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Operating and Maintenance Manual
Limbach L 2400 EF/DF
Engine for Powered Gliders and
Very Light Aircraft
Edition: 20.06.2018
This manual is approved in accordance with the procedures 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
ET/DT
DX/DS
250.253.501.000
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Table of Contents
Related Manuals for LIMBACH L 2400 EF
Summary of Contents for LIMBACH L 2400 EF
- Page 1 Operating and Maintenance Manual Limbach L 2400 EF/DF ET/DT DX/DS Engine for Powered Gliders and Very Light Aircraft Edition: 20.06.2018 This manual is approved in accordance with the procedures 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.
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Page 2: Table Of Contents
LIMBACH L 2400 ET/DT ........................... 10 LIMBACH L 2400 DX ..........................12 LIMBACH L 2400 DS ..........................14 Performance ..............................16 Performance Graph LIMBACH L 2400 EF/DF ..................16 5.1.1 Performance Data L 2400 EF/DF ......................17 Performance Graph LIMBACH L 2400 ET/DT ..................18 5.2.1... - Page 3 Operating Manual L 2400 EF/DF/ET/DT/DX/DS 8.13 Turbocharger Check L 2400 ET/DT/DX ..................... 38 8.14 Bowden Cable Check..........................38 8.15 Emergency Battery and Harness Check ....................38 8.16 Check of Bolted Connections ........................38 8.17 Engine Test Run ............................38 8.18 Engine Preservation ...........................
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Page 4: Change Index
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Change Index This Edition replaces the Operating and Maintenance Manual from 19.02.2016 This manual 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... -
Page 5: Introduction
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Introduction This manual is meant to instruction for proper operation and maintenance of the aircraft engine. Modifications to the engine are only permitted with the approval of our development department. Caution: The specially identifies safety notes must be observed to prevent accidents with personal injuries and to prevent damage to the engine. -
Page 6: Engine Description
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Engine Description • Horizontally Opposed 4-Cylinder 4-Stroke Reciprocating Engine • Combined Liquid Cooling for the Cylinder Heads • Ram Air Cooling for the Cylinders • Wet Sump Forced Lubrication • Single Electronic Engine Management System Providing Spark and Fuel •... -
Page 7: Cylinder Designation
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Cylinder Designation left bottom right rear = accessory mounting side front = propeller side cylinder 1 cylinder 2 cylinder 3 cylinder 4 arrow crankshaft rotation Page: 7/53 Edition: 20.06.2018... -
Page 8: Technical Data
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Technical Data LIMBACH L 2400 EF/DF Dimensions Bore 97 mm Stroke 82 mm Displacement per Cyl. 606 cm³ Total Displacement 2424 cm³ Compression Ratio 9.5 : 1 Crankshaft Rotation counterclockwise Ignition Timing variable mapped Firing Order... - Page 9 Operating Manual L 2400 EF/DF/ET/DT/DX/DS Pressures and Temperatures Fuel Pressure 2.5 bar / 14.6 psi (measured relative to the manifold pressure) Engine Oil Pressure max. 7 bar / 101.5 psi min. 1 bar / 14.5 psi at 2500 rpm Engine Oil Temperature max.*) 120 °C...
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Page 10: Limbach L 2400 Et/Dt
Operating Manual L 2400 EF/DF/ET/DT/DX/DS LIMBACH L 2400 ET/DT Dimensions Bore 97 mm Stroke 82 mm Displacement per Cyl. 606 cm³ Total Displacement 2424 cm³ Compression Ratio 8.0 : 1 Crankshaft Rotation counterclockwise Ignition Timing variable mapped Firing Order 1-3-2-4... - Page 11 Operating Manual L 2400 EF/DF/ET/DT/DX/DS Pressures and Temperatures Fuel Pressure 2.5 bar / 14.6 psi (measured relative to the manifold pressure) Engine Oil Pressure max. 7 bar / 101.5 psi min. 1 bar / 14.5 psi at 2500 rpm Engine Oil Temperature max.*) 120 °C...
