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
RotorWay International INTRODUCTION
RI600 Engine Manual Page 2
Revision Date Description Approved By:
1.0 May-19-2009 Initial rewrite documenting Talon updates RMc
RotorWay International INTRODUCTION
RI600 Engine Manual Page 3
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.
RotorWay International INTRODUCTION
RI600 Engine Manual Page 4
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.
RotorWay International INTRODUCTION
RI600 Engine Manual Page 5
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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RI600 Engine Manual Page 6
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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RI600 Engine Manual Page 7
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
RotorWay International SECTION - 1
RI600 Engine Manual Page 8
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.
RotorWay International SECTION - 1
RI600 Engine Manual Page 9
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 (405) 270-6200.
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.
RotorWay International SECTION - 1
RI600 Engine Manual Page 10
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.
RotorWay International SECTION - 1
RI600 Engine Manual Page 11
H. Component Specifications and Wear Limits
CYLINDERS
Bore Size STD..................................................................................................... 4.0005" ± .0005"
MAX ...................................................................................................................4.0035"
Max. Taper.......................................................................................................................................................0010"
Max. Egg..........................................................................................................................................................0060"
Bore to Bore Distance........................................................................................................................ 4.410" ± .002"
CRANKSHAFT
Mains STD..................................................................................................... 2.1645" ± .0003"
MIN ....................................................................................................................2.1637"
Rods STD.................................................................................................... 2.0860" / 2.0865"
MIN ....................................................................................................................2.0855"
End Play STD............................................................................................................ .004" / .006"
MAX ...................................................................................................................... .014"
CASE
Main Bore...................................................................................................................................... 2.5590" / 2.5600"
Cam Bore....................................................................................................................................... 1.0830" ± .0003"
PISTON
All Ring Gaps (Standard) ..................................................................................................................... .018" / .020"
All Ring Gaps (ACIS Supercharger)..................................................................................................... .024" / .026"
CAMSHAFT
Journal MIN .......................................................................................................................9830"
Lobe Height MIN .........................................................................................................................326"
Timing (in crank degrees) ................................................................................................................. 4° Retard ± 1°
End Play STD............................................................................................................ .002" / .006"
MAX ........................................................................................................................025"
RODS
Small End STD........................................................................................................ .9275" / .9278"
MAX ......................................................................................................................9281"
Big End ........................................................................................................................................... 2.2430" ±.0005"
VALVE SEAT
Exhaust Width STD........................................................................................................... .080" / .090"
Intake Width STD........................................................................................................... .060" / .070"
Approx. Grind Angles (degrees)..................................................................................................... 15°, 44-1/2°, 60°
VALVE GUIDES
Exhaust ID Clearance STD....................................................................................................... .0009" / .0011"
MAX .................................................................................................................... .0020"
MAX TAPER ....................................................................................................... .0008"
Intake ID Clearance STD........................................................................................................ .0005" / .0007"
MAX .................................................................................................................... .0015"
MAX TAPER ....................................................................................................... .0008"
VALVE SPRINGS (@ 1.125" Compressed Height)................................................................................... 155 / 180 lbs.
VALVE LIFT @ Valve STD........................................................................................................... .467" ± .005"
MIN ....................................................................................................................... .440"
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RotorWay International SECTION - 2
RI600 Engine Manual Page 13
SECTION 2: Individual System Procedures
A. Introduction
Every basic system required for powerplant operation is covered individually within this manual. The following topics are
addressed only in this section:
1. Correct Installation
2. Preparation For Start-Up
3. Initial Start-Up Procedures
4. Maintenance Procedures
5. Diagnostic Procedures
Read each section entirely, including the diagnostic procedures, as this will help provide an overview and insight leading to
successful and long lasting powerplant operation.
B. Fuel System
1. Introduction
RotorWay helicopters are currently the only piston powered helicopters that utilize a fully redundant, electronic fuel injection
system. Electronic fuel injection has long been the norm in the automotive industry, but unfortunately these automotive
systems are not suitable for aviation use because they do not provide the required redundancy. General Aviation has not been
in a position to make the change to electronics because of the extremely high costs involved in developing and certifying this
type of system.
