Service Manual Aerohonda_BF50D
Contents
1. 0 25 mm PART 7 REPAIRS 7 1 INTRODUCTION Any damages occured even the smallest one must be reported to engine manufacturer DO NOT PERFORM ANY REPAIRS WITHOUT CONTACT WITH THE MANUFACTURER OF AEROHONDA BE 50D ENGINE PART 8 LUBRICANTS TABLE MANUFACTURER RECOMMENDS USING SYNTHETIC OIL VISCOSITY CLASS OF 5W 30 IN TOTAL AMBIENT TEMPERATURE RANGE 13 J amp AS Aero Design Sp Z 0 0 AEROHONDA BF 50D ENGINE SERVICE MANUAL PART 9 TORQUE MOMENTS Torque moments are given in HONDA MARINE BF 40D BF 50D SHOP MANUAL issued by HONDA MOTOR CO LTD march 2008 Other moments as follows Torque moment for M8 Bolts that fasten tarnsmission housing to engine corpus is 2 2 kGm Torque moment for nuts that fasten propeller is 1 5 kGm M8 Tabel of standard torque moments Type of connection Thread diameter Torque moment kGm 5mm 0 5 6mm 1 0 Bolts and nuts 8 mm 2 1 10 mm 3 5 12mm 5 5 6mm 1 2 8 mm 2 7 Bolts and flange nuts 10 mm 3 5 12 mm 6 0 5mm 0 4 Screws 6mm 0 9 142. HONDA BF 50D engine was made as the result of adjustments the drive to motorglider outboard motorboats Adaptation consisted mainly of repositioning the engine from vertical to lateral setting the crankshaft axis and the addition of a belt transmission decreasing routes Engine mount viewed from the one side and from the side of the transmission J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp z 0 0 SERVICE MANUAL 2 2 DESCRIPTION 3 1 3 2 3 1 Three cylinders 4 strokes spark plag ignition in line engine Cooling liquid forced by pump in closed system Lubricating pressure dry sump additional oil reservoir Feeding direct injection programmable Ignition magnetos electronic single Propeller drive unit by belt transmission Electrical starter AC generator Mechanical end electrical fuel pump PART 3 TECHNICAL DATA TECHNICAL DATA POWER CHARACTERISTIC TECHNICAL DATA 3 1 1 Weight and dimensions Cylinder diameter 70 mm Piston travel 70 mm Piston displacement 808 cm Compression ratio O24 Propeller torque direction to the left viewed from the side of propeller transmission Engine weight including transmission liquids and radiators 56 kg 3 1 2 Equipment Magneto electronic maintenance free CDI Advance angle 5 32 before top dead centre Ignition sequence 1 3 2 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp
3. ONTHS e Replace oil and strainer e Check and if needed adjust throttle e Check connections of electrical wires e Check and if needed clean all spark plugs e Check all bolts and nuts and if needed tighten them e Check fuel filters high and low pressure INSPECTION AFETR 200 HOURS OR 12 MONTHS e Change oil in gearing e Check condition and tension of camshaft belt e Check tapet clearance and if needed adjust e Check operation of thermostat e Replace spark plugs e Replace V belt of cooling system pump 10 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL 5 5 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 1 e Check internal anode e Clean fuel filters and tanks e Check venting e Check cooling system pump INSPECTION AFETR 400 HOURS OR 2 YEARS e Replace tothed belt of propeller transmission e Replace ignition harness e Change cooling liquid unless manufacturer recommends shorter time of replacing e Replace fuel filters high and low pressure e Replace fuel lines PART 6 MAINTENANCE OIL CHANGE COMPRESSION CHECK REPLACEMENT AND MAINTENANCE OF SPARK PLUGS INSPECTION AND TENSION ADJUSTMENT OF PROPELLER TRANSMISSION TOTHED BELT OIL STRAINER REPLACEMENT FULE FILTER REPLACEMENT TAPPED CLEARANCE OIL CHANGE After heating the oil to a temperature above 50 C drain the oil from the reservoir that is located inside the hull For this action is to be prepared so as not
4. RT 4 MANUAL SHUTTING DOWN AND STARTING DURING THE FLIGHT Has everyday inspection been made Chceck for leakage under engine cowling Make sure for sufficient level of oil and cooling liquids Throtlle must be in closed position and check for free of movement STARTING UP Caution chceck if the propeller area is clear Fule valve Throttle Battery master Ignition Starter switch After start up immidiately switch off the starter Check oil pressure should increase in around 20 sec WARMING UP In low temperatures below 5 C warming up should be performed at 2500 3000 rpm not longer than 1 min Do not exceed 5750rpm and permissible oil and colling liquid temperatures Next perform run up test open close on on on 4 4 4 5 4 6 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL e check maximum rpm value according to airframe service manual e check minimum and maximum rpm passage and opposite e check if the engine has no tendency to shutting down when moving throtlle rapidly from minimum to maximum position e check regurality of engine working at minimum and maximum rpm CAUTION In the time of engine run in that takes around 30 hours slowly increase and decrease the rpm without overloading not a long time to work at high speed the engine START Smoothly open throttle up to maximum position and continue take off to 100m AGL the