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Page 12: Limbach L 2400 Dx
Operating Manual L 2400 EF/DF/ET/DT/DX/DS LIMBACH L 2400 DX Dimensions Bore 97 mm Stroke 82 mm Displacement per Cyl. 606 cm³ Total Displacement 2424 cm³ Compression Ratio 8.0 : 1 Crankshaft Rotation counterclockwise Ignition Timing variable mapped Firing Order 1-3-2-4... - Page 13 Operating Manual L 2400 EF/DF/ET/DT/DX/DS Pressures and Temperatures Fuel Pressure 2.5 bar / 14.6 psi (measured relative to the manifold pressure) Engine Oil Pressure max. 7 bar / 101.5 psi min. 1 bar / 14.5 psi at 2500 rpm Engine Oil Temperature max.*) 120 °C...
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Page 14: Limbach L 2400 Ds
Operating Manual L 2400 EF/DF/ET/DT/DX/DS LIMBACH L 2400 DS Dimensions Bore 97 mm Stroke 82 mm Displacement per Cyl. 606 cm³ Total Displacement 2424 cm³ Compression Ratio 9.5 : 1 Crankshaft Rotation counterclockwise Ignition Timing variable mapped Firing Order 1-3-2-4... - Page 15 Operating Manual L 2400 EF/DF/ET/DT/DX/DS Pressures and Temperatures Fuel Pressure 2.5 bar / 14.6 psi (measured relative to the manifold pressure) Engine Oil Pressure max. 7 bar / 101.5 psi min. 1 bar / 14.5 psi at 2500 rpm Engine Oil Temperature max.*) 120 °C...
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Page 16: Performance
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Performance Performance Graph LIMBACH L 2400 EF/DF RPM (1/min) Page: 16/53 Edition: 20.06.2018... -
Page 17: Performance Data L 2400 Ef/Df
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 5.1.1 Performance Data L 2400 EF/DF Power values in kW (HP values in parentheses) Manifold Pressure 2400 rpm 2500 rpm 2600 rpm 2700 rpm 2800 rpm 2900 rpm 3000 rpm (inHg) 28 (38) 33 (45) 34 (46) 37.5 (51) -
Page 18: Performance Graph Limbach L 2400 Et/Dt
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Performance Graph LIMBACH L 2400 ET/DT RPM (1/min) Page: 18/53 Edition: 20.06.2018... -
Page 19: Performance Data L 2400 Et/Dt
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 5.2.1 Performance Data L 2400 ET/DT Power values in kW (HP values in parentheses) Manifold Pressure (inHg) 2200 rpm 2400 rpm 2600 rpm 2800 rpm 3000 rpm 34.5 (47) 37 (50) 40 (54) 42 (57) -
Page 20: Performance Graph Limbach L 2400 Dx
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Performance Graph LIMBACH L 2400 DX Page: 20/53 Edition: 20.06.2018... -
Page 21: Performance Data L 2400 Dx
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 5.3.1 Performance Data L 2400 DX Power values in kW (HP values in parentheses) Manifold 2000 min 2200 min 2400 min 2600 min 2800 min 3000 min Pressure (inHg) 28 (38) 30 (41) 32,5 (44) -
Page 22: Performance Graph Limbach L 2400 Ds
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Performance Graph LIMBACH L 2400 DS Page: 22/53 Edition: 20.06.2018... -
Page 23: Performance Data L 2400 Ds
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 5.4.1 Performance Data L 2400 DS Power values in kW (HP values in parentheses) Manifold 2000 min 2200 min 2400 min 2600 min 2800 min 3000 min 3200 min 3400 min Pres- sure (inHg) 33 (45) -
Page 24: Operating Instructions
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Operating Instructions Strict adherence to the information contained in this operating manual is the basis for undisturbed opera- tion of your engine. Before Starting Perform daily check (see section 7.1) Move throttle lever to the full power position. -
Page 25: Runup, Performance Check
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Turn emergency switch to normal mode The emergency indication disappears. Move the throttle lever to 5-10 % power. Check propeller clearance Start engine. When the engine is firing, release starter button and set engine speed to appr. -
Page 26: Take-Off
