RotorWay RI 600 Series User manual

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

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Revision Date Description Approved By:
1.0 May-19-2009 Initial rewrite documenting Talon updates RMc

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WARNING
The construction and operation of “Home-Built Aircraft” of this type is demanding and could inflict serious injury and possible
death. No such operation, construction or undertaking should be initiated unless thorough and complete knowledge,
preparation and instruction are available and utilized. The seller (and its agents, servants, employees, contractors, successors,
and assigns) makes no warranties express or implied regarding the clarity or correctness of the plans, ease of construction or
operation nor the safety of this aircraft or any part thereof. Furthermore, buyer (and his heirs, administrators and assigns)
releases and holds said seller (and its agents, servants, employees, contractors, successors, and assigns) harmless from any
and all liability, damages, and causes of action which may be incurred by buyer or any third party as a result of the purchase,
use, construction and/or operation of said aircraft (or any part thereof) or plans for same. Buyer assumes all risk and
responsibility relative to the construction and/or operation of said aircraft. Seller admits no liability by publication of this
warning.

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Introduction
The RI 600 powerplant from RotorWay International has been completely assembled and dynamometer tested by
factory technicians. Precise parts tolerances, assembly techniques and performance parameters are required of
every engine leaving the factory. The oil pressure and ignition timing was adjusted to specification and fuel flow
verified to be in the proper range at various power levels. The engine has been run long enough for the initial
seating of the piston rings to occur. While the extended initial run-in period on your engine is very important, this
critical period of “break in” was conducted in a tightly controlled and monitored condition in a dynamometer. As a
result, every engine leaving the factory meets a tight parameter of torque and horsepower requirements.
After the engine has successfully completed its dynamometer run, a variety of additional adjustments and checks
are performed prior to crating and shipment. This includes a valve lash adjustment and a re-torque of all bolts to
specification. All open passages are plugged to help prevent moisture and dirt contamination.
It is very important to store the engine in a clean and dry environment prior to installation in the helicopter.
From this point on, the responsibility for longevity and reliability of the engine is yours. Before you remove the lid
from your engine crate, it is important to read and familiarize yourself with this entire manual. We have attempted
to address even the most basic procedures involving the proper maintenance and operation of the power plant. It
is essential that proper and timely maintenance be performed. If you have any questions or if there is anything
you are not sure about, please give our customer service department a call.
We advise you to attend our training program prior to starting the engine. The hands on instruction regarding the
proper care and operation of the engine is extremely valuable to even the best mechanic.
A recommended maintenance schedule for the powerplant is included in this manual. You should purchase a log
book formatted for powerplant maintenance. An accurate record of the work preformed on the engine is a
valuable tool in evaluating future maintenance requirements.
The factory provides a complete rebuilding service for the powerplant. In the event you elect to perform the “TBO”
procedures on the powerplant yourself, we have provided the necessary specifications in this manual. All of the
parts necessary for a rebuild are depicted in this manual and are available from the factory.
Your engine will only perform well if you treat it properly. You must understand its needs and attend to them by monitoring and
maintaining it. By combining the information in this manual with the knowledge gained in our factory training program you will
be able to maintain peak performance from your powerplant.

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Contents
SECTION 1: General Service Information ................................................................................................................. 8
A.RI600 Engine Specifications...................................................................................................................................................................8
B.Torque Requirements .............................................................................................................................................................................8
C.Oil Requirements and Specifications......................................................................................................................................................9
D.Grease Requirements and Specifications for the Main Drive Pulley ......................................................................................................9
E.Fuel Requirements and Fuel Consumption ..........................................................................................................................................10
F.FADEC System Specifications .............................................................................................................................................................10
G.Cooling System Specifications and Limits ............................................................................................................................................10
H.Component Specifications and Wear Limits .........................................................................................................................................11
I.Cylinder Head Torque Specifications ...................................................................................................................................................12
SECTION 2: Individual System Procedures ............................................................................................................ 13
A.Introduction ...........................................................................................................................................................................................13
B.Fuel System..........................................................................................................................................................................................13
1.Introduction .......................................................................................................................................................................................13
2.Fuel Requirements............................................................................................................................................................................14
3.Preparation........................................................................................................................................................................................14
4.Component Service...........................................................................................................................................................................17
a)Injectors........................................................................................................................................................................................17
b)Air and Water Temperature Sensors ...........................................................................................................................................17
c)Barometric and Manifold Pressure Sensors.................................................................................................................................18
d)Primary and Secondary Throttle Position Sensors ......................................................................................................................18
e)Throttle Shaft Assembly ...............................................................................................................................................................19
f)Air Filter........................................................................................................................................................................................20
g)Fuel Pump....................................................................................................................................................................................20
h)Fuel Filter .....................................................................................................................................................................................20
i)Fuel Shut-Off Valve/Filter Assembly ............................................................................................................................................20
j)Engine Control Unit ......................................................................................................................................................................21
k)Secondary Engine Control Unit ....................................................................................................................................................21
l)Fuel Pump Inertia Switches .........................................................................................................................................................21
m)Engine Coolant Temperature (ECT) sensor, and Intake Air Temperature (IAT) sensor..............................................................21
n)Manifold Absolute Pressure (MAP) sensor ..................................................................................................................................22
o)Throttle Position (TP) Sensor.......................................................................................................................................................22
p)Knock Sensor...............................................................................................................................................................................22
5.Diagnostics........................................................................................................................................................................................22
a)Introduction ..................................................................................................................................................................................22
b)FADEC Power Supply..................................................................................................................................................................22
c)Secondary System Operation ......................................................................................................................................................23
d)Wiring and Connector/Plug Faults ...............................................................................................................................................23
e)Fuel Pressure Irregularities ..........................................................................................................................................................23
f)FADEC Wiring Harness ...............................................................................................................................................................24
g)FADEC Harness Wiring Guide .....................................................................................................................................................26
C.Cooling System.....................................................................................................................................................................................32
1.Coolant Requirements ......................................................................................................................................................................32
2.Preparation........................................................................................................................................................................................33
3.Filling the System, Removing Air and Priming the Water Pump .......................................................................................................33