The introduction of the RotorWay FADEC (Fully Automated Digital Electronic Control) System is the result of over four years of
development and testing. It is a totally unique and customized system designed especially for use in RotorWay helicopters. It
delivers fuel with extremely accurate air/fuel ratios. It automatically adjusts for changes in altitude, engine condition and
outside temperature. Information regarding the system’s condition is clearly presented to the pilot via warning lights and a
digital display screen.
The FADEC System incorporates two separate and complete Engine Control Systems. Should the primary system become
unable to properly control the engine, FADEC will automatically switch to the secondary or backup system.
The primary system uses a sophisticated Engine Control Unit (ECU) to assimilate information from a number of primary and
secondary sensors. It then delivers the proper fuel mixture based on these values.
Primary sensors monitor two important engine conditions, RPM and Load. These values are essential elements in computing
and delivering an accurate air/fuel ratio. FADEC “backs up” both primary sensors through specific ECU programming.
Although only one RPM value is needed by the ECU, duplicate values are constantly monitored from each of the independent
ignition systems. For load value, the ECU uses information from a MAP (Manifold Pressure). Should this sensor fail, the
secondary system will take over.
This additional redundancy also applies to the barometric and air temperature sensors that both primary and secondary
systems have.
Secondary sensors are not essential for engine operation while operating on the primary system. The ECU for the secondary
system is capable of adjusting for altitude and temperatures the same as the primary ECU. Should both primary and
secondary sensors fail, the ECUs are programmed to revert to preset default values.
The loss or intermittent failure of any sensor will be brought to the pilot’s attention via a red blinking warning light on the
instrument panel.
RotorWay International SECTION - 2
RI600 Engine Manual Page 14
In the unlikely event that the MAP sensor fails or if a green FADEC primary light turns off and a red light turns on there is a
Main ECU loss or malfunction, FADEC will automatically transfer control of the engine to the secondary system. A red warning
light will illuminate on the instrument panel to inform the pilot of the deactivation of primary system. This “back up” is an
independent system with its own ECU and MAP sensor.
WARNING: Although the pilot has the ability to manually activate the secondary engine control system by turning off the
primary switch on the overhead panel, this system is not intended to be used as a regular means of engine control. The pilot
should carefully land at the nearest safe site if the secondary system activates.
While the inner workings of the FADEC System are sophisticated and rather complex, the skills and tools needed to service
the system are not. If you carefully follow all of the procedures contained in this section of the manual, you should have no
difficulty understanding and maintaining the FADEC system. It is important to note that 99% of all problems with electronic
engine control systems are wiring related. These problems include damaged wiring and faulty or loose connectors. Pay special
attention to these components during construction and maintenance of the helicopter.
It is important for you to understand the FADEC system and the following procedures. This knowledge is essential for you to
properly construct, maintain and fly the helicopter. If you have questions about the FADEC system or if you are unclear about
any of the procedures, please call our customer service department.
2. Fuel Requirements
The RI 600 powerplant is designed to burn premium unleaded or leaded automotive gasoline which has a minimum octane
rating of 91. Use only gasoline from a known major brand station which has fuel specially formulated for fuel injection, such as
Mobil, Texaco, Arco, etc. 100 low lead aviation gasoline may also be used.
NOTE: Regular maintenance includes rebuilding the cylinder heads at 500 hours if unleaded fuel is used. This is reduced to
250 hours if using 100 low lead or leaded automotive gasoline.
Do not attempt to use old gasoline because it may not deliver the required performance. In addition to possible moisture
contamination, gasoline volatility is adjusted by the suppliers seasonally and geographically to reduce the chance of problems.
5-10% alchol content is ok to use.
3. Preparation
WARNING: This fuel system is designed to operate at pressures up to 60 PSI. A fuel leak in this system could cause a
fire or even an explosion. If you do not completely understand any of the following procedures please call customer service for
additional assistance.
CAUTION: DO NOT connect the battery, put gasoline in the fuel tanks or turn on the fuel pumps until advised to do so
during these procedures.
