Page 1 Document Line Maintenance Manual SPIRIT E-DMC.E10.1 Engines Edition Revision SPIRIT TURBO MAINTENANCE Manual SPIRIT engines SPIRIT TURBO TRANSLATED FREE DISCLOSURE Page 1 di 149...
Page 2 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Before starting any maintenance work, carefully read the regular maintenance manual and the overhaul maintenance manual: these documents contain important information for carrying out checks and repairs in compliance and in safety. The information contained in them must be evaluated and integrated by technicians with adequate experience and with specific training on the engine.
Page 3: Table Of Contents
Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO INDICE 01-00-00 INTRODUCTION 01-01-00 Identification Data 01-01-01 Standard or Non-standard Motor Definition 01-02-00 Documentation 01-02-01 Notes for Consultation 01-02-02 Unit of Measure 01-02-03 Technical Documentation Available 01-03-00 Safety 01-04-00...
Page 4 Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 05-20-03 Scheduled Maintenance Table 12-00-00 INSTRUCTIONS FOR MAINTENANCE 12-01-00 Tightening Torques 12-02-00 Locking the Crankshaft 12-02-01 Motors without Gearbox 12-02-02 Motors with Gearbox 12-02-03 Locking for Timing without Removing the Reducer or Front Cover...
Page 5 Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-24-04 Check for the Presence of Particulate Matter 12-24-05 Spectrographic Analysis of Engine Oil 12-25-00 Fuel System 12-25-01 Check 12-25-02 System Depressurization 12-25-03 FD-m 12-25-04 Fuel Shunt and Pressure Regulator...
Page 6 Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-32-00 Checks after Use Outside the Operating Limits 12-32-01 Operation with Coolant Temperature too High 12-32-02 Use with too Low Coolant Temperature 12-32-03 Use with too High Engine Oil Temperature...
Page 7: Introduction
Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 01-00-00 INTRODUCTION SPIRIT SPIRIT Turbo series of engines are designed and manufactured using the most modern motor technology with the purpose of achieving good performance combined with a high level of passive safety. If the engine is used correctly it will return years of pleasure and reliable service.
Page 8: Identification Data
For greater clarity, the following table shows the type of motor (STD or NOSTD) for each motor model of the Spirit series: the product code is present on the identification plate of each motor. “x” must be replaced with “0” in the case of tractor applications or “1”...
Page 9: Documentation
Spirit 160 PSRU L Wx25 NOSTD Spirit 160 PSRU R Wx26 Spirit Turbo180 PSRU L Wx27 NOSTD Spirit Turbo 180 PSRU R Wx28 Spirit Turbo 210 PSRU L Wx29 NOSTD Spirit Turbo 210 PSRU R Wx30 Spirit Turbo 240 PSRU L...
Page 10 Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO into topics. The title of each chapter, section, paragraph or topic is highlighted as follows. CHAPTER Section Paragraph Topic The numbering system of the contents of the manual consists of a numerical code using the following criterion.
Page 11 Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO The triad of reference axes used in the manual is a right triad that originates on the helix axis, at the intersection with the helix support plane: the x axis originates on the...
Page 12: Unit Of Measure
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 01-02-02 Unit of Measure All the units of measurement reported in this and other MWfly manuals are expressed in technical units (ST), judged to be more usable and understandable than the units of the International System (SI).
Page 13: Technical Documentation Available
Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO psi = 0,0689bar = Pa = 10 -5 bar = 10 - 68,9mbar Pressure mbar 2 mbar in Hg = 0,0338bar = 33,8mbar Torque Nm = 9,81Kgm ft lb = 0,138Kgm...
Page 14: Safety
Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO DME.E10 - illustrated spare parts catalogue: contains the list of spare parts and  accessories expected. DSL.E10 - service letter: contains information aimed at improving the product or  use of the same.
Page 15 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO All safety sealing elements, such as self-locking nuts or washers must be installed according to the prescriptions and replaced at each disassembly: this serves to guarantee the function of safety elements. Never carry out test engine start-ups before having totally completed the maintenance work, and having made sure that you have reassembled the propeller in all its parts.
Page 16: Maintenance Criteria
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Always keep the engine in perfect working order by following the maintenance table contained in this manual and performing the coupons at the envisaged intervals. Replace the sealing elements (gaskets), the fixing elements (screws, bolts) and all the details which, upon disassembly, show damage or reduced functionality, even if not explicitly prescribed in the manual.
Page 17: Regular Maintenance
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Any interventions carried out with criteria other than those described in the maintenance manuals can be very dangerous for safety and harmful for the integrity of the engine, and must be absolutely avoided.
Page 18: Workshop Tools
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO recalled separated by the semicolon sign; in the case of combined use of torque wrench and insert, they will be recalled separated by the + sign. 01-05-01 Workshop Tools Torque wrench from 50 and from 150 Nm ...
Page 19: Consumables
Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Differential pressure gauge with compensation orifice with 1 mm diameter and 10  mm length M10 spark plug adapter for differential pressure gauge  If the use of a torque wrench is prescribed in the description of maintenance operations, all the tools listed must be supplemented with the corresponding inserts required to perform torque tightening.
