES m Instrumentation ES m and EMS m instrumentation is an integral part of every engine ensuring the correct and safe use of the engine Through this instrumentation the operator can monitor the operating status of the ECUs fuel pumps batteries and generator The HSA M can also record the values of all the operat...

Page 65: ...MCP 2950 3560 3930 65 MCP 2880 3470 3830 60 MCP 2800 3380 3730 55 MCP 2720 3280 3620 50 MCP 2640 3180 3510 idle 950 1050 1350 1700 950 1050 950 1050 Best range 2700 3000 3400 3750 3400 4200 B 7 1 1 C B25 Version RPM B25D B25H B25L B25R Take Off max 5 minuts 3400 4300 3950 4200 4550 4700 Max Continuous Power MCP 3330 4070 4500 95 MCP 3270 4000 4420 90 MCP 3220 3930 4350 85 MCP 3150 3860 4260 80 MCP...

Page 66: ...esolved It is mandatory to monitor the fuel pressure during the flight in order to detect any abnormalities that may affect safety It is strongly suggested to install an auxiliary fuel pump to be used in case of failure of the main pump in flight or in conditions of safety critical flight takeoff and landing B 7 1 3 Engine oil pressure The engine oil pressure is read by a sensor placed on the main...

Page 67: ...re The engine oil temperature is read by a sensor mounted in the rear of the oil sump B22 Version Engine Oil Temperature C B22D B22H B22L B22R Max 130 130 130 130 Min before flight 50 50 50 50 Nominal 85 100 100 120 85 105 95 110 Typical 90 110 95 102 B 7 1 5 C B25 Version Engine Oil Temperature C B25D B25H B25L B25R Max 130 130 130 130 Min before flight 50 60 50 50 Nominal 85 100 100 120 90 100 9...

Page 68: ... gearbox B 7 1 6 Coolant Temperature The temperature of the cooling liquid is detected by a sensor one for each bank Coolant Temperature C B22D B25D B22H B25H B22L B25L B22R B25R Max 102 102 102 102 Min in flight 72 72 72 72 Nominal 75 90 85 98 75 90 80 95 Typical 85 92 87 90 B 7 1 9 C It is mandatory to monitor the temperature of the coolant during the flight in order to detect any abnormalities ...

Page 69: ...el injector system is instead substantially insensitive to the conditions of contingency Acceleration g All versions Longitudinal axis X 10 Trasversal axis Y 10 Vertical axis Z 10 0 5 max 5 second B 7 1 11 C B 7 1 9 Inclination Angle Similar as to what is described for the load factor the limits on the angles of inclination of the engine with respect to the horizontal position are to guarantee ade...

Page 70: ...d coolants these liquids must be mixed with water The protection from freezing is guaranteed up to 40 C when diluted 50 for different dilutions refer to the graph A 9 5 1 C The recommended coolant is the SYNAVIO M AF concentrate which unlike other anti freezes can be diluted with water even with a high lime content tap water Do not use propylene glycol coolants the use of these coolants will rende...

Page 71: ...iod of time it is advisable to change the oil before use B 7 2 3 Reduction Gear Box Oil Use specific lubricants for use with hypoid gears of thermal grade 80W 90 The recommended lubricant is the SYNAVIO MG 90 Gear Lubricant which is specifically formulated for heavy duty gears with high stress Synavio provides a free service of spectrographic analysis of the oil removed C 6 12 5 The maximum gearbo...

Page 72: ...o use fuel prepared for the climatic condition in which the engine operates Avoid storing fuel for months with the risk of using winter fuel in summer time Summer fuel has less evaporation capacity because the more volatile components are removed and this decreases the risk of vapor lock in the fuel system B 7 3 General Criteria to Operate the Engine To preserve the integrity and efficiency of you...

Page 73: ...y or with a dipstick The expansion tank must be filled to at least two thirds of the height about 0 45 liters The total capacity of the expansion tank is 0 7 liters If necessary top up coolant with the same quality as the one in the engine Any excess liquid refrigerant is ejected from the system through the tube arranged on the cap of the expansion tank once the engine has reached operating temper...

Page 74: ...itting or yellowing and have a uniform glossy appearance For tightening and removing the filler cap you can use the tool code X283 Apply a light load on the end of a propeller blade by hand first in one direction then in the opposite Do not turn the engine shaft This makes it possible to evaluate the clearance between the gears of the gearbox When the engine is cold the movement of the blade shoul...

Page 75: ...t all electrical connectors and especially the state of the cables from the connectors check the tightness of the ground connections and the positive power and check the spark plug wires and the clamping on the spark plug Check that all the fixing points of the wiring to the engine are properly tightened Check the efficiency of all the fuses and if the fuse and relays in the engine compartment are...

Page 76: ...ssage of fuel e Push the starter button The start button should not be pressed for more than 10 seconds continuously If after this period the engine has not started before a second attempt it is necessary to wait at least 1 minute This is to safeguard the electric starter from overheating If after the third attempt the engine does not start desist from any further attempts and perform the checks i...

Page 77: ... off it is necessary to perform some checks and some operational tests of the engine as described below a Verify that the fuel pressure in idle condition is greater than 2 9 bar b Verify that the oil pressure in idle condition in greater than 0 1 bar c Run the engine at 2700 rpm and perform the following checks d Rendundancy Check Alternately turn off each of the two injection systems After a shor...

Page 78: ...within the limits specified in section B 7 1 To avoid overloading the transmission system do not act on the throttle suddenly to either increase or decrease the engine rpm Never take off with the engine cold as it can cause serious damage to the engine and may cause a dangerous situation by stopping the engine in flight B 7 3 6 Cruise a Set the throttle in order to get the desired cruise attitude ...