A. Review the plans to ensure that the proper routing and attachment of all fuel system components is correct. This
includes fuel hoses, wiring and all individual components such as filters, pressure regulator, shut-off valve, etc.
B. Inspect all of the installed fuel hoses and make certain that you have complied with the following general rules:
1. Make sure that there is adequate clearance between the hose ends and anything they might be able to contact.
While the hose is flexible, the hose ends are not.
2. Do not allow a hose to contact a sharp corner, nut, bolt, rivet stem or anything else that might cause damage.
RotorWay International SECTION - 2
RI600 Engine Manual Page 15
3. Do not allow a hose to rub against anything, even if the surface on which it rubs is flat. The stainless steel braid
is a very efficient low speed file and will abrade through anything that it moves against. In order to prevent
chafing and to keep your hoses where you want them, support the hoses with wire ties or cushion loop clamps.
4. Do not force the hoses to bend too tight. Do not kink the hose, either by bending too tight, by misalignment
between the hose end and fitting on short assemblies, or by getting the whole assembly into a helix on long
assemblies.
5. Check tightness of all fuel hoses. Do not over-tighten the hose ends onto the adapter fittings. The seal is
achieved by the design of the mating surfaces, not by muscle. If it leaks, it has probably been assembled
incorrectly. Damage to the cone and seat can be caused by various mistakes on assembly, the most common of
which are dirt and over-tightening.
C. Prepare for the inspection of FADEC System components by carefully adhering to the following procedures.
1. At the starter, disconnect the wire between the starter and the starter relay. Insure that this wire can not short
against anything when the battery is eventually connected. This is done to protect against an inadvertent start of
the powerplant and to allow a later testing of the starter relay.
2. Inspect the routing, security and condition of the FADEC wiring harness. It must be well supported and not
allowed to chafe against any other component. Wires should not be pulled tight or radically bent. Connector
plugs should be secured and not allowed to vibrate excessively. All plugs should be checked for proper
connection (locking tabs engaged).
NOTE: Before installing a connector, inspect for any debris or damage inside the plug and make sure that the pins
are straight. Confirm that the weather-tight seals are in place on plugs that are equipped with them. You
should never have to force a plug together. This would be an indication of a broken plug, misaligned seal or
a damaged pin.
3. Connect the battery. First make sure that all of the overhead switches are off. It is also a good practice to verify
that there is not a short in the system before connecting the battery for the first time. This can be accomplished
by using an ohm meter between the positive and negative battery cables.
NOTE: During the following initial testing, if any of the switches fail to function properly, use the appropriate wiring
harness schematic to troubleshoot the problem. Using a volt meter, check for power at the switch and at the
line termination point to determine if the problem is the wiring or a part. If a switch is incorrectly wired, (it
performs the wrong function), trace the wire through the harness to determine if a pin has been incorrectly
positioned in a plug.
WARNING: Do NOT attempt to disassemble any FADEC connector plug without first contacting Customer
Service. Special tools and procedures must be used on these parts to prevent damage and
possible component failure. Handling of circuit boards can cause damage from static discharge.
D. Test the fuel pumps for proper operation by turning the switches on and off, one at a time. You should be able to hear
a pump when it is operating. Run the pumps for as short a time as possible since running a pump dry can cause
damage. By feeling the body of a pump you can tell if it is running or not. Each switch should operate one and only
one pump.
E. Test the fuel pump inertia switches. This is accomplished by unbolting an inertia switch, holding it upright in one hand
and striking it sharply with the other hand. Turn on the corresponding fuel pump switch. The fuel pump should remain
OFF. (This can be verified by checking the fuel pressure gauge.) Reset the inertia switch by pushing downwards on
RotorWay International SECTION - 2
RI600 Engine Manual Page 16
the top of the switch. This should cause the fuel pump to turn on. Turn off the fuel pump switch and re-bolt the inertia
switch to the bracket. Test the other inertia switch in the same manner.
F. Test the ignition switches. Begin by disconnecting plugs numbered 28 and 29 on the FADEC wiring harness. These
plugs attach to the 4 pin receptacles of the ignition modules. Turn the switches on and off, one at a time, and verify
voltage to pin D. The switches should remain off after testing. Do not reconnect plugs 28 and 29 at this time.
