LIMBACH L 2400 EF Operating instructions

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.
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 250.253.501.000

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Edition: 20.06.2018
Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
Table of Contents
1.1 Change Index...............................................................................................................................................4
1.2 Release........................................................................................................................................................4
2Introduction....................................................................................................................................................5
3Engine Description.........................................................................................................................................6
3.1 Model Designation .......................................................................................................................................6
3.2 Cylinder Designation....................................................................................................................................7
4Technical Data...............................................................................................................................................8
4.1 LIMBACH L 2400 EF/DF.............................................................................................................................8
4.2 LIMBACH L 2400 ET/DT...........................................................................................................................10
4.3 LIMBACH L 2400 DX................................................................................................................................12
4.4 LIMBACH L 2400 DS................................................................................................................................14
5Performance ................................................................................................................................................16
5.1 Performance Graph LIMBACH L 2400 EF/DF..........................................................................................16
5.1.1 Performance Data L 2400 EF/DF ..............................................................................................................17
5.2 Performance Graph LIMBACH L 2400 ET/DT..........................................................................................18
5.2.1 Performance Data L 2400 ET/DT ..............................................................................................................19
5.3 Performance Graph LIMBACH L 2400 DX ...............................................................................................20
5.3.1 Performance Data L 2400 DX....................................................................................................................21
5.4 Performance Graph LIMBACH L 2400 DS ...............................................................................................22
5.4.1 Performance Data L 2400 DS....................................................................................................................23
6Operating Instructions..................................................................................................................................24
6.1 Before Starting...........................................................................................................................................24
6.2 Engine Start-Up..........................................................................................................................................24
6.3 Runup, Performance Check.......................................................................................................................25
6.3.1 Performance Check ...................................................................................................................................25
6.3.2 Ignition Check L 2400 DF/DT/DX/DS.........................................................................................................25
6.4 Hot Engine Start-Up...................................................................................................................................25
6.5 Take-Off .....................................................................................................................................................26
6.6 Engine Shut-Down.....................................................................................................................................26
6.7 Inflight Shut-Down and Restarting .............................................................................................................26
6.8 Emergency Procedures .............................................................................................................................27
6.8.1 Version with engine Emergency Switch.....................................................................................................27
6.8.2 Version with electronic engine display.......................................................................................................28
7Maintenenance Schedule ............................................................................................................................29
7.1 Daily Check................................................................................................................................................29
7.2 Periodical Checks ......................................................................................................................................29
7.2.1 If the Engine is not Operated for more than 3 Months...............................................................................29
7.2.2 Every 2 Years.............................................................................................................................................29
7.2.3 Every 5 Years after New or Main Overhaul ...............................................................................................29
7.3 Operating Time related Inspections...........................................................................................................30
7.3.1 After the first 5 Operating Hours ................................................................................................................30
7.3.2 After the first 25 Operating Hours ..............................................................................................................30
7.3.3 Every 50 Operating Hours .........................................................................................................................30
7.3.4 Every 100 Operating Hours .......................................................................................................................31
7.3.5 Every 200 Operating Hours .......................................................................................................................31
7.3.6 Every 500 Operating Hours .......................................................................................................................31
8Maintenance Instructions.............................................................................................................................32
8.1 Oil Change .................................................................................................................................................32
8.2 Cleaning of Air Filter...................................................................................................................................33
8.3 Adjust Idling Speed....................................................................................................................................33
8.4 Fuel Filter Cleaning....................................................................................................................................33
8.5 Fuel, Lubrication and Cooling System Check............................................................................................33
8.6 Crankcase Ventilation Check.....................................................................................................................33
8.7 Compression Check...................................................................................................................................34
8.8 Check and Setting of Valve Clearance......................................................................................................34
8.9 Check of Valve Shaft Projecting Length ....................................................................................................35
8.10 Cleaning, Check and Setting of Spark Plugs.............................................................................................35
8.11 Drive Belt Check, Tensioning and Replacement .......................................................................................37
8.12 Exhaust System Check..............................................................................................................................37