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Take-Off Increase engine speed steadily to full throttle and perform first part of climb with this setting, then reduce power. Observe coolant, oil temperature and pressure. The limits may not be exceeded. Caution: With increasing ambient temperatures the engine power and the lift up of the wings will be reduced. -
Page 27: Emergency Procedures
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Emergency Procedures If engine operation is disturbed, the emergency switch (S) should be set to emergency mode. When in emergency mode some engines sensors are deactivated resp. replaced with reserve sensors. Also a reserve fuel pump is selected. -
Page 28: Version With Electronic Engine Display
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 6.8.2 Version with electronic engine display After activating the emergency mode the mes- sage „Emergency“ comes on. 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”... -
Page 29: Maintenenance Schedule
L 2400 EF/DF/ET/DT/DX/DS Maintenenance Schedule Maintenance at Limbach aircraft engines is to be performed after fixed time periods or when reaching a certain interval of operating hours. In addition, a “daily check” has to be performed before each flight. Note: On turbocharged engines ET/DT/DX models the exhaust collector (pipes running from the engine to the turbocharger) are part of the engine. -
Page 30: Operating Time Related Inspections
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Operating Time related Inspections section 7.3.1 7.3.3 7.3.4 7.3.5 7.3.6 After 5 Operating hours After 25 Operating hours Every 50 Operating hours Every 100 Operating hours Every 200 Operating hours Every 500 Operating hours 7.3.1 After the first 5 Operating Hours •... -
Page 31: Every 100 Operating Hours
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 7.3.4 Every 100 Operating Hours • Change oil and 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 •... -
Page 32: Maintenance Instructions
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Maintenance Instructions This chapter describes the performance of maintenance work. In addition, the preservation of engines as well as winter and tropical operation is covered. Caution: Disconnect spark plug connectors before performing any work on the engine. -
Page 33: Cleaning Of Air Filter
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Cleaning of Air Filter Remove air filter. Clean air filter, using compressed air, blowing from inside outwards. Special filters are to be cleaned according to the aircraft manufacturer’s instructions. Adjust Idling Speed The idling speed may be adjusted via the adjusting screw on the throttle body. The speed should be adjusted to 800 ±100 rpm. -
Page 34: Compression Check
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Compression Check Compression checks should be performed when the engine is “warm to touch”. Remove spark plugs and the connectors from the injectors. Measure compression by means of a compression pressure recorder. Perform measurement with throttle full open. Record compression pressure at starting rpm for every cylinder until the pressure indicated on the recorder does nor rise anymore. -
Page 35: Check Of Valve Shaft Projecting Length
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Check of Valve Shaft Projecting Length Remove cylinder head covers. Dismount rocker arm shafts. Measurement of valve shaft projecting length by means of measuring device P/N: 803.001.130. If the projecting length is less than 24 mm for the intake and exhaust valve the cylinder heads have to be replaced by new ones. - Page 36 Operating Manual L 2400 EF/DF/ET/DT/DX/DS The electrode gap is 0.7 mm. Reinstall spark plugs and connect spark plug connectors. Grease spark plug thread with graphite grease P/N: 170.210.010. Torque to 20 Nm. Caution: Electrodes must always be free from graphite grease! Do not use copper paste.