G. ARM the FADEC System. Refer to the A600 Talon Pilot Operating Handbook and follow the detailed procedures.
Turn each FADEC switch on and off, one at a time, to insure that each provides an independent source of power. The
green and red light on the instrument panel should indicate which system is operating. If any problems are
encountered, refer to the diagnostic section under ARM FADEC.
H. Test the operation of the starter relay. DO NOT engage the starter at this time. Connect a volt meter between the
frame ground and the previously disconnected relay wire. Turn on the instrument switch and the key. Engage the
starter button. The meter should indicate 12 volts. Turn off the key and verify lock out of the starter circuit. Turn off all
switches. Reconnect the starter relay wire to the starter. DO NOT crank the engine at this time. If a problem is
encountered use the wiring schematic and a volt meter to resolve it.
I. Test the fuel system for leakage. Read the Preface in Section 20 of the Construction Manual. Carefully observe the
following procedures:
CAUTION: DO NOT perform the following test until the helicopter is ready for the first start up. Have a fire
extinguisher by the helicopter and wear eye protection. If you have a leak, the pressure of this system
can cause fuel to be sprayed surprisingly far and fast.
1. Put a total of three to four gallons of fuel in the fuel tanks. This is adequate for testing and for the initial start of
the helicopter. Turn on the fuel valve. Turn on the instruments. Turn on one fuel pump and check for leaks.
Immediately turn off the fuel pump and fuel valve if a leak is detected. Repair the leak.
WARNING: If a leak is found, pressure will remain in the system AFTER the pumps and valve have been turned off.
SLOWLY disconnect the hose at the spot of the leak and be prepared for fuel to spray from the
connection.
2. Turn on the second pump. Carefully re-check for leaks. One good way to check for small leaks is to run a clean
finger around all of the connections on the fuel system. Even a small drop can be found using this procedure.
(Smelling the drop should verify if it is fuel or simply oil used during the installation process.) We stress the
importance of this inspection because A FUEL LEAK ON THIS SYSTEM CAN BE EXTREMELY DANGEROUS!
Even the smallest leak can develop into a large one in a system operating at high pressure.
NOTE:Fuel is constantly being pumped in a circle when the pumps are running. (Gasoline is being returned to the
fuel tank continuously.) The sounds which the fuel pumps make will change as the air is removed from the
system. If you turn off the fuel valve when the pumps are running you will hear the sound change. This sound
change is the result of the restriction on the inlet of the pumps. DO NOT OPERATE THE PUMPS WITH THE
FUEL VALVE OFF.
3. The fuel pressure gauge should be reading approximately 55 PSI. Production differences between gauges,
pressure senders and pressure regulators can cause a variance in the indicated pressure of up to 5 PSI. There
should be a 1 to 3 PSI difference in pressure between operation with one and two pumps. The pressure regulator
is designed to maintain a steady differential pressure between the fuel rails and the intake manifold. You should
notice a decrease in the indicated fuel pressure when the motor is started and develops a vacuum in the intake
manifold.
RotorWay International SECTION - 2
RI600 Engine Manual Page 17
4. After the initial leak testing is complete, turn off all switches and turn off the fuel valve. CONTINUE TO
REGULARLY INSPECT THE FUEL SYSTEM FOR LEAKAGE. This is especially important during the first few
hours of operation and during each pre-flight inspection!
M. Carefully connect the ignition modules. Install the seat back panel and check the security of the wiring. Arm the
FADEC System to test for proper re-connection of the components. Turn off all switches and verify that the fuel valve
is off.
N. Before starting the helicopter for the first time, perform all procedures relating to “Preparation” in the Cooling, Oil and
Ignition Sections of this Manual.
O. During the “First Hour Service” in Section 3, you will be instructed to perform an additional inspection on the FADEC
System. This inspection can only be accomplished when the engine is running.
4. Component Service
a) Injectors
Maintenance is not normally required on these components. If a problem should develop which requires injector
replacement, refer to the following service procedures.