5. SERVICE MANUAL WITH PERIODIC INSPECTIONS TIMETABLE ENGINE AEROHONDA BF 50D J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL CONTENTS a GENERAL INFORMATION DESCRIPTION TACHNICAL DATA MANUAL PERIODIC INSPECTIONS MAINTENANCE REPAIRS LUBRICANTS TABLE TORQUE MOMENTS oo lJ A aA A UUN me PART1 GENERAL INFORMATION 1 1 INTRODUCTION 1 2 BASE OF APPROVAL 1 3 CAUTIONS WARNINGS REMARKS 1 1 INTRODUCTION This Service Manual has been prepared to provide pilots and mechanics with neccesary information needed for safe and efficient use of AEROHONDA BF 50D engine installed on J 6 Fregata motorglider 1 2 BASE OF APPROVAL This engine has been approved with the J 6 Fregata motorglider by the Civil Aviation Authority in accordance with the SPECIAL categories TEMPORARY AIRCRAFT TESTING RULES built in single copies 1 3 CAUTIONS WARNINGS REMARKS CAUTION INDICATES THAT THE FAILURE OF FOLLOWING APPLICABLE PROCEDURE WILL ENDANGER OR DETERIORATE FLIGHT SAFETY WARNING INDICATES THAT THE FAILURE OF FOLLOWING PROCEDURE LEADS TO MINOR OR LONG TERM MORE OR LESS FLIGHT SAFETY DETERIORATION REMARK Draws attention to detail not related directly to the safety of the flight but important or unusual J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp z 0 0 SERVICE MANUAL PART 2 DESCRIPTION 2 1 INTRODUCTION 2 2 DESCRIPTION 2 1 INTRODUCTION AERO
6. TOTHED BELT Measurement carried out by pressing the tension force of 1 kg in the middle of the strip The deflection of the belt measured in relation to the state of no pressure should be in the range of 7 8 mm In case of improper tension too big or too small deflection of toothed belt the adjustment should be carried out To do this loosen the three screws fixing the bushing bearings in the propeller gearbox housing Then turn the bushing and using the eccentric rear bar lead to the correct tension Torque moment is 1 kgm OIL STARINER REPLACEMENT After 100 hours or 12 months during oil change the oil strainer must be replaced as well FUEL FILTERS REPLACEMENT After 400 hours or 2 years fuel filters must be replaced with new After closing the fuel valve all the unscrew the fuel lines Then replace the filters installing new fuel lines and hose clamps to seal it 12 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL 6 7 TAPPET CLEARANCE After gaining access to the shaft levers set the timing of the first cylinder piston at top dead center and using traditional method check and set the correct tappet clearance Then turning the crankshaft by 120 just set the clearance for the second cylinder After turning by 120 repeate procedure for the third cylinder Tappet clearance on a cold engine must contain in the following limits Intake valve 0 13 0 17 mm Exhaust valve 0 21
7. Z 0 0 SERVICE MANUAL Spark plugs NKG DR7EA or ND X 22 ESR U Spark air gap 0 6 0 7 mm Ignition harness one set Injection indirect programmable Fuel pump mechanical and elecrical Generator AC generator placed inside handwheel Starter electrical Transmission double reduction final belt and mechanic drive total ratio 1 2 12 Propeller hub shaft shoulder 3 1 3 Power Take off 5 minutes 36 8 kW 50 KM at 5750 rpm Continuous 34 8 kW 46 3 KM at 5250 rpm 3 1 4 RPM of the engine The highest take off value 5750 rpm Maximum continuous value 5250 rpm Idle cut off value around 1000 rpm 3 1 5 Fuel and oil Fuel automotive unleaded anti knock value min 95 or AVGAS 100 LL 85ul Oil minimum SAE 5W 30 synthetic recommended 5W 30 Oil pressure min 1 5 kG cm Oil temp minimum 40 C 104 F maximum 120 C 248 F 3 1 6 Cooling liquid J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL automotive liquid for coolers based on glycol according to specification of ASTM D3306 and ASTM D4985 boiling temperature above 120 C 3 2 POWER CHARACTERISTIC Nm 190 180 170 160 150 140 130 120 110 100 4 1 4 2 4 3 J amp AS Aero Design Sp Z 0 0 AEROHONDA BF 50D ENGINE SERVICE MANUAL 4 1 4 2 4 3 4 4 4 5 4 6 BEFORE STARTING UP BEFORE START UP STARTING UP WARMING UP START SHUTTING DOWN PA
