MW Fly Spirit 100 Direct L User manual

Line maintenance manual
SPIRIT engines
Document
E-DMC.E10.1
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LINE MAINTENANCE Manual
SPIRIT engines

Line maintenance manual
SPIRIT engines
Document
DMC.E10.1
Edition
Revision
A
1
TRANSLATED
FREE DISCLOSURE
Page 2 of 140
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.
The interventions must be carried out with professional
equipment, supplemented by tools specifically designed to
work on the engine components.
All information, illustrations, instructions and technical data contained in this
manual are current at the time of printing. MWfly reserves the right to make
changes at any time, without notice and without incurring any obligation.
Reproduction of any part of this publication is prohibited without the written
authorization of MWfly.
This manual is an integral part of the propeller, and must be kept with it,
even if it is sold.
The original document is written in Italian, which is valid for any dispute of a
technical or legal nature.

Line maintenance manual
SPIRIT engines
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INDEX
01-00-00 INTRODUCTION 7
01-01-00 Identification Data 8
01-01-01 Standard or Non-standard Motor Definition 8
01-02-00 Documentation 9
01-02-01 Notes for Consultation 9
01-02-02 Unit of Measure 11
01-02-03 Technical Documentation Available 13
01-03-00 Safety 14
01-04-00 Maintenance Criteria 16
01-04-01 Line Maintenance 17
01-04-02 Heavy Maintenance 17
01-05-00 Maintenance Equipment 17
01-05-01 Workshop Tools 17
01-05-02 Special Tools 18
01-05-03 Consumables 18
01-06-00 Prolonged Inactivity 19
01-06-01 Preservation 20
01-06-02 Resumption of Service 21
01-07-00 Motor Shipping Precautions 22
01-08-00 MWfly Authorized Service Centres 23
04-00-00 AIRWORTHINESS LIMITATIONS 24
05-00-00 PERIODIC MAINTENANCE 25
05-01-00 Authorized personnel 25
05-02-00 Preparing the aircraft for maintenance 26
05-03-00 Safety locks and seals 27
05-04-00 Troubleshooting 27
05-10-00 Operational limits 27
05-10-01 Hourly operating limit 28
05-10-02 Calendar operating limit 29
05-10-03 Operational limit of lubricants 29
05-10-04 Operating limit of the refrigerant 29
05-10-05 Operating limit of plastic parts 29
05-10-06 Operating limit of other components 30
05-20-00 Periodic maintenance program 30
05-20-01 General rules for maintenance 31
05-20-02 Engine logbook 32

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05-20-03 Scheduled maintenance table 32
12-00-00 INSTRUCTIONS FOR MAINTENANCE 37
12-01-00 Tightening torques 37
12-02-00 Locking the crankshaft 40
12-02-01 Motors without gearbox 40
12-02-02 Motors with gearbox 41
12-02-03 Locking for timing without removing the reducer or front cover 42
12-03-00 Engine test after maintenance or periodic inspection 43
12-04-00 Removal and reassembly of the engine from the aircraft 45
12-04-01 Removal 46
12-04-02 Installation 47
12-10-00 Supplies 48
12-10-01 Cooling liquid 49
12-10-02 Motor oil 50
12-10-03 Gearbox oil 51
12-20-00 Scheduled maintenance 53
12-21-00 Engine cleaning 53
12-22-00 General checks 54
12-22-01 Check for leaks 54
12-22-02 Check crankcase breather 57
12-22-03 Engine suspension check 58
12-22-04 Cylinder compression control 59
12-22-05 Check the tension of the distribution chain 61
12-22-06 Check general smoothness 62
12-22-07 Endoscopic inspection 65
12-22-08 Annual inspection 69
12-23-00 Cooling system 70
12-23-01 Control and cleaning 70
12-23-02 Emptying 71
12-23-03 Check expansion tank 72
12-23-04 Thermostatic valve and pump manifolds 74
12-23-05 Radiator 77
12-23-06 System filling and venting 78
12-24-00 Engine lubrication system 79
12-24-01 Oil change 79
12-24-02 Oil filter replacement 81
12-24-03 Oil sump cleaning 82
12-24-04 Check for the presence of particulate matter 84