INJECTOR PART # MFG. MFG.NUMBER RESISTANCE
(ALL) A24-5530 AC Delco 12561462 12.5 OHMS
GM 0-280-155-931
TESTING: Carefully remove the connector plug from the injector. Use an ohm meter to measure the resistance between
the two terminals of the injector. Compare this value against the injector’s specified resistance. We recommend replacing
an injector if the resistance reading is incorrect and you suspect that it is not properly delivering fuel. Comprehensive
testing and cleaning of injectors can only be accomplished using special equipment. The flow rate and the spray pattern
must be measured and analyzed to determine if the injector is performing according to all specifications.
REMOVAL: Carefully bleed off the fuel pressure and drain the fuel from the fuel rail assembly. Disconnect both fuel lines
from the fuel rail and remove the retention bolts. Support the injectors to keep them from falling out of the fuel rail.
Withdraw the parts collectively by moving them from side to side while pulling the injectors out of the intake manifold.
Carefully remove the injectors from the fuel rail with the same wiggling motion.
REPLACEMENT: Clean the fuel rail and inspect its injector bores. These bores must have a good finish and be free of
scratches. If an injector is being reused, the O-rings must be replaced. Before installing the injectors, apply a light film of
engine oil to the O-rings and to the bores into which the injectors will be inserted. Install both injectors in the fuel rail by
pushing them into the bores while wiggling them from side to side. Install this assembly into the plenum bores using the
same wiggling motion. Install and lightly snug the retention bolts. The fuel rail bolt holes are large enough to allow
adjustment of the final mounting position. The alignment of the injectors must not be binding. Injectors must have
clearance to easily move up and down in the bores. Once this alignment is correct, torque the bolts and safety wire them.
b) Air and Water Temperature Sensors
These sensors require no maintenance. Testing is accomplished by using an ohm meter to measure the resistance
across the two terminals. Resistance at room temperature is approximately 2500 ohms. The value will vary with
temperature. A failure of these components will normally result in an “open line” or a zero ohm condition.
RotorWay
I
RI600 Engi
n
c)
Baro
m
Thes
e
press
u
excep
t
acco
m
senso
d)
Prim
a
Thes
e
harne
s
CAU
T
The
m
senso
help y
M
T
E
N
1
-
1
-
2
-
REMOVA
L
Assembly)
remove th
e
counter to
all traces
o
I
nternationa
l
n
e Manua
l
m
etric and M
a
e
sensors requi
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re sensors wi
t
A and C. T
h
m
plished by sw
r, the sensor i
s
a
ry and Seco
n
e
sensors requi
s
s connector p
T
ION: DO N
O
neces
s
proper
perfor
m
m
easured resi
s
rs. Comparing
ou verify a fau
l
M
EASURE
E
RMINAL
UMBERS
-
2
-
3
-
3
L
: Refer to the
and note the
e
se parts fro
m
the throttle sh
a
o
f this silicone
p
a
nifold Press
u
re no mainten
a
ll cause incorr
e
h
is resistance
itching the wir
i
s
defective.
n
dary Throttl
e
re no mainten
a
lugs between
t
O
T loosen th
e
s
ary. The rela
t
signals to th
e
m
ance.
s
tance values
b
the values m
e
l
t in the senso
r
Plenum Asse
m
relative arra
n
m
the plenum.
Y
a
ft. You will als
p
rior to replaci
n
u
re Sensors
a
nce and are i
n
e
ct calculation
s
should be a
p
i
ng harness c
o
e
Position Se
n
a
nce. Testing
o
t
he two sensor
s
e
retention bol
t
ive position o
f
e
primary and
b
etween the t
h
e
asured on a q
r
. (The number
APPRO
X
CLOSE
D
RESIST
A
1K OHM
4K OHM
4K OHM
m
bly parts dra
n
gement of pa
Y
ou will notic
e
o notice that s
i
n
g these parts.
n
terchangeabl
e
s
by the ECU.