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L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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...................................................................................................................................39
8.18.1 Compliance ................................................................................................................................................39
8.19 Operation at low ambient Temperatures ...................................................................................................40
8.20 Operation in Tropical Conditions................................................................................................................41
8.21 Miscellaneous ............................................................................................................................................41
9Overhaul ......................................................................................................................................................42
9.1 Major Overhaul...........................................................................................................................................42
9.2 Major Repair...............................................................................................................................................42
10 Lubricants, Coolants, Fuels.........................................................................................................................43
10.1 List of Lubricants........................................................................................................................................43
10.2 Coolant.......................................................................................................................................................44
10.3 Fuels ..........................................................................................................................................................44
11 Recommended Nut Torques........................................................................................................................45
12 Trouble Shooting .........................................................................................................................................46
12.1 Engine Starting Trouble .............................................................................................................................46
12.2 Engine Operating Trouble..........................................................................................................................48
12.2.1 Fuel Supply................................................................................................................................................48
12.2.2 Ignition........................................................................................................................................................49
12.2.3 Cooling.......................................................................................................................................................49
12.2.4 Lubrication..................................................................................................................................................50
12.3 Exhaust / Turbocharger System L 2400 ET/DT/DX...................................................................................51
12.4 Mechanical System....................................................................................................................................52
12.5 Engine Operating Trouble in Normal Mode, no Trouble in Emergency Mode...........................................53

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Edition: 20.06.2018
Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
1.1 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
Replaces edition from 04.03.2001
15.01.2014
Replaces edition from 01.12.2005
19.02.2016
Replaces edition from 15.01.2014
20.06.2018
Replaces edition from 19.02.2016
1.2 Release
Relased and approved on: 20.06.2018
Dipl.-Ing. P. Stolinski

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
2 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.
Please also observe the instructions of the aircraft manufacturer. They are specially adapted for opera-
tion of the engine in the aircraft.
Caution:
Familiarize yourself with the layout oft he engine controls in your aircraft according tot he
instructions oft he aircraft manufacturer. Pay special attention to those controls needed to
master an emergency situation.

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
3 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
•Direct Propeller Drive
•Electrical Starter
•Alternator
3.1 Model Designation
L
2400
E
F
1
.
X
X
1.
2.
3.
4.
5.
6.
7.
1. LIMBACH (Manufacturer)
2. Displacement Class in cm3
3. (E) Single Ignition
(D) Dual Ignition
4. Equipment - Basic Type of Construction
F = Tractor Propeller
Electronic engine management
Liquid cooling for cylinder heads
Ram air cooling for cylinders
Generator rear
Starter rear
T/X = Tractor Propeller
Turbocharger, Intercooler
Electronic engine management
Liquid cooling for cylinder heads
Ram air cooling for cylinders
Generator rear
Starter rear
5. Type of Propeller Flange
1 = Flange for Variable-Pitch Propeller
2 = Flange for Fixed-Pitch Propeller
3 = Flange for Fixed-Pitch Propeller (SAE 1)
6 + 7. Installation
Type Differences with regard to installation related changes
X = Experimental Engine without Certification

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
3.2 Cylinder Designation
I
=
top
II
=
left
III
=
bottom
IV
=
right
V
=
rear = accessory mounting side
VI
=
front = propeller side
1
=
cylinder 1
2
=
cylinder 2
3
=
cylinder 3
4
=
cylinder 4
arrow
=
crankshaft rotation

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
4 Technical Data
4.1 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
1-3-2-4
Equipment
Engine management system
Weber Alpha PI 38
Weber Alpha PI 48
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BOSCH 14V-33A
BOSCH 14V-55A
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
74 kW / 100 HP at 3000 rpm
30 inHg
Max. Continuous Power
62 kW / 84.5 HP at 3000 rpm
28 inHg
Engine Rotational Speeds
Max. permissible speed
3200 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2400 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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
Schmieröltemperatur min
50 °C (indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatuopt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
4.2 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
Equipment
Engine management system
Weber Alpha PI 38
Weber Alpha PI 48
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BOSCH 14V-33A
BOSCH 14V-55A
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Turbocharger
250.173.100
250.173.105
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
96 kW / 130 HP at 3000 rpm
40 inHg***)
41 inHg****)
Max. Continuous Power
85 kW / 115 HP at 3000 rpm
38 inHg***)
39 inHg****)
Engine Rotational Speeds
Max. permissible speed
3200 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2400 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001
***)
With turbocharger 250.173.100
****)
With turbocharger 250.173.105

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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
Schmieröltemperatur min.
50 °C ((indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatu opt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
4.3 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
Equipment
Engine management system
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Turbocharger
250.173.105
Propeller Flange
250.031.304*)
Engine Ratings
Max. Take-Off Power
118 kW / 160 HP at 3000 rpm
48 inHg
Max. Continuous Power
103 kW / 140 HP at 3000 rpm
44 inHg
Engine Rotational Speeds
Max. permissible speed
3100 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2200 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 250.031.013