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12-24-05 Spectrographic analysis of engine oil 87
12-25-00 Fuel system 87
12-25-01 Check 87
12-25-02 System depressurization 88
12-25-03 FD-m 88
12-25-04 Fuel shunt and pressure regulator 92
12-26-00 Air intake system 95
12-26-01 Removal 95
12-26-02 Reassembly 96
12-26-03 Air filter replacement 97
12-27-00 Exhaust system 98
12-27-01 Removal 98
12-27-02 Control and recovery 99
12-27-03 Installation 100
12-28-00 Electrical components 100
12-28-01 Wiring check 100
12-28-02 Spark plugs 101
12-28-03 Ignition coils and cables 104
12-28-04 Battery and charging system 107
12-28-05 IJ-m 110
12-28-06 AG-m 113
12-29-00 Transmission 114
12-29-01 Direct engine tightenings 114
12-29-02 PSRU engine tightenings 115
12-29-03 Oil change 118
12-29-04 Check magnetic filter 120
12-29-05 Spectrographic analysis of oil 120
12-29-06 Vent control 121
12-29-07 Gear gap control 121
12-29-08 Damper torque control 122
12-30-00 Unscheduled maintenance 124
12-31-00 Warnings and checks for use in extreme climatic conditions 124
12-32-00 Checks after use outside the operating limits 125
12-32-01 Operation with coolant temperature too high 125
12-32-02 Use with too low coolant temperature 126
12-32-03 Use with too high engine oil temperature 126
12-32-04 Use with too low engine oil temperature 127
12-32-05 Operation with gear oil temperature too high 128

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12-32-06 Operation with too low engine oil pressure 128
12-32-07 Use with control units and current regulator temperatures too high 129
12-32-08 Exceeding the maximum number of revolutions 129
12-33-00 Checks after use with unfulfilled prescriptions 130
12-33-01 Ignition spark plug specifications not respected 130
12-33-02 Coolant specifications not respected 131
12-33-03 Engine oil specifications not respected 131
12-33-04 Gearbox oil specifications not respected 132
12-33-05 Fuel specifications not respected 133
12-33-06 Moment of inertia and loads on the propeller shaft higher than allowed 134
12-34-00 Checks for anomalies 134
12-34-01 Accidental impact of the propeller against the ground 134
12-34-02 Excessive vibrations 135
12-34-03 Difficult starting 136
12-34-04 Irregular running at idle 136
12-34-05 Reduction of maximum power (maximum revolutions with fixed pitch propeller) 136
12-34-06 Excessive or abnormal noise 137
12-34-07 Unwanted stopping of the thruster 137
12-34-08 Excessive consumption of engine oil 137
12-34-09 Excessive consumption of gear oil 137
12-34-10 Excessive accumulation of particulates on the magnetic filters 137
12-34-11 Excessive consumption of coolant 137
12-34-12 Presence of water in the engine oil 138
12-35-00 Communication of operating anomalies 138
LIST OF REVISIONS TO THE DOCUMENT 140

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SPIRIT engines
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01-00-00 INTRODUCTION
The SPIRIT 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.
Please read this manual carefully before using the engine and apply all safety
standards contained in it, in addition to those that your experience and common sense
suggest.
Remember that regular maintenance and a thorough inspection before take-off are
essential safety factors.
MWfly will be happy to provide additional information and all the technical support you
will need.
This manual collects the essential information to be able to carry out maintenance
work on SPIRIT engines. The operating, installation, extraordinary maintenance
manual and anything else published by MWfly, completes the information contained in
this manual, which must be taken into account to carry out maintenance work. The
technician who performs maintenance is also required to have specific theoretical and
experimental training on the type of engine.
All of this forms the basis for carrying out maintenance safely and without
compromising the reliability of the engine.
Scrupulously follow all the instructions provided in this manual and request further
information or clarification if deemed necessary for carrying out the maintenance
operations in safety.
This engine has not received any certification for suitability
for aeronautical use.
Its use is intended exclusively for experimental or non-
certified aircraft, on which a possible engine failure does not
compromise flight safety.
For engine maintenance, follow any rules and laws in force in the
country where the engine is used.