Page 20: Preservation
Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 1. Torque wrench 50 Nm 2. Socket wrench for 16 mm spark plugs 3. 17 mm hex wrench 4. Kerosene or white petroleum (3 litres) 5. 2 x 5 later liquid container 6.
Page 21: Resumption Of Service
DMC.E10.1 Engines Edition Revision SPIRIT TURBO During the activation of the starter motor, there must be no electric arcs in the vicinity of the spark plug caps: otherwise it is necessary to isolate them better. Repeat the previous action three times, at intervals of about 10 seconds, each time switching off and on the master relay.
Page 22: Motor Shipping Precautions
DMC.E10.1 Engines Edition Revision SPIRIT TURBO After carefully checking them, tighten [1 + 3] the fuel pipes to the fuel shunt and to the pump unit inlet to the prescribed torque. Fill the fuel system. Refit the used spark plugs.
Page 23: Mwfly Authorized Service Centres
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 01-03-P All openings must be protected with covers that prevent the entry of foreign bodies or moisture: preferably use the covers installed on the new engine, and removed after installation. The engine must be delivered with all accessories that may be installed, excluding the propeller.
Page 24: Airworthiness Limitations
Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 04-00-00 AIRWORTHINESS LIMITATIONS At the date of publication of this manual there are no limitations regarding the SPIRIT SPIRIT Turbo installation of engines on any type of aircraft, both fixed-wing and rotary-wing.
Page 25: Periodic Maintenance
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 05-00-00 PERIODIC MAINTENANCE SPIRIT This chapter shows the periodic inspection program to be carried out on the SPIRIT Turbo motors. Some general rules for carrying out maintenance work are mentioned below.
Page 26: Preparing The Aircraft For Maintenance
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 05-02-00 Preparing the Aircraft for Maintenance To carry out maintenance work safely, the following safety instructions must be observed. Main switch in off position. Both injection switch (kill switch) in the off position.
Page 27: Safety Locks And Seals
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 05-03-00 Safety Locks and Seals All safety locks, such as self-locking nuts, washers, special screws, seeger rings, etc. once removed they must be replaced; the same is true for all gaskets and sealing elements.
Page 28: Hourly Operating Limit
05-01-C * calculate the data by verifying the production date entered in the engine logbook With the exception of the Spirit 135 Direct and Spirit 160 Direct models, any other engines used on helicopters or aircraft comparable to them have an hourly TBO equal to 65% of what is declared in the table;...
Page 29: Calendar Operating Limit
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Engines that have reached TBO should no longer be used until overhaul. 05-10-02 Calendar Operating Limit Some engine components are subject to wear linked to environmental parameters, such as the presence of salt or humidity, ultraviolet rays or ozone. In particular, all parts made of plastic or rubber are subject to environmental deterioration, therefore independent of the frequency of use.
Page 30: Operating Limit Of Other Components
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Expansion vessel breather pipes Expansion tank caps Crankcase vapor vent pipe Cooling pump inlet manifold Cooling pump outlet manifold Turbo Engines - Intake System Silicone Fittings Mechanical seal breather pipe...
Page 31: Periodic Maintenance Program
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 05-20-00 Periodic Maintenance Program This section lists the periodic inspections to be carried out at the end of a certain number of operating hours. The 25-hour inspection must be performed only after the first 25 hours of operation from a new or overhauled engine.
Page 32: Engine Logbook
Engines Edition Revision SPIRIT TURBO considering that the tolerance has been applied: this means that, for example, if the intervention of 100 hours is was performed at 90 hours, the next 200-hour intervention cannot be performed at 200 ± 10 hours, but at most at 190 ± 10 hours.
Page 33 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO *** = replace every four years or at the indicated operating hours: of the two  deadlines apply the more stringent TRANSLATED FREE DISCLOSURE Page 33 of 149...
Page 34 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Term (hours) Activities 50 100 200 500 900 Engine cleaning Visual check to identify oil, petrol or coolant leaks or areas of overheating of the bonnet Inspection of anti-vibration mounts...
Page 35 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Term (hours) Activities 50 100 200 500 900 Pre-flight inspection: liquid level check in expansion tank, absence of leaks from system and mechanical seal vent, radiator integrity and retained clamp...
Page 36 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Term (hours) Activities 50 100 200 500 900 Pre-flight inspection: check for the absence of leaks from the circuit and purge the decanter filter Change fuel filter ** Fuel pumps replacement...
Page 37 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 50 100 200 500 900 Boroscopic inspection of crankshaft Qualitative verification of piston thermal fatigue Check cylinder compression Starter inspection: check free wheel, gears and starter clutch wear Check the wear of the tensioner...
Page 38: Instructions For Maintenance
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-00-00 INSTRUCTIONS FOR MAINTENANCE This chapter contains the instructions for carrying out the refuelling and routine SPIRIT SPIRIT Turbo maintenance operations on the engines 12-01-00 Tightening Torques All tightening must be performed with a torque wrench, respecting the prescribed torque.
Page 39 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Tightening Type of Screw or Nut Torque [Nm] Ignition coil screw (M4) 3 + FM Rpm sensor screw (M5) 6 + FD Screw fixing coil brackets (M5) 6 + FD...