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D.Oil System ............................................................................................................................................................................................34
1.Preparation and Priming ...................................................................................................................................................................34
2.Oil Pressure Adjustment ...................................................................................................................................................................35
I.Ignition System .....................................................................................................................................................................................36
1.Introduction .......................................................................................................................................................................................36
2.Preparation........................................................................................................................................................................................36
3.Installation Drawing...........................................................................................................................................................................38
4.Component Service...........................................................................................................................................................................39
a)Ignition Sensors ...........................................................................................................................................................................39
b)Ignition Modules ...........................................................................................................................................................................39
c)Spark Plug Wires .........................................................................................................................................................................39
d)Spark Plugs..................................................................................................................................................................................40
5.Diagnostics........................................................................................................................................................................................40
a)Engine Will Not Start - Signs of combustion are evident, (such as backfire or sputter) ..............................................................40
b)ENGINE WILL NOT START - Signs of spark are evident, (such as backfire or sputter) .............................................................41
c)ENGINE RUNS ON ONE SYSTEM ONLY. .................................................................................................................................42
6.Ignition Timing...................................................................................................................................................................................43
J.Valve Train............................................................................................................................................................................................43
1.Valve Cover Removal and Installation ..............................................................................................................................................43
2.Valve Train Inspection.......................................................................................................................................................................43
a)25 Hour Valve Train Inspections ..................................................................................................................................................43
b)Lash Cap, Rocker and Pushrod ...................................................................................................................................................44
c)Camshaft Lift Inspection...............................................................................................................................................................45
3.Valve Lash Adjustment .....................................................................................................................................................................45
K.Main Drive Pulley..................................................................................................................................................................................48
1.Removal ............................................................................................................................................................................................48
2.Installation .........................................................................................................................................................................................48
3.Bearing Replacement........................................................................................................................................................................49
SECTION 3: Start-up and Initial Run-in Procedures................................................................................................ 51
A.Introduction ...........................................................................................................................................................................................51
B.First Start Outline Summary .................................................................................................................................................................51
C.Maintenance Requirements..................................................................................................................................................................52
FIRST HOUR SERVICE .............................................................................................................................................................................52
FIRST FIVE HOUR SERVICE ....................................................................................................................................................................53
FIRST TEN HOUR SERVICE .....................................................................................................................................................................53
FIRST 25 HOUR SERVICE ........................................................................................................................................................................53
SECTION 4: Inspection and Maintenance Schedule............................................................................................... 54
A.Introduction ...........................................................................................................................................................................................54
B.25 Hour Service ....................................................................................................................................................................................54
C.50 Hour Service ....................................................................................................................................................................................55
D.100 Hour Service ..................................................................................................................................................................................55
E.250 Hour Service ..................................................................................................................................................................................55
F.500 Hour Service ..................................................................................................................................................................................56
G.1000 Hour Service ................................................................................................................................................................................56
SECTION 5: Drawings and Parts Lists .................................................................................................................... 57