Line maintenance manual
SPIRIT engines
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01-01-00 Identification Data
The engine serial number is stamped
on the top of the engine, near the
gearbox. It consists of the model
identification code (72-02-C) followed
by a six-digit number, of which the
first four indicate the serial number
and the last two indicate the year of
manufacture.
01-01-P
Removing or modifying the serial number will revoke any warranty and obligation by
MWfly toward current owner.
Provide the serial number on any request for an engine part or technical information.
01-01-01 Standard or Non-standard Motor Definition
In some maintenance operations described in this manual, reference is made to
standard motor versions (abbreviated STD) or non-standard motors (abbreviated
NOSTD).
This definition complies with the SAE J824-199506 standard according to which an
engine is standard if, when viewed from the power take-off side, it rotates counter
clockwise.
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.

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Name
Product
code
Engine
type
Spirit 100 Direct L
W011
STD
Spirit 100 Direct R
W012
NOSTD
Spirit 115 Direct L
W013
STD
Spirit 115 Direct R
W014
NOSTD
Spirit 135 Direct L
W017
STD
Spirit 135 Direct R
W018
NOSTD
Spirit 160 Direct L
W023
STD
Spirit 160 Direct R
W024
NOSTD
Spirit 122 PSRU L
W015
NOSTD
Spirit 122 PSRU R
W016
STD
Spirit 135 PSRU L
W019
NOSTD
Spirit 135 PSRU R
W020
STD
Spirit 140 PSRU L
W021
NOSTD
Spirit 140 PSRU R
W022
STD
Spirit 160 PSRU L
W025
NOSTD
Spirit 160 PSRU R
W026
STD
01-01-C
01-02-00 Documentation
01-02-01 Notes for Consultation
This manual was originally printed in Italian. This will be the only language used for
any reference or dispute.
The manual is divided into chapters; each chapter is divided into sections; each
section is divided into paragraphs; within each paragraph there may be a further
subdivision into topics. The title of each chapter, section, paragraph or topic is
highlighted as follows.
CHAPTER
Section
Paragraph
Topic

Line maintenance manual
SPIRIT engines
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The numbering system of the contents of the manual consists of a numerical code
using the following criterion.
The content of each document is numbered and divided as follows.
CC-SS-PP
where:
CC indicates the chapter of the document
SS indicates the section of the document
PP indicates the paragraph of the document
The subdivision into CC (chapters) will follow the ATA-100 scheme. The subdivision of
the first digit of each section will also respect the ATA 100 scheme; the second digit of
each section is assigned by MWfly, to correctly subdivide the topic.
Within each section, the numbering in paragraphs will follow a progressive numbering,
starting from number 01.
The identification of the figures and tables shows the chapter number and a
progressive number, followed by the letter P for the figures and the letter C for the
tables (e.g. 21-03-P).
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 support
plane of the flange itself and
is positive in the direction of
the engine, the y axis is
positioned with origin on the
centre line of the engine and
is positive in the direction of
the cylinder bank # 1, the z
axis originates on the
propeller shaft and is
positive upwards, on the
intake manifold side.
Symbols used in this manual have the following meaning.
WARNING: Not following this instruction can cause severe
personal injury or loss of life.
CAUTION: Not following this instruction could cause severe damage
to the engine or other components and cause the engine to stop.
01-02-P