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RotorWay RI 600 Series Operation And Maintenance Manual

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RI 600 ENGINE MANUAL
OPERATION AND MAINTANCE OF
RI600N (NORMALLY ASPIRATED)
AND
RI600S (SUPERCHARGED)
HELICOPTER ENGINES
MAY 2009, REV – 1.0

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Summary of Contents for RotorWay RI 600 Series

  • Page 1 RI 600 ENGINE MANUAL OPERATION AND MAINTANCE OF RI600N (NORMALLY ASPIRATED) RI600S (SUPERCHARGED) HELICOPTER ENGINES MAY 2009, REV – 1.0...
  • Page 2 RotorWay International INTRODUCTION RI600 Engine Manual Page 2 Revision Date Description Approved By: May-19-2009 Initial rewrite documenting Talon updates...
  • Page 3 RotorWay International INTRODUCTION RI600 Engine Manual Page 3 WARNING The construction and operation of “Home-Built Aircraft” of this type is demanding and could inflict serious injury and possible death. No such operation, construction or undertaking should be initiated unless thorough and complete knowledge, preparation and instruction are available and utilized.
  • Page 4 Page 4 Introduction The RI 600 powerplant from RotorWay International has been completely assembled and dynamometer tested by factory technicians. Precise parts tolerances, assembly techniques and performance parameters are required of every engine leaving the factory. The oil pressure and ignition timing was adjusted to specification and fuel flow verified to be in the proper range at various power levels.

  • Page 5: Table Of Contents

    RotorWay International INTRODUCTION RI600 Engine Manual Page 5 Contents   SECTION 1: General Service Information ......................... 8     RI600 Engine Specifications ................................... 8     Torque Requirements ..................................... 8     Oil Requirements and Specifications ..............................9    ...
  • Page 6 RotorWay International INTRODUCTION RI600 Engine Manual Page 6     Oil System ......................................34     Preparation and Priming ................................... 34     Oil Pressure Adjustment ................................... 35     Ignition System ..................................... 36     Introduction ....................................... 36  ...
  • Page 7 RotorWay International INTRODUCTION RI600 Engine Manual Page 7     Rotating Parts Assembly ..................................57     Main Drive Pulley Assembly ................................. 59     Crankcase Assembly .................................... 60     Lower Cover Assembly ..................................61     Water Jacket Assembly ..................................63  ...

  • Page 8: Section 1: General Service Information

    RotorWay International SECTION - 1 RI600 Engine Manual Page 8 SECTION 1: General Service Information A. RI600 Engine Specifications Rated Horsepower @ 4250 RPM ........................ 150 Torque @ 4250 RPM ........................... 185 ft.lb. Max Torque @ 3950 RPM ........................191 ft.lb.

  • Page 9: Oil Requirements And Specifications

    RotorWay International SECTION - 1 RI600 Engine Manual Page 9 C. Oil Requirements and Specifications AMBIENT AIR TEMPERATURE GRADE OF OIL (MULTI- VISCOSITY) Above 40° F ............................. 20 - 50 SF 0° F to 60° F ............................. 10 - 40 SF Below 0°...

  • Page 10: Fuel Requirements And Fuel Consumption

    RotorWay International SECTION - 1 RI600 Engine Manual Page 10 E. Fuel Requirements and Fuel Consumption Minimum Octane Rating ..........................91 Fuel Pressure, PSI ..........................40 - 60 Fuel Consumption at Full Power (approximately) ................68 lbs./hr. Varies depending upon manifold pressure.

  • Page 11: Component Specifications And Wear Limits

    RotorWay International SECTION - 1 RI600 Engine Manual Page 11 H. Component Specifications and Wear Limits CYLINDERS Bore Size STD ..................... 4.0005" ± .0005" MAX ........................4.0035" Max. Taper ...............................0010" Max. Egg ................................0060" Bore to Bore Distance ........................4.410" ± .002"...

  • Page 12: Cylinder Head Torque Specifications

    RotorWay I International SECT ION - 1 RI600 Engin ne Manual Page 12 Cylin der Head To orque Specifi ications Installation n Torque Proce edures: Pre-che eck thread qua ality and install ed bolt depths s by applying a a film of Anti-Se...