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A.Rotating Parts Assembly ......................................................................................................................................................................57
B.Main Drive Pulley Assembly .................................................................................................................................................................59
C.Crankcase Assembly ............................................................................................................................................................................60
D.Lower Cover Assembly.........................................................................................................................................................................61
E.Water Jacket Assembly ........................................................................................................................................................................63
F.Cylinder Head Assembly ......................................................................................................................................................................64
G.Plenum and Manifold Assembly ...........................................................................................................................................................66
H.Fuel Shut-off Valve / Filter Assembly....................................................................................................................................................68
I.Electrical System ..................................................................................................................................................................................69
J.Oil System ............................................................................................................................................................................................70
K.Gaskets and O-Rings ...........................................................................................................................................................................71
L.Altitude Compensation Induction System .............................................................................................................................................72
SECTION 6: Hourly Service Chart........................................................................................................................... 74

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SECTION 1: General Service Information
A. RI600 Engine Specifications
Rated Horsepower @ 4250 RPM ................................................................................................................150
Torque @ 4250 RPM........................................................................................................................... 185 ft.lb.
Max Torque @ 3950 RPM ................................................................................................................... 191 ft.lb.
Operational RPM (Calibrate with rotor RPM) ............................................................................................. 4250
Idle RPM .........................................................................................................................................1750 - 2000
Bore, inches................................................................................................................................................4.00
Stroke, inches ...........................................................................................................................................3.228
Displacement, cubic inches .........................................................................................................................162
Compression Ratio (Standard) ..................................................................................................................9.4:1
Compression Ratio (ACIS Supercharger) ..................................................................................................8.5:1
Flywheel Rotation (viewed from above) .............................................................................................Clockwise
Firing Order...................................................................................................................................... 1 - 2 - 3 - 4
Ignition Systems (Dual-Independent)................................................................................................. Electronic
Ignition Timing .............................................................................................................. Variable 14°-38° BTDC
Spark Plug Gap ............................................................................................................................ .040" - .044"
Ignition Sensor/Timing Wheel Gap ........................................ 0.025" (both sensors within .004” of each other)
Valve Lash Clearance................................................................................................................... .004" - .006"
Engine Dry Weight (includes main drive pulley, flywheel, water manifolds, dual ignition systems, and starter) ................................. 187 lbs.
NOTE: Measurements and adjustments must be made when the engine is cool and stable in temperature.
See valve adjustment section.
B. Torque Requirements
Main Drive Pulley Bolts 1.................................................................................................................... 28 ft. lbs.
Main Drive Flange Nut 1................................................................................................................... 200 ft. lbs.
Cam Gear Bolts 2............................................................................................................................... 18 ft. lbs.
Connecting Rod Bolts 3...................................................................................................................... 42 ft. lbs.
Main Stud Nuts ................................................................................................................................... 40 ft. lbs.
Cylinder Head Bolts (Final Torque Value)........................................................................................... 22 ft. lbs.
Intake Manifold Bolts........................................................................................................................... 15 ft. lbs.
Exhaust Manifold Bolts .....................................................................................................................120 in. lbs.
Polyloc Set Screws (Rocker Arms) ...................................................................................................120 in. lbs.
Ignition Sensor Bolts 1........................................................................................................................15 in. lbs.
Oil Pressure Adjustment Plug 1.......................................................................................................... 40 ft. lbs.
Oil Pressure Adjustment Jam Nut.....................................................................................................108 in. lbs.
Case Bolts .......................................................................................................................................... 15 ft. lbs.
Starter Bolts ........................................................................................................................................ 18 ft. lbs.
Starter Mount Bolts ............................................................................................................................. 15 ft. lbs.
Lower Cover Bolts .............................................................................................................................. 15 ft. lbs.
Oil Pump Cover Bolts.......................................................................................................................... 15 ft. lbs.
Throttle Shaft Bearing Retention Bolt 1..............................................................................................15 in. lbs.
Valve Cover Bolts ........................................................... see page 43 - Valve Cover Removal and Installation
Knock Sensor ..................................................................................................................................... 16 ft. lbs.
Ignition Module Mounting Bolts...........................................................................................................75 in. lbs.
Throttle Position Sensor Bolts.............................................................................................................25 in. lbs.
Plenum Cable Bracket Bolts ...............................................................................................................96 in. lbs.
Fuel Rail Retention Bolts ....................................................................................................................96 in. lbs.
Rocker Arm Studs 1........................................................................................................................... 40 ft. lbs.
Spark Plugs
2..................................................................................................................................... 10 ft. lbs.
Timing Wheel Bolts 1..........................................................................................................................96 in. lbs.
Cam End Plate....................................................................................................................................96 in. lbs.
1Install with service removable Loctite #242
2Install with Loctite #271
3All rod bolts should be thoroughly oiled before installing.