8. l oil and cooling system lines chceck if there is no oil fuel and cooling liquid leakage check mounting of all engine components check condition and tension of tothed belt and clearance for propeller shaft check condition and tension of V belt that drives cooling system pump check mounting of engine cowlings chceck mounting of exhaust silencer PERIODIC INSPECTION After first 20 hours or after 1 month whichever comes first perform maintenance according to point 5 3 next maintenace must be performed after 100 hours or after six months whichever comes first and every time after next 100 hours according to point 5 4 After every 200 hours or after 12 months whichever comes first additionally perform maintenace according to point 5 5 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp z 0 0 SERVICE MANUAL 5 2 5 3 5 4 After every 400 hours or after 24 months whichever comes first additionally perform maintenace according to point 5 6 INSPECTION AFTER FIRST 20 HOURS OR 1 MONTH e Replace oil and strainer e Check and if needed adjust throttle e Grease lubricant fitting e Check connections of electrical wires e Check all nuts and bolts e Check torque moments of bolts pins and nuts and if needed tighten them propeller to hub engine to engine mount engine mount to fuselage Secure connections of bolts and nuts INSPECTION AFTER 100 HOURS OR 6 M
9. n reduce power to 5250rpm Pay attention on oil pressure and temperature Do not exceed permissible limitations SHUTTING DOWN Under normal conditions the cooling system keeps the temperature of the engine that allows shutting down after taxiing or after the run up test However if the coolant temperature is close to the maximum 100 120 C the engine should be cooled to a temperature of about 80 C SHUTTING DOWN AND STARTING DURING THE FLIGHT In order to shut down set throttle to idle cut off position reduce velocity to around 100kph and off ignition Starting engine in the air Permorm start up as usuall done on the ground and lead all the parameters to normal values J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp z 0 0 SERVICE MANUAL 5 1 5 2 5 3 5 4 5 5 5 6 5 1 PART5 PERIODIC INSPECTIONS DAILY INSPECTION PERIODIC INSPECTION INSPECTION AFTER FIRST 20 HOURS OR 1 MONTH INSPECTION AFTER 100 HOURS OR 6 MONTHS INSPECTION AFETR 200 HOURS OR 12 MONTHS INSPECTION AFETR 400 HOURS OR 2 YEARS DAILY INSPECTION remove engine cowlings if any leakage of oil or cooling liquid was found thoroughly check the engine if there is no lack or loose nuts bolts pins etc check security places exposed to friction and ignition wires check control surfaces and throttle for proper movements check oil quantity in reservoir check cooling liquid quantity check mounting of all fue
10. to pour the hot oil to the interior of the hull Then drain the additional starting tank placed in the engine and after oil filling plug to installation Fill the oil tank to the required level In case of any doubts that may indicate oil contamination for example fillings check oil stariner by unscrewing cutting it and examining the oil strainer element 11 J amp AS Aero Design AEROHONDA BF 50D ENGINE Sp Z 0 0 SERVICE MANUAL 6 2 6 3 6 4 6 5 6 6 COMPRESSION CHECK If you suspect that the compression in any of the cylinders can be reduced it should be measured by the direct method at around 500rpm Compare the result with a nominal value of 15 1 kG cm REPLACEMENT AND MAINTENANCE OF SPARK PLUGS After 100 hours all the spark plugs must be removed from engine head Before removing clean seats of dust and dirt Check clearance of electrodes that contains between 0 6 0 7 mm adjusting by side bend the electrode Visually inspect the insulators for cracks or defects In the case of detection of such defects in at least one spark plug should all be replaced Spark plugs with new unused sealed screw using your fingers and then use a spark plug wrench tighten by turn If the seal has been used but the state does not raise any objections it can be used it with your fingers tightening and tightening spark plugs with key by turn INSPECTION AND TENSION ADJUSTMENT OF PROPELLER TRANSMISSION
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