  • Page 13: Section 2: Individual System Procedures

    The introduction of the RotorWay FADEC (Fully Automated Digital Electronic Control) System is the result of over four years of development and testing. It is a totally unique and customized system designed especially for use in RotorWay helicopters. It delivers fuel with extremely accurate air/fuel ratios.

  • Page 14: Fuel Requirements

    RotorWay International SECTION - 2 RI600 Engine Manual Page 14 In the unlikely event that the MAP sensor fails or if a green FADEC primary light turns off and a red light turns on there is a Main ECU loss or malfunction, FADEC will automatically transfer control of the engine to the secondary system. A red warning light will illuminate on the instrument panel to inform the pilot of the deactivation of primary system.
  • Page 15 RotorWay International SECTION - 2 RI600 Engine Manual Page 15 Do not allow a hose to rub against anything, even if the surface on which it rubs is flat. The stainless steel braid is a very efficient low speed file and will abrade through anything that it moves against. In order to prevent chafing and to keep your hoses where you want them, support the hoses with wire ties or cushion loop clamps.
  • Page 16 RotorWay International SECTION - 2 RI600 Engine Manual Page 16 the top of the switch. This should cause the fuel pump to turn on. Turn off the fuel pump switch and re-bolt the inertia switch to the bracket. Test the other inertia switch in the same manner.

  • Page 17: Component Service

    RotorWay International SECTION - 2 RI600 Engine Manual Page 17 After the initial leak testing is complete, turn off all switches and turn off the fuel valve. CONTINUE TO REGULARLY INSPECT THE FUEL SYSTEM FOR LEAKAGE. This is especially important during the first few hours of operation and during each pre-flight inspection! M.

  • Page 18: C) Barometric And Manifold Pressure Sensors

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 1 c) Barom metric and Ma anifold Pressu ure Sensors These e sensors requi re no maintena ance and are in nterchangeable e. They both ha ave a range of f 2 BARS.

  • Page 19: E) Throttle Shaft Assembly

    RotorWay International SECTION - 2 RI600 Engine Manual Page 19 REPLACEMENT: While it is not essential that the plenum assembly be removed from the engine compartment, removal will simplify the sensor adjustment process and make safety wiring of the sensor retention bolts easier.

  • Page 20: F) Air Filter

    RotorWay International SECTION - 2 RI600 Engine Manual Page 20 fully closed position. The shaft must then rotate with no binding or drag. All other components are then replaced. Be careful to accurately adjust the “full open” and “idle” positions of the throttle. Carefully follow the procedure for throttle position sensor replacement.

  • Page 21: J) Engine Control Unit

    Engine Control Unit This component is NOT serviceable by anyone other than RotorWay International. DO NOT attempt to disassemble the ECU. DO NOT perform any resistance or voltage checks on the ECU. Call the Factory if you find or suspect that there is a problem with this component.

  • Page 22: N) Manifold Absolute Pressure (Map) Sensor

    RotorWay International SECTION - 2 RI600 Engine Manual Page 22 n) Manifold Absolute Pressure (MAP) sensor This sensor responds to changes in manifold pressure. The ECM receives this information as a signal voltage that will vary from about 1.0 - 1.5 volts at idle to about 4.0 - 4.5 volts at wide open throttle (WOT).

  • Page 23: C) Secondary System Operation

    Disassemble the connector and carefully examine the pins in question. If the main FADEC wiring harness becomes damaged you should call RotorWay Customer Service to discuss the repair. We do not recommend that you attempt pin replacement in these harnesses because special tools and techniques are required to properly complete the assembly.

  • Page 24: F) Fadec Wiring Harness

    RotorWay International SECTION - 2 RI600 Engine Manual Page 24 FADEC Wiring Harness...
  • Page 25 RotorWay International SECTION - 2 RI600 Engine Manual Page 25...