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C. Oil Requirements and Specifications
AMBIENT AIR TEMPERATURE GRADE OF OIL (MULTI- VISCOSITY)
Above 40° F ..................................................................................................................................... 20 - 50 SF
0° F to 60° F..................................................................................................................................... 10 - 40 SF
Below 0° F ....................................................................................................................................... 10 - 40 SF
NOTE:Pre-warming of the engine and oil may be necessary when ambient air temperature is below 0° F.
Oil System Capacity, U. S. quarts....................................................................................................................5
Minimum Run-up Oil Temp. (Above 2000 rpm) ...................................................................................... 140° F
Minimum Climb-out Oil Temperature ...................................................................................................... 150° F
Normal Operating Oil Temperature................................................................................................ 160 - 210° F
Caution Operating Oil Temperature ............................................................................................... 210 - 240° F
Maximum Oil Temperature ..................................................................................................................... 240° F
Oil Pressure Requirements:
MINIMUM at IDLE .................................................................................................................... 30 PSI
MINIMUM at 4250 RPM ........................................................................................................... 45 PSI
MAXIMUM ................................................................................................................................ 80 PSI
Adjust warm (180-200 F) @ 4250 RPM............................................................................. 50 - 55 PSI
CAUTION: The powerplant can be damaged during the first start-up if adequate oil pressure is not
attained within the prescribed time limits.
CAUTION: Do not overfill the oil sump. If too much oil is added, the sump must be drained and then
re-filled to the proper level. If any oil is spilled, it must be cleaned up before flight.
D. Grease Requirements and Specifications for the Main Drive Pulley
GREASE SERVICE INTERVAL: 3 “shots” every 25 hours.
One shot of grease equals one full stroke from a standard 14 oz. cartridge, lever action grease gun. The approximate
shot dimension is .25 inch diameter by 1.5 inches long.
Use the main drive pulley grease tool, part number E38-6700. Remove the set screw in the bottom groove of the
pulley (the groove for the ACIS supercharger belt). Screw the threaded end of the tool into the hole and apply the
grease. When done, remove the tool and reinstall the set screw, making sure the screw is tight. Wipe away excess
grease.
CAUTION: Grease must be pumped in very slowly. Rapid introduction of grease may cause the
bearing seals to blow out.
GREASE TYPE: Determine which type of grease is appropriate for the climate you will be operating in.
For flight operating conditions ABOVE 0° F, use Mystik JT-6 Multi-Purpose Hi-Temp Grease.
Mystik JT-6 is a product of Cato Oil and Grease Company. The nearest distributor can be found by
calling [phone].
If flight operating conditions are BELOW 0° F, use Ronex MP.
Ronex MP is an Exxon product.
NOTE: It is not recommended to use Ronex MP if ambient air temperatures above 80° F are regularly encountered.
The correct grease for use in the main drive pulley is also the correct type for use in all other parts of the helicopter.
Since use of the correct type of grease is essential to proper performance, it is advisable to dedicate a grease gun
specifically for helicopter service.
Bearing Replacement at 500 Hours: Refer to the bearing replacement procedures in Section 2 of this manual. This is
also a service offered by the factory. Contact a customer service representative to schedule this service.

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E. Fuel Requirements and Fuel Consumption
Minimum Octane Rating ................................................................................................................................91
Fuel Pressure, PSI 1..............................................................................................................................40 - 60
Fuel Consumption at Full Power (approximately) .............................................................................. 68 lbs./hr.
1Varies depending upon manifold pressure.
F. FADEC System Specifications
Throttle Idle Speed Screw.................................................................................................1-7/8 to 2 turns open
Primary Throttle Position Sensor Idle Setting ..............................................................................................0%
Secondary Throttle Position Sensor Idle Setting...........................................................................................0%
G. Cooling System Specifications and Limits
Antifreeze Type..................................................................................................Propylene Glycol with Additive
Replacement Interval.......................................................................................................250 Hours or 2 Years
Cooling system Capacity (Approx.)......................................................................................................9-10 qts.
Minimum Climb-out Water Temperature 2.............................................................................................. 160° F
Normal Operating Water Temperature............................................................................................165°-190° F
Caution Operating Water Temperature...........................................................................................190°-215° F
Maximum Operating Water Temperature................................................................................................ 215° F
CAUTION: Engine RPM should NOT exceed an idle until the coolant temperature reaches a minimum of 160° F,
or damage to the engine and cooling system may result.
The powerplant can also be damaged during the first start-up by improper bleeding of the cooling system,
indicated by a rapid increase of engine and water temperature.
2In extremely cold operating conditions, it is recommended that the radiator be partially blocked off to achieve a
stabilized coolant temperature of 165° to 190° F at full operating RPM. Contact customer service for further
details.