Flygas F.050 Installation And Maintenance Manual

Mechanical fuel pump

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INSTALLATION AND

MAINTENANCE MANUAL FOR

MECHANICAL FUEL PUMP

Cod. F.050 and F.051

Version 1.2 "Experimental"

All the information, the technical data and the specific drawings reported in this manual are owned by FLYGAS

and they cannot be reproduced neither entirely nor partially without previous agreement and written authorisation

by FLYGAS ITALIA.

Approval of translation to best knowledge and judgement – in any case the original text in Italian language is

authoritative.

Installation and maintenance manual for mechanical fuel pump FLYGAS – Version 1.2 Experimenter

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Page 1 Cod. F.050 and F.051 Version 1.2 “Experimental” All the information, the technical data and the specific drawings reported in this manual are owned by FLYGAS and they cannot be reproduced neither entirely nor partially without previous agreement and written authorisation by FLYGAS ITALIA.
Page 2: Table Of Contents
INSTALLATION ON ROTAX 914: .................. 10 OPERATION ........................16 FUEL SYSTEM ........................17 FIRST STARTING ......................20 BEFORE EACH START ....................21 10. POSSIBLE FAILURES ...................... 22 11. MAINTENANCE SYSTEM ....................23 Installation and maintenance manual for mechanical fuel pump FLYGAS – Version 1.2 Experimenter...
Page 3 In this case Flygas reserves to repay the full amount paid (equal to the invoice) and collect all the material, as long as it is intact in all its parts, not altered or defaced and stored under appropriate conditions, without charge or duty by the purchaser.
Page 4: Foreword
Engine type: ________________ Serial Number : ________________ Within 30 days from the date of purchase the buyer must send to Flygas the sheet in which is clearly indicated the date and the effective hours till the date of the installation.
Page 5 The information and the description contained in this Installation Manual are correct at the time of publication. FLYGAS, however, maintains a policy of continuous improvement both in terms of the performance and of reliability of its products, without imposing any obligation to install them to update the products built previously.
Page 6 Moreover, FLYGAS gives no warranties regarding the compatibility of this kit with any other parts, element or system that can be chosen by the manufacturer / user for the application on the plane.
Page 7 In addition to compliance of the instructions contained in our manual and that of the engine manufacturer, all the general measures of safety and accident prevention must be observed, as well as legal laws and the rules of any aviation authorities. Installation and maintenance manual for mechanical fuel pump FLYGAS – Version 1.2 Experimenter...
Page 8: Kit Fuel Pump For Rotax Description Of The Parts
Flow of gasoline in function of RPM and Pressure None of these elements has been designed and built for flight. Their use on aircraft is at the sole judgment of the user of the vehicle Installation and maintenance manual for mechanical fuel pump FLYGAS – Version 1.2 Experimenter...
Page 9: Installation
4. INSTALLATION Before installing read this book carefully. The manual provides basic information for the correct installation of the entire system on the engine and its proper maintenance. A lack of attention may cause serious damage to both structural (weakening of the engine or mechanical parts directly linked to it) and physical. Since the reading of the instructions will not eliminate the risks, the understanding and application of the information listed below will allow proper installation, operation and maintenance.
Page 10: Installation On Rotax 914
"green" normally sold in Italy without any additives. Any forcible action, intervention or replacement of parts without written permission from Flygas, discharge the manufacturer from any liability in case of damage or malfunction of the system...
Page 11 1. Install the Driving Joint with Loctite 243 2. Tight the Driving Joint with torque aprox 30Nm 3. Insert N°2 pin 4mm diameter in Rotax case...
Page 12 4. Install the support plate, with N°3 Allen screw M6 5. Insert the drive pin 6mm (That temporary operations is necessary to find a right Axial Alignment between Fuel Pump and Crank-Shaft ) 6. Install the Fuel Pump and Bell and screw with Loctite 243 the N°3 Allen Screw M5 (after never remove more this N°3 Screw, otherwise will be necessary repeat this operations)
Page 13 7. Check the distance/space from the tooth of Drive Shaft and from tooth of Pump Shaft; Minimum distance must be 0,65mm “0 Plus 0,1mm” 8. After remove the Plate, the Bell and the Pump without disconnect this 3 parts! During installation and maintenance be sure that no pipe or electric cable is near to potential electrical shortcuts, electrical shocks (always possible especially coming from high voltage cables candles) and close to hot surfaces (above 50 °...
Page 14 Use the entire length of wedge to make the pipe as fit as possible to the plug. In order to avoid the pipe to slip off from its housing accidentally, fasten it using the proper clamps free from edges that may cut it. nsert a anti pulsations.
Page 15 10. Install again the Plate, The Belt and Fuel Pump and tight N°3 Allen Screw M6 at 10Nm...
Page 16: Operation
6. OPERATION Performance Test of Mechanical Fuel Pump installed on your engine Fuel Pressure Draft Depth Fuel Level: Flow 2000 2500 Fuel Temperature: 3000 3500 Hour/Km: 4000 4500 Data: 5000 5500 5800 Never carry out the steps during the flight only for testing. Perform tests on the ground with tied or braked vehicle and be sure to observe all the safety instructions.
Page 17: Fuel System
7. FUEL SYSTEM Shape and arrangement of the fuel system must ensure the functioning of the engine within the limits given. Fuel pressure at the carburettor system in atmospheric conditions Rotax 914: Maximum …..………………..0,35bar Minimum ……….…………..0,15bar Nominal …….……….……..…0,25bar Minimum Flow …..95 Lt/hour @5800rpm The exceeding of the specified maximum fuel pressure can lead to a overtaking of the seal of the float valve inside the carburettor resulting in an engine shutdown.
Page 18 1. Fuel Tank 2. Gascolator (filter and water trap) 3. Pierburg electrical 1bar Fuel pump 4. Flygas mechanical Fuel Pump 5. Optional: Restrictor Jet for air bubble (not plus of 1mm hole diameter) 6. Check Valves 7. Regulator Fuel Pressure 8.
Page 19 (In a case of E.F.I. engine) The disassembly and assembly of the mechanical fuel pumps MUST BE DONE ONLY FROM FLYGAS. A disassembly of the pump without written authorization from Flygas, lifts Flygas from any responsibility.
Page 20: First Starting
8. FIRST STARTING Once the installation is completed, before the first starting is carried out, follow the instructions below:  Recheck all the connections of the various pipes, gasoline and air.  Visually check that there are no electrical parts or pipes accidentally leaned (or very near) against the engine exhausts since they reach within few seconds temperatures like 700/900 °...
Page 21: Before Each Start
9. BEFORE EACH START Have a look of the emergency drops tubes , and check eventually gasoline leakage from that hole Verify the Check-List of the aircraft manufacturer and depending on engine type used. Verify that the level of the fuel is sufficient to support the planned travel. Verify that the fuel valves are open.
Page 22: Possible Failures
10. POSSIBLE FAILURES Please note that this kit is built by parts which are not designed and constructed for use in flight, in fact, their use in flight is prohibited by the manufacturers and therefore it is not possible to guarantee the correct operation. As with any products is always to be considered that a possible break (partial or total) or a failure of any component within the system may occur (The engine, therefore, could suddenly shut down or malfunction due to changes in injection timing that are going to "lean"...
Page 23: Maintenance System
Every 250 hours or anyway every year, check the conditions of spring and ball of the “By-Pass Valve”, corrosion could be damage its. Every 1500 hours Replace Mechanical Fuel Pump After 1500 hours of use send the mechanical fuel pump to the Flygas he will arrange its revision and the replacement of the worn parts.

This manual is also suitable for:

F.051