  • Page 26: G) Fadec Harness Wiring Guide

    RotorWay International SECTION - 2 RI600 Engine Manual Page 26 g) FADEC Harness Wiring Guide WIRING GUIDE TALON CIRCUIT PLUG DESCRIPTION TO: PLUG / PIN / WIRE # PLUG PRIMARY ECU J1 CAVITY PLUG CAVITY PLUG CAVITY PLUG JUMPER CAVITY PLUG...
  • Page 27 RotorWay International SECTION - 2 RI600 Engine Manual Page 27 VR REFERANCE LOW 21-B FUEL INJECTOR B DRIVER 31-C4     CAVITY PLUG 30-A, 5-A, 1-13, 1-28, 1-29, 3-28, 3-29, 28-C, POWER GND 29-C TACH OUTPUT 33-D     CAVITY PLUG  ...
  • Page 28 RotorWay International SECTION - 2 RI600 Engine Manual Page 28 BARO SENSOR SIGNAL 26-B CAVITY PLUG CAVITY PLUG CAVITY PLUG CAVITY PLUG IGNITION CONTROL PRIMARY 31-D8 CAVITY PLUG PLUG SECONDARY ECU J2 5-F, 2-1, 31-B1, 31-D1, 31-A1, 7-A, 10-1, 11-1,...
  • Page 29 RotorWay International SECTION - 2 RI600 Engine Manual Page 29 33-E-F, 5-F, 2-1, 4-1, 31-B-1, 31-D-1, 31-A-1, POWER 38-I 10-1, 11-1, 12-1, 13-1 CHECK ENGINE LIGHT 47-C 1-9, 3-9 CONTROL #1 37-B 31-C-2, 31-D-7, 31-D-9, 31-D-3, 31-D-5 WARNING 1 CONTROL #2...
  • Page 30 RotorWay International SECTION - 2 RI600 Engine Manual Page 30 ANALOG GND 14-D 4-3, 25-A, 27-A, 17-A, 19-A THROTTLE POSITION 2 4-23 VOLTAGE REFERANCE 13-D 4-2, 25-C, 27-C PLUG MANIFOLD PRESSURE SENSOR PRIMARY ANALOG GND 12-B 2-3, 26-A, 22-1, 16-A, 18-A...
  • Page 31 RotorWay International SECTION - 2 RI600 Engine Manual Page 31 AA-1 CAVITY PLUG 33-E-F, 5-F, 2-1, 4-1, 31-B-1, 31-D-1, 7-A, 10-1, POWER 38-H 11-1, 12-1, 13-1 SAFE 31-B-2 WATER PUMP 1-22, 3-22 WATER PUMP CAVITY PLUG CAVITY PLUG CAVITY PLUG...

  • Page 32: Cooling System

    NEVER USE WATER ONLY IN THE COOLING SYSTEM. Never mix tap water or well water with the antifreeze concentrate. Use ONLY DISTILLED WATER to mix with the antifreeze solution. RotorWay recommends that you have the coolant/anti-freeze solution tested once every year. Fleetgaurd coolant test strips (CC2602A) for measuring freezing point, molybdate and nitrite.

  • Page 33: Preparation

    RotorWay International SECTION - 2 RI600 Engine Manual Page 33 2. Preparation Review the Prints and Manuals to ensure that all cooling system components are attached and routed correctly. Verify that all hoses are secure and that hose clamps are installed past the bead or flare on the end of the adjoining tube or fitting.

  • Page 34: Oil System

    RotorWay International SECTION - 2 RI600 Engine Manual Page 34 Any air remaining in the system can be heard as gurgling. While the pump is running, the bleed valves on the inlet manifold and on the engine should be opened occasionally to allow air to escape. Rocking the aircraft on the ground handling wheels can help move air pockets to the bleed valve areas.

  • Page 35: Oil Pressure Adjustment

    RotorWay International SECTION - 2 RI600 Engine Manual Page 35 CAUTION: If proper oil pressure is NOT obtained after 5 seconds of running, STOP the engine and re-prime the pump as explained in step C above. Adjust the oil pressure if necessary (see Oil Pressure Adjustment section below).