Page 79: ...e starter d After stopping the engine switch off the main switch master B 7 3 9 Use of the Engine in Winter Season If using the engine during winter or in a cold climate area you must follow the instructions below a Coolant Increase the proportion of water antifreeze mixture in accordance with the paragraph B 7 2 1 and the manufacturer s instructions b Lubricant Make sure the engine and gearbox lu...

Page 80: ... the fuel it is necessary to provide the fuel circuit with a gascolator to be placed at the lowest point in the circuit itself before the fuel pumps This will collect by gravity the water which may be present in the tanks Be aware that under certain conditions the presence of small drops of water on the electrodes of the spark plugs can cause irreversible damage An advantage of the fuel injection ...

Page 81: ...on of the auxiliary pump and the selection of the auxiliary rpm sensor serves to exclude prior two possible causes of the shutdown without wasting time in their detection e Put the throttle lever to the idle position f Push the starter switch If the engine fails to start repeat the operation by selecting the second ECU g Land as soon as possible to identify and remove the cause of the failure B 7 ...

Page 82: ...cause the decompressor cannot be maintained in the closed position by oil pressure It is necessary to take this limit into account while operating in emergency maneuvers c Land as soon as possible B 7 4 6 Oil Pressure Below the Limit on the Ground a Stop the engine b Check the amount of lubricant in the oil sump and if necessary top up c Check for leaks in the lubrication system by checking the ar...

Page 83: ...4 9 Battery Voltage Over the Limit a Check the position of the main switch master to ensure it is in the on position b If the voltage does not reduce the engine speed decreases according to the flight conditions to prevent damage to electronic components c Land as soon as possible B 7 4 10 Battery Voltage Below the Limit Check for generator alarm or the status of generator alarm light o In case th...

Page 84: ...possible B 7 4 12 Generator Alarm a Check the status of the 30A fuse mounted to protect the charging system and if possible restore it b Verify the presence of overload in the electrical system and possibly disconnect utilities unnecessary or faulty c Turn off the control unit and the auxiliary fuel pump circuit B on order to decrease power consumption as much as possible d Set the speed of the en...

Page 85: ...etting in which the vibrations are lower o Land as soon as possible B 7 4 14 Irregular Operation o Verify on the ES m instrument the operational status of the ECUs and fuel pumps and eventually exclude the component in failure If the ES m instrument is not installed select the auxiliary ECU or the auxiliary RPM sensor depending on the engine version o Make sure the fuel valve is not accidentally c...

Page 86: ...s necessary to protect them from moisture and acidic compounds that may be formed during operation of the engine In addition valves valve guides and valve seats are subject to deterioration during inactivity if not properly protected a Warm up the engine to operating temperatures then turn it off and change the engine oil and filter b Remove the air filters and put into the intake collectors about...

Page 87: ...t engine on the ground according to the procedure described in paragraph C 6 5 9 k Replace fuel filter according to the procedure described in paragraph C 6 8 4 B 8 4 Engine Protection When Used in Cold Climates a Make sure to use the most correct thermal grade for the engine and gearbox oil b Change the mixing of the antifreeze liquid with water to ensure the right protection against icing Check ...

Page 88: ...o Make sure that the fuel pressure is at least 3 3 bar otherwise switch on the auxiliary fuel pump or in the case that is not installed power off and on the ECU switch o Select the auxiliary rpm sensor only not dual version o Check that there is fuel in the tanks o Replace the fuel filter o Replace the spark plugs Coolant temperature too low o The radiator dimensions are too big Reduce the radiati...

Page 89: ...ne Excessive vibration o Propeller tightening incorrect restore it o Propeller is unbalanced due to the presence of deposits or damage o Spark plugs dirty or damaged replace them o Try both ECUs in case the vibration is only with one of the two ECUs replace the damaged unit o Cylinder banks are not synchronized correctly contact an authorized service center o ADC system is not working correctly co...

Page 90: ... serious Yes 0 bar Input barametric pressure Non serious Yes 0 bar Coil control Serious No Injector control Serious No Microprocessor consistancy Serious No B 9 2 1 C In case of a serious error it is necessary to exclude the circuit that presents the anomaly and land as soon as possible If the error is non serious the flight may continue but it will be necessary to subject the engine to an inspect...

Page 91: ...ame Fist name Tel N E mail Aircraft manufacturer Aircraft model Propeller model N of blades Tractor Pushing N of hours Main use School Flight 1 hour Flight 1 hour Frequency of use Daily Weekly Occasional Environment temp Less than 10 C 10 35 C More than 35 C Malfunction desciption Recursion Permanent Frequent Occasional Note ...

Page 92: ...HORIZED DISTRIBUTOR SOUTH AFRICA Albasera Aircraft NORTH AMERICA MW Fly Sales and Service North America AUSTRALIA and NEW ZEALAND Corvus Aero Australia CHINA and ASIA Bushcaddy International Inc The complete list and full name of the authorized service centers is available on the website http www mwfly it ...

Page 93: ...a 001911 B 8 Engine Control All 07 02 2013 1 Da 001911 B 9 Malfunction resolution All 07 02 2014 1 Da 001911 B 10 Authorized Distributor All 07 02 2014 1 Da 001911 B 7 1 10 Electrical Voltage All 05 05 2014 3 Da 001911 B 1 Summary All 02 24 2015 3 Da 001911 B 2 Introduction All 02 24 2015 3 Da 001911 B 3 Safety All 02 24 2015 3 Da 001911 B 4 Engine Description All 02 24 2015 3 Da 001911 B 5 Techni...

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MW Fly B22 AeroPower, Operation Manual

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