p
proximately 1
o
nnector plugs
n
sors
o
f these comp
o
s
. If the fault f
o
ts of the thro
t
f
each sensor
secondary sy
s
h
ree terminals
uestionable s
e
1 sensor term
X
IMATE
D
THROTTLE
A
NCE
S
S
S
wing (see SE
C
rts numbered
e
that the sen
s
i
licone has be
e
e
. They both h
a
The resistan
c
350 ohms. T
e
between the t
w
o
nents is most
o
llows the sen
s
t
tle position s
e
to the throttl
e
s
tems. Incorre
c
of a throttle
p
e
nsor with the
“
inal is the top
o
C
TION 5: Dra
w
1 through 6.
s
ors have an i
e
n applied to t
h
a
ve a range o
f
c
e should be “
o
e
sting of thes
e
w
o pressure s
e
easily accom
p
s
or, the sensor
e
nsors unless
e
shaft is car
e
c
t “referencing
p
osition senso
“
trend” sugges
t
o
ne.)
APPR
O
FULL
O
RESI
S
4K O
H
4K O
H
1K O
H
w
ings and Par
t
Carefully rem
o
nternal spring
h
e surfaces be
t
f
2 BARS. The
o
pen line” acr
o
e
components
e
nsors. If the
f
p
lished by swit
c
is defective.
replacement
e
fully adjusted
” will adversel
r will vary bet
w
t
ed by the foll
o
O
XIMATE
O
PEN THRO
T
S
TANCE
H
MS
H
MS
H
MS
t
s Lists, Plenu
m
o
ve the conn
e
which causes
t
ween parts 4
a
SECTION -
2
Page 1
use of differe
n
o
ss all terminal
s
is most easil
y
f
ault follows th
e
c
hing the wirin
g
of a sensor i
to provide th
e
y affect engin
e
w
een individu
a
o
wing table ma
y
T
TLE
m
and Manifol
d
e
ctor plugs an
d
them to rotat
e
a
nd 5. Clean o
f
2
8
n
t
s
y
e
g
s
e
e
a
l
y
d
d
e
f
f
RotorWay International SECTION - 2
RI600 Engine Manual Page 19
REPLACEMENT: While it is not essential that the plenum assembly be removed from the engine compartment, removal will
simplify the sensor adjustment process and make safety wiring of the sensor retention bolts easier.
NOTE: Replacement of throttle position sensors is a service offered by the factory. Please call Customer Service to schedule
this work.
Check the fit of each sensor on the throttle shaft. They MUST slide easily on the shaft. De-burring of the sensor slot may be
necessary. Be careful not to damage the sensors by allowing dirt to contaminate the internal rotating components. Final
assembly of the throttle position sensors requires a bead of silicone to be applied to the area around the protruding ring of the
TPS Spacer. The silicone will form a seal between the secondary throttle position sensor and the TPS spacer. This is done to
prevent moisture contamination of the sensor. Since it is important to insure that the inside of the sensor assembly does not
become contaminated, silicone must be applied only to the area outside of the protruding ring of the TPS Spacer.
NOTE: The replacement process is an important and tedious procedure. We suggest that you practice the sensor installation
process before applying silicone to the parts for the final assembly.
Install all of the components on the throttle shaft. Lightly snug the retention bolts after positioning the sensors in the center
range of their travel. (The bolts must be loose enough to allow adjustment of both sensors.) Install the primary and secondary
connector plugs onto the proper throttle position sensors.
Insure that the throttle is at idle and that the throttle return spring is attached. Adjust the position of each throttle position
sensor to meet all of the following conditions:
1. With the primary system engaged, the digital display monitor indicates a throttle position of 0.0%.
2. When a .002" feeler gauge is placed between the throttle stop roll pin and the throttle stop arm, (partially opening
the throttle), the indicated throttle position is 0.5% to 1.0%.
3. After disconnecting the throttle return spring, the throttle shaft moves freely with no evidence of binding. It should
easily return to the idle stop using only the self contained springs of the throttle position sensors.
4. Repeat the above steps for secondary TPS sensors, or by reading secondary values on display.
Torque the sensor retention bolts to 25 in. lbs. This additional tightening of the bolts may cause the sensor adjustment to
change. Verify that ALL of the preceding conditions are still satisfied. Re-adjust the sensor positions if necessary. Once proper
sensor adjustment has been verified, safety wire the retention bolts.