  • Page 36: Ignition System

    RotorWay International SECTION - 2 RI600 Engine Manual Page 36 Ignition System 1. Introduction The dual ignition system utilized on the RI 600 engine is extremely reliable and easy to maintain. It should provide many hours of trouble free performance. Many types of ignition systems were analyzed and evaluated before deciding to use this system.
  • Page 37 RotorWay International SECTION - 2 RI600 Engine Manual Page 37 by these wires is very weak and interference from other wires close by could cause false signals to be sent to the ignition modules. Pay close attention to the routing of these wires in relation to the spark plug wires as they are proven the most likely source of interference.

  • Page 38: Installation Drawing

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 3 3. Instal llation Drawi CAUT TION: USE O ONLY GROUN DING STRAPS S AND WIRES S SUPPLIED B BY ROTORWA AY AND SPEC CIFIED BELOW BY PAR RT NUMBER.

  • Page 39: Component Service

    RotorWay International SECTION - 2 RI600 Engine Manual Page 39 4. Component Service a) Ignition Sensors The inboard and outboard ignition sensors are identical. TESTING: Disconnect the sensor at the plug connector by lifting the lock tab and pulling the connector apart. Pull on the connector body only, not on the wires themselves.

  • Page 40: D) Spark Plugs

    RotorWay International SECTION - 2 RI600 Engine Manual Page 40 DO NOT use any wire because you believe it to be similar to the factory supplied type! A damaged spark plug wire will test as a “short” or have a high resistance value.

  • Page 41: B) Engine Will Not Start - Signs Of Spark Are Evident, (Such As Backfire Or Sputter)

    RotorWay International SECTION - 2 RI600 Engine Manual Page 41 If the engine will not start on either system, check the sensor gap on both the outboard and the inboard systems. Install a timing light on #1 outboard spark plug wire. With only the outboard system turned on, crank the engine to check for spark.

  • Page 42: C) Engine Runs On One System Only

    RotorWay International SECTION - 2 RI600 Engine Manual Page 42 Install a timing light on #1 outboard wire. With only the outboard system on, crank the engine to check for spark. Repeat as necessary on the remaining wires to determine if a spark is being produced. (Do not crank engine for a prolonged period as this could damage the starter and the engine.)

  • Page 43: Ignition Timing

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 43 6. Ignitio on Timing The ignition n timing may v ary depending on whether th e engine is ope erating on the p primary system m or on the sec...

  • Page 44: B) Lash Cap, Rocker And Pushrod

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 44 Valve Stem m and Spring K Keeper: If you look closely a at the top of e each valve ass sembly you wi ill notice a gap between the...

  • Page 45: C) Camshaft Lift Inspection

    RotorWay International SECTION - 2 RI600 Engine Manual Page 45 Perform if lash is found to be in excess of .008". Rotate the engine to the proper position for valve adjustment of the individual valve to be inspected. (See Valve Adjustment). Loosen the set screw and rocker nut. Remove the rocker nut with set screw.
  • Page 46 RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 4 Remov ve both valve c covers. (See “V Valve Cover Re emoval”) C. Rotate e the engine in n a counter clo ockwise directi ion (looking do own from the t...
  • Page 47 RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 47 G. Rotate e the engine u ntil another se et of valves are e fully open. M Measure and a adjust the lash on the oppos site valve in the same manner.

  • Page 48: Main Drive Pulley

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 4 Figu ure 3 - Fully Op pen Valve K. Main Drive Pulley 1. Remo oval The drive p pulley, flywhee el and drive flan nge are indexe ed with punch m marks.

  • Page 49: Bearing Replacement

    RotorWay I International SECTION - 2 RI600 Engin ne Manual Page 4 The indica ator should con ntact the pulle ey on the outs side surface a pproximately . 150" from the e top of the pu ulley. The tota...
  • Page 50 RotorWay International SECTION - 2 RI600 Engine Manual Page 50 moisture contamination on the shaft using acetone. Put a light film of #609 loctite on the portion of the shaft which will contact the top bearing. Similarly place a light film on the I.D. of the bottom bearing. Immediately install the cup assembly. It should drop in.