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Page 37: Drive Belt Check, Tensioning And Replacement
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 8.11 Drive Belt Check, Tensioning and Replacement Drive belt check. Check for wear, cracks and oil traces. Drive belt tension check. It must be possible to push the drive belt through with a strong thumb load by 5 to 10 mm. -
Page 38: Turbocharger Check L 2400 Et/Dt/Dx
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 8.13 Turbocharger Check L 2400 ET/DT/DX Check turbocharger for secure mounting. Check hose to boost pressure limiter for fit, tightness and damage. Check routing of turbocharger drain line (it must be routed with a constant declination towards the valve cover and have no bucklings, no reduction in cross-sectional area). -
Page 39: Engine Preservation
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Engine performance check Move throttle lever to full-throttle stop. Engine has to reach the full-throttle static speed (refer to flight and maintenance manual of aircraft manufacturer). Set variable-pitch propellers to Take-off pitch. 8.18 Engine Preservation Engines that are taken out of operation for more than 6 months shall be preserved. -
Page 40: Operation At Low Ambient Temperatures
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 8.19 Operation at low ambient Temperatures In general, engine maintenance should be performed before the beginning of the cold season. Furthermore, the following hints for operation at extremely low ambient temperatures should be observed: Electrical system At low ambient temperatures, the capacity of the starting battery is reduced. -
Page 41: Operation In Tropical Conditions
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 8.20 Operation in Tropical Conditions The following measures are necessary to protect the engine against heat and dust: Air filter If the engine is operated in areas of high dust accumulation install larger air filter (contact your aircraft manufacturer for details). -
Page 42: Overhaul
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Overhaul Major Overhaul Major overhaul must be performed by the manufacturer or overhaul shops, authorized by the manufacturer. Therefore, the engine has to be forwarded to the manufacturer or an authorized overhaul shop, after the operating time limit has been reached. -
Page 43: Lubricants, Coolants, Fuels
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Lubricants, Coolants, Fuels 10.1 List of Lubricants Do not use ash less dispersant or straight mineral aircraft engine oils! Do not use fully synthetic oils! Use only brand name oils according to spezification API-SG, or higher. (eg. API-SH, SI, SJ, S…) as well as one of Volkswagen-specs VW 500 00, VW 501 01 or VW 502 00. -
Page 44: Coolant
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 10.2 Coolant The cooling system is filled with a mixture of water and anti-freeze and corrosion protection for all seasons. The amount of coolant is approximately 3.5 ltrs. The mixing ratio may be varied between the following limits:... -
Page 45: Recommended Nut Torques
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Recommended Nut Torques 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... -
Page 46: Trouble Shooting
Operating Manual L 2400 EF/DF/ET/DT/DX/DS Trouble Shooting “Small”, apparently negligible causes are often responsible for a “big” effect, i.e. disturbance of engine operation. Detection of the causes is not always easy. The hints to possible trouble causes and their correction contained in this section serve as a guideline for the engine user, listing the most frequent faults. - Page 47 Operating Manual L 2400 EF/DF/ET/DT/DX/DS Possible Cause: Remedy: Ignition module defective. Check ignition module(s). Replace if neces- sary. Ignition coil defective. Check ignition coil(s). Replace if necessary. Spark plugs wet due to excess fuel. Remove spark plugs, clean and dry. Deter- mine and eliminate cause of excess fuel.
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Page 48: Engine Operating Trouble
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.2 Engine Operating Trouble The following phenomena are considered to be engine operating trouble: • uneven and irregular engine run • temporary interruptions • low power • engine overheat • rough engine run Consider reasons as per section 12.1 besides the ones listed below. -
Page 49: Ignition
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.2.2 Ignition Possible Cause: Remedy: Ignition module defective. Check ignition module, replace if necessary. Ignition coil defective. Check ignition coil, replace if necessary. Spark plug defective. Replace spark plug. Wrong spark plugs. Use specified spark plugs. -
Page 50: Lubrication
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.2.4 Lubrication Possible Cause: Remedy: Bad engine oil quality. Change oil. Use specified oil. Oil filter or cooler blocked. Change oil filter. Clean oil cooler, replace if necessary. Note: At low ambient temperatures the oil may be overcooled in the oil cooler, thus causing blockage and high oil pressures. -
Page 51: Exhaust / Turbocharger System L 2400 Et/Dt/Dx
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.3 Exhaust / Turbocharger System L 2400 ET/DT/DX Remedy: Possible Cause: Induction system leaking. Check seals, rubber boots and hose clamps, replace if neccessary. Intercooler leaking. Replace intercooler. Exhaust system leaking. Check joints, replace springs if neccessary. -
Page 52: Mechanical System
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.4 Mechanical System Possible Cause: Remedy: No valve clearance. Set valve clearance. Note: This symptom may be indication of an over- heating engine, check cooling system, injec- tion and ignition. Leaking or sticking valve. Repair cylinder head. -
Page 53: Engine Operating Trouble In Normal Mode, No Trouble In Emergency Mode
Operating Manual L 2400 EF/DF/ET/DT/DX/DS 12.5 Engine Operating Trouble in Normal Mode, no Trouble in Emergency Mode The following phenomena are considered to be engine operating trouble: • uneven and irregular engine run • temporary interruptions • low power •...