If the plenum was removed to facilitate replacement, re-install the plenum and carefully leak check the fuel system before
starting the powerplant.
e) Throttle Shaft Assembly
Maintenance is not normally required on this component. The replacement of this component is a service offered by the
Factory. Please contact Customer Service to schedule this service.
REMOVAL AND REPLACEMENT: The plenum must be removed from the engine. All components must be removed from the
throttle shaft. The throttle shaft bearings are Loctited into the plenum and onto the throttle shaft. The plenum must be warmed
to 250° F before attempting to remove the shaft and bearings. The air temperature sensors must be removed from the plenum
before heating. Do not exceed 275° F or you will damage the heat treatment of the aluminum. During the replacement process
these bearings must be loctited. The Loctite must be allowed to “set” with the butterfly installed and with the shaft placed in the
RotorWay International SECTION - 2
RI600 Engine Manual Page 20
fully closed position. The shaft must then rotate with no binding or drag. All other components are then replaced. Be careful to
accurately adjust the “full open” and “idle” positions of the throttle. Carefully follow the procedure for throttle position sensor
replacement. Failure to adjust these settings accurately will cause serious damage to the engine. Install the plenum and leak
test the fuel connections prior to starting the engine.
f) Air Filter
The air filter must remain clean in order to maintain proper engine performance. A common cause of power loss is a clogged
or dirty air filter. A restrictive air filter will cause the engine to operate in an overly rich condition which could cause engine
damage! If the air filter appears dirty or if it has been contaminated with grease, cleaning and re-oiling is required. If any
damage is evident or if it can not be properly cleaned, replace the air filter. Certain local conditions may warrant an inspection
and cleaning on a more regular basis than the 25 hour interval recommended in this manual.
CAUTION: Use ONLY “K&N” brand air filter oil and cleaning agent.
CLEANING: Lightly brush and tap off any surface dirt. (Heavy brushing will damage the gauze.) Pour the K&N cleaning agent
into a “paint-tray” type pan. Roll the filter in the solution to dissolve and detach the grease and dirt. Keep the level of the
cleaning solution in the pan low enough so that the inside of the filter does not become contaminated. Rinse the filter with cold
water from the INSIDE outward. Shake the filter to remove as much water as possible and then allow it to air dry. Do NOT
attempt to accelerate the drying process by using compressed air to blow through the filter. This WILL damage the air filter!
OILING: Holding the spray can approximately 3" away from the filter, make one pass along each pleat. Allow twenty minutes
for the oil to spread and dry. Do not oil the filter twice. If the oil is properly applied, the filter’s gauze should appear red, have
no white spots and be “dripless”.
g) Fuel Pump
Maintenance is not normally required to be performed on this component. One fuel pump will always produce 2 to 4 PSI less
pressure than both pumps will produce when operating simultaneously. Check both fuel filters for contamination before
assuming that the fuel pump, or pumps, are responsible for low fuel pressure. If a pump fails to operate, check the fuse and
check for power and “ground” at the pump. If it is necessary to replace a fuel pump, turn off all of the switches and disconnect
the wiring before removing the fuel hoses. After replacing a fuel pump, carefully leak check the fuel system before starting the
engine.
h) Fuel Filter
The fuel filter should be replaced prior to the recommended interval if your fuel quality is questionable or if lower than normal
fuel pressure is encountered. The inlet and outlet fittings on the fuel filter are reusable. The two crush washers must be
replaced during each filter change. After changing the fuel filter, always leak check the fuel system before starting the engine.
i) Fuel Shut-Off Valve/Filter Assembly
Refer to the parts drawing in Section 5 for the detailed breakdown of this component. It will be necessary to carefully drain the
fuel tanks to service the entire assembly. However, with the shut-off valve in the off position, the filter can be serviced without
draining the tank.
SERVICE FILTER: Have a fire extinguisher nearby. Position an appropriate container under the helicopter and fabricate a tray
to direct any spilled fuel into the container. Hold fitting #15 with a wrench and disconnect the fuel hose. Be prepared for fuel to
come out of the assembly at this time. Hold fitting #16 with a wrench and remove fitting #14. The fitting should loosen with a
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