  • Page 51: Section 3: Start-Up And Initial Run-In Procedures

    RotorWay International SECTION - 3 RI600 Engine Manual Page 51 SECTION 3: Start-up and Initial Run-in Procedures A. Introduction It is important that you read this entire manual as vital procedures are contained throughout. Each section contains relevant information essential to properly start and operate the powerplant. It is mandatory that you read Section 2 (Individual System Procedures) prior to starting the power plant for the first time.

  • Page 52: Maintenance Requirements

    RotorWay International SECTION - 3 RI600 Engine Manual Page 52 Pay special attention to: Leaks, which present a fire hazard Oil pressure C. Water temperature D. Rotating parts We advise you to attend our training program prior to starting the engine. The hands-on instruction regarding the proper care and operation of the engine is extremely valuable to even the best mechanic.

  • Page 53: First Five Hour Service

    RotorWay International SECTION - 3 RI600 Engine Manual Page 53 WARNING: All four gaskets should be replaced at the first hint of flange leakage. Any type of exhaust system leak may allow carbon monoxide fumes to enter the cabin area. Exposure to these fumes can be fatal and any indication of leakage must be corrected before operation is continued.

  • Page 54: Section 4: Inspection And Maintenance Schedule

    RotorWay International SECTION - 4 RI600 Engine Manual Page 54 SECTION 4: Inspection and Maintenance Schedule A. Introduction The following schedule is presented as a guide to the regular maintenance required on the engine. It should be followed exactly, as all of the procedures are essential to achieving a long lasting and reliable powerplant. In no way does this mean this is all of the maintenance YOUR engine may require! By closely monitoring all systems and analyzing any problems you encounter, you may find that you need to increase the amount of the attention you give to an individual system or component.

  • Page 55: 50 Hour Service

    RotorWay International SECTION - 4 RI600 Engine Manual Page 55 INSPECT EXHAUST SYSTEM: Check entire exhaust system for cracks and leaks. Proper fit of each exhaust manifold to its mating port is important. Proper fit can be verified while idling the engine and positioning your finger approximately 1/2"...

  • Page 56: 500 Hour Service

    RotorWay International SECTION - 4 RI600 Engine Manual Page 56 REPLACE AIR FILTER REPLACE ALL WATER HOSES: Replace all water hoses, hose clamps and coolant. Replace every five years even if 250 hours of operation has not yet occurred. REPLACE CAM GEAR REBUILD CYLINDER HEADS (IF USING 100 LOW LEAD OR LEADED AUTOMOTIVE GASOLINE): Specifications have been given to perform this service and all of the necessary parts are available from the factory.

  • Page 57: Section 5: Drawings And Parts Lists

    RotorWay International SECTION - 5 RI600 Engine Manual Page 57 SECTION 5: Drawings and Parts Lists A. Rotating Parts Assembly REF. # PART # DESCRIPTION QTY. 1 ....E00-2611 .... Bolt 3/8-24 X 1-1/4 SHCS ......................3 2 ....E00-4600 .... AN960-616 3/8 Regular Washer ....................3 3 ....
  • Page 58 RotorWay I International SECTION - RI600 Engin ne Manual Page 5...

  • Page 59: Main Drive Pulley Assembly

    RotorWay I International SECTION - RI600 Engin ne Manual Page 5 B. Main Drive Pulley y Assembly REF. # PART # DESCR RIPTION QTY. 1 ....A24-1601 1 ..Upper D Drive Cup ......................1 2 ..

  • Page 60: Crankcase Assembly

    RotorWay I International SECTION - RI600 Engin ne Manual Page 60 C. Crank kcase Assem mbly REF. # PART # DESCR RIPTION QTY. 1 ....A24-2001 1 ..Crankca ase ........................1 2 ..

  • Page 61: Lower Cover Assembly

    RotorWay International SECTION - 5 RI600 Engine Manual Page 61 D. Lower Cover Assembly REF. # PART # DESCRIPTION QTY. 1 ....A24-2007 ..Lower Cover ......................... 1 2 ....A24-2010 ..Oil Exit Fitting ....................... 1 3 ....A24-2015 ..Bushing-Lower Cover ....................1 4 ....
  • Page 62 RotorWay International SECTION - 5 RI600 Engine Manual Page 62...

  • Page 63: Water Jacket Assembly

    RotorWay I International SECTION - RI600 Engin ne Manual Page 63 E. Wate r Jacket Ass sembly REF. # PART # DESCR RIPTION QTY. 1 ....A24-3040 0 ..Waterja acket Elbow, Ta apped ..................1 2 ..

  • Page 64: Cylinder Head Assembly

    RotorWay International SECTION - 5 RI600 Engine Manual Page 64 F. Cylinder Head Assembly REF.# PART # DESCRIPTION QTY. 1 ....A24-4002 ..Intake Valve ......................... 4 2 ....A24-4003 ..Intake Valve Seat ......................4 A24-4004 ..Intake Valve Guide ....................... 4 3 ....
  • Page 65 RotorWay International SECTION - 5 RI600 Engine Manual Page 65...

  • Page 66: Plenum And Manifold Assembly

    RotorWay International SECTION - 5 RI600 Engine Manual Page 66 G. Plenum and Manifold Assembly REF. # PART # DESCRIPTION QTY. 1 ....E00-2324 ..Bolt 3/16 X 1-7/8 Drilled Head ..................2 2 ....E00-4301 ..AN960-10 3/16 Regular Washer .................. 4 3 ....
  • Page 67 RotorWay I International SECTION - RI600 Engin ne Manual Page 67...

  • Page 68: Fuel Shut-Off Valve / Filter Assembly

    RotorWay I International SECTION - RI600 Engin ne Manual Page 6 H. Fuel S Shut-off Valv ve / Filter As sembly REF. # PART # DESCR RIPTION QTY. E25-4660 0 ..Fuel Sh ut-off Valve/Fil ter Assy ............

  • Page 69: Electrical System

    RotorWay I International SECTION - RI600 Engin ne Manual Page 6 Elect rical System REF. # PART # DESCR RIPTION QTY. 1 ....A24-5410 0 ..Inboard Ignition Senso or ....................1 2 ....A24-5411 1 ..

  • Page 70: Oil System

    RotorWay I International SECTION - RI600 Engin ne Manual Page 70 J. Oil Sy ystem REF. # PART # DESCR RIPTION QTY. 1 ....E28-6112 2 ..Oil Hose e, Sump to Oil Pump ..................1 2 ..

  • Page 71: Gaskets And O-Rings

    RotorWay International SECTION - 5 RI600 Engine Manual Page 71 K. Gaskets and O-Rings PART # DESCRIPTION QTY. PER ENGINE A24-1101 ..Complete set ..........................1 A24-2016 ..Main Galley O-Ring ........................1 A24-2103 ..Oil Seal-Crankshaft ........................1 A24-2402 ..Oil Pump Cover O-Ring (Small) ..................... 1 A24-2403 ..

  • Page 72: Altitude Compensation Induction System

    RotorWay International SECTION - 5 RI600 Engine Manual Page 72 L. Altitude Compensation Induction System REF. # PART # DESCRIPTION QTY. 28 ... E38-4020 ... Flapper ......... 1 1 ..... E38-3000 ... Supercharger Assy ......1 E38-4040 ... Flapper Pin ........2 2 .....
  • Page 73 RotorWay I International SECTION - RI600 Engin ne Manual Page 73...

  • Page 74: Section 6: Hourly Service Chart

    RotorWay International SECTION - 6 RI600 Engine Manual Page 74 SECTION 6: Hourly Service Chart DESCRIPTION 1000 SERVICE AIR FILTER GREASE MAIN DRIVE PULLEY TORQUE CYLINDER HEAD BOLTS INSPECT AND ADJUST VALVES INSPECT COOLING SYSTEM INSPECT OIL SYSTEM INSPECT FUEL SYSTEM...

This manual is also suitable for:

Ri 600sRi 600n

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