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Edition: 20.06.2018
Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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
Schmieröltemperatur min.
50 °C ((indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatu opt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
4.4 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
Equipment
Engine management system
trijekt bee
Spark Plugs
NGK DCPR7E
Ignition Cable
LIMBACH
Ignition Harness
LIMBACH
Injectors
IWP 43
Fuel Pump
PIERBURG
Alternator
BRISE 14V-55A
Starter
MAGNETON 1 kW
Oil Pump
Geared Pump
Oil Filter
241.083.001
Propeller Flange
250.031.301*)
250.031.302**)
Engine Ratings
Max. Take-Off Power
85 kW / 116 HP at 3400 rpm
29 inHg
Max. Continuous Power
78 kW / 106 HP at 3400 rpm
28 inHg
Engine Rotational Speeds
Max. permissible speed
3400 rpm
Max. speed for cruise
See flight and maintainance manual
of airframe manufacturer.
Min. continuous speed
2300 rpm
Idle speed
800 ±100 rpm
Fuel and Oil
Fuel
see section 10
Engine Oil
see section 10
Coolant
see section 10
*)
With crankshaft 241.031.013
**)
With crankshaft 241.031.001

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Edition: 20.06.2018
Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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
Schmieröltemperatur min
50 °C (indicated)
Schmieröltemperatur opt.
approx. 80 °C
Water Temperature max.*)
110 °C
Kühlmitteltemperatuopt.
70 to 90 °C (at cruise)
Liquid quantities
Engine Oil Charge max.
3.5 ltrs
Schmieröl min.
2.75 ltrs
Coolant
approx. 3.5 ltrs
*)
The max. permissible temperatures constitute operating limitations to be maintained for a short
period of time only. Continuous operation of the engine at these temperatures may impair engine life.

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
5 Performance
5.1 Performance Graph LIMBACH L 2400 EF/DF
RPM (1/min)

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
5.1.1 Performance Data L 2400 EF/DF
Power values in kW (HP values in parentheses)
Manifold
Pressure
(inHg)
2400 rpm
2500 rpm
2600 rpm
2700 rpm
2800 rpm
2900 rpm
3000 rpm
20
28 (38)
21
33 (45)
22
34 (46)
37.5 (51)
23
38 (52)
42 (57)
24
42.5 (58)
46 (63)
25
44 (60)
48 (65)
55 (75)
26
48.5 (66)
53 (72)
27
54.5 (74)
58 (79)
28
60 (82)
62.5 (85)
29
67 (91)
30
56 (76)
60 (81)
64 (87)
68 (92)
70 (95)
72 (98)
74 (100)

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L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
5.2 Performance Graph LIMBACH L 2400 ET/DT
RPM (1/min)

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
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
*)
**)
23
24
29 (40)
34.5 (47)
37 (50)
40 (54)
42 (57)
24
25
31.5 (43)
37 (50)
39 (53)
42 (57)
44 (60)
25
26
34 (46)
38 (52)
40.5 (55)
44 (60)
46 (63)
26
27
36 (49)
40 (54)
42 (57)
46 (63)
48.5 (66)
27
28
38 (52)
42 (57)
43.5 (59)
49 (67)
51.5 (70)
28
29
40.5 (55)
44 (60)
45.5 (62)
51.5 (70)
54.5 (74)
29
30
42 (57)
45.5 (62)
49 (67)
53.5 (73)
57.5 (78)
30
31
44 (60)
48 (65)
53 (72)
57 (77)
61 (83)
31
32
45.5 (62)
50 (68)
57 (77)
60 (81)
64 (87)
32
33
48.5 (66)
52 (71)
60 (82)
63 (86)
67 (91)
33
34
51 (69)
55 (75)
62 (84)
67 (91)
51 (96)
34
35
53 (72)
57.5 (78)
63 (87)
69 (94)
73.5 (100)
35
36
55 (75)
60 (81)
66 (90)
71.5 (97)
76 (103)
36
37
57.5 (78)
62.5 (85)
68.5 (93)
74 (101)
79.5 (108)
37
38
60 (82)
65.5 (89)
71 (97)
78 (106)
82.5 (112)
38
39
62.5 (85)
69 (94)
75 (102)
82 (111)
86 (117)
39
40
73 (99)
79 (107)
85 (116)
90 (122)
40
41
84 (114)
90.5 (123)
96 (131)
*)
Applies to turbocharger 250.173.100
**)
Applies to turbocharger 250.173.105

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Operating Manual
L 2400 EF/DF/ET/DT/DX/DS
250.253.501.000
5.3 Performance Graph LIMBACH L 2400 DX