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Wastegate Adjust

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h&jeuropa

Joined: 07 Nov 2006
Posts: 645

Posted: Sat Jul 26, 2008 6:13 pm Post subject: Wastegate Adjust

I have recently reinstalled my 914 on my Europa.  It is also equipped with an Airmaster prop.  I flew this setup for about 60 hours with no problems.  Took it all apart to repair ground loop damage.  I carefully measured the position of the Bowden cable on the wastegate prior to disassembly and reset it the same.  However, I can not get full power from the engine.  When I go to 115% throttle, I get about 5600 rpm and 32 inHg man press.  I can adjust the rpm with the prop pitch stops, but the man press is still low.  I have run the tlr46 monitor program and the throttle percentages are correct.  So is the tach.  I think I noticed that the servo position started at 100% (I think that means full closed), then varied down around 40% or 50% and then went to 100% at full throttle.  This seems reasonable.



I'm thinking the wastegate is not completely closed when the servo thinks it is and that should be an adjustment of the Bowden cable.  The MM isn't too clear.  Looking at section 78-00-00/19, 20 & 21.  I think I should power up the TCU, let it go thru it's start cycle and then shut off the power to it.  Then disconnect the spring (1) and the Bowden cable and see if the wastegate can be closed more (closed is clockwise direction when looking from the bottom of the engine at the turbo, correct?).  If so, adjust the cable to close it completely.  



Does this make sense?  Anyone got other ideas?  Better way to properly adjust the wastegate?



Thank you.



Jim Butcher

Europa N241BW

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robertpeterfrost

Joined: 07 Jan 2008
Posts: 13
Location: Wakefield. UK

Posted: Tue Jul 29, 2008 2:58 am Post subject: Wastegate Adjust

Hi Jim,  

   

I have been in touch with the Rotax Service Centre in the UK (Skydrive) and they have advised me as follows: -  

   

“Please see section 78-00-00 page 20 of the Heavy Maintenance Manual for the correct setting of the servo cable.    

   

The manual is on the CD supplied with the engine or download from www.rotax-aircraft-engines.com  

   

Please ensure the waste gate is fully closed i.e. no slack in the cable when the throttle is closed (tcu turned on) (it should not be possible to move the waste gate lever when the throttle is closed).  

   

If the cable is set correctly you can monitor the airbox pressure using the TLR4* program.  Using the monitor sub menu you can see the target pressure (set point) and achieved (airbox) pressure.  Both should be close to each other other than at low engine speed (below 3500rpm).  

   

You can also see servo position.”  

   

I have downloaded this data and it looks fairly simple to do, however you will need cowls off and an assistant to confirm the wastegate I shut when you set the cable at the servo drive motor. I haven’t done mine yet as the aircraft is at an airfield some 60 miles from my home where it is undergoing it’s final test flights, I hope to set this up later this week.  

   

I hope this helps.  

   

Regards  

   

Robert  Frost  

Europa XS. G-RPAF  

Wakefield  

Yorkshire  

U.K.  

   

   

413 Cutler Heights Lane Bradford BD4 9JL, Tel: 01274 656200, Fax: 01274 669612  

Refrigeration Services (Northern) Ltd.Co. Reg. No. 2071495  

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Robert

h&jeuropa

Joined: 07 Nov 2006
Posts: 645

Posted: Wed Jul 30, 2008 4:12 am Post subject: Re: Wastegate Adjust

A update.  I found the wastegate wasn't fully closed when the servo drove it to closed.  Adjusted the cable per 12-00-00 and now everything is working correctly. 



Thanks to all.



Jim Butcher

Europa N241BW

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