Page 40 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Spark plug (M10) Cap for reverse flight preparation 25 + FM Chain sprocket screw and camshaft washer (M16) Tightening Type of Screw or Nut Torque [Nm] Shaft butterfly screw (M4)
Page 41: Locking The Crankshaft
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Driven shaft tightening screw (M27) 450 + FM Propeller flange tightening nut direct drive engine (M30) 290 + FM 12-01-C Legend FD = weak thread lock  FM = medium threadlocker ...
Page 42: Motors With Gearbox
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-01-P Screw [3] the flange locking tool [7] to the propeller flange, using the provided screws and washers. Hold the tool lever [7] while applying the tightening torque, to prevent rotation of the crankshaft.
Page 43: Locking For Timing Without Removing The Reducer Or Front Cover
Engines Edition Revision SPIRIT TURBO Before starting the engine, remember to remove the locking device [6] of the crankshaft and screw [5] the gearbox oil filler cap: it is good practice to always rotate the propeller by hand, to check that rotation occurs freely.
Page 44: Engine Test After Maintenance Or Periodic Inspection
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-04-P Check the effective locking of the shaft during operations on the engine, retightening the screw if necessary. At the end of the work, remove the locking screw and screw the service screw back to a torque of 15 Nm.
Page 45 DMC.E10.1 Engines Edition Revision SPIRIT TURBO Never leave the aircraft with the engine running. Before starting, check that the engine has no detached or not completely fixed components. Also check that there are no forgotten tools near or on the engine.
Page 46: Removal And Reassembly Of The Engine From The Aircraft
Engines Edition Revision SPIRIT TURBO Never open the cap of the pressurized cooling circuit when the engine is hot. If it is necessary to carry out checks, unscrew the cap slowly, holding it with a rag soaked in cold water; vent the circuit gradually, stopping during opening.
Page 47: Removal
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Disassembly and reassembly can be carried out in a short time and with minimal equipment, operating as described below. Necessary Material Torque wrench 50 Nm 3mm Allen T-handle wrench 5mm Allen T-handle wrench...
Page 48: Installation
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Remove [2] the cooling radiator only if necessary. If using a non-original radiator, follow the instructions of the aircraft manufacturer. Remove the lubricant cooler, only if necessary. Screw [5] the lifting tool [9] engine.
Page 49: Supplies
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Screw [1 + 8; 5] to the torque prescribed by the aircraft manufacturer (between 35 and 45 Nm), ensuring tightening with thread lock. Remove [4] the lifting tool. Install all accessories, if not already installed.
Page 50: Motor Oil
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO With the engine off, unscrew the black cap of the cooling circuit expansion cap counter clockwise. Check that it is full for at least 2/3 of the height by inserting a finger or the shaft of a screwdriver inside.
Page 51 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Necessary Material 1. Oil filler cap tightening tool (X283) 2. Blotting paper Place the aircraft in an area where a horizontal engine position is guaranteed. Bear in mind that the engine is not always mounted in such a way that with the aircraft on a horizontal plane it is also horizontal.
Page 52: Gearbox Oil
Engines Edition Revision SPIRIT TURBO Check that the level is between the bottom of the rod and the notch; in case of doubts about the actual level, use absorbent paper [2] to check up to what level the dipstick is wet with oil.
Page 53 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-10-P If the oil does not come out, slowly add oil of the prescribed type until you see oil coming out of the inspection hole, after removing [3] the filler cap. 12-11-P If the engine has been used with the gearbox oil level below the minimum level by more than 150cc, it is necessary to remove [4] the drain plug with magnetic filter and inspect the collected particulate to identify any damage (12-20- 5).
Page 54: Scheduled Maintenance
DMC.E10.1 Engines Edition Revision SPIRIT TURBO The total oil quantity must comply with table 12-11-C of this manual. 12-20-00 Scheduled Maintenance This chapter collects inspections or ordinary maintenance operations. All the checks described in this section must be carried out with the engine off, after having waited for it to cool completely.
Page 55: General Checks
DMC.E10.1 Engines Edition Revision SPIRIT TURBO If it is installed inside the engine hood, avoid directing the water jet on the injection control unit, to prevent any infiltrations. After washing, provide adequate rinsing to remove all traces of detergent from the engine.
Page 56: Check For Leaks
Engines Edition Revision SPIRIT TURBO damage the hose itself; after tightening, always check that the connection is secure, by trying to extract the hose. Always check that the clamp is correctly positioned on the hose itself, i.e. with the closing axis aligned with the axis of the hose; also check that the clamp is positioned beyond the edge of the coupling tube, and not astride the edge itself.
Page 57 Engines Edition Revision SPIRIT TURBO Perform the same check on the exhaust system: if necessary, retighten the screws locking the manifolds to the head; if the leak is persistent, unscrew the manifolds from the head, replace the gaskets and lock them again. The dark halo caused by the exhaust gas vent can be removed using an abrasive sponge and denatured alcohol.
Page 58: Check Crankcase Breather
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-16-P Check the area near the filler caps on the expansion tank: any leaks must be resolved by replacing the caps. Check the engine oil and gearbox oil filler cap: in the event of leaks it is necessary to replace the sealing O-ring placed on the cap itself.
Page 59: Engine Suspension Check
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Type of Quantity Possible Problem Control or Remedy Fluid Slight greasiness None None Operating Lower the operating Slight deposit temperature too high temperature Elastic bands Slight deposit Compression test...
Page 60: Cylinder Compression Control
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 1. Torque wrench 50 Nm 2. 17 mm fixed wrench 3. 8 mm Allen key 4. 6 mm Allen key Check the integrity of the anti-vibration elements. These components are made of plastic material, which can degrade in the event of prolonged exposure to the sun or excessive temperatures or in the event of contamination by hydrocarbons.
Page 61 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 5. 700mm lever with ¾” square (PSRU versions) 6. cPropeller shaft rotation key (PSRU versions) (X546) 7. Differential pressure gauge with compensation orifice with 1 mm diameter and length 6 mm 12-19-P 8.
Page 62: Check The Tension Of The Distribution Chain
Engines Edition Revision SPIRIT TURBO Take the reading on the measuring pressure gauge by slightly moving the propeller, in both directions: the correct reading is the maximum verifiable, corresponding to the real top dead center of the piston under test; write down the reading.
Page 63 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 5. 5 mm Allen key 6. 6 mm blade screwdriver Wait for the engine to cool down. Remove [6] the air filter by loosening the metal clamp retaining the airbox. Remove the fuel pressure and temperature sensor connectors.
Page 64: Check General Smoothness
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Return the lever to the rest position and check if it is possible to screw [5] the supplied screw to the crankcase by inserting it in the hole in the lever marked with # 1 (STD motors) or # 2 (NOSTD motors).
Page 65: Minimum Value
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 6. Other tools according to the materials chosen during installation Operate with a warm engine. Remove the power supply to the motor to prevent accidental start-ups. Remove [6] the propeller, according to the procedure indicated by the manufacturer.
Page 66: Endoscopic Inspection
Engines Edition Revision SPIRIT TURBO Rotate the propeller shaft in the direction of travel of the motor by acting on the key [1 + 4] and at the same time supporting the key [6] in a horizontal position, to prevent it from getting stuck in the thread during the ascent of the piston.
Page 67 DMC.E10.1 Engines Edition Revision SPIRIT TURBO To rotate the crankshaft during the endoscopic inspection, act on the propeller, or by engaging a 32 mm socket wrench (36 for direct motors) on the tightening nut of the propeller flange; avoid rotating the shaft in the opposite direction to normal rotation.
Page 68 DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-24-P Insert the endoscope probe into the hole. The hole allows access to the inside of the crankcase between the crankshaft and the partition of the oil pan. Rotate the crankshaft and check the integrity of the cylinder liners, pistons, main and connecting rod bearings and finally the timing chains of both banks.
Page 69 DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-26-P Introduce the endoscopic probe and check the service status of the camshaft, tappets and tips of the decompression device. As regards the camshafts, check that there are no scoring or seizure marks at the point of maximum lift of the eccentrics.
Page 70 Engines Edition Revision SPIRIT TURBO To reassemble, follow the disassembly operations in reverse order, considering that the tightening torque of the inspection screw is equal to 12Nm and that of the fixing screws of the suction unit is equal to 22 Nm; the copper gasket located under the inspection cap must be replaced;...
Page 71: Annual Inspection
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-29-P Also check the piston crown, especially in the peripheral part: there must be no pitting or upsetting of material, sign of detonation. By rotating the endoscope head 180°, check the condition of the valve stems, seats and head, especially in the squish area near the barrel: in this case too, there should be no pitting.
Page 72: Cooling System
DMC.E10.1 Engines Edition Revision SPIRIT TURBO magnifying glass is useful. If in doubt about the actual state of conservation of the components subject to inspection, do not hesitate to replace them, so as not to compromise safety. The components to be inspected annually are listed below; for inspection refer to the dedicated paragraphs.
Page 73: Control And Cleaning
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-23-01 Control and Cleaning Check that there are no coolant leaks along the entire circuit, paying particular attention to the connection points between the pipe and sleeves: any leakage is recognizable by the presence of blue salty-looking deposits.
Page 74 Engines Edition Revision SPIRIT TURBO Place a pan [1] under the engine to contain the liquid escaping from the engine. Remove the 4 cooling system bleed screws from the cylinder heads. Open the pressurized circuit cap located on the expansion tank (red cap). If the radiator used has a drain plug, remove it;...
Page 75: Check Expansion Tank
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-23-03 Check Expansion Tank The expansion tank is a fundamental component for the efficiency of the engine cooling system, as it guarantees an adequate amount of coolant in the circuit in all thermal and operating conditions.
Page 76 Engines Edition Revision SPIRIT TURBO Unscrew both plastic caps: check the integrity of the rubber sealing washer placed inside; also check that, in the internal part of the pressurization cap, the brass surfaces of the valve are not encrusted or eroded: in case of non-compliance and calendar expiration, replace the cap.
Page 77: Thermostatic Valve And Pump Manifolds
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-23-04 Thermostatic Valve and Pump Manifolds The thermostatic valve controls the amount of coolant that passes through the radiator: its failure is highlighted by difficulty in heating or by overheating of the engine and can be caused by the use of improper coolants, by impurities in the cooling system or from long periods of inactivity of the engine.
Page 78 DMC.E10.1 Engines Edition Revision SPIRIT TURBO Once the tube has been removed, extract the sealing ring from its seat, which is located inside the hole on the rear cover. To facilitate extraction, use a small screwdriver [2] or a marking tip.
Page 79: Radiator
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Position the manifold locking ring nut and tighten [3] the three screws: use the thread locking compound [5] on the thread. Refit the two connecting pipes between the engine and the radiator, tightening [1] the sealing clamps.
Page 80: System Filling And Venting
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Control and Recovery Check the external surface of the connection pipes, which must not show swelling or cracks; even in case of doubt, replace the components. Check the internal surface of the pipes and the radiator, which must not have traces of limestone or sandy deposits: otherwise, clean the circuit.
Page 81 SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO The lubricant and its filter are highly polluting: do not disperse them in the environment but give them to the collection centres. Necessary Material 1. 5 litre basin for the collection of fluids 2.
Page 82: Oil Filter Replacement
DMC.E10.1 Engines Edition Revision SPIRIT TURBO In case of doubts or the obvious presence of foreign bodies in the oil or on the magnetic filter, do not use the engine for any reason and have it checked. The oil removed from the engine must not be reused for any reason.
Page 83 DMC.E10.1 Engines Edition Revision SPIRIT TURBO The oil filter must be replaced when the engine is cold and stopped for at least two hours. The oil filter is highly polluting: avoid dispersing it in the environment, but deliver it to the designated collection points.
Page 84: Oil Sump Cleaning
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO tightening it is necessary to turn at least three quarters of a turn. Only install new filters. If there are doubts about the actual tightening of the filter by hand, use the wrench, taking care not to damage the sheet metal casing of the filter.
Page 85 Engines Edition Revision SPIRIT TURBO Natural aspired engine- If the original exhaust system is used, it is not necessary to disassemble it, both in the case of pulling applications and in the case of pushing applications. If not, the exhaust system may need to be removed.
Page 86: Check For The Presence Of Particulate Matter
DMC.E10.1 Engines Edition Revision SPIRIT TURBO When reassembling, both cup gaskets must be replaced, which are identical to each other. Sprinkle Vaseline [13] on the sealing surfaces to prevent the gasket from sticking. Place the first gasket on the oil pan: pay attention to the direction of assembly, since the shape of the gasket must match that of the sealing surface of the sump.
Page 87 DMC.E10.1 Engines Edition Revision SPIRIT TURBO following image on the left there is a normal accumulation of particulates, on the right an excessive accumulation with large fragments. 12-42-P Clean the magnetic filter of the engine oil drain plug with a white paper cloth [1] and wait about 15 minutes, so that the oil can separate from the metal particles by capillarity.
Page 88: Spectrographic Analysis Of Engine Oil
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO chain tension Mechanical moving parts in Check breaker-generator contact with castings tightening Check the main and connecting rod supports and crankshaft support Main or connecting rod Check support service status...
Page 89: Fuel System
DMC.E10.1 Engines Edition Revision SPIRIT TURBO The spectrographic control is carried out in appropriate analysis laboratories: a sample of the removed oil (about 100cc) must be collected in a container and sent to the laboratory. Through the spectrographic analysis it is possible to verify which elements are present in the lubricant and in what quantities;...
Page 90: System Depressurization
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-25-02 System Depressurization Petrol is a pollutant: do not dispose of it in the environment. In case of interventions on the fuel system it is first necessary to eliminate the pressure: proceed as follows.
Page 91 DMC.E10.1 Engines Edition Revision SPIRIT TURBO In case of doubts about the efficiency of the fuel pump it is necessary to replace it, as the pump is a fundamental component for the operation of the engine and the safe conduct of flight activity.
Page 92 Engines Edition Revision SPIRIT TURBO Remove the fuel duct from the front of the cabinet: above and below it there are gasket washers, which must be replaced upon reassembly. Using the wrench [6] on the lower operating hexagon of the filter, loosen both filters, keeping [7] in position the connection with the fuel pump.
Page 93 Engines Edition Revision SPIRIT TURBO hand, oily paraffinic residues are attributable to long periods of inactivity, to dirty or degraded tanks (in the case of plastic resin tanks). If the presence of substantial residues has been found inside the fuel filter, before carrying out any activity it is necessary to check and clean the entire system, to avoid the possibility of sudden engine shutdowns.
Page 94: Fuel Shunt And Pressure Regulator
Engines Edition Revision SPIRIT TURBO Repeat the same operations for fitting the second fuel filter. Insert the fuel outlet duct into the slots in the upper part of the cabinet. Manually screw the swivel screws of the fuel outlet duct to the pumps, interposing new gasket washers above and below the holes in the duct;...
Page 95 Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Remove the fuel shunt from its seat on the crankcase. Using the seeger-lever pliers [7], remove the pressure regulator retaining seeger from the throat. Remove the pressure regulator by hand from the seat on the shunt, pulling forcefully outwards;...
Page 96: Air Intake System
Engines Edition Revision SPIRIT TURBO Place the fuel shunt in the seat on the rear cover. Tighten [1+5] the two fixing screws of the shunt to the prescribed torque (10Nm). Rotate the regulator in its seat until the nozzle of the vacuum intake is directed downwards, to avoid the accumulation of water or humidity inside it.
Page 97: Reassembly
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-47-P 12-48-P Unscrew [3] the two manifolds from the heads, progressively proceeding on both fixing screws. Be careful not to lose the gasket located under the manifold flange (12-49-P). Unscrew [3] the two rear fixing screws of the airbox (12-50-P).
Page 98 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 2. 4 mm blade screwdriver 3. 4 mm Allen key 4. 6 mm Allen key 5. 7 mm socket wrench 6. Medium threadlocker 7. Vaseline Refer to the figures in the previous paragraph.
Page 99: Air Filter Replacement
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-26-03 Air Filter Replacement Using the engine without an air filter or with an unsuitable filter can cause serious damage and sudden engine shutdown. Using the engine with a dirty filter reduces the life of the mechanical...
Page 100: Exhaust System
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Introduce a certain quantity of white petroleum [2] into the intercooler and shake repeatedly: this will remove any oily residues that may be present inside the intercooler. Repeat the operation several times. Blow [3] the inside of the intercooler to dry any liquid residues.
Page 101: Ex-M Control And Recovery
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-51-P To complete the disassembly of the exhaust system, it is necessary to remove [1] the four fixing springs of the exhaust manifolds to the silencer. When reassembling it is advisable to replace all the fixing springs, even if they are apparently in good condition.
Page 102: Ex-M Installation
Engines Edition Revision SPIRIT TURBO During the heating and especially cooling phase of the exhaust system with the engine off, metal clicking sounds are audible: all this is perfectly normal, and is caused by the mutual sliding of the hot surfaces of the manifolds and silencer.
Page 103 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO cylinders proceeding gradually. A certain hardness in unscrewing may be caused by the use of threadlocker. Under each nut there is a safety washer, which can be reused; the...
Page 104: Check And Restore Turbo Engine Exhaust System
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-58-P Unscrew [2] the 5 fixing screws of turbocharger exhaust manifold: under each screw there is a safety washer. 12-59-P 12-27-05 Check and restore turbo engine exhaust system The exhaust system of turbocharged engines is subjected to very strong thermal and mechanical stress during use, and for this reason it is good practice to periodically check its service status.
Page 105: Turbo Engine Exhaust System Installation
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Any gasket residues present on the manifolds and their respective seats on the cylinder heads must be removed using an abrasive sponge before reassembly, in order to ensure adequate gas sealing. Using the engine with a damaged exhaust system is potentially very dangerous as the exhaust gases are harmful to inhalation and can cause fainting or death.
Page 106: Electrical Components
Engines Edition Revision SPIRIT TURBO Screw [1+5] the load assembly fixing bracket to the 4-in-1 manifold flange: the screws must be tightened to 10Nm; apply threadlock [12] to the thread. Insert the 4 hose clamps onto the 4-in-1 manifold and then the exhaust manifolds into their respective positions: to make insertion easier, help them with small blows [11], rotating at the same time;...
Page 107: Spark Plugs
DMC.E10.1 Engines Edition Revision SPIRIT TURBO 4. Allen key from 6 mm Inspect all the electrical connectors and especially the condition of the cables coming out of the connectors; the cable must have the usual stiffness and must not show folds, abrasions or overheating;...
Page 108 Engines Edition Revision SPIRIT TURBO Remove the spark plug cables by acting on the rubber part of the pipette; you can feel some resistance to detachment, and then pull firmly. Blow with compressed air [3] the insertion area of the spark plugs in the cylinder head, to remove all traces of dirt.
Page 109 DMC.E10.1 Engines Edition Revision SPIRIT TURBO In case of doubts about the efficiency of the candles it is advisable to replace them. It is possible to find a colour difference between the spark plug of one cylinder and that of another if, before stopping to read the spark plugs, the engine has been running at idle for a few minutes: this difference, if not marked, is all normal.
Page 110 DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-09-C It is not allowed to use spark plugs of a thermal grade and brand other than those prescribed. The use of spark plugs other than those prescribed causes the cancellation of the guarantee and can cause serious damage to the engine.
Page 111: Ignition Coils And Cables
Engines Edition Revision SPIRIT TURBO Avoid cleaning with solvents or brushing the candles in order to clean them: it is a useless operation as well as damaging the integrity of the candles. Candles found to be dirty or defective must be replaced without delay.
Page 112 Engines Edition Revision SPIRIT TURBO Unscrew [3] the lower and upper coil fixing brackets [3] from the crankcase. If necessary, unscrew [2; 4] the coils from their respective brackets. Extract the high voltage cable pipettes from the spark plugs, pulling hard to release the internal retaining clip.
Page 113 Engines Edition Revision SPIRIT TURBO circumference must be free of notches or abrasions; the fixing slot must be intact. Any replacement must be carried out by removing the spark plug cables from the side of the coil connector (the smallest); to insert the cables into the new ring, use petroleum jelly [9], making sure to arrange the cables flat and respecting the fixing sequence of the spark plug caps on the cylinder head.
Page 114: Battery And Charging System
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-68-P 12-69-P Insert the ignition control connectors on the respective coils, making sure that the safety clip is engaged. The connectors with a red marking are to be inserted on the coils of the auxiliary system (circuit B, coils near the head), the black connectors without marking are to be inserted on the coils of the main system (circuit A, internal coils).
Page 115 Engines Edition Revision SPIRIT TURBO A battery in good efficiency increases passive safety considerably as it guarantees a greater number of minutes of operation in the event of a fault in the charging circuit. In case of doubts about the state of efficiency and in any case every four years it is highly advisable to replace the battery.
Page 116 Engines Edition Revision SPIRIT TURBO Unscrew [5; 6] the two screws fixing the regulator support bracket to the motor. Unscrew [6; 7] the screw with nut fixing the regulator to the bracket. Inserting a screwdriver [3] on the connector side, pry to remove the connector from the current regulator.
Page 117: Ij-M
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Screw the regulator support bracket to the motor and tighten [1 + 5; 1 + 6] the screw above 15Nm and the screw below 10Nm. 12-28-05 IJ-m The breaking of a fuse or the detachment...
Page 118 Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 3. Main relay ECU A 7. Fuses Consolle 4. Main relay ECU B Check that all component fixing screws [1] are tight. Set the master switch to the on position. Check that all the LEDs on the fuse console are off: if not, replace the blown fuse, as shown below.
Page 119: Ag-M
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Function Value [A] GEN = generator ECU B = circuit control unit B COIL 1A = coil #1 ignition circuit A COIL 2A = coil #2 ignition circuit A...
Page 120 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-78-P 12-79-P Necessary Material Torque wrench 1 ÷ 10 Nm Torque wrench 20 ÷ 100 Nm 3 mm Allen key 6 mm Allen key 13 mm fixed wrench Medium threadlocker...
Page 121: Transmission
Engines Edition Revision SPIRIT TURBO Once the correct voltage has been found, tighten [4+2] the upper screw of the generator and then [5+2] also the lower one; for both the prescribed torque is 22 Screw [5] the supplied nut to the protruding part of the lower screw, and tighten [5+2] to 22 Nm keeping the screw in position with a second wrench.
Page 122: Psru Engine Tightening's
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Insert the supplied bushings into the tool [4] and into two adjacent holes of the propeller flange. Keeping the lever [4] in position, check [1+2] the tightening torque of the union nut of the propeller shaft with the crankshaft: the correct torque is 180 Nm.
Page 123 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Remove reduction gear filler cap. Insert the comb of the tool [9] into the gearbox oil supply compartment and screw the fixing ring nut by hand: if the comb does not fit properly and causes difficulties in screwing the ring nut, move the propeller shaft slightly.
Page 124 Engines Edition Revision SPIRIT TURBO Replace the sealing O-ring located on the compartment cover. In the case of governor motors replace the O-rings from the governor body and pump cover as well as the one placed inside the reducer itself.
Page 125: Oil Change
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-29-03 Oil Change After the first 25 hours of operation it is necessary to change the engine oil. For the indication of the recommended engine lubricant refer to 61-03- 00 of the installation manual.
Page 126 DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-71-P Pay the utmost attention to avoid getting burned with hot oil. The drain plug is equipped with a magnetic filter, necessary to collect metal dust that can develop during the use of the engine, especially during the running-in phase.
Page 127: Check Oil Fiter Vpp
Engines Edition Revision SPIRIT TURBO Observe the O-ring on the filler cap: in case of damage, it must be replaced. Screw the gear oil cap by hand. After an oil change and before a flight, an engine test run on the ground must be performed.
Page 128: Check Magnetic Filter
Engines Edition Revision SPIRIT TURBO Reinsert the filter inside the filter holder respecting the original direction. Insert the filter holder into the seat on the reducer and tighten [1+3] the cap to 12Nm; threadlock [8] must be applied to the thread.
Page 129: Vent Control
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-29-06 Vent Control The gearbox is equipped with a relief valve set at 0.3 bar, which discharges the overpressure generated by the heating of the gearbox oil and the consequent release of gas inside it in the crankcase. It is necessary to check the functionality of the breather at the scheduled deadlines and in the event that there is an excessive consumption of gearbox oil.
Page 130 Engines Edition Revision SPIRIT TURBO Verify, by acting on the propeller flange, the total absence of axial and radial play of the shaft. A more accurate check is possible by removing the reduction unit from the motor and verifying that the drive shaft is also free from radial and axial play.
Page 131: Damper Torque Control
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-29-08 Damper Torque Control The procedure is applicable only on some engines, depending on the year of construction. The check must be carried out with a cold and horizontal engine, after the first 25 hours of operation and at least every 100 hours.
Page 132: Unscheduled Maintenance
Engines Edition Revision SPIRIT TURBO Adjust the key [1] to a torque of 150Nm and try to rotate it in the opposite direction to the previous one If the propeller moves before hearing the click on the key [1], the...
Page 133: Warnings And Checks For Use In Extreme Climatic Conditions
Engines Edition Revision SPIRIT TURBO 12-31-00 Warnings and Checks for Use in Extreme Climatic Conditions Using the engine in desert areas or areas with a strong presence of dust causes premature wear of many components: in these cases, it is recommended to intensify the frequency of periodic checks.
Page 134: Operation With Coolant Temperature Too High
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-32-01 Operation with Coolant Temperature too High Search for Causes Wait for the engine to cool down for at least 30 minutes and carry out the operations described below. Bleed the cooling system.
Page 135: Use With Too High Engine Oil Temperature
Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check the correct operation of the thermostat.  Check the section of the air intakes which could be excessive for the climatic  conditions of the flight. Check at room temperature if the sensors and liquid temperature indicator show ...
Page 136: Operation With Gear Oil Temperature Too High
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check the section of the ventilation air intakes, which may be excessive for the  climatic conditions of the flight. In case of use in a cold climate, consider partializing the inlet of the air intake or the heat exchange surface of the radiator with cloth tape.
Page 137: Operation With Too Low Engine Oil Pressure
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check that there are no oil leaks in the area where the propeller shaft comes out of the reducer. Carry out the pressure test of the reducer. 12-32-06 Operation with too Low Engine Oil Pressure Search for Causes Check the engine oil level.
Page 138: Use With Control Units And Current Regulator Temperatures Too High
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check the integrity of the head gasket. 12-32-08 Use with Control Units and Current Regulator Temperatures Too High What is specified below for the control unit group is applicable only if the group itself is installed in the engine compartment.
Page 139: Checks After Use With Unfulfilled Prescriptions
Engines Edition Revision SPIRIT TURBO Carry out an endoscopic inspection of the spark plug holes to locate any bends in the valve stems (it is more likely to occur on the exhaust valve). Carry out an endoscopic inspection of the spark plug holes to identify any bends in the valve stems (this is more likely to occur on the exhaust valve).
Page 140: Coolant Specifications Not Respected
Engines Edition Revision SPIRIT TURBO Check the inside of the combustion chamber with an endoscope, using the low spark plug seats as the inlet hole (circuit B): inspect the piston crown, especially near the edges, the upper part of the cylinder liner, the head gasket , the valve seats and the valves themselves, the peripheral area of the combustion chamber.
Page 141: Gearbox Oil Specifications Not Respected
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Seizure between camshaft and seats.  Seizure between secondary shaft and seats.  Turbo Engines - Turbocharger Failure  Checks and Remedies Check the general smoothness. Remove the oil from the engine.
Page 142: Fuel Specifications Not Respected
Engines Edition Revision SPIRIT TURBO Insert an endoscope inside the reducer using the oil filling hole and inspect the service status of the driving gear: in no point should you find signs of premature wear, overheating, or damage from exceeding the specific pressure (pitting).
Page 143: Moment Of Inertia And Loads On The Propeller Shaft Higher Than Allowed
Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO 12-33-06 Moment of Inertia and Loads on the Propeller Shaft Higher than Allowed Possible Damage Overload damage to the gear teeth.  Overload damage to the gearbox bearings. ...
Page 144: Excessive Vibrations
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check the engine for damage or for any detachment of components: in the event of non-compliance, it is necessary to repair or overhaul the engine, depending on the anomalies found. Carry out the general check of the smoothness of the motor.
Page 145: Difficult Starting
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO If the engine has been running for long periods in the presence of strong vibrations, it must be serviced. 12-34-03 Difficult Starting Make sure you have positioned the throttle lever below 10% open.
Page 146: Excessive Or Abnormal Noise
DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check the fuel system pressure and replace the filter and fuel pump if necessary. Check opening of the accelerator control. Check the throttle position sensor. Perform a inlet air pressure and temperature sensor check.
Page 147: Excessive Accumulation Of Particulates On The Magnetic Filters
SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Check for the presence of gearbox oil leaks. Check the state of the reducer breather valve. 12-34-10 Excessive Accumulation of Particulates on the Magnetic Filters Overhaul the motor or gearbox as soon as possible.
Page 148 Line Maintenance Manual Document SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO Anomaly Communication Form Date Serial number Last name First name Telephone number E-mail Aircraft Aircraft model manufacturer Propeller model Number of blades Total hours Appl. pulling Appl. pushing Main use School Missions>1 hour...
Page 149: List Of Revisions To The Document
Document Line Maintenance Manual SPIRIT DMC.E10.1 Engines Edition Revision SPIRIT TURBO LIST OF REVISIONS TO THE DOCUMENT Edition/ Modification Applicability Chapter Page Revision date From #031324 01-00-00: Introduction 23/04/2025 From #031324 04-00-00: Airworthiness Limitations 23/04/2025 From #031324 05-00-00: Periodic